Toyota - Tacoma Prerunner Extra - Workshop Manual - 2000 - 2000

Exhaust System - Manifold Heat Shield Rattle Noise Heat Shield: Customer Interest Exhaust System - Manifold Heat Shield Rattle Noise Engine EG004-00 June 2, 2000 Title: EXHAUST MANIFOLD HEAT SHIELD RATTLE NOISE Models: '95 - '00 Tacoma Introduction Some Tacoma vehicles may experience a rattle noise caused by the exhaust manifold heat shield. Two wire mesh grommets and a reinforcement patch on the underside have been added to reduce the possibility of the exhaust manifold heat shield rattle noise. Applicable Vehicles ^ 1995 - 2000 model year Tacoma vehicles (except CA Spec.) equipped with 2RZ-FE or 3RZ-FE engines produced before the VINs listed. Production Change Information Parts Information Repair Procedure 1. Inspect the Exhaust Manifold Heat Shield for cracking around the 2 bolts and 2 studs. 2. If cracking is found, replace the Exhaust Manifold Heat Shield, Bolts, Washers, Studs, and Nuts in specified quantities. 3. Insert 2 bolts. (P/N 90110-06894) 4. Reuse studs/nuts in the specified areas. Warranty Information Locations Page 3222 Splice Point J: Indicates a wiring Splice Point (Codes are "E"for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I 5 is indicated by the shaded section. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. N: Page No. How to Read Ground Points How to Read Ground Points Input Signal Check Cruise Control Switch: Testing and Inspection Input Signal Check DENSO Made HINT: 1. For check No.1 - No.2: Turn the ignition switch ON. 2. For check No.3: - Turn ignition switch ON. - Shift to D position. 3. For check No.4: - Jack up the vehicle. - Start the engine. - Shift to D position. a. Press the control switch to SET/COAST or RES/ACC position and hold it down or hold it up "1". b. Push the main switch ON "2". c. Check that the CRUISE MAIN indicator light blinks twice or 3 times repeatedly after 3 seconds. d. Turn the SET/COAST or RES/ACC switch OFF. e. Operate each switch as listed in the table. Specifications Camshaft Gear/Sprocket: Specifications Tightening Torque Crankshaft Pulley ................................................................................................................................ ..................................................... 250 Nm (184 ft.lb) Camshaft Timing Pulley ................................... .......................................................................................................................................... 110 Nm (81 ft.lb) Page 3027 Fuse: Application and ID Engine Room R/B # 2 Page 800 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 4962 INSPECT REAR WIPER AND WASHER SWITCH CONTINUITY If continuity is not as specified, replace the switch. INSPECT WASHER LINKED OPERATION a. Connect the positive (+) lead from the battery to terminal 16 and the negative (-) lead to terminal 2. b. Connect the positive (+) lead from the voltmeter to terminal 7 and the negative (-) lead to terminal 2. c. Push in the washer switch, and check that the voltage changes as shown in the table. If operation is not as specified, replace the wiper and washer switch. Page 1362 Camshaft Position Sensor: Service and Repair COMPONENTS REPLACEMENT 1. REMOVE NO.2 TIMING BELT COVER 2. REMOVE CAMSHAFT POSITION SENSOR a. Disconnect the sensor connector. b. Remove the bolt and sensor. 3. REINSTALL NEW CAMSHAFT POSITION SENSOR a. Install a new sensor with the bolt. Torque: 7.8 Nm (80 kg.cm, 69 in.lb) b. Connect the sensor connector. Page 1136 Catalytic Converter: Testing and Inspection 1. INSPECT EXHAUST PIPE ASSEMBLY a. Check the connections for looseness or damage. b. Check the clamps for weakness, cracks or damage. 2. INSPECT TWC Check for dents or damage. If any part of the protector is damaged or dented to the extent that it contacts the TWC, repair or replace it. 3. INSPECT TWC HEAT INSULATOR a. Check the heat insulator for damage. b. Check for adequate clearance between the TWC and heat insulator. Specifications Wheel Bearing: Specifications On models with serviceable wheel bearings, use a Lithium Multipurpose Grease. Removal and Installation Heater Core Case: Service and Repair Removal and Installation Cooling / Heating Units COMPONENTS REMOVAL 1. REMOVE COOLING UNIT 2. DRAIN ENGINE COOLANT FROM RADIATOR Page 3010 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source How to Read Power Source Page 245 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Page 1577 CHART 2 CHART 3 CHART 4 Testing and Inspection Antenna Relay: Testing and Inspection Auto Antenna Models: INSPECT ANTENNA MOTOR CONTROL RELAY CIRCUIT Disconnect the connector from the relay and inspect the connector on wire harness side, as shown in the chart below. Page 607 Compression Check: Testing and Inspection INSPECTION HINT: If there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure. 1. WARM UP AND STOP ENGINE Allow the engine to warm up to normal operating temperature. 2. REMOVE SPARK PLUGS 3. CHECK CYLINDER COMPRESSION PRESSURE a) Insert a compression gauge into the spark plug hole. b) Fully open the throttle. c) While cranking the engine, measure the compression pressure. HINT: Always use a fully charged battery to obtain engine speed of 250 rpm or more. d) Repeat steps a) through c) for each cylinder. NOTICE: This measurement must be done in as short a time as possible. Compression pressure: 1,200 kPa (12.2 kgf/cm2, 174 psi) or more Minimum pressure: 1,000 kPa (10.2 kgf/cm2, 145 psi) Difference between each cylinder: 100 kPa (1.0 kgf/cm2, 15 psi) or less e) If the cylinder compression in 1 or more cylinders is low, pour a small amount of engine oil into the cylinder through the spark plug hole and repeat steps a) through c) for cylinders with low compression. If adding oil helps the compression, it is likely that the piston rings and/or cylinder bore are worn or damaged. - If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket. 4. REINSTALL SPARK PLUGS Page 3180 Part 2 Of 2 REMOVAL Page 2497 1. INSPECT PROPELLER SHAFT AND INTERMEDIATE SHAFT FOR DAMAGE OR RUNOUT a. Inspect the shafts for wear or damage. b. Using a dial indicator, check the runout of the shafts. Maximum runout: 0.8 mm (0.031 inch) If the shaft runout exceeds the maximum, replace the shaft. 2. INSPECT SPIDER BEARING a. Inspect the spider bearings for wear or damage. b. Using a dial indicator, check the spider bearing axial play by turning the yoke while holding the shaft tightly. Maximum bearing axial play: 0.05 mm (0.0020 inch) If the spider bearing axial play exceeds the maximum, replace the spider bearing. Refer to Universal Joint, Drive/Propeller Shaft; Service and Repair. 3. 3-joint type: INSPECT CENTER SUPPORT BEARING FOR WEAR OR DAMAGE Check that the bearing turns freely. If the bearing is damaged, worn, or does not turn freely, replace it. 4. w/ Double cardan joint propeller shaft: INSPECT WITH DOUBLE CARDAN JOINT PROPELLER SHAFT a. Inspect the shaft for wear or damage. b. Inspect the double cardan joint for wear or damage. If any problem is found, replace the propeller shaft assembly. REASSEMBLY NOTICE: Be careful not to grip the propeller shaft tube too tightly in a vise as this will cause deformation. Page 4360 f. Read the blinking pattern of the CRUISE MAIN indicator light. g. After performing the check, turn the main switch OFF. HINT: When 2 or more signals are input to the ECU, the lowest numbered code will be displayed first. FORD Made HINT: 1. For check No.1 - No.2: Turn the ignition switch ON. 2. For check No.3: - Turn ignition switch ON. - Shift to D position. 3. For check No.4: - Jack up the vehicle. - Start the engine. - Shift to D position. a. Press the control switch to SET/COAST or RES/ACC position and hold it down or hold it up "1". b. Press the main switch ON "2". c. Check that the CRUISE MAIN indicator light blinks twice or 3 times repeatedly after 3 seconds. d. Turn the SET/COAST or RES/ACC switch OFF. e. Operate each switch as listed in the table. Page 3428 c. Support the brake caliper securely. 7. DISCONNECT LOWER BALL JOINT Remove the 4 bolts and disconnect the lower ball joint. Torque: 80 Nm (820 kgf-cm, 59 ft. lbs.) 8. REMOVE STEERING KNUCKLE a. Remove the cotter pin and loosen the nut. Torque: 105 Nm (1,100 kgf-cm, 80 ft. lbs.) HINT: At the time of installation, if the holes for the cotter pin are not aligned, tighten the nut further up to 60°. b. Using SST, disconnect the steering knuckle. SST 09950-40011 (09951-04010, 09952-04010, 09553-04020, 09554-04010, 09955-04031, 09958-04011) c. Remove the nut and steering knuckle. NOTICE: 4WD: Be careful not to damage the oil seal and drive shaft boot. HINT: 4WD: When it is difficult to disconnect the drive shaft, tap the tip of the drive shaft with a plastic hammer. INSTALLATION Installation is in the reverse order of removal. HINT: After installation, bleed the brake system , check the front wheel alignment and ABS speed sensor signal. Page 644 Drive Belt: Service and Repair REMOVAL 1. REMOVE PS PUMP DRIVE BELT 2. REMOVE ENGINE UNDER COVER 3. LOOSEN IDLE PULLEY LOCK NUT Torque: 39 Nm (400 kg.cm, 29 ft.lb) 4. REMOVE COMPRESSOR DRIVE BELT Loosen drive belt tension by adjusting bolt and remove the drive belt. INSTALLATION 1. TIGHTEN IDLE PULLEY LOCK NUT TEMPORALLY Torque: 2.5 Nm (25 kg.cm, 22 in.lb) 2. INSTALL DRIVE BELT 3. USING ADJUSTING BOLT, ADJUST DRIVE BELT TENSION Drive belt tension New belt: 160 ± 25 lb Used belt: 100 ± 25 lb 4. TIGHTEN IDLE PULLEY LOCK NUT Torque: 39 Nm (400 kg.cm, 29 ft.lb) 5. INSTALL PS PUMP DRIVE BELT 6. INSTALL ENGINE UNDER COVER Page 1382 Fuel Pressure: Specifications Volume Specification Information not supplied by the manufacturer. Page 2446 7. 3RZ-FE, 5VZ-FE w/ Diff. lock: REMOVE FRONT BEARING OUTER RACE AND OIL STORAGE RING a. Using SST, remove the front bearing outer race. SST 09308-00010 b. Using a screwdriver, bend the oil storage ring and remove it. 8. REMOVE BEARING SPACER a. 3RZ-FE, 5VZ-FE w/o Diff. lock: Remove the 2 washers. b. Remove the bearing spacer. 9. INSTALL NEW BEARING SPACER a. Install a new bearing spacer. b. 3RZ-FE, 5VZ-FE w/o Diff. lock: Install the 2 washers. 10. 3RZ-FE, 5VZ-FE W/ Diff. lock: INSTALL OIL STORAGE RING AND FRONT BEARING OUTER RACE a. Using SST and a hammer, install a new oil storage ring. SST 09316-60011 (09316-00011, 09316-00021) b. Using SST and a hammer, install the front bearing outer race. SST 09316-60011 (09316-00011, 09316-00021) 11. INSTALL FRONT BEARING a. Place the front bearing. b. Except 3RZ-FE, 5VZ-FE w/o Diff. lock: Place the oil slinger. c. Using SST and the companion flange, install the front bearing then remove the companion flange. SST 09950-30011 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020, 09956-03050) 12. INSTALL NEW OIL SEAL Component Locations Dome Lamp: Component Locations Page 4714 Stop Light: Harness Locations Page 4982 If seam is not sealed properly, clean vertical and horizontal seam area with Acrysol(TM) cleaner. Use an air hose to dry all seams before applying sealer. NOTE: Hole is located behind fender. 15. Attach a 12 to 18 inch length of plastic tubing to tip of Kent High Tech(TM) Clear Seam Sealer. 16. Seal entire vertical joint with High Tech(TM) clear seam sealer. Allow sealer to dry according to instructions on tube. NOTE: Seams are inside boxed area and accessed through the square hole as shown. 17. Flood cowl area with water to confirm that there are no cowl seam leaks into cab. If water leaks are still present and there are no cowl area seam leaks, reinstall front fender and inspect for water entry along lower edge of interior door trim panel; then proceed as follows: 18. Remove door trim panel. 19. Flood R/F door glass area (spray water at door glass, belt-molding area). 20. Inspect sealer between plastic sheeting (moisture barrier) and metal door panel for voids/skips in sealer. If there are voids/skips between the plastic sheet and the door panel, it will need to be resealed. A. Using a heat gun, heat the butyl tape securing the plastic sheet to make removal easier. B. Use Kent Acrysol to clean the door panel and plastic sheet. NOTE: ^ Follow the directions provided by the cleaning agent. ^ To ensure proper sealing of the plastic sheeting, it is important that the door panel and plastic sheeting is extremely clean. C. Use 3M 8.0 mm butyl tape (P/N 08610) to reattach the plastic sheet to the door panel. Make sure there is a continuos solid bead sealing the plastic sheet to the door panel. 21. Inspect drain-back holes (small slits in metal door panel, near bottom of sealer) to determine if holes are covered by sealer material. If sealer covers drain-back holes (small slits in metal door panel) carefully pull up a portion of plastic sheet, clean out drain-back holes and Page 1580 CHART 8 CHART 9 Component Tests and General Diagnostics Engine Control Module: Component Tests and General Diagnostics CIRCUIT DESCRIPTION When the ignition switch is turned ON, battery positive voltage is applied to coil, closing the contacts of the EFI main relay (Marking: EFI) and supplying power to terminal +B of the ECM. WIRING DIAGRAM Brakes - Pad Clicking Noise Brake Pad: Customer Interest Brakes - Pad Clicking Noise BRAKES BR004-00 October 20, 2000 Title: BRAKE PAD CLICKING NOISE Models: '90- '00 All Models Introduction A clicking type noise may be noticed when first applying the brakes after changing vehicle travel direction (Drive/Forward to Reverse, Reverse to Drive/Forward). This is a normal noise caused by the required brake pad-to-caliper clearances. When the direction of travel is changed, the brake pads may "shift" towards the new direction of travel. When the brake pad contacts the caliper, a clicking noise may be heard. To minimize this clicking noise, a disc brake caliper grease has been made available for use during brake service/maintenance operations. Under normal usage conditions this grease should be effective for a period of 6 months to 1 year. Applicable Vehicles ^ 1990 - 2000 model year Toyota vehicles, all models. Parts Information Warranty Information Application Procedure There are two types of brake calipers: floating and fixed. Check the type of brake caliper installed on the vehicle by removing the wheel assembly. 1. Floating Type Brake Caliper A. Lift up or remove the brake caliper and suspend it securely. HINT: Do not disconnect the flexible hose from the brake caliper. B. If equipped with anti-squeal spring: Remove the anti-squeal springs. C. Remove the brake pads with anti-squeal shims. D. Remove the pad support plates from the torque plate. Clean any dust from the pad support plates, torque plates and brake pads. Testing and Inspection Dimmer Switch: Testing and Inspection W/ Tachometer (DLX Grade M/T Vehicle) INSPECT LIGHT CONTROL RHEOSTAT a. Turn the rheostat knob OFF and check that no continuity exists between terminals (Rheostat knob turned to fully counterclockwise). b. Gradually, turn the rheostat knob from the dark side to bright side and check that the resistance decreases from 10 to 0 Ohm. (Rheostat knob turned to clockwise) If operation is not as specified, replace the rheostat. ELECTRICAL TYPE (W/ All A/T Vehicle and SR5 Grade M/T Vehicle): INSPECT LIGHT CONTROL RHEOSTAT a. Connect terminals 1 and 3 through a 3.4 W test bulb. b. Connect the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal 2. c. Turn the rheostat knob to fully counterclockwise and check that the test bulb goes out. d. Gradually turn the rheostat knob to clockwise and check that the test bulb brightness changes from dark to bright. If operation is not as specified, replace the rheostat. Page 3272 1. REMOVE 2 TURN PRESSURE TUBES a. Using SST, remove the tube. SST 09633-00020 b. Remove the union seat from the rack housing. c. Remove the union seat from the control valve housing. 2. SECURE PS GEAR ASSEMBLY IN VISE Using SST and 2 bolts, secure the gear assembly in a vise, as shown in the illustration. SST 09612-00012 Reference: Bolt: 90105-10346 Nut: 90170-10198 HINT: Use 2 of the same type of SST 3. REMOVE RH AND LH TIE ROD ENDS AND LOCKNUTS Place matchmarks on the tie rod end and rack end. 4. REMOVE RH AND LH CLIPS, RACK BOOTS AND CLAMPS NOTICE: Be careful not to damage the boot. Mark the RH and LH boots. 5. REMOVE RH AND LH RACK ENDS AND CLAW WASHERS Page 2888 Wheel Speed Sensor: Service and Repair Speed Sensor, Rear REMOVAL REMOVE SPEED SENSOR a. Disconnect the speed sensor connector, and pull out the sensor wire harness with grommet. b. Remove the 5 resin clips, 2 clamp set bolts and 2 nuts holding the sensor wire harness from the side rail, fuel tank and axle housing. Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.) c. Remove the 2 mounting bolts and speed sensor. Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.) NOTICE: At the time of installation, please refer to the following items. ^ There are no objects on the sensor or the part of the axle end to which the sensor is to be installed. ^ The sensor is installed flat against the axle end when you tighten the bolt. ^ When installing the resin clips, use new ones. INSTALLATION Installation is in the reverse order of removal. NOTICE: After installation, check the speed sensor signal. Page 2337 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Collision / Non-Collision Inspections Impact Sensor: Testing and Inspection Collision / Non-Collision Inspections INSPECTION 1. VEHICLES NOT INVOLVED IN COLLISION Do a diagnostic system check. * 2. VEHICLES INVOLVED IN COLLISION a. Do a diagnostic system check. * b. If the front fender of the car or its periphery is damaged, do a visual check for damage to the front airbag sensor, which includes the following items even if the airbag was not deployed: Check the bracket deformation. - Check the paint peeling off the bracket. - Check the cracks, dents or chips in the case. - Check the cracks, dents, chipping and scratches in the connector. - Check the peeling off of the label or damage to the serial number. * Refer to SRS Warning Light Check, and How to Display and Read Diagnostic Trouble Codes. See: Restraint Systems/Air Bag Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Displaying & Reading Trouble Codes Air Bag System Repairs and Inspections Required After a Collision: Service and Repair Air Bag System REPAIRS AND INSPECTIONS REQUIRED AFTER A COLLISION FRONT PASSENGER AIRBAG ASSEMBLY 1. VEHICLE NOT INVOLVED IN COLLISION a. Do a diagnostic system check. b. Do a visual check which includes the following items with the front passenger airbag assembly installed in the vehicle. Check for cuts, minute cracks or marked discoloration of the front passenger airbag door. 2. VEHICLE INVOLVED IN COLLISION AND AIRBAG IS NOT DEPLOYED a. Do a diagnostic system check. b. Do a visual check which includes the following items with the front passenger airbag assembly removed from the vehicle. - Check for cuts and cracks in, or marked discoloration of the front passenger airbag door. - Check for cuts and cracks in wire harnesses, and for chipping in connectors. - Check for deformation of the instrument panel and instrument panel reinforcement. HINT: If the instrument panel or instrument panel reinforcement is deformed, never repair it. Always replace it with a new one. - There should be no interference between the instrument panel and front passenger airbag door, or the glove compartment door and front passenger airbag door. The clearance should be uniform all the way around when the new airbag assembly is installed on the instrument Page 3850 c. Install the SST. 1. Connect the 2 SST, then connect them to the seat belt pretensioner. SST 09082-00700,09082-00740 NOTE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. 2. Place the front seat outer belt on the ground and cover it with the disc wheel with tire. NOTE: Place the front seat outer belt as shown in the illustration. 3. Move the SST as least 10 m (33 ft) away from the disc wheel. NOTE: Take care not to damage the SST wire harness. d. Activate the seat belt pretensioner. 1. Connect the SST red clip to the battery positive (+) terminal and black clip to the battery negative (-) terminal. 2. Check that no one is within 10 m (33 ft) area around the disc wheel. 3. Press the SST activation switch and activate the seat belt pretensioner. HINT: The seat belt pretensioner operates simultaneously as the LED of the SST activation switch lights up. Page 3343 a. As shown in the illustration, flip the ball joint stud back and forth 5 times, before installing the nut. b. Using a torque wrench, turn the nut continuously 1 turn each 2-4 seconds and take the torque reading on the 5th turn. Turning torque: 0.7-4.4 Nm (7-45 kgf-cm, 6-39 inch lbs.) REPLACEMENT 1. REMOVE UPPER BALL JOINT a. Remove the wire and boot. b. Using a snap ring expander, remove the snap ring. c. Using SST and a deep socket wrench, remove the upper ball joint. SST 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04031, 09957-04010, 09958-04011) 2. INSTALL UPPER BALL JOINT a. Using SST and a socket wrench, install a new ball joint. SST 09309-37010 b. Using a snap ring expander, install a new snap ring. c. Install a new boot and fix it with a new wire. HINT: Use the grease supplied in the kit. INSTALLATION INSTALL STEERING KNUCKLE WITH AXLE HUB Page 4449 Clock: Fuse and Fusible Link Locations Relay Box / No. 2 Page 3135 2. INSTALL CAMBER-CASTER-KING PIN GAUGE OR POSITION VEHICLE ON WHEEL ALIGNMENT TESTER Follow the specific instructions of the equipment manufacturer. 3. INSPECT CAMBER, CASTER AND STEERING AXIS INCLINATION Camber, caster and steering axis inclination: RZN161L Model RZN1171L Model RZN191L model RZN196L model VZN170L model Page 2426 Differential Lock: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Page 3895 WARRANTY INFORMATION PROGRAMMING PROCEDURE AUTOMATIC (IGNITION-CONTROLLED) DOOR LOCKING/UNLOCKING FUNCTION The factory setting for the AUTOMATIC DOOR LOCKING/UNLOCkING FUNCTION is "ON". To change this feature's operation, follow the steps below: 1. Sit in the driver's seat with driver's door open. 2. Insert the key into the ignition switch, and turn it to 'ON" position (not "ACC") 5 times (ON > LOCK > ON > LOCK> ON > LOCK > ON> LOCK > ON) within a 10 second period. System Response: The STATUS MONITOR's LED turns on, and the PIEZO BUZZER sounds once. NOTE: You must perform the next steps within 30 seconds. 3. Select the customer's preferred operating mode. Exhaust System - Manifold Heat Shield Rattle Noise Heat Shield: All Technical Service Bulletins Exhaust System - Manifold Heat Shield Rattle Noise Engine EG004-00 June 2, 2000 Title: EXHAUST MANIFOLD HEAT SHIELD RATTLE NOISE Models: '95 - '00 Tacoma Introduction Some Tacoma vehicles may experience a rattle noise caused by the exhaust manifold heat shield. Two wire mesh grommets and a reinforcement patch on the underside have been added to reduce the possibility of the exhaust manifold heat shield rattle noise. Applicable Vehicles ^ 1995 - 2000 model year Tacoma vehicles (except CA Spec.) equipped with 2RZ-FE or 3RZ-FE engines produced before the VINs listed. Production Change Information Parts Information Repair Procedure 1. Inspect the Exhaust Manifold Heat Shield for cracking around the 2 bolts and 2 studs. 2. If cracking is found, replace the Exhaust Manifold Heat Shield, Bolts, Washers, Studs, and Nuts in specified quantities. 3. Insert 2 bolts. (P/N 90110-06894) 4. Reuse studs/nuts in the specified areas. Warranty Information Page 2750 Brake Caliper: Service and Repair Disassembly and Assembly DISASSEMBLY 1. REMOVE CYLINDER BOOT SET RINGS AND BOOTS Using a screwdriver, remove the 4 cylinder boot set rings and boots. 2. REMOVE PISTONS FROM CYLINDER Diagram Information and Instructions Horn: Diagram Information and Instructions Key to Diagrams Key to Diagrams A: System Title. B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: (1) Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. Specifications Engine Oil Pressure: Specifications Oil Pressure At idle ................................................................................................................................................... .............. 29 kPa (0.3 kgf/cm2, 4.3 psi) or More At 3,000 rpm ............................................................................................................................................. 245 - 520 kPa (2.5 - 5.3 kgf/cm2, 36 - 75 psi) Page 1188 Part 1 Of 2 (Except California Spec.) Page 2552 Splice Locations Specifications Clutch Fluid: Specifications Fluid Type FMVSS 116 DOT 3 Brake Fluid Page 3631 CAUTION: Be sure to follow the correct procedure for removal and installation of the steering wheel pad. 3. VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED a. Do a diagnostic system check. b. Do a visual check which includes the following items with the steering wheel pad (with airbag) removed from the vehicle. - Check the deformation on the horn button contact plate of the steering wheel. - Check the damage on the spiral cable connector and wire harness. HINT: If the horn button contact plate of the steering wheel is deformed, never repair it. Always replace the steering wheel assembly with a new one. - There should be no interference between the steering wheel pad and steering wheel, and the clearance should be uniform all the way around when the new steering wheel pad is installed on the steering wheel. CAUTION: Be sure to follow the correct procedure for removal and installation of the steering wheel pad. Page 3134 Alignment: Specifications NOTE: RZN161L: 4WD Regular Cab, Short Wheelbase with 3RZ-FE engine RZN171L: 4WD Extra Cab, Extra Long Wheelbase with 3RZ-FE engine RZN191L: 2WD PreRunner Regular Cab, Short Wheelbase with 3RZ-FE engine RZN196L: 2WD PreRunner Extra Cab, Extra Long Wheelbase with 3RZ-FE engine VZN170L: 4WD Extra Cab, Extra Long Wheelbase with 5VZ-FE engine VZN195L: 2WD PreRunner Extra Cab, Extra Long Wheelbase with 5VZ-FE engine INSPECTION HINT: PreRunner is the model described below. RZN191L-TRPDKAB, RZN196L-CRPDKAB, VZN195L-CRPDKAB 1. MEASURE VEHICLE HEIGHT Vehicle Height: Measuring points: A: Ground clearance of spindle center. B: Ground clearance of front adjusting cam bolt center. C: Ground clearance of leaf spring front hanger pin bolt center. D: Ground clearance of rear axle shaft center. NOTICE: Before inspecting the wheel alignment, adjust the vehicle height to the specified value. If the vehicle height is not the specified value, try to adjust it by pushing down on or lifting the body. Page 963 Timing Belt: Diagrams TIMING BELT REPLACEMENT W/ RELATED COMPONENTS Part 1 Of 2 Part 1 of 2 Page 4569 Page 2548 Junction Box / No. 3 Page 1616 INSPECTION 1. INSPECT HEATER RESISTANCE OF HEATED OXYGEN SENSOR a. Disconnect the sensor connector. b. Using an ohmmeter,measure the resistance between terminals +B and HT. Resistance: at 20 °C (68 °F) 11 - 16 ohms at 800 °C (1,472 °F) 23 - 32 ohms If the resistance is not as specified, replace the sensor. Torque: 20 Nm (200 kg.cm, 14 ft.lb) c. Reconnect the oxygen sensor connector. 2. Bank 1 Sensor 1: INSPECT OPERATION OF HEATED OXYGEN SENSOR 3. Bank 1 Sensor 2: INSPECT OPERATION OF HEATED OXYGEN SENSOR Collision / Non-Collision Inspections Impact Sensor: Testing and Inspection Collision / Non-Collision Inspections INSPECTION 1. VEHICLES NOT INVOLVED IN COLLISION Do a diagnostic system check. * 2. VEHICLES INVOLVED IN COLLISION a. Do a diagnostic system check. * b. If the front fender of the car or its periphery is damaged, do a visual check for damage to the front airbag sensor, which includes the following items even if the airbag was not deployed: Check the bracket deformation. - Check the paint peeling off the bracket. - Check the cracks, dents or chips in the case. - Check the cracks, dents, chipping and scratches in the connector. - Check the peeling off of the label or damage to the serial number. * Refer to SRS Warning Light Check, and How to Display and Read Diagnostic Trouble Codes. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Displaying & Reading Trouble Codes Page 421 Mass Air Flow Meter: Testing and Inspection INSPECTION 1. INSPECT MAF METER RESISTANCE Using an ohmmeter, measure the resistance between terminals THA and E2. If the resistance is not as specified, replace the MAF meter. Temperature Resistance at -20 °C (-4 °F) 13.6 - 18.4 Kohms at -20 °C (68 °F) 2.2 - 2.7 Kohms at -60 °C (140 °F) 0.5 - 0.7 Kohms 2. INSPECT MAF METER OPERATION a. Connect the MAF meter connector. b. Using a voltmeter, connect the positive (+) tester probe to terminal VG, and negative (-) tester probe to terminal E2G. c. Turn the ignition switch ON. d. Blow air into the MAF meter, and check that the voltage fluctuates. If operation is not as specified, replace the MAF meter. e. Turn the ignition switch OFF. f. Disconnect the MAF meter connector. Page 1965 Throttle Position Sensor: Service and Repair Refer to Fuel Delivery and Air Induction / Throttle Body / Service and Repair, for removal and installation of this component. Page 2448 14. ADJUST DRIVE PINION PRELOAD 15. STAKE DRIVE PINION NUT 16. CONNECT REAR PROPELLER SHAFT 17. FILL DIFFERENTIAL WITH HYPOID GEAR OIL Torque: 49 Nm (500 kgf-cm, 39 ft. lbs.) Oil type: Hypoid gear oil API GL-5 Recommended oil viscosity: Above-18°C (0°F) SAE 90 Below -18°C (0°F) SAE80W or 80W-90 Capacity: Page 1561 A/F and 02 Sensor Identification Page 3467 Blower Motor Resistor: Service and Repair REMOVAL 1. REMOVE GLOVE COMPARTMENT DOOR 2. REMOVE BLOWER RESISTOR a. Disconnect the connector. b. Remove the 2 screws and blower resistor. INSTALLATION Installation is in the reverse order of removal. Testing and Inspection Headlamp Dimmer Relay: Testing and Inspection INSPECT HEADLIGHT DIMMER RELAY CONTINUITY If continuity is not as specified, replace the relay. Page 3502 Control Module HVAC: Service and Repair REMOVAL 1. REMOVE GLOVE COMPARTMENT DOOR 2. REMOVE AMPLIFIER a. Disconnect the connector from the amplifier. b. Remove amplifier cover. c. Remove the amplifier from the cooling unit. INSTALLATION Installation is in the reverse order of removal. Page 237 Key Reminder Switch: Fuse and Fusible Link Locations Relay Box / No. 2 Page 2966 b. Check for the commutator circle runout. 1. Place the commutator on V-blocks. 2. Using a dial gauge, measure the circle runout. Maximum circle runout: 0.05 mm (0.0020 in.) If the circle runout is greater than maximum, correct it on a lathe. c. Using vernier calipers, measure the commutator diameter. Standard Diameter Standard diameter: Minimum Diameter Minimum diameter: If the diameter is less than minimum, replace the armature. d. Check that the undercut depth is clean and free of foreign materials. Smooth out the edge. Replacement Requirements Impact Sensor: Service and Repair Replacement Requirements REPLACEMENT REQUIREMENTS In the following cases, replace the front airbag sensor. - If the SRS has been deployed in a collision. (Replace both the left and right airbag sensors.) - If the front airbag sensor has been found to be faulty in troubleshooting. - If the front airbag sensor has been found to be faulty during checking items. - If the front airbag sensor has been dropped. CAUTION: Be sure to follow the correct procedure for removal and installation of the front airbag sensor. Page 2949 SST 09820-00021 NOTE: Be careful not to damage the fan. b. Remove the bearing cover (inside). c. Place the bearing cover (inside) on the rotor d. Using SST and a press, press in a new bearing. SST 09820-00030 e. Using SST, push in the bearing cover (outside). SST 09285-76010 Page 462 Impact Sensor: Service and Repair Removal and Installation COMPONENT REMOVAL NOTE: - If the wiring connector of the SRS is disconnected with the ignition switch at ON or ACC position, DTCs will be recorded. - Never use SRS parts from another vehicle. When replacing parts, replace then with new parts. - Never reuse the sensor involved in a collision when the SRS has deployed. - Never repair a sensor in order to reuse it. 1. REMOVE BATTERY a. Remove the bolt and battery clamp. b. Remove the battery and battery carrier. Page 4617 Junction Box / No. 1 Page 538 INSPECT REAR WIPER AND WASHER SWITCH CONTINUITY If continuity is not as specified, replace the switch. INSPECT WASHER LINKED OPERATION a. Connect the positive (+) lead from the battery to terminal 16 and the negative (-) lead to terminal 2. b. Connect the positive (+) lead from the voltmeter to terminal 7 and the negative (-) lead to terminal 2. c. Push in the washer switch, and check that the voltage changes as shown in the table. If operation is not as specified, replace the wiper and washer switch. Page 334 Oxygen Sensor: Technical Service Bulletins Engine Controls - O2 Sensor Monitor Threshold Values SPECIAL SERVICE TOOLS SS002-03 December 17, 2003 Title O2S TEST RESULTS (MODE 05) Models All '96 - '03, '04 Corolla, ECHO, Matrix, Sienna & Scion xA & xB Introduction This Service Bulletin contains Oxygen Sensor (O2S) Monitor threshold values for all models from 1996 to 2003 and some 2004 models. Starting in 2004, the O2S Monitor threshold values can be found in the repair manual. These values are used when analyzing the O2S test results to determine the O2S condition. Applicable Vehicles ^ All 1996 - 2003 model year Toyota vehicles. ^ 2004 model year Corolla, ECHO, Matrix and Sienna vehicles. ^ 2004 model year Scion xA and xB vehicles. Function Description Checking O2S Test Results To view O2S test results, the O2S Monitor must be completed and the test results must be checked within the same key cycle. If the ignition key is cycled OFF, the O2S test results will be set to the minimum or maximum limits, and all test results will be erased. The O2S test results are stored in the ECU (SAE term: Powertrain Control Module/PCM) when the monitor is completed. The test results are static and will not change once the monitor is complete. The process for checking 02S test results is described in the following three basic steps: 1. Completing the O2S Readiness Monitor. 2. Accessing O2S Test Results. 3. Comparing O2S Test Results to Failure Thresholds. Required SSTs NOTE: Additional Diagnostic Tester Kits, Program Cards or other SSTs may be ordered by calling SPX-OTC at 1-800-933-8335. Warranty Information Completing O2S Readiness Monitor 1. Clear any stored Diagnostic Trouble Codes (DTCs) using the Toyota Diagnostic Tester. Capacity Specifications Refrigerant Oil: Capacity Specifications When Replacing, Add: Receiver 20 cc Condenser 40 cc Evaporator 40 to 50 cc Page 1290 CHART 23 Page 1477 Page 4082 Roof Headlining (Extra Cab) Page 871 b) Turn the crankshaft 2/3 of a revolution (240°), and check only the valves indicated in the illustration. Measure the valve clearance. (See step (a)) c) Turn the crankshaft a further 2/3 of a revolution (240°), and check only the valves indicated in the illustration. Measure the valve clearance. (See step (a)) 5. ADJUST VALVE CLEARANCE a) Remove the adjusting shim. 1) Turn the camshaft so that the cam lobe for the valve to be adjusted faces up. 2) Turn the valve lifter with a screwdriver so that the notches are perpendicular to the camshaft. 3) Using SST (A), press down the valve lifter and place SST (B) between the camshaft and valve lifter. Remove SST (A). SST 09248-55040 (09248-05410, 09248-05420) System Outline Seat Belt Reminder Lamp: Description and Operation System Outline Current always flows to TERMINAL 12 of the integration relay through the DOME fuse. 1. SEAT BELT WARNING SYSTEM When the ignition SW is turned ON, current flows from the GAUGE fuse to TERMINAL 6 of the integration relay. At the same time, current flows to TERMINAL A 2 of the relay from the GAUGE fuse through the seat belt warning light. This current activates the integration relay and, for approx. 4-8 seconds, the current flowing through the warning light flows from TERMINAL A 2 of the relay to TERMINAL A 7 to GROUND, causing the warning light to light up. At the same time as the warning light lights up, a buckle SW ON signal is input to TERMINAL A 3 of the integration relay, the current flowing from TERMINAL 12 of the integration relay flows to TERMINAL A 7 to GROUND and the seat belt warning buzzer sounds for approx. 4 - 8 seconds. However, if the seat belt is put ON (Buckle SW OFF) during this period (while the buzzer is sounding), a signal input to TERMINAL A 3 of the integration relay stops and the current flowing from TERMINAL 12 of the integration relay to TERMINAL A 7 to GROUND is cut, causing the buzzer to stop. 2. KEY REMINDER SYSTEM With the ignition key inserted in the key cylinder (Unlock warning SW ON), the ignition SW still oft and front LH door open (Door courtesy SW ON), a signal is input to TERMINAL A 10, A 5 of the integration relay, the integration relay operates and current flows from TERMINAL 6 of the relay to TERMINAL A 7 to GROUND and the key reminder buzzer sounds. Page 1199 Part 2 Of 2 (Except California Spec.) *1: A/T *2: M/T Page 3052 Engine Compartment Instrument Panel Locations Lower Page 1475 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source How to Read Power Source Page 2378 Valve Body: Specifications Tightening Specifications Upper Valve Body X Lower Valve Body ........................................................................................................................... 6.4 Nm (65 kg-cm, 56 inch lbs.) Detent Spring X Valve Body ................................................................................................................................................... 10 Nm (100 kg-cm, 7 ft. lbs.) Oil Strainer X Valve Body ...................................................................................................................................................... 10 Nm (100 kg-cm, 7 ft. lbs.) Valve Body X Transmission Case ........................................................................................................................................... 10 Nm (100 kg-cm, 7 ft. lbs.) Solenoid X Valve Body ........................................................................................................................................................... 10 Nm (100 kg-cm, 7 ft. lbs.) Page 3528 Heater Core Case: Service and Repair Disassembly and Reassembly DISASSEMBLY 1. REMOVE HEATER RADIATOR a. Remove the 3 screws and 2 plates and clamp. b. Pull out the heater radiator. c. Remove the 2 screws and 2 clips, then disconnect the heater radiator pipes. HINT: At the time of reassembly, please refer to the following item. Do not reuse 2 O-rings. 2. REMOVE AIR VENT DUCT Remove the 2 screws and duct. REASSEMBLY Reassembly is in the reverse order of disassembly. Page 1415 Spark Plug: Specifications Torque Specification Spark Plug x Cylinder Head ................................................................................................................ ......................................................................... 18 Nm Page 2617 Step 3 Page 1023 Spark Plug: Application and ID Recommended Spark Plugs ND K16TR11 NGK BKR5EKB-11 Airbag(s) Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Airbag(s) Arming and Disarming CAUTION: * Work must be started 90 seconds after the ignition switch is turned to the "LOCK" position and the negative (-) terminal cable is disconnected from the battery. (The SRS is equipped with a back-up power source so that if work is started within 90 seconds of disconnecting the negative (-) terminal cable of the battery, the SRS may be deployed.) * When the negative (-) terminal cable is disconnected from the battery, the memory of the clock and audio system will be canceled. So before starting work, make a record of the contents memorized in the audio memory system. When work is finished, reset the audio systems as before and adjust the clock. To avoid erasing the memory of each memory system, never use a backup power supply from outside the vehicle. * Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during repairs. * Do not expose the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor directly to hot air or flames. AIR BAG SYSTEM DISARMING The Air Bag/Supplemental Restraint System (SRS) incorporates a backup energy source that maintains sufficient deployment voltage for up to 90 seconds after the ignition is turned Off and the battery has been disconnected. Before disconnecting battery, note radio station settings, since all vehicle memory will be lost. Never use a backup power source from outside the vehicle. 1. Turn ignition to Lock, then disconnect battery ground cable. 2. Wait at least 90 seconds after disconnection before beginning service or diagnostic procedures. AIR BAG SYSTEM ARMING 1. Ensure ignition is in Lock position. 2. Connect battery ground cable. 3. Wait at least 10 seconds before turning ignition from Lock position. 4. Turn ignition to ACC or On position and ensure SRS lamp lights, then goes off after approximately six seconds. If lamp remains lit, an SRS condition is indicated. Refer to Restraint Systems, Air Bag Systems, Testing And Inspection. See: Testing and Inspection Page 2945 b. Using a 29 mm socket wrench and press, slowly press in the rectifier end frame. c. Install the 4 nuts. Torque: 4.5 Nm (45 kg.cm, 39 in.lb) 3. INSTALL PULLEY a. Install the pulley to the rotor shaft by tightening the pulley nut by hand. b. Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque. SST 09820-63010 Torque: 39 Nm (400 kg.cm, 29 ft.lb) c. Check that SST (A) is secured to the pulley shaft. d. As shown in the illustration, mount SST (C) in a vise, and install the generator with SST (A) and (B) to SST (C). e. To torque the pulley nut, turn SST (A) in the direction shown in the illustration. Torque: 110 Nm (1,125 kg.cm, 81 ft.lb) f. Remove the generator with SST (A) and (B) from SST (C). g. Turn SST (B) and remove SST (A) and (B). Testing and Inspection Power Window Relay: Testing and Inspection INSPECT POWER MAIN RELAY CONTINUITY If continuity is not as specified, replace the relay. Page 1061 Coolant: Service and Repair REPLACEMENT 1. DRAIN ENGINE COOLANT a) Remove the radiator cap. CAUTION: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure. b) Loosen the drain plugs, and drain the engine coolant. c) Close the drain plugs. 2. REFILL WITH ENGINE COOLANT a) Slowly fill the system with engine coolant. ^ Use of improper coolants may damage engine cooling system. ^ Use "TOYOTA Long Life Coolant" or equivalent and mix it with plain water according to the manufacturer's directions. ^ Use of the coolant which includes more than 50% (freezing protection down to -35°C (-31°F)) or 60% (freezing protection down to -50°C (-58°F)) of ethylene-glycol is recommended, but not more than 70%. NOTICE: ^ Do not use an alcohol type engine coolant. ^ The engine coolant should be mixed with demineralized water or distilled water. Capacity: b) Reinstall the radiator cap. c) Start the engine, and bleed the cooling system. d) If necessary, refill engine coolant into the reservoir until it is "FULL" line. 3. CHECK ENGINE COOLANT FOR LEAKS Page 2117 WIRING DIAGRAM Step 1 Page 1045 Water Pump: Testing and Inspection Page 478 Step 4 INSPECTION PROCEDURE Page 4679 Step 2 Step 3 INSPECTION PROCEDURE Page 5006 Applicable Warranty*: This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Repair Procedure 1. Remove Wiper Arms, Plastic Cowl Cover and Wiper Motor (store wiper links up against bottom of windshield). NOTE: Mark wiper arm linkage attached to wiper motor and wiper motor splined shaft prior to removing the 12 mm retaining nut. 2. Spray Acrysol(TM) under entire lip of 1/2" pinch weld and wipe dry with a clean paper towel. FOLLOW DIRECTIONS ON SIDE OF CAN CAREFULLY. Dry open seam with compressed air prior to applying sealer. NOTE: Do not use a red shop towel to wipe surfaces because shop towels are contaminated with silicone. 3. Apply a small bead of Kent High Tech(TM) Clear Seam Sealer to underside front edge of the pinch weld from fender to fender as shown. 4. Apply Kent High Tech(TM) Clear Seam Sealer on all spot welds located on the floor of cowl panel. 5. Apply Kent High Tech(TM) Clear Seam Sealer around outside base of hood safety stops, and seal outside corner, under the "L" bracket as shown. Paint - Iron Rust Contamination Repair Paint: All Technical Service Bulletins Paint - Iron Rust Contamination Repair PAINT PA005-04 REVISED November 16, 2004 Title IRON PARTICLE RUST CONTAMINATION REPAIR Models '94 - Current Toyota & '04 - Current Scion TSB REVISION NOTICE: ^ December16, 2004: Text has been revised to more accurately describe cleaner (Auto Magic © Special Cleaner Concentrate is not an oxalic acid solution); Applicable Vehicles has been defined more clearly. The previous TSB should be discarded. Introduction The purpose of this bulletin is to provide information regarding the proper procedures to clean vehicles that may have been subjected to contamination by airborne iron particles such as rail dust. Applicable Vehicles ^ 1994 - Current model year Toyota vehicles. ^ 2004 - Current model year Scion vehicles. Condition During rail transportation or extended storage near industrial areas vehicles may occasionally be subjected to contamination by airborne iron particles shed from railroad tracks train wheels exposure to heavy machinery facilities gnnding welding etc. Inspection This type of contamination can be identified by the presence of small red or brown particles on the paint surface. These particles are often difficult to see on dark color paints but can be easily felt when brushing a hand across horizontal body surfaces such as hood roof or deck lid. Caution: Because of the abrasiveness of these small iron particles, polishing or buffing procedures should not be affempted to repair the paint surface of an affected vehicle. This will result in further paint damage and detract from vehicle appearance. Repair Washing the affected paint surfaces with Auto Magic © Special Cleaner Concentrate is the recommended method to dislodge embedded iron particles and remove the surrounding rust stains. The correct usage of Auto Magic © Special Cleaner Concentrate is described in this bulletin. Warranty Information Required Tools & Materials General Precautions Page 3291 Locations Vehicle Speed Sensor: Locations CIRCUIT DESCRIPTION The speed sensor for ABS detects the wheel speed and sends the appropriate signals to the ABS ECU. The ECU converts these signals into a pulse signal and outputs it to the combination meter. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. Page 1128 Page 4520 a. Connect the positive (+) lead from the battery to terminal 12. b. Connect the negative (-) lead from the battery to terminals 5,7 and 10. c. Check the chime sounds. d. Disconnect the negative (-) lead from the battery to terminal 10. e. Check that the chime stops sounding. f. Connect the negative (-) lead from the battery to terminal 10. g. Connect the positive (+) lead from the battery to terminal 6. h. Check that the chime stops sounding. If operation is not as specified, replace the relay. 4. INSPECT INTEGRATION RELAY CIRCUIT a. Remove the relay from the junction block No.1 and inspect the connectors on the junction block side. Page 643 Drive Belt: Testing and Inspection A/C System 1. INSPECT DRIVE BELT'S INSTALLATION CONDITION Check that the drive belt fits properly in the ribbed grooves. 2. INSPECT DRIVE BELT TENSION Using a belt tension gauge, check the drive belt tension. Drive belt tension: New belt 160 ± 25 lb Used belt 100 ± 20 lb HINT: "New belt" refers to a belt which has been used less than 5 minutes on a running engine. - "Used belt" refers to a belt which has been used on a running engine for 5 minutes or more. - After installing the drive belt, check that it fits properly in the ribbed grooves. Testing and Inspection Oil Pressure Sender: Testing and Inspection INSPECT LOW OIL PRESSURE SWITCH a. Disconnect the connector from the switch. b. Check that continuity exists between terminal and ground with the engine stopped. c. Check that no continuity exists between terminal and ground with the engine running. HINT: Oil pressure should be over 49 kPa (0.5 kg/sq.cm, 7.1 psi). If operation is not as specified, replace the switch. Page 2625 Capacity Specifications Refrigerant Oil: Capacity Specifications When Replacing, Add: Receiver 20 cc Condenser 40 cc Evaporator 40 to 50 cc Page 2545 Connector Locations Page 2482 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 Description and Operation ABS Light: Description and Operation Testing and Inspection Page 2994 Auxiliary Power Outlet: Fuse and Fusible Link Locations Relay Box / No. 2 Page 944 Page 3619 Airbag Sensor Assembly: Service and Repair Removal and Installation COMPONENTS REMOVAL NOTE: Do not open the cover or the case of the ECU and various electrical devices unless absolutely necessary. If the IC terminals are touched, the IC may be destroyed by static electricity. 1. REMOVE FRONT CONSOLE BOX 2. REMOVE LOWER CENTER COVER Page 1861 If the CO/HC concentration does not comply with regulations, troubleshoot in the order given. 1) Check the A/F sensor or heated oxygen sensor operation. 2) See the table for possible causes, and then inspect and correct the applicable causes if necessary. Page 2885 Wheel Speed Sensor: Description and Operation Speed Sensor The speed sensor detects wheel speed and sends the appropriate signals to the ECU. These signals are used to control the ABS system. Each of the front and rear rotors has 48 serrations. When the rotors rotate, a magnetic field emitted by a permanent magnet in the speed sensor generates an AC voltage. Since the frequency of this AC voltage changes in direct proportion to the speed of the rotor, the frequency is used by the ECU to detect the speed of each wheel. Page 2238 Page 2948 c. Solder the brush wire to the brush holder at the specified exposed length. Exposed length: 9.5 - 11.5 mm (0.374 - 0.453 in.) d. Check that the brush moves smoothly in the brush holder. e. Cut off the excess wire. f. Apply insulation paint to the soldered area. 2. REPLACE FRONT BEARING a. Remove the 4 screws, bearing retainer and bearing. b. Using a socket wrench and press, press out the bearing. c. Using SST and a press, press in a new bearing. SST 09950-60010 (09951-00500) d. Install the bearing retainer with the 4 screws. Torque: 2.6 Nm (27 kg.cm, 23 in.lb) 3. REPLACE REAR BEARING a. Using SST, remove the bearing cover (outside) and bearing. Page 2307 Step 3 Page 1036 Page 2538 Shift Indicator: Fuse and Fusible Link Locations Relay Box / No. 2 Page 1584 CHART 14 Locations Timing Component Alignment Marks: Locations CAUTION: Incorrect removal or installation of the timing belt can result in damage to internal engine components. For complete Timing Belt Removal and Installation information, please refer to Timing Belt; Service and Repair. See: Timing Belt/Service and Repair INSTALL TIMING BELT NOTICE: The engine should be cold. a) Remove any oil or water on the pulleys, and keep them clean. NOTICE: Only wipe the pulleys; do not use any cleansing agent. b) Face the front mark on the timing belt forward. c) Install the timing belt to the LH camshaft timing pulley. Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley. d) Install the timing belt to the No.2 idler pulley. e) Install the timing belt to the RH camshaft timing pulley. Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley. f) Install the timing belt to the water pump pulley. g) Install the timing belt to the crankshaft timing pulley. Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley. h) Install the timing belt to the No.1 idler pulley. Page 4719 Splice Point J: Indicates a wiring Splice Point (Codes are "E"for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I 5 is indicated by the shaded section. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. N: Page No. How to Read Ground Points How to Read Ground Points Page 3280 3. INSTALL STEERING RACK a. Install SST to the rack. SST 09631-00350 HINT: If necessary, scrape the burrs off the rack teeth end and burnish. b. Coat SST with power steering fluid. c. Install the rack into the rack housing. d. Remove the SST. 4. INSTALL OIL SEAL a. Install SST to the steering rack opposite end. SST 09631-00350 b. Coat SST with power steering fluid. c. Coat a new oil seal lip with power steering fluid, and install it by pushing it onto the SST without tilting. NOTICE: Make sure to install the oil seal facing the correct direction. d. Remove the SST 5. INSTALL CYLINDER END STOPPER a. Coat a new O-ring with power steering fluid, and install it to the stopper. b. Using SST, torque the stopper. SST 09922-10010 Torque: 59 Nm (597 kgf-cm, 43 ft. lbs.) Page 1304 Oxygen Sensor: Mechanical Specifications HEATED OXYGEN SENSOR Torque: ................................................................................................................................................ ................................. 20 N.m (200 kgf.cm, 14 ft.lbf) AIR-FUEL RATIO (A/F) SENSOR Torque: ................................................................................................................................................ ................................. 20 N.m (200 kgf.cm, 14 ft.lbf) Page 4429 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Page 3102 Interior Fuse Box Interior Panel Fuse Details Page 1460 Step 2 OBD II scan tool (excluding TOYOTA hand-held tester): Page 2244 Splice Locations Page 3003 Splice Locations Page 3854 i. Remove the retractor of front seat outer belt. CAUTION: Never disassemble the front seat outer belt. NOTE: When removing the retractor of front seat outer belt, take care not to pull the seat belt pretensioner wire harness. 1. Disconnect the retractor switch connector. 2. Disconnect the pretensioner connector as shown in the illustration. CAUTION: When removing the seat belt pretensioner, work must be started 90 seconds after the ignition switch is turned to the "LOCK" position and the negative (-) terminal cable is disconnected from the battery. 3. Remove the 2 bolts and retractor of front seat outer belt. REPLACEMENT REPLACE REQUIREMENTS In the following cases, replace the seat belt pretensioner. - If the seat belt pretensioner has been activated. - If the seat belt pretensioner has been found to be faulty in troubleshooting. - If the front seat outer belt has been found to be faulty during checking in items 1-(b) or 2-(b). - If the front seat outer belt has been dropped. CAUTION: For removal and installation of the seat belt pretensioner.Be sure to follow the correct procedure. INSTALLATION NOTE: - Never use seat belt pretensioner from another vehicle. When replacing parts, replace them with new parts. - Make sure that the front seat outer belt is installed with the specified torque. - If the front seat outer belt has been dropped, or there are cracks, dents or other defects in the case or connector, replace the front seat outer belt with a new one. - When installing the front seat outer belt, take care that the wiring does not interfere with other parts and is not pinched between other parts. 1. Extra cab: INSTALL FRONT SEAT OUTER BELT a. Install the retractor of front seat outer belt. Page 2420 D: Indicates related system. Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V). Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, 1H2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green O = Orange P = Pink R = Red SB = Sky Blue V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Description and Operation Braking Sensor/Switch: Description and Operation Stop Light Switch This stop light switch senses whether the brake pedal is depressed or released, and sends the signal to the ECU. Page 1180 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Page 2720 O/D Cancel Signal Circuit Overdrive Indicator Lamp: Testing and Inspection O/D Cancel Signal Circuit CIRCUIT DESCRIPTION While driving uphill with cruise control activated, in order to minimize gear shifting and provide smooth cruising O/D may be prohibited temporarily under some conditions. The cruise control ECU sends O/D cut signals to the ECM as necessary and the ECM cancels O/D shifting until these signals are discontinued. WIRING DIAGRAM Page 1648 Step 1 Step 2 Specifications Camshaft Bearing: Specifications INSTALL CAMSHAFTS NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, these steps should be carried out. a. Install the intake camshaft of the RH cylinder head. 1. Apply new engine oil to the thrust portion and journal of the camshaft. 2. Place the intake camshaft at 90° angle of timing mark (2 dot marks) on the cylinder head. 3. Apply MP grease to a new oil seal lip. 4. Install the oil seal to the camshaft. 5. Remove any old packing (FIPG) material. 6. Apply seal packing to the No.1 bearing cap. Seal packing: Part No. 08826-00080 or equivalent 7. Install the 5 bearing caps in their proper locations. Page 2937 Generator: Testing and Inspection INSPECTION 1. INSPECT ROTOR a. Check the rotor for open circuit. Using an ohmmeter, check that there is continuity between the slip rings. Standard resistance: 2.1 2.5 Ohm at 20 °C (68 °F) If there is no continuity, replace the rotor. b. Check the rotor for ground. Using an ohmmeter, check that there is no continuity between the slip ring and rotor. If there is continuity, replace the rotor. c. Check that the slip rings are not rough or scored. If rough or scored, replace the rotor. d. Using vernier calipers, measure the slip ring diameter. Standard diameter: 14.2 - 14.4 mm (0.559-0.567 in.) Minimum diameter: 12.8 mm (0.504 in.) If the diameter is less than minimum, replace the rotor. 2. INSPECT STATOR (DRIVE END FRAME) Locations Page 4509 Key Reminder Switch: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Locations Fusible Link: Locations Relay Box / No. 2 Testing and Inspection Fuel Gauge Sender: Testing and Inspection INSPECT FUEL SENDER GAUGE RESISTANCE Measure the resistance between terminals 2 and 3. 68 L 57 L If resistance value is not as specified, replace the sender gauge. Description and Operation Braking Sensor/Switch: Description and Operation Stop Light Switch This stop light switch senses whether the brake pedal is depressed or released, and sends the signal to the ECU. Page 818 NOTE: After "Dinghy" Towing, or at the recommended distance limits, let the Engine idle for more than 3 minutes before operating the vehicle or resuming towing. NOTE: Vehicles that are Dinghy towable will not sustain internal damage to the transmission or transfer components, as long as speed/distance limits are observed. The transmission must be placed in the "neutral" position when Dinghy towing. Dinghy towing these vehicles does not eliminate the possibility of damage to other vehicle systems (Body, Chassis, Electrical Systems, etc.). Page 3370 4. DISCONNECT REAR SHOCK ABSORBER Remove the bolt and disconnect the shock absorber from the spring seat. Torque: 2WD: 26 Nm (260 kgf-cm, 19 ft. lbs.) 4WD and PreRunner: 71 Nm (730 kgf-cm, 53 ft. lbs.) 5. REMOVE U-BOLTS a. Remove the 4 U-bolt mounting nuts and washers. b. Remove the spring seat and U-bolts. Torque: 123 Nm (1,250 kgf-cm, 90 ft. lbs.) HINT: At the time of installation, tighten the U-bolts; so that the length of all the U-bolts under the spring seat is the same. c. 4WD and PreRunner: Remove the spring bumper. 6. REMOVE LEAF SPRING a. Remove the nut, washer and hanger pin bolt. Torque: 157 Nm (1,600 kgf-cm, 116 ft. lbs.) HINT: At the time of installation, after stabilizing the suspension, torque the nut. b. Remove the 2 shackle pin mounting nuts and washers. Torque: 92 Nm (930 kgf-cm, 67 ft. lbs.) HINT: At the time of installation, after stabilizing the suspension, torque the nut. c. Remove the shackle pin, plate, and rear leaf spring. REPLACEMENT Page 3872 Impact Sensor: Service and Repair Removal and Installation COMPONENT REMOVAL NOTE: - If the wiring connector of the SRS is disconnected with the ignition switch at ON or ACC position, DTCs will be recorded. - Never use SRS parts from another vehicle. When replacing parts, replace then with new parts. - Never reuse the sensor involved in a collision when the SRS has deployed. - Never repair a sensor in order to reuse it. 1. REMOVE BATTERY a. Remove the bolt and battery clamp. b. Remove the battery and battery carrier. Page 2075 WIRING DIAGRAM Page 3090 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Engine/Transmission Controls - Resetting ECM Memory Engine Control Module: Technical Service Bulletins Engine/Transmission Controls - Resetting ECM Memory TRANSMISSION & CLUTCH TC002-03 REVISED Title: ECM RESET MEMORY FUNCTION Models: '00 - '05 All Models June 10, 2003 TSB REVISION NOTICE: ^ December 20, 2004: Applicable Vehicles section has been updated - 2004 and 2005 model years added, models and model years updated for various models; and Reset Procedure 2 has been revised. ^ January 16, 2004: Tundra vehicles were added to the Applicable Vehicles chart. ^ December 17, 2003: T-100 vehicles were removed from the Applicable Vehicles chart. Previous versions of this TSB should be discarded. Introduction Whenever an automatic transmission is replaced, overhauled or individual components are replaced, use this procedure to clear Engine Control Module (ECM, SAE term: Powertrain Control Module, PCM) "Learned Values" to minimize subsequent performance concerns. CAUTION: Failure to follow the procedure below may lengthen the time to readjust the ECM "Learned Values," potentially resulting in performance concerns. Required SSTs Warranty Information Applicable Vehicles Page 319 COMPONENTS INSPECTION 1. DRAIN ENGINE COOLANT 2. REMOVE AIR CLEANER HOSE 3. REMOVE NO.2 TIMING BELT COVER 4. REMOVE INTAKE AIR CONNECTOR ASSEMBLY 5. REMOVE FUEL PRESSURE REGULATOR 6. REMOVE INTAKE MANIFOLD ASSEMBLY Seat Belts - Shoulder Belt Particle (Dirt) Buildup Seat Belt: Customer Interest Seat Belts - Shoulder Belt Particle (Dirt) Buildup BODY BO019-01 August 10, 2001 Title: SHOULDER BELT ANCHOR TAPE SET Models: All Applicable Models Introduction To assist customers in preventing particle buildup and preserve the appearance of the shoulder belt anchor, the following procedure has been developed. Applicable Vehicles ^ 1996-2001 model year 4Runner*1 vehicles. ^ 1996-2001 model year Land Cruiser vehicles. ^ 1996-2001 model year RAV4*2 vehicles. ^ 2001 model year Sequoia vehicles. ^ 1996-1998 model year T100 trucks. ^ 1996-2001 model year Tacoma*1 trucks. ^ 2000-2001 model year Tundra trucks. *1 Except rear seat belt. *2 Except rear seat belt of soft top models. Parts Information Warranty Information Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Installation Procedure 1. CLEAN SHOULDER BELT ANCHOR NOTE: ^ Do not install the tape when the vehicle temperature is below the freezing point. ^ Do not re-use removed fluorocarbon resin tape. Page 2630 Junction Box / No. 3 Page 1891 d. Position the injector connector outward. e. Place the 4 spacers in position on the intake manifold. f. Place the delivery pipes with the 6 injectors in position on the intake manifold. g. Temporarily install the 4 bolts holding the delivery pipes to the intake manifold. h. Check that the injectors rotate smoothly. HINT: If injectors do not rotate smoothly, the probable cause is incorrect installation of O-rings. Replace the O-rings. i. Position the injector connector outward. 2. CONNECT INJECTOR CONNECTORS 3. INSTALL FUEL PIPE AND TIGHTENING DELIVERY PIPE HOLDING BOLTS a. Install the fuel pipe with 4 new gaskets and the 2 union bolts. Torque: 34.3 Nm (350 kg.cm, 25 ft.lb) b. Tighten the 4 bolts holding the delivery pipes to the intake manifold. Torque: 13 Nm (130 kg.cm, 10 ft.lb) Page 99 b. Inspect the relay operation. 1. Apply battery positive voltage across terminals 3 and 5. 2. Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. 3. Apply battery positive voltage across terminals 2 and 4. 4. Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. 3. REINSTALL CIRCUIT OPENING RELAY Page 1887 Description and Operation Brake Signal: Description and Operation Stop Light Switch Signal Engine This signal is used to detect when the brakes have been applied. The STP signal voltage is the same as the voltage supplied to the stop lights. The STP signal is used mainly to control the fuel cut-off engine speed (The fuel cut-off engine speed is reduced slightly when the vehicle is braking.). Automatic Transaxle The purpose of this circuit is to prevent the engine from stalling, while driving in lock-up condition, when brakes are suddenly applied. When the brake pedal is operated, this switch sends a signal to ECM. Then the ECM cancels operation of the lock-up clutch while braking is in progress. Page 1706 2. Start the engine. 3. Perform the drive pattern to run and complete the Oxygen Sensor (O2S) Monitor. HINT: The 02S Monitor is completed when the following conditions are met: ^ Two (2) minutes or more passed after the engine start. ^ The Engine Coolant Temperature (ECT) is 167°F (75°C) or more. ^ Cumulative running time at 30 mph (48 km/h) or more exceeds 6 minutes. ^ Vehicle is in closed loop. ^ The fuel-cut is operated for 8 seconds or more (for Rear O2S Monitor). A. Allow the engine to idle for two minutes. B. Warm up the engine until the Engine Coolant Temperature (ECT) reaches 167°F (75°C). C. Drive the vehicle over 30 mph (48 km/h) for more than 40 seconds. D. Stop the vehicle and allow the engine to idle for more than 20 seconds. E. Repeat steps C and D at least 8 times in one driving cycle. (Do not cycle the ignition key.) In addition, perform the following steps for the Rear O2S Readiness Monitor: A. Select second gear. B. Allow the vehicle to run at 30 mph (48 km/h) or more. C. Keep the accelerator pedal "off-idle" for more than 10 seconds. D. Immediately after step C, release the accelerator pedal for at least 10 seconds without depressing the brake pedal (to execute the fuel-cut). E. Decelerate the vehicle until the vehicle speed reaches less than 6mph (10km/h). F. Repeat steps B - E at least twice in one driving cycle. Accessing O2S Test Results 1. On the Diagnostic Tester* screen, select the following menus: ^ DIAGNOSTICS ^ CARB OBD II Page 3083 Page 2635 Capacity Specifications Coolant: Capacity Specifications Drain and Refill Drain and Refill Capacity (with manual transmission) 10.3 qt (US) Capacity (with automatic transmission) 10.0 qt (US) Page 2407 Clutch Switch: Testing and Inspection FORD Made Clutch Switch Circuit CIRCUIT DESCRIPTION When the clutch pedal is depressed, the clutch switch sends a signal to the cruise control ECU. When the signal is input to the cruise control ECU during cruise control driving, the cruise control ECU cancels cruise control. Wiring Diagram Page 2231 Shift Indicator: Ground Locations Page 3711 Page 3311 d. Install the SST. CAUTION: Place the disc wheel on the level ground. 1. Connect the connectors of the 2 SST to the steering wheel pad connector. SST 09082-0700, 09082-0760 NOTE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. Also, secure some slack for the SST wire harness inside the disc wheel. 2. Move the SST to at least 10 m (33 ft) away from the steering wheel pad tied down on the disc wheel. e. Cover the steering wheel pad with a cardboard box or tires. - Covering method using a cardboard box: Cover the steering wheel pad with the cardboard box and weight the cardboard box down in 4 places with at least 190 N (20 kg, 44 lb). Size of cardboard box: Must exceed the following dimensions: X = 460 mm (18.11 in.) Y = 650 mm (25.59 in.) NOTE: When dimension Y of the cardboard box exceeds the diameter of the disc wheel with tire to which the steering wheel pad is tied, X should be the following size. X = 460 mm (18.11 in.) + width of tire - If a cardboard box smaller than the specified size is used, the cardboard box will be broken by the shock from the airbag deployment. - Covering method using tires: Place at least 3 tires without disc wheel on top of the disc wheel with tire to which the steering wheel pad is tied. Tire size: Must exceed the following dimensions- Width: 185 mm (7.87 in.) Page 3751 Seat Belt: Diagrams Seat Belt Page 3988 2. Scrub the bumper covers with the soap and water solution, making sure all difficult-to-reach areas are thoroughly cleaned. 3. Rinse the entire bumper cover with clean deionized water, making sure all difficult-to-reach areas are thoroughly rinsed. 4. Dry the surface with a clean towel before water dries on the surface. Clean, dry compressed air from an oil-less compressor may be substituted for drying with a towel. 5. Degrease the surface with a wax, grease, and silicone remover. Note: Lacquer thinner or brake cleaner will NOT remove silicone. You MUST use a wax, grease, and silicone remover. Carefully follow application instructions on the container label. Fish eyes or other paint irregularities may result from not following instructions. 6. Apply a generous amount of sanding paste with a gray 3M ScotchBrite pad. Only a gray pad should be used during the sanding process. Sand the entire bumper cover surface. Be sure all difficult-to-reach areas are thoroughly sanded. 7. Clean the entire bumper cover with car wash soap and water. Be sure all difficult-to-reach areas are thoroughly cleaned. 8. Rinse the entire bumper with clean deionized water. Be sure all difficult-to-reach areas are thoroughly rinsed. 9. Degrease the surface with an anti-static plastic parts cleaner and a white body shop towel or paper towel. Note: Never use a red shop towel to wipe the surface (contains silicone). 10. Assure the bumper is firmly held in place to a steady fixture. 11. Apply a plastic parts adhesion promoter to the surface, according to the manufacturer's recommendations. 12. Apply plastic parts primer to the surface, according to the paint manufacturer's recommendations. 13. Since bumpers are made of flexible plastic urethane material, use a two-part urethane finish paint system with plasticizer (flex agent) for all bumper and cladding repairs. Apply the appropriate top coat to the surface, according to the paint manufacturer's recommendations. 14. If heat is applied to cure the paint, assure the surface temperature does not exceed 80°C (176°F.) For additional information concerning the refinish process for plastic bumpers/cladding, please contact your respective refinish paint manufacturer's local representative. Testing and Inspection Turn Signal Switch: Testing and Inspection INSPECT TURN SIGNAL SWITCH CONTINUITY If continuity is not as specified, replace the switch. Testing and Inspection Backup Lamp Relay: Testing and Inspection INSPECT BACK-UP LIGHT RELAY CONTINUITY If continuity is not as specified, replace the relay. Page 3324 Page 2225 Page 4363 Step 1 Steps 2 - 3 INSPECTION PROCEDURE FORD Made CIRCUIT DESCRIPTION When the cruise control main switch is turned off, the cruise control does not operate. Page 3232 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 4624 D: Indicates related system. Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V). Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, 1H2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green O = Orange P = Pink R = Red SB = Sky Blue V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Page 2592 Step 1 Page 1473 D: Indicates related system. Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V). Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, 1H2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green O = Orange P = Pink R = Red SB = Sky Blue V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Page 2295 Heated Oxygen Sensor Oxygen Sensor: Description and Operation Heated Oxygen Sensor Heated Oxygen Sensor The ECM observes the waveform of the heated oxygen sensor located behind the catalyst to determine whether the catalyst performance has deteriorated. If the catalyst is functioning normally, the waveform of the heated oxygen sensor located behind the catalyst switches back and forth between rich and lean much more slowly. When the waveform of the heated oxygen sensor located behind the catalyst alternates flutteringly between rich and lean, it indicates that catalyst performance has deteriorated. Page 1410 d. Reconnect and install the high-tension cords as shown in the illustration. Page 4500 Key Reminder Switch: Splice Locations Page 3582 Note 3 - Inspect and if necessary replace the Steering Wheel: ^ If the steering wheel is diagnosed as needing replacement during inspection Note 4 - Replace the Passenger Airbag assembly: ^ If the passenger airbag has been deployed or dropped ^ If the airbag is diagnosed as needing replacement when troubleshooting or during inspection Note 5 - Visually inspect and if necessary replace the following items if deformed: ^ Instrument panel and instrument panel reinforcement ^ Glove compartment or glove compartment door Note 6 - Replace the Front Impact Sensors: ^ If either the driver or passenger airbag has deployed (replace both front impact sensors) ^ If a front airbag sensor is diagnosed as needing replacement when troubleshooting or during inspection Note 7 - Replace the Airbag Sensor Assembly: ^ If any airbag has been deployed in a collision or the airbag sensor assembly has been dropped or is diagnosed as needing replacement when troubleshooting Note 8 - Inspect and if necessary replace the Wire Harness assembly: ^ If any part of the SRS wire harness or any connector is diagnosed as needing replacement when troubleshooting or during inspection Note 9 - Replace the: ^ Side Impact Airbag if it has been deployed dropped or is diagnosed as needing replacement when troubleshooting or during inspection ^ Seat cover if it has cuts and/or frayed seams or is diagnosed as needing replacement during inspection ^ Seat frame if it is bent or has become damaged Note 10 - Replace the Side Impact Sensors: ^ If the side airbag assembly has been deployed dropped or is diagnosed as needing replacement when troubleshooting or during inspection Note 11 - In the event of driver or passenger airbag deployment replace all seatbelt Pretensioners. DISPOSAL HINT: When scrapping vehicle equipped with an SRS or disposing of a steering wheel pad (with airbag), always first deploy the airbag in accordance with the procedure described below. If any abnormality occurs with the airbag deployment, contact the SERVICE DEPT. of TOYOTA MOTOR SALES, U.S.A. INC. When disposing of a steering wheel pad with an airbag deployed in a collision, follow the same procedure given in step 1-(d) in "DISPOSAL" CAUTION: - Never dispose of a steering wheel pad which has an undeployed airbag. - The airbag produces a sizeable exploding sound when it deploys, so perform the operation out of doors and where it will not create a nuisance to nearby residents. - When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool). Perform the operation in a place away from electrical noise. SST 09082-00700 - When deploying an airbag, perform the operation at least 10m (33ft) away from the steering wheel pad. - The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment. Page 602 Spark Plug: Testing and Inspection INSPECT SPARK PLUGS a. Disconnect the 3 high-tension cords. b. Remove the 3 ignition coils. c. Using a 16 mm plug wrench, remove the 6 spark plugs. d. Clean the spark plugs. If the electrode has traces of wet carbon, allow it to dry and then clean with a spark plug cleaner. Air pressure: Below 588 kPa (6 kg/Sq.cm, 85 psi) Duration: 20 seconds or less HINT: If there are traces of oil, remove it with gasoline before using the spark plug cleaner. e. Visually check the spark plug for thread damage and insulator damage. If abnormal, replace the spark plug. Recommended spark plug: DENSO made K16TR11 NGK made BKR5EKB-11 Front Wheel Fastener: Service and Repair Front REPLACEMENT HINT: PreRunner is the model described below. RZN191L-TRPDKAB, RZN196L-CRPDKAB, VZN195L-CRPDKAB 1. REMOVE FRONT WHEEL 2. REMOVE BRAKE CALIPER AND DISC 3. REMOVE HUB BOLT Using SST, remove the hub bolt. SST 09650-17011 4. INSTALL HUB BOLT a. Install a washer and nut to a new hub bolt as shown in the illustration. b. Using a hammer handle or an equivalent to hold, install the bolt by torquing the nut. 5. INSTALL BRAKE DISC AND CALIPER 6. INSTALL FRONT WHEEL Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.) 7. DEPRESS BRAKE PEDAL SEVERAL TIMES Testing and Inspection EFI Main Relay: Testing and Inspection 1. REMOVE EFI MAIN RELAY (Marking: EFI) 2. INSPECT EFI MAIN RELAY a. Inspect the relay continuity. 1. Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. 2. Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. b. Inspect the relay operation. 1. Apply battery positive voltage across terminals 1 and 2. 2. Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. 3. REINSTALL EFI MAIN RELAY Page 1038 c) Install a new adjusting shim. 1) Place a new adjusting shim on the valve lifter, with imprinted numbers facing down. 2) Using SST (A), press down the valve lifter and remove SST (B). SST 09248-55040 (09248-05410, 09248-05420) d) Recheck the valve clearance. 6. REINSTALL CYLINDER HEAD COVERS 7. REINSTALL INTAKE AIR CONNECTOR Page 761 Engine Compartment Instrument Panel Locations Page 69 Page 4309 Steps 3 - 4 INSPECTION PROCEDURE Page 1717 CHART 7 Page 3532 Hose/Line HVAC: Testing and Inspection 1. INSPECTION HOSE AND TUBE CONNECTIONS FOR LOOSENESS 2. INSPECT HOSES AND TUBES FOR LEAKAGE Using a gas leak detector, check for leakage of refrigerant. Page 1190 Engine Control Module: Description and Operation DESCRIPTION The Engine Control Module (ECM) controls all phases of electrical engine operation. In order to accomplish this control, the ECM relies on the input from a variety of engine operation sensors. The ECM compares input signals with those stored in memory to determine what steps should be taken to achieve maximum performance, fuel economy, and meet emission standards. The ECM outputs the necessary signals to the fuel system, ignition system, emission control systems, etc.. Page 2441 Fluid - Differential: Fluid Type Specifications Differential Fluid Grade ................................................................................................................................................... .................................................... GL-5 or equivalent Above -18° C (0° F) ......................................... .......................................................................................................................................................... SAE 90 Below -18° C (0° F) ................................................................................................................ ............................................................. SAE 85W-90 or 80W Body - Water Leaks to The Interior Wiper Motor: All Technical Service Bulletins Body - Water Leaks to The Interior BODY BO026-00 Title: WATER LEAK FIELD-FIX REPAIR INSTRUCTIONS Models: '97 - '04 Tacoma October 27, 2000 TSB Revision Notice: ^ January 12, 2005: Applicable Vehicles has been updated to include 2004 model year. ^ August 25, 2003: VIN and Applicable Model Information has changed, and repair procedure has been expanded and clarified. ^ October 27, 2000: This TSB updates B0016-98 dated June 12, 1998. B016-98 is now obsolete and should be discarded. Previous versions of this TSB should be discarded. Introduction Use the following field-fix procedures if water is present on the floor carpeting and it can be confirmed that the water is leaking into the cab from either the upper cowl or side cowl seam, or moisture barrier behind the door trim panel. Applicable Vehicles 1997 - 2004 model year Tacoma vehicles. Required Materials Warranty Information Page 992 u. Remove the other union bolt, 3 gaskets and fuel pipe from the delivery pipes. v. Reinstall the fuel pipe with 4 new gaskets and the 2 union bolts. Torque: 34.3 Nm (350 kg.cm, 25 ft.lb) w. Reconnect the negative (-) terminal cable to the battery. x. Check for fuel leaks. 3. INSPECT FUEL PUMP RESISTANCE Using an ohmmeter, measure the resistance between terminals 4 and 5. Resistance: 0.2 - 3.0 ohms at 20 °C (68 °F) If the resistance is not specified, replace the fuel pump and/or lead wire. 4. INSPECT FUEL PUMP RESISTANCE Connect the positive (+) lead from the battery to terminal 4 of the connector, and the negative (-) lead to terminal 5. Check that the fuel pump operates. NOTE: These tests must be done quickly (within 10 seconds) to prevent the coil from burning out. - Keep the fuel pump as far away from the battery as possible. - Always do switching at the battery side. If operation is not as specified, replace the fuel pump and/or lead wire. Page 3305 2. Check that no one is within 10 m (33 ft) area around the disc wheel which the steering wheel pad is tied to. 3. Press the SST activation switch and deploy the air-bag. HINT: The airbag deploys simultaneously as the LED of the SST activation switch lights up. h. Dispose of the steering wheel pad (with airbag). CAUTION: The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment. - Use gloves and safety glasses when handling a steering wheel pad with the deployed airbag. - Always wash your hands with water after completing the operation. - Do not apply water, etc. to a steering wheel pad with the deployed airbag. 1. Remove the steering wheel pad from the disc wheel. 2. Place the steering wheel pad in a vinyl bag, tie the end tightly and dispose of it in the same way as other general parts disposal. Deployment When Scrapping Vehicle DISPOSAL HINT: When scrapping vehicle equipped with an SRS or disposing of a steering wheel pad (with airbag), always first deploy the airbag in accordance with the procedure described. If any abnormality occurs with the airbag deployment, contact the SERVICE DEPT. of TOYOTA MOTOR SALES, U.S.A., INC. When disposing of a steering wheel pad with an airbag deployed in a collision, follow the same procedure given in step (d) in "AIRBAG DEPLOYMENT WHEN SCRAPPING VEHICLE". CAUTION: - Never dispose of a steering wheel pad which has an undeployed airbag. - The airbag produces a sizeable exploding sound when it deploys, so perform the operation out-of-doors and where it will not create a nuisance to nearby residents. - When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool). Perform the operation in a place away from electrical noise. SST 09082-00700 - When deploying an airbag, perform the operation at least 10 m (33 ft) away from the steering wheel pad. Page 1589 Page 1267 A. The Diagnostic Tester displays 17" as a value of the Time $81" (see illustration). B. Find the Conversion Factor value of Time $81" in the O2S Failure Threshold chart. 0.3906 is specified for Time $81 in this chart. C. Multiply "17" in step "A" by 0.3906 (Conversion Factor) in step "B." 17 x 0.3906 = 6.6% D. If the answer is within the Standard Value of TEST LIMIT, the Time $81" can be confirmed to be normal. NOTE: ^ "LOW SW V" indicates the O2S voltage when the O2S status changes from rich to lean. ^ "HIGH SW V" indicates the O2S voltage when the O2S status changes from lean to rich. ^ If the O2S voltage is lower than "LOW SW V," the O2S status is lean. ^ If the O2S voltage is higher than "HIGH SW V," the O2S status is rich. NOTE: Before the O2S Monitor completes or after the ignition switch is turned OFF, the Diagnostic Tester displays the viewable upper limit or a lower limit of the test value (example: 0 V, 1.275 V, Os [seconds], 10.2s, 0 and 255). Page 2429 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. On-Vehicle Cleaning Radiator: Service and Repair On-Vehicle Cleaning ON-VEHICLE CLEANING Using water or a steam cleaner, remove any mud or dirt from the radiator core. NOTICE: If using a high pressure type cleaner, be careful not to deform the fins of the radiator core. (i.e. Maintain a distance between the cleaner nozzle and radiator core) Supercharger - Squeak/Rattle Noises From Idler Pulley Idler Pulley: Customer Interest Supercharger - Squeak/Rattle Noises From Idler Pulley REF.: 3.4L V6 SUPERCHARGER NO.: SC001-00 DATE: AUGUST 1, 2000 MODEL: 4Runner, Tacoma, T100, and Tundra with 3.4L V6. SUPERCHARGER DRIVE-BELT IDLER PULLEY Due to a possible out-of-tolerance condition on the idler pulley shaft, some pulleys may have bearings that spin on the inner shaft and may cause a squeaking or rattling noise. The supercharger may be perfectly fine and the source of the noise may simply be the idler pulley PART NUMBER INFORMATION PRODUCTION EFFECTIVE: Supercharger Assemblies with Serial Numbers from: 10481 to: 10990 CHECK PROCEDURE: This condition can be verified by removing the supercharger drive belt and checking the movement of the pulley on the shaft The pulley should not slide fore and aft on the shaft. INSTALLATION PROCEDURE: Loosen the drive belt. Remove the idler plate assembly. Retain all the hardware. Remove the idler pulley sub-assembly from the idler plate assembly. Replace it with the supplied new idler pulley sub-assembly. Replace the idler plate assembly and all of the hardware. The tightening torques are shown in the table. Reinstall and tension the drive belt to 120-ft lbs. for a new belt or 80 ft lbs. for a used belt (any belt used for more than 10 minutes). WARRANTY INFORMATION:* * The idler pulley assembly is warrantable only for 12 months from the point-of-first-sale. If the supercharger assembly was dealer installed, then TRD matches the balance of the new vehicle powertrain warranty. Page 2761 E. Apply a small amount of the disc brake caliper grease (1-2 mm thick) to both sides of the pad support plates. NOTE: Do NOT apply grease to the friction surfaces of the brake pads or the disc rotor. F. If the pad support plate is fixed to the torque plate with adhesive tape, perform the operation according to the flow chart. G. Apply a small amount of the disc brake caliper grease (1-2 mm thick) to the caliper as indicated in the illustration. H. Install the brake pads with the anti-squeal shims. I. If equipped with anti-squeal spring: Install the anti-squeal springs. J. Press the piston in firmly and install the brake caliper. NOTE: ^ Clean excess grease. from brake pad and caliper. ^ Do NOT apply grease to the friction surfaces of the brake pads or the disc rotor. K. Install the wheel assembly. 2. Fixed Type Brake Caliper There are two types of brake pads: Page 4421 Relay Box / No. 2 Ground Locations Page 1044 Part 3 of 3 Page 74 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 2242 Relay Box / No. 2 Ground Locations Page 3234 Body - Water Leaks to The Interior Cowl: Customer Interest Body - Water Leaks to The Interior BODY BO026-00 Title: WATER LEAK FIELD-FIX REPAIR INSTRUCTIONS Models: '97 - '04 Tacoma October 27, 2000 TSB Revision Notice: ^ January 12, 2005: Applicable Vehicles has been updated to include 2004 model year. ^ August 25, 2003: VIN and Applicable Model Information has changed, and repair procedure has been expanded and clarified. ^ October 27, 2000: This TSB updates B0016-98 dated June 12, 1998. B016-98 is now obsolete and should be discarded. Previous versions of this TSB should be discarded. Introduction Use the following field-fix procedures if water is present on the floor carpeting and it can be confirmed that the water is leaking into the cab from either the upper cowl or side cowl seam, or moisture barrier behind the door trim panel. Applicable Vehicles 1997 - 2004 model year Tacoma vehicles. Required Materials Warranty Information Page 3540 Receiver Dryer: Service and Repair REMOVAL 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM HINT: At the time of installation, please refer to the following item. Evacuate air from refrigeration system. Charge system with refrigerant and inspect for leakage of refrigerant. Specified amount: 600 ± 50 g (21.16 ± 1.76 oz.) 2. DISCONNECT LIQUID TUBE BETWEEN RECEIVER AND COOLING UNIT Remove the bolt and disconnect the liquid tube. Torque: 6.0 Nm (60 kg.cm, 52 in.lb) NOTE: Cap the open fittings immediately to keep moisture or dirt out of the system. HINT: At the time of installation, please refer to the following item. Lubricate a new O-ring with compressor oil and install the tube. 3. REMOVE LIQUID TUBE BETWEEN RECEIVER AND CONDENSER a. Loosen the nut and disconnect the liquid tube from condenser. Torque: 14 Nm (140 kg.cm, 10 ft.lb) b. Remove the 2 bolts and disconnect the both tubes. Torque: 6.0 Nm (60 kg.cm, 52 in.lb) NOTE: Cap the open fittings immediately to keep moisture or dirt out of the system. HINT: At the time of installation, please refer to the following item. Lubricate 3 new O-rings with compressor oil and install the tube. 4. REMOVE RECEIVER FROM RECEIVER HOLDER Remove the holder bolt and pull the receiver upward from the holder HINT: At the time of installation, please refer to the following item. If receiver is replaced, add compressor oil to receiver. Add 20 cc (0.71 fl.oz.) Compressor oil: ND-OIL 8 or equivalent INSTALLATION Installation is in the reverse order of removal. Page 1987 Throttle Body: Service and Repair COMPONENTS REMOVAL 1. DRAIN ENGINE COOLANT 2. DISCONNECT CABLES: a. w/ Cruise Control: Disconnect the cruise control actuator cable. b. Disconnect the accelerator cable. c. A/T: Disconnect the throttle cable. 3. REMOVE AIR CLEANER HOSE Page 1372 Page 1802 Vehicle Speed Sensor: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Locations Knock Sensor: Locations Page 4087 Remove the 4 bolts and outer belt shoulder anchors. Torque: 43 N.m (440 kgf.cm, 32 ft.lbf) 15. REMOVE LOCK HANDLE a. Using a screwdriver, remove the cover. HINT: Tape the screwdriver tip before use. b. Remove the 2 screws and lock handle. c. Employ the same manner described above to the other side. 16. REMOVE QUARTER TRIM a. Remove the screw and coat hook. b. Using a screwdriver, remove the quarter trim. HINT: Tape the screwdriver tip before use. NOTE: Paying enough attention remove the clip on the quarter trim shown in the illustration. Otherwise, the quarter trim or the front pillar garnish might be broken. c. Employ the same manner described above to the other side. 17. REMOVE FRONT PILLAR GARNISHES 18. REMOVE ROOF HEADLINING a. Using a clip remover, remove the 2 clips. b. Remove the roof headlining. INSTALLATION Installation is in the reverse order of removal. Page 4334 Step 1 Steps 2 - 3 INSPECTION PROCEDURE FORD Made CIRCUIT DESCRIPTION When the cruise control main switch is turned off, the cruise control does not operate. Page 163 Wheel Speed Sensor: Description and Operation Speed Sensor The speed sensor detects wheel speed and sends the appropriate signals to the ECU. These signals are used to control the ABS system. Each of the front and rear rotors has 48 serrations. When the rotors rotate, a magnetic field emitted by a permanent magnet in the speed sensor generates an AC voltage. Since the frequency of this AC voltage changes in direct proportion to the speed of the rotor, the frequency is used by the ECU to detect the speed of each wheel. Page 2959 Steps 3 - 4 INSPECTION PROCEDURE Page 3684 Airbag Sensor Assembly: Testing and Inspection Replacement Requirements REPLACEMENT REQUIREMENTS In the following cases, replace the airbag sensor assembly. - If the SRS has been deployed in a collision. - If the airbag sensor assembly has been found to be faulty in troubleshooting. - If the airbag sensor assembly has been dropped. CAUTION: For removal and installation of the airbag sensor assembly. Be sure to follow the correct procedure. Page 3069 Page 1810 Vehicle Speed Sensor: Testing and Inspection INSPECT VEHICLE SPEED SENSOR OPERATION a. Connect the positive (+) lead from the battery to terminal 1 and negative (-) lead to terminal 2. b. Connect the positive (+) lead from the tester to terminal 3 and the negative (-) lead to terminal 2. c. Rotate the shaft. d. Check that there is voltage change from approx. 0 V to 11 V or more between terminals 2 and 3. HINT: The voltage change should be performed 4 times for every revolution of the speed sensor shaft. If operation is not as specified, replace the sensor. Page 3590 b. Do a visual check which includes the following items with the steering wheel pad (with airbag) removed from the vehicle. - Check cuts, minute cracks or marked discoloration on the steering wheel pad top surface and in the grooved portion. - Check cuts and cracks in wire harness, and chipping in connectors. - Check the deformation of the horn button contact plate of the steering wheel. HINT: If the horn button contact plate of the steering wheel is deformed, never repair it. Always replace the steering wheel assembly with a new one. - There should be no interference between the steering wheel pad and steering wheel, and the clearance should be uniform all the way around when the new steering wheel pad is installed on the steering wheel. CAUTION: Be sure to follow the correct procedure for removal and installation of the steering wheel pad. 3. VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED a. Do a diagnostic system check. b. Do a visual check which includes the following items with the steering wheel pad (with airbag) removed from the vehicle. - Check the deformation on the horn button contact plate of the steering wheel. - Check the damage on the spiral cable connector and wire harness. HINT: Page 1277 CHART 8 CHART 9 Description and Operation Evaporative Vapor Pressure Sensor: Description and Operation Evaporative Emissions System The vapor pressure sensor and VSV for vapor pressure sensor are used to detect abnormalities in the evaporative emission control system. The ECM decides whether there is an abnormality in the evaporative emission control system based on the vapor pressure sensor signal. Page 657 Oil Filter: Tools and Equipment Toyota Oil Filter Wrench Set AST tool# TOY 300 This set includes our tool numbers TOY640, TOY730, and M0219. With the TOY300 you have every gas engine Toyota/Lexus model covered between 1980 and 2009. - Covers all Toyota and Lexus vehicles 1980-2009, based on factory filters. Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 This Kit Contains the Following Tools: TOY 640 - Toyota Oil Filter Wrench Page 3325 Page 1373 Knock Sensor: Description and Operation Knock Sensor Each knock sensor is fitted to the right bank and left bank of the cylinder block to detect engine knocking. This sensor contains a piezoelectric element which generates a voltage when it becomes deformed, which occurs when the cylinder block vibrates due to knocking. If engine knocking occurs, ignition timing is retarded to suppress it. Page 3496 d. Adjust air mix control cable. Pull the air mix link at "COOL" position, connect the control cable and lock the clamp. HINT: Lock the clamp during lightly pushing the outer cable in the direction, as shown in the illustration. e. Adjust water valve control cable. Pull the water valve control lever at "COOL" position, connect the control cable and lock the clamp. HINT: Lock the clamp during lightly pushing the outer cable in the direction, as shown in the illustration. Page 2946 4. INSTALL RECTIFIER HOLDER a. Install the 4 rubber insulators on the lead wires. NOTE: Be careful of the rubber insulators installation direction. b. Install the rectifier holder while pushing it with the 4 screws. Torque: 2.0 Nm (20 kg.cm, 18 in.lb) 5. INSTALL BRUSH HOLDER AND VOLTAGE REGULATOR a. Install the brush holder cover to the brush holder. NOTE: Be careful of the holder installation direction. b. Install the voltage regulator and brush holder to the rear end frame horizontally as shown in the illustration. HINT: Check that the brush holder's cover doesn't slip to one side during installation. Page 1573 Page 4101 Wireless Transmitter Identification Page 4236 Paint: Locations BODY PANEL ANTI CHIPPING PAINT APPLICATION AREAS HINT: 1. Anti chipping paint should be applied to some areas before the second coat and to others after the top coat. 2. If other areas are accidentally coated, wipe of the paint immediately with a rag soaked in a grease, wax and silicone remover. Page 779 Replacement Requirements Airbag Sensor Assembly: Service and Repair Replacement Requirements REPLACEMENT REQUIREMENTS In the following cases, replace the airbag sensor assembly. - If the SRS has been deployed in a collision. - If the airbag sensor assembly has been found to be faulty in troubleshooting. - If the airbag sensor assembly has been dropped. CAUTION: For removal and installation of the airbag sensor assembly. Be sure to follow the correct procedure. Description and Operation Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor The crankshaft position sensor, which detects the engine speed and crankshaft angle signal (NE signal), has been installed on the oil pump body. The NE signal plate has 34 teeth. The NE signal sensor generates 34 signals at every engine revolution. The ECM detects the standard crankshaft angle based on the G signal, and the actual crankshaft angle and the engine speed by the NE signal. Page 3136 VZN195L model If the steering axis inclination is not within the specified value, after the camber and caster have been correctly adjusted, recheck the steering knuckle and front wheel for bearing or looseness. 4. ADJUST CAMBER AND CASTER a. Loosen the front and/or rear adjusting cam nuts. b. Adjust the camber and caster by front and/or rear adjusting cams (See adjustment chart). HINT: Try to adjust the camber and caster to the center of the specified values. Testing and Inspection Expansion Valve: Testing and Inspection Expansion Valve 1. CHECK QUANTITY OF GAS DURING REFRIGERATION CYCLE 2. SET ON MANIFOLD GAUGE SET 3. RUN ENGINE a. Run the engine at 1,500 rpm for at least 5 minutes. b. Then check that the high pressure reading is 1.37 - 1.57 MPa (14 - 16 kg/Sq.cm, 199 - 228 psi). 4. CHECK EXPANSION VALVE If the expansion valve is faulty, the low pressure reading will drop to 0 kPa (0 kg/Sq.cm, 0 psi) HINT: When the low pressure drops to 0 kPa (0 kg/Sq.cm, 0 psi), check the receiver's IN and OUT sides for no temperature difference. Testing and Inspection Control Module HVAC: Testing and Inspection Air Conditioning Amplifier INSPECT AMPLIFIER CIRCUIT a. Remove the glove compartment door. b. Disconnect the amplifier connector and inspect the connector on wire harness side, as shown in the chart. Test conditions: - Turn ignition switch to ON - Blower speed switch HI If the circuit is not as specified, inspect the circuits connected to other parts. c. Connect the connector to amplifier and inspect wire harness side connector from the back side, as shown in the chart. Test conditions - Running engine at idle speed - Blower speed switch at "HI" position - A/C switch ON - Temperature control lever at "COOL" position - Set on manifold gauge set Page 1889 g. Connect SST (wire) to the injector and battery for 15 seconds, and measure the injection volume with a graduated cylinder. Test each injector 2 or 3 times. SST 09842-30070 Volume: 56 - 69 Cu.cm (3.4 - 4.2 cu in.) per 15 sec . Difference between each injector: 1.3 Cu.cm (0.08 cu in.) or less If the injection volume is not as specified, replace the injector. 3. INSPECT LEAKAGE a. In the condition above, disconnect the tester probes of SST (wire) from the battery and check the fuel leakage from the injector. SST 09842-30070 Fuel drop: 1 drop or less per 12 minutes b. Turn the ignition switch OFF. c. Disconnect the negative (-) terminal cable from the battery. d. Remove the SST. SST O9268-41047, 09842-30070 e. Disconnect the TOYOTA hand-held tester from the DLC3. Page 4670 Junction Box / No. 3 Fuse and Fusible Link Locations Page 1558 Applicable Vehicles Page 3687 Airbag Sensor Assembly: Service and Repair Removal and Installation COMPONENTS REMOVAL NOTE: Do not open the cover or the case of the ECU and various electrical devices unless absolutely necessary. If the IC terminals are touched, the IC may be destroyed by static electricity. 1. REMOVE FRONT CONSOLE BOX 2. REMOVE LOWER CENTER COVER Page 3296 Steering Wheel: Testing and Inspection Replacement Requirements REPLACEMENT REQUIREMENTS In the following cases, replace the steering wheel pad, steering wheel or spiral cable CAUTION: Be sure to follow the correct procedure for removal and installation of the steering wheel pad. Page 3402 1. INSTALL NEW BEARING a. Using SST and a press, install a new bearing to the steering knuckle. SST 09527-17011, 09950-60020 (09951-00910) b. Using snap ring pliers, install a snap ring. 2. INSTALL NEW OIL SEAL (OUTSIDE) a. Using SST and a plastic hammer, install a new oil seal (outside). SST 09223-15030, 09527-17011 b. Coat the oil seal lip with MP grease. 3. INSTALL AXLE HUB TO STEERING KNUCKLE a. Install the dust cover to the steering knuckle with the 4 bolts. Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.) b. Using SST and a press, install the axle hub to the steering knuckle. SST 09649-17010 4. INSTALL ABS SPEED SENSOR ROTOR/SPACER NOTICE: Do not scratch the serration of the speed sensor rotor. 5. w/ Freewheel hub: INSTALL NEW LOCK NUT a. Using SST, install and torque a new lock nut to the axle hub. SST 09318-12010 Torque: 274 Nm (2,800 kgf-cm, 203 ft. lbs.) Service Precautions Service Reminder Indicators: Service Precautions SERVICE PRECAUTION All Service Reminder Indicators should be investigated or serviced immediately. Vehicle damage may result if the indicator is ignored. Description and Operation Idle Up Control Valve: Description and Operation Intake Air Control Valve The rotary solenoid type IAC valve is located on the throttle body and intake air bypassing the throttle valve is directed to the IAC valve through a passage. In this way the intake air volume bypassing the throttle valve is regulated, controlling the engine speed. The ECM operates only the IAC valve to perform idle-up and provide feedback for the target idling speed. Page 1123 Water Pump: Testing and Inspection Page 4580 Junction Box / No. 3 Page 1585 CHART 15 Page 4174 Page 4450 Clock: Ground Locations Page 4414 Junction Box / No. 3 Page 1801 Page 3641 e. Cover the steering wheel pad with a cardboard box or tires. - Covering method using a cardboard box: Cover the steering wheel pad with the cardboard box and weight the cardboard box down in 4 places with at least 190 N (20 kg, 44 lb). Size of cardboard box: Must exceed the following dimensions: X = 460 mm (18.11 in.) Y = 650 mm (25.59 in.) NOTE: When dimension Y of the cardboard box exceeds the diameter of the disc wheel with tire to which the steering wheel pad is tied, X should be the following size. X = 460 mm (18.11 in.) + width of tire - If a cardboard box smaller than the specified size is used, the cardboard box will be broken by the shock from the airbag deployment. - Covering method using tires: Place at least 3 tires without disc wheel on top of the disc wheel with tire to which the steering wheel pad is tied. Tire size: Must exceed the following dimension Width: 185 mm (7.87 in.) Inner diameter: 360 mm (14.17 in.) CAUTION: Do not use tires with disc wheels. NOTE: The tires may be marked by the airbag deployment, so use the redundant tires. f. Deploy the airbag. 1. Connect the SST red clip to the battery positive (+) terminal and the black clip to the battery negative (-) terminal. 2. Check that no one is within 10 m (33 ft) area around the disc wheel which the steering wheel pad is tied to. 3. Press the SST activation switch and deploy the airbag. HINT: The airbag deploys simultaneously as the LED of the SST activation switch lights up. g. Dispose of the steering wheel pad (with airbag). Page 2144 Transmission Speed Sensor: Description and Operation CIRCUIT DESCRIPTION The speed sensor for ABS detects the wheel speed and sends the appropriate signals to the ABS ECU. The ECU converts these signals into a pulse signal and outputs it to the combination meter. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. Page 2574 c. Cover the shift lever cap with a cloth. d. Pressing down on the shift lever cap and rotate it counterclockwise to remove. e. Pull out the shift lever. HINT: At the time of installation, please refer to the item. Apply MP grease to the tip of the shift lever. 2. RAISE VEHICLE AND DRAIN TRANSMISSION OIL Oil grade: API GL-4 or GL-5 Viscosity: SAE 75W-90 Capacity: 2.6 liters (2.7 US qts, 2.3 Imp. qts) Torque: 37 Nm (380 kgf-cm, 27 ft. lbs.) 3. REMOVE PROPELLER SHAFT 4. REMOVE FRONT EXHAUST PIPE a. Disconnect the 2 heated oxygen sensor connectors. b. Remove the 2 bolts, nuts and gasket. Torque: 48 Nm (490 kgf-cm, 35 ft. lbs.) c. Remove the 3 bolts and bracket. Torque: 44 Nm (450 kgf-cm, 33 ft. lbs.) d. Remove the 3 nuts, front exhaust pipe and 2 gaskets. Torque: 62 Nm (630 kgf-cm, 46 ft. lbs.) 5. DISCONNECT VEHICLE SPEED SENSOR AND BACK-UP LIGHT SWITCH CONNECTORS 6. DISCONNECT CLUTCH RELEASE CYLINDER Remove the 4 bolts, release cylinder and line. Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.) 7. REMOVE STARTER a. Disconnect the connector and wire from the starter. b. Remove the 2 bolts and starter. Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.) 8. REMOVE REAR END PLATE Remove the 4 bolts and rear end plate. Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.) 9. JACK UP TRANSMISSION SLIGHTLY Page 205 Step 1 Steps 2 - 3 INSPECTION PROCEDURE FORD Made CIRCUIT DESCRIPTION When the cruise control main switch is turned off, the cruise control does not operate. Page 583 c. When connecting the flare nut on the high pressure pipe union, observe these procedures: 1. Apply a light coat of engine oil to the flare and tighten the flare nut by hand. 2. Using SST, tighten the flare nut to the specified torque. SST 09631-22020 Torque: 28 Nm (285 kg.cm, 21 ft.lb) HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). d. Observe these precautions when removing and installing the injectors. 1. Never reuse the O-ring. 2. When placing a new O-ring on the injector, take care not to damage it in any way. 3. Coat a new O-ring with spindle oil or gasoline before installing-never use engine, gear or brake oil. e. Install the injector to the delivery pipe and intake manifold, as shown in the illustration. f. Check that there are no fuel leaks after doing maintenance anywhere on the fuel system. 1. Connect a TOYOTA hand-held tester to the DLC3. Page 1636 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Page 4815 Front Page 1291 Page 3800 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Page 3660 2. REMOVE FRONT AIRBAG SENSOR RH a. Disconnect the front airbag sensor connector. NOTE: Disconnect the connector with the front airbag sensor installed. b. Remove the 2 nuts and front airbag sensor RH. 3. REMOVE FRONT AIRBAG SENSOR LH a. Disconnect the front airbag sensor connector. NOTE: Disconnect the connector with the front airbag sensor installed. b. Remove the 2 bolts and front airbag sensor LH. INSTALLATION 1. INSTALL FRONT AIRBAG SENSOR LH AND RH a. Install the front airbag sensor with the 2 bolts and 2 nuts with the arrows on the sensors facing toward the front of the vehicle. Torque: 20 Nm (205 kg.cm, 15 ft.lb) NOTE: Connection of the connector is done after the sensor has been installed. - Make sure the sensor is installed with the specified torque. Page 3328 A. Move the hub up and down by hand (most models with wishbone suspension): a. Remove the tire. b. Install the 2 lug nuts. c. Inspect the free play while moving the lug nuts up and down at a force of 67 lbf (294 N, 30 kgf). B. Move the lower arm using a lever (some models with double wishbone type suspension): a. Lift up the vehicle. b. Place the tip of the lever to the wheel and inspect the free play while moving the lower arm up and down. C. Move the lower arm by hand (all models with strut type suspension and some models with wishbone type suspension): a Lift up the vehicle. b. Inspect the free play while moving the lower arm up and down at a force of 67 lbf (294 N, 30 kgf). 2. Inspect Upper Ball Joint Free Play A. Move the upper arm by hand (models with the LOWER control arm linked by a torsion bar, and all models using a coil spring). a. Remove the front tire. b. Inspect the free play while moving the upper arm up and down at a force of 67 lbf (294 N, 30 kgf). B. Move the tire with a lever (models with the UPPER control arm linked by a torsion bar). Page 1309 Oxygen Sensor: Description and Operation Air / Fuel Sensor Air / Fuel Sensor To obtain a high purification rate for the CO, HC and NOx components of the exhaust gas, a three-way catalytic converter is used, but for the most efficient use of the three-way catalytic converter, the air-fuel ratio must be precisely controlled so that it is always close to the stoichiometric air-fuel ratio. The A/F sensor has the characteristic that provides output voltage* approximately proportional to the existing air-fuel ratio. The A/F sensor output voltage* is used to provide feedback for the ECM to control the air- fuel ratio. By the A/F sensor output, the ECM can determine the deviation amount from the stoichiometric air-fuel ratio and control the proper injection time immediately. If the A/F sensor is malfunctioning, ECM is unable to perform accurate air-fuel ratio control. The A/F sensor is equipped with a heater which heats the zirconia element. The heater is controlled by the ECM. When the intake air volume is low (the temp. of the exhaust gas is low), current flows to the heater to heat the sensor for accurate oxygen concentration detection. * The voltage value changes at the inside of the ECM only. Page 338 Page 1485 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Page 1189 Part 2 Of 2 (Except California Spec.) *1: A/T *2: M/T Specifications Axle Nut: Specifications Front Wheel Hub Lock Nut 235 Nm (174 ft.lb) Page 3586 If continuity is not as specified, replace the switch. 2. INSPECT PASSENGER AIRBAG MANUAL ON-OFF INDICATOR OPERATION (a) Check that continuity exists between 5 and 6. (b) Connect the positive (+) lead from the battery to terminal I and negative (-) lead to terminal 2. (c) Check that the indicator light lights up. If the operation is not as specified, replace the indicator. Component Tests and General Diagnostics Shift Indicator: Component Tests and General Diagnostics A/T.P. (Automatic Transmission Parking) Indicator Circuit CIRCUIT DESCRIPTION The propeller shaft and wheels are free even when the transmission shift lever is set to P as long as the transfer shift lever is in Neutral position. The A/T.P. indicator light lights up to warn the drive that the propeller shaft and wheels are not locked. If the A/T.P. indicator light goes on, the transfer shift lever should be shifted out of N position WIRING DIAGRAM Step 1 Page 799 b. Using a chisel and hammer, stake the lock nut. 6. w/o Free wheel hub (4WD only): INSTALL BEARING SPACER Using SST and a press, install the bearing spacer. SST 09950-60010 (09951-00650), 09950-70010 (09951-07150) 7. 4WD: INSTALL NEW OIL SEAL (INSIDE) a. Using SST and a plastic hammer, install a new oil seal (inside). SST 09527-17011 HINT: Strike the SST on its circumference evenly. b. Coat the oil seal lip with MP grease. 8. PreRunner: INSTALL GREASE CAP Page 2495 1. 4WD: REMOVE FRONT PROPELLER SHAFT a. Place matchmarks on the propeller shaft and front differential flanges. b. Remove the 4 nuts, bolts and washers. Torque: 74 Nm (750 kgf-cm, 54 ft. lbs.) c. Suspend the front side of the propeller shaft. d. Place matchmarks on the propeller shaft and transfer flanges. e. Remove the 4 nuts and washers. Torque: 74 Nm (750 kgf-cm, 54 ft. lbs.) f. Remove the front propeller shaft. 2. REMOVE PROPELLER SHAFT (PRE RUNNER) AND REAR PROPELLER SHAFT (4WD) a. Place matchmarks on the propeller shaft, transmission (pre runner) and transfer (4WD) flanges. b. Remove the 4 nuts and washers. Torque: 74 Nm (750 kgf-cm, 54 ft. lbs.) c. Place matchmarks on the propeller shaft and rear differential flanges. d. Remove the 4 nuts, bolts and washers. Torque: 74 Nm (750 kgf-cm, 54 ft. lbs.) e. 3-joint type: Remove the center support bearing 2 set bolts and 2 plates from the frame crossmember. Torque: 36 Nm (370 kgf-cm, 27 ft. lbs.) f. Remove the propeller shaft. DISASSEMBLY NOTICE: Be careful not to grip the propeller shaft tube too tightly in a vise as this will cause deformation. Locations Starter Motor: Locations Page 292 Mass Air Flow Meter: Service and Repair REMOVAL 1. REMOVE AIR CLEANER CASE a. Disconnect the air cleaner hose. b. Disconnect the MAF meter connector. c. Remove the 3 bolts and air cleaner case. 2. REMOVE MAF METER a. Remove the 2 screws and MAF meter. b. Remove the O-ring from the MAF meter. INSTALLATION 1. INSTALL MAF METER a. Install the O-ring to the MAF meter. b. Install the MAF meter with the 2 screws. 2. INSTALL AIR CLEANER CASE a. Install the air cleaner case with the 3 bolts. b. Connect the MAF meter connector. c. Connect the air cleaner hose. Page 1385 u. Remove the other union bolt, 3 gaskets and fuel pipe from the delivery pipes. v. Reinstall the fuel pipe with 4 new gaskets and the 2 union bolts. Torque: 34.3 Nm (350 kg.cm, 25 ft.lb) w. Reconnect the negative (-) terminal cable to the battery. x. Check for fuel leaks. 3. INSPECT FUEL PUMP RESISTANCE Using an ohmmeter, measure the resistance between terminals 4 and 5. Resistance: 0.2 - 3.0 ohms at 20 °C (68 °F) If the resistance is not specified, replace the fuel pump and/or lead wire. 4. INSPECT FUEL PUMP RESISTANCE Connect the positive (+) lead from the battery to terminal 4 of the connector, and the negative (-) lead to terminal 5. Check that the fuel pump operates. NOTE: These tests must be done quickly (within 10 seconds) to prevent the coil from burning out. - Keep the fuel pump as far away from the battery as possible. - Always do switching at the battery side. If operation is not as specified, replace the fuel pump and/or lead wire. Page 162 Page 2763 Type "B" Brake Pad A. Remove the clip, pins and anti-rattle spring/pad retainer clip. B. Remove the brake pads with the anti-squeal shims. C. Clean any dust from the brake pads. D. Apply a small amount of the disc brake caliper grease (1-2 mm thick) to the areas indicated in the illustration. NOTE: Do NOT apply grease to the friction surfaces of the brake pads or the disc rotor. E. Install the brake pads with the anti-squeal shims. NOTE: Clean excess grease from the brake pads and caliper. F. Install the pad guide pin, clip and anti-squeal spring. G. Install the wheel assembly. Page 3497 Control Assembly: Service and Repair Disassembly and Reassembly DISASSEMBLY 1. REMOVE BULB 2. REMOVE HEATER CONTROL CABLES a. Using a screwdriver, spread the claw of the cable clamp and disconnect the outer cable. HINT: Tape the screwdriver tip before use. b. Remove the inner cable from the heater control base. REASSEMBLY Reassembly is in the reverse order of disassembly. Page 1912 Fuel Pump Relay: Testing and Inspection 1. REMOVE CIRCUIT OPENING RELAY 2. INSPECT CIRCUIT OPENING RELAY a. Inspect the relay continuity. 1. Using an ohmmeter, check that there is no continuity between terminals 1 and 2. If there is continuity, replace the relay. 2. Check that there is continuity between terminals 2 and 4. If there is no continuity, replace the relay. 3. Check that there is continuity between terminals 5 and 5. If there is no continuity, replace the relay. Diagrams Power Steering Pump: Diagrams Part 1 Of 2 Page 1609 Heated Oxygen Sensor Page 711 Engine Oil: Fluid Type Specifications Engine Oil Type GRADE ..................................................................................................................................... API SJ Energy-Conserving or ILSAC multigrade engine oil All temperatures ............................................ ..................................................................................................................................................... SAE 5W-30 Above 0° F ............................................................................................................................... ................................................................................. 10W-30 Testing and Inspection Wiper Switch: Testing and Inspection INSPECT FRONT WIPER AND WASHER SWITCH CONTINUITY W/ Mist w/ MIST: Specifications Firing Order: Specifications Firing Order 1 - 2 - 3 - 4 - 5 - 6 Page 3209 An airbag activation prevention mechanism is built into the connector for the squib circuit of the SRS. When release of the airbag activation prevention mechanism is directed in the troubleshooting procedure, as shown in the illustration of the connectors on the next pages, insert paper which has the same thickness as the male terminal between the terminal and the short spring. CAUTION: Never release the airbag activation prevention mechanism on the squib connector. NOTE: - Do not release the airbag activation prevention mechanism unless specifically directed by the troubleshooting procedure. - If the inserted paper is too thick the terminal and short spring may be damaged, so always use paper with the same thickness as the male terminal. Testing and Inspection Igniter: Testing and Inspection ON-VEHICLE INSPECTION NOTE: "Cold" and "Hot" in these sentences express the temperature of the coils themselves. "Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F). INSPECT IGNITOR AND SPARK TEST Check that the spark occurs. 1. Disconnect high-tension cords from spark plug. 2. Remove the spark plug. 3. Install the spark plug to each high-tension cord. 4. Ground the spark plug. 5. Check if spark occurs while engine is being cranked. NOTE: To prevent excess fuel being injected from the injectors during this test, do not crank the engine for more 5 - 10 seconds at a time. If the spark does not occur, do the test as per the flow chart. 6. Using a 16 mm plug wrench, install the spark plugs. Torque: 18 N.m (195 kgf.cm, 15 ft.lbf) 7. Reinstall the ignition coil with ignitor. Page 1341 Vehicle Speed Sensor: Testing and Inspection INSPECT VEHICLE SPEED SENSOR OPERATION a. Connect the positive (+) lead from the battery to terminal 1 and negative (-) lead to terminal 2. b. Connect the positive (+) lead from the tester to terminal 3 and the negative (-) lead to terminal 2. c. Rotate the shaft. d. Check that there is voltage change from approx. 0 V to 11 V or more between terminals 2 and 3. HINT: The voltage change should be performed 4 times for every revolution of the speed sensor shaft. If operation is not as specified, replace the sensor. Page 89 Part 1 Of 2 (Except California Spec.) O/D Cancel Signal Circuit Overdrive Indicator Lamp: Testing and Inspection O/D Cancel Signal Circuit CIRCUIT DESCRIPTION While driving uphill with cruise control activated, in order to minimize gear shifting and provide smooth cruising O/D may be prohibited temporarily under some conditions. The cruise control ECU sends O/D cut signals to the ECM as necessary and the ECM cancels O/D shifting until these signals are discontinued. WIRING DIAGRAM Description and Operation Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Sensor A thermistor that is built into the engine coolant temperature sensor changes the resistance value according to the engine coolant temperature. The lower the engine coolant temperature sensor, the greater the thermistor resistance value, and the higher the engine coolant temperature sensor temperature, the lower the thermistor resistance value. The engine coolant temperature sensor is connected to the ECM. The 5 V power source voltage in the ECM is applied to the engine coolant temperature sensor from the terminal THA via a resistor R. That is, the resistor R and the engine coolant temperature sensor are connected in series. When the resistance value of the engine coolant temperature sensor changes in accordance with changes in the engine coolant temperature, the potential at terminal THA also changes. Based on this signal, the ECM increases the fuel injection volume to improve driveability during cold engine operation. Page 3472 Page 3314 - The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment. - Use gloves and safety glasses when handling a steering wheel pad with the deployed airbag. - Always wash your hands with water after completing the operation. - Do not apply water, etc.to a steering wheel pad with the deployed airbag. CAUTION: - The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment. - When moving a vehicle for scrapping which has a steering wheel pad with the deployed airbag, use gloves and safety glasses. - Use gloves and safety glasses when handling a steering wheel pad with deployed airbag. - Always wash your hands with water after completing the operation. - Do not apply water, etc.to a steering wheel pad with deployed airbag. 1. Remove the steering wheel pad from the steering wheel. 2. Place the steering wheel pad in a vinyl bag, tie the end tightly and dispose of it in the same way as other general parts disposal. Page 1130 a) Remove the 4 nuts and fan from the fluid coupling. b) Check that the fluid coupling is not damaged and that no silicon oil leaks. If necessary, replace the fluid coupling. c) Reinstall the fan to the fluid coupling with the 4 nuts. Torque: 7.4 Nm (75 kgf-cm, 65 inch lbs.) 3. INSPECT FAN PULLEY BRACKET Check the turning smoothness of the fan pulley. If necessary, replace the pulley bracket. 4. INSPECT TIMING BELT COMPONENTS INSTALLATION 1. INSTALL WATER PUMP a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the water pump and cylinder block. ^ Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove. ^ Thoroughly clean all components to remove all the loose material. ^ Using a non-residue solvent, clean both sealing surfaces. b) Apply seal packing to the water pump groove as shown in the illustration. Seal packing: Part No. 08826-00100 or equivalent ^ Install a nozzle that has been cut to a 2 - 3 mm (0.08 - 0.12 inch) opening. ^ Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied. ^ Immediately remove nozzle from the tube and reinstall cap. c) Install the water pump with the 7 bolts. Locations Intake Air Temperature Sensor: Locations The Intake Air Temperature (IAT) Sensor is installed in the Mass Air Flow (MAF) Meter. Page 4488 An airbag activation prevention mechanism is built into the connector for the squib circuit of the SRS. When release of the airbag activation prevention mechanism is directed in the troubleshooting procedure, as shown in the illustration of the connectors on the next pages, insert paper which has the same thickness as the male terminal between the terminal and the short spring. CAUTION: Never release the airbag activation prevention mechanism on the squib connector. NOTE: - Do not release the airbag activation prevention mechanism unless specifically directed by the troubleshooting procedure. - If the inserted paper is too thick the terminal and short spring may be damaged, so always use paper with the same thickness as the male terminal. Page 506 Step 3 Page 382 Oxygen Sensor: Testing and Inspection Heated Oxygen Sensor Heated Oxygen Sensor COMPONENTS Locations Transmission Speed Sensor: Locations CIRCUIT DESCRIPTION The speed sensor for ABS detects the wheel speed and sends the appropriate signals to the ABS ECU. The ECU converts these signals into a pulse signal and outputs it to the combination meter. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. Page 4411 Cigarette Lighter: Connector Locations Page 4428 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source How to Read Power Source Page 3249 Part 3 Of 3 POWER STEERING GEAR REPLACEMENT AND OVERHAUL W/ RELATED COMPONENTS Page 1285 CHART 20 Page 1124 DENSO Made Clutch Switch: Testing and Inspection DENSO Made Clutch Switch Circuit CIRCUIT DESCRIPTION When the clutch pedal is depressed, the clutch switch sends a signal to the cruise control ECU. When the signal is input to the cruise control ECU during cruise control driving, the cruise control ECU cancels cruise control. Wiring Diagram Specifications Firing Order: Specifications Firing Order 1 - 2 - 3 - 4 - 5 - 6 Page 2985 2. Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. 3. REINSTALL STARTER RELAY Specifications Piston Ring: Specifications Standard Ring Groove Clearance No.1 ............................................................................................... ............................................................................................................ 0.040 - 0.080 mm No.2 ........... .............................................................................................................................................................. .................................. 0.030 - 0.070 mm Standard End Gap No.1 ...................................................................................................................... ..................................................................................... 0.300 - 0.500 mm No.2 .................................. .............................................................................................................................................................. ........... 0.400 - 0.600 mm Oil (side rail) ............................................................................................... ............................................................................................... 0.150 - 0.550 mm Maximum End Gap No.1 ..................................................................................................................... ..................................................................................................... 1.10 mm No.2 ................................ .............................................................................................................................................................. ............................ 1.20 mm Oil (side rail) ............................................................................................ ................................................................................................................ 1.15 mm Specifications Extension Housing: Specifications Service Specifications Extension Housing Bushing, Maximum .......................................................................................................................................... 40.09 mm (1.5783 inch) Page 1114 If the valve lift is not as specified, replace the thermostat. d) Check that the valve is fully closed when the thermostat is at low temperatures (below 40°C (104°F)). If not closed, replace the thermostat. Page 2392 c. A340E: Install the 17 bolts. Torque: 10 Nm (100 kgf-cm, 7 ft. lbs.) Bolt length: Bolt A: 23 mm (0.91 inch) Bolt B: 32 mm (1.26 inch) d. A340F: Install the 16 bolts. Torque: 10 Nm (100 kgf-cm, 7 ft. lbs.) Bolt length: Bolt A: 23 mm (0.91 inch) Bolt B: 32 mm (1.26 inch) 13. CONNECT 3 CONNECTORS TO EACH SHIFT SOLENOID VALVE 14. A340E: INSTALL OIL PIPE Using a plastic hammer, install the 2 pipes into position. NOTICE: Be careful not to bend or damage the pipes. - Make sure that the oil pipes or magnet do not interfere with the oil pan. Diagram Information and Instructions Differential Lock: Diagram Information and Instructions Key to Diagrams Key to Diagrams A: System Title. B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: (1) Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. Page 1808 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Page 560 d. Torque the front and/or rear adjusting cam nuts. Torque: 130 Nm (1,325 kgf-cm, 96 ft. lbs.) Measuring Point Reference 5. INSPECT TOE-IN Toe-In: If the toe-in is not within the specified value, adjust the rack ends. Service and Repair Fuel Pressure Release: Service and Repair 1. BEFORE WORKING ON FUEL SYSTEM, DISCONNECT NEGATIVE (-) TERMINAL CABLE FROM BATTERY HINT: Any diagnostic trouble code retained by the computer will be erased when the negative (-) terminal cable is removed from the battery. Therefore, if necessary, read the diagnosis before removing the negative (-) terminal cable from the battery. 2. DO NOT SMOKE OR WORK NEAR AN OPEN FLAME WHEN WORKING ON FUEL SYSTEM 3. KEEP GASOLINE AWAY FROM RUBBER OR LEATHER PARTS 4. FUEL SYSTEM a. When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe these procedures: 1. Disconnect the fuel pump connector. 2. Start the engine. After the engine has stopped on its own, turn the ignition switch OFF. 3. Put a container under the connection. 4. Slowly loosen the connection. 5. Disconnect the connection. 6. Plug the connection with a rubber plug. b. When connecting the union bolt on the high pressure pipe union, observe these procedures: 1. Always use 2 new gaskets. 2. Tighten the union bolt by hand. 3. Tighten the union bolt to the specified torque. Torque: 34.3 Nm (350 kg.cm, 25 ft.lb) Page 1455 5. REMOVE ECT SENSOR a. Disconnect the ECT sensor connector. b. Using a 19 mm dean socket wrench, remove the ECT sensor and gasket. 6. INSPECT ECT SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: Refer to the graph If the resistance is not as specified, replace the ECT sensor. 7. REINSTALL ECT SENSOR a. Install a new gasket to the ECT sensor. b. Using a 19 mm deep socket, install the ECT sensor. Torque: 20 Nm (200 kg.cm, 14 ft.lb) c. Connect the ECT sensor connector. 8. REINSTALL FUEL PIPE Install the fuel pipe with 4 new gaskets and the 2 union bolts. Torque: 34.3 Nm (350 kg. cm, 25 ft.lb) 9. REINSTALL NO.2 TIMING BELT COVER 10. RECONNECT UPPER RADIATOR HOSE TO WATER OUTLET 11. REFILL WITH ENGINE COOLANT Page 1696 Applicable Vehicles Page 3075 Harness Locations Page 2257 Page 1898 COMPONENTS REMOVAL 1. REMOVE AIR CLEANER HOSE 2. REMOVE INTAKE AIR CONNECTOR ASSEMBLY 3. DISCONNECT FUEL RETURN HOSE FROM FUEL PRESSURE REGULATOR CAUTION: Put a shop rag under the pressure regulator. 4. REMOVE FUEL PRESSURE REGULATOR a. Remove holding bolt the engine wire to the LH cylinder head cover. b. Disconnect the protector from the bracket on the RH cylinder head cover, and lift up the engine wire. Page 4565 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 2236 Page 1639 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2613 Step 2 Step 3 INSPECTION PROCEDURE Page 3731 CAUTION For this procedure, do not use pliers. They may damage the webbing. C. Tighten the c-clamp until the space between its jaws are 4.5 - 5.0 mm (0.18 in. -0.20 in.) Figures 5&6 Description and Operation Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Sensor A thermistor that is built into the engine coolant temperature sensor changes the resistance value according to the engine coolant temperature. The lower the engine coolant temperature sensor, the greater the thermistor resistance value, and the higher the engine coolant temperature sensor temperature, the lower the thermistor resistance value. The engine coolant temperature sensor is connected to the ECM. The 5 V power source voltage in the ECM is applied to the engine coolant temperature sensor from the terminal THA via a resistor R. That is, the resistor R and the engine coolant temperature sensor are connected in series. When the resistance value of the engine coolant temperature sensor changes in accordance with changes in the engine coolant temperature, the potential at terminal THA also changes. Based on this signal, the ECM increases the fuel injection volume to improve driveability during cold engine operation. Page 2724 Wheel Speed Sensor: Service and Repair Speed Sensor, Rear REMOVAL REMOVE SPEED SENSOR a. Disconnect the speed sensor connector, and pull out the sensor wire harness with grommet. b. Remove the 5 resin clips, 2 clamp set bolts and 2 nuts holding the sensor wire harness from the side rail, fuel tank and axle housing. Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.) c. Remove the 2 mounting bolts and speed sensor. Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.) NOTICE: At the time of installation, please refer to the following items. ^ There are no objects on the sensor or the part of the axle end to which the sensor is to be installed. ^ The sensor is installed flat against the axle end when you tighten the bolt. ^ When installing the resin clips, use new ones. INSTALLATION Installation is in the reverse order of removal. NOTICE: After installation, check the speed sensor signal. Page 2131 Step 3 Page 1464 Crankshaft Position Sensor: Testing and Inspection INSPECT CRANKSHAFT POSITION SENSOR a. Remove the sensor connector. b. Using an ohmmeter, measure the resistance between the terminals. Resistance: Cold 1,630 - 2,740 ohms Hot 2,065 - 3,225 ohms c. Reinstall the sensor. Page 3776 Page 505 Step 1 Step 2 Testing and Inspection Backup Lamp Switch: Testing and Inspection INSPECT BACK-UP LIGHT SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 731 Refrigerant Oil: Fluid Type Specifications Type ND-OIL 8 Page 5007 6. Mask-off wiper motor opening. 7. Attach Kent(TM) 12" extension tube (P/N 90175) to the nozzle on the can of Leak-Chek(TM) (P/N 50087). NOTE: Direct Leak-Chek(TM) spray material approximately 1 inch above seam. Spray force is very strong - make several test passes before actually spraying material into seam. 8. Spray Leak-Chek(TM) through the wiper motor opening. a. Spray material inside upper cowl, beginning in lower corner, and continuing toward the centerline of vehicle. b. Remove wand from the wiper motor opening and insert it into larger cowl openings on the right hand side. Continue spraying material along entire seam until seam is filled from R/F fender to L/F fender area. Spray Leak-Chek(TM) into seam a total of 3 times, allowing Leak-Chek(TM) to flash dry for 30-45 minutes between applications. (Drying time increases as outside temperature decreases.) 9. After final application of Leak-Chek(TM) has been allowed to dry for approximately one hour, flood area with water for 5-10 minutes. NOTE: Hold garden hose at top right front corner of windshield and point hose downward toward lower right hand corner of windshield as shown. 10. Check inside cab behind Heater/Air Conditioner box for evidence of water leakage during water leak check. 11. Carefully inspect "T" joint on right and left sides (close to heater motor box, and brake booster) for evidence of water leaks. 12. If no leaks are found, cowl area leak repair is complete. Reinstall wiper motor, cowl trim panel, wiper arms, and hood. Wiper Arm Torque: 20 N.m (205 kgf.cm, 15 ft.lbf) If water leaks are still present and are coming in from the cowl area, remove right front fender and proceed as follows: 13. Seal around entire perimeter of "L" bracket with Kent High Tech(TM) Clear Seam Sealer (see drawing for location of "L" bracket). 14. Using a flashlight, look through the 2" x 3" rectangular hole on side of vertical cowl panel and locate vertical seam that connects side of cowl to front cowl. Initial Inspection and Diagnostic Overview Multiplex Communication System: Initial Inspection and Diagnostic Overview HINT: The multiplex communication system is connected to different ECU's and control systems. BODY CONTROL MODULE DRIVER POSITION MEMORY SYSTEM Page 1798 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source How to Read Power Source Page 621 Part 2 Of 2 Part 2 of 2 Page 2544 Page 3377 Page 4245 Sliding Roof: Service and Repair REMOVAL 1. REMOVE SUNSHADE TRIM 2. REMOVE LOCK HANDLE AND LOCK BASE a. Remove the 2 screws and lock garnish. b. Remove the lock handle and holders with 2 bolts. Torque: 2.9 N.m (30 kgf.cm, 26 in.lbf) c. Remove the lock base and spacer with 2 screws. Torque: 5.9 N.m (60 kgf.cm, 52 in.lbf) 3. REMOVE WIND DEFLECTOR PANEL a. Remove the clip as shown in the illustration. b. Using a screwdriver, remove the wind deflector panel as shown in the illustration. c. Employ the same manner described above to the other side. Page 3430 HINT: PreRunner is the model described below. RZN191L-TRPDKAB, RZN196L-CRPDKAB, VZN195L-CRPDKAB 1. 4WD: REMOVE OIL SEAL (INSIDE) a. Clamp the axle hub in a soft jaw vise. HINT: Close vise until it holds hub bolts. Do not tighten further. b. Using a screwdriver, remove the oil seal (inside). 2. PreRunner: REMOVE GREASE CAP a. Clamp the axle hub in a soft jaw vise. HINT: Close vise until it holds hub bolts. Do not tighten further. b. Using a screwdriver, remove the grease cap. Locations Specifications Band Apply Servo: Specifications Second Coast Brake Piston Stroke ..................................................................................................... ................................................................ 1.5 - 3.0 mm (0.059 - 0.118 inch) Piston Rod Length ......... .............................................................................................................................................................. ........ 72.9 mm (2.870 inch) .............................................................................................................................................................. .......................... 71.4 mm (28.11 inch) Page 363 CHART 25 Page 1091 Required SSTs Radiator Cap Identification Procedure 1. Use the illustration below to identify the vehicle's radiator cap type and kPa rating. 2. Proceed to the required inspection procedure for the radiator cap and kPa rating. Radiator Cap Inspection Procedure Type: N-cap, 88 kPa 1. Remove coolant and any foreign material on rubber points "A," "B," and "C." 2. Check that points "A," "B," and "C" are not deformed, cracked, or swollen. 3. Check that points "C" and "D" are not stuck together. 4. Apply engine coolant to points "B" and "C" before using the radiator cap tester. ^ Radiator Cap Tester: Snap-On/Sun P/N SVTS262A (or equivalent) Collision / Non-Collision Inspections Airbag Sensor Assembly: Testing and Inspection Collision / Non-Collision Inspections VEHICLE NOT INVOLVED IN COLLISION Check a diagnostic system. VEHICLE INVOLVED IN COLLISION WITH AIRBAG NOT DEPLOYED Check a diagnostic system. * VEHICLE INVOLVED IN COLLISION WITH AIRBAG DEPLOYED Replace the airbag sensor assembly. * * Refer to SRS Warning Light Check, and How to Display and Read Diagnostic Trouble Codes. See: Restraint Systems/Air Bag Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Displaying & Reading Trouble Codes Page 387 Throttle Position Sensor: Service and Repair Refer to Fuel Delivery and Air Induction / Throttle Body / Service and Repair, for removal and installation of this component. Page 1623 Refer to Reset Procedure 2 for the vehicles with Electronically Controlled Automatic Transmissions: Reset Procedure 1 1. Connect the Toyota Diagnostic Tester to the vehicle. 2. Reset the ECM (PCM). Refer to the procedures below. Page 2543 Locations Page 1113 Thermostat: Testing and Inspection INSPECTION INSPECT THERMOSTAT HINT: Thermostat is numbered according to the valve opening temperature. a) Immerse the thermostat in water and gradually heat the water. b) Check the valve opening temperature. Valve opening temperature: 80 - 84°C (176 - 183°F) If the valve opening temperature is not as specified, replace the thermostat. c) Check the valve lift. Valve lift: 8.5 mm (0.335 inch) or more at 95°C (203°F) Page 343 CHART 1 Page 3385 b. Remove the rear shock absorber. INSPECTION INSPECT SHOCK ABSORBER Compress and extend the shock absorber rod and check that there is no abnormal resistance or unusual operation sounds. If there is any abnormality, replace the shock absorber with a new one. NOTICE: When discarding the shock absorber, see DISPOSAL. DISPOSAL 1. FULLY EXTEND SHOCK ABSORBER ROD 2. DRILL HOLE TO REMOVE GAS FROM CYLINDER Using a drill, make a hole in the cylinder, as shown in the illustration to remove the gas inside. CAUTION: The discharged gas is harmless, but be careful of chips which may fly up when drilling. INSTALLATION Installation is in the reverse order of removal. Page 2090 Junction Box / No. 3 Page 4821 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 3240 b. Disconnect the connector from the integration relay and inspect the connectors on the wire harness side. Page 2212 Step 2 Step 3 INSPECTION PROCEDURE Page 2284 Step 1 Page 558 VZN195L model If the steering axis inclination is not within the specified value, after the camber and caster have been correctly adjusted, recheck the steering knuckle and front wheel for bearing or looseness. 4. ADJUST CAMBER AND CASTER a. Loosen the front and/or rear adjusting cam nuts. b. Adjust the camber and caster by front and/or rear adjusting cams (See adjustment chart). HINT: Try to adjust the camber and caster to the center of the specified values. Page 3158 Repair Procedure 1. Disconnect the cable from the negative (-) battery terminal for MORE THAN two (2) seconds. 2. Reconnect the cable to the negative (-) battery terminal. 3. Perform the applicable zero point calibration of the yaw rate sensor and/or the steering angle sensor. HINT Refer to the applicable TSB or Repair Manual for the zero point calibration procedure. 4. Re-initialize all applicable systems available on the vehicle (power window sunroof power lift door etc.). Page 4523 Key Reminder Switch: Pinout Values and Diagnostic Parameters B 6 BUCKLE SW 1-2 : Open with driver's seat belt in use D 15 DOOR COURTESY SW LH 1-GROUND : Closed with LH door open I 15-A SEAT BELT WARNING RELAY [INTEGRATION RELAY] 6-GROUND : Approx. 12 volts with ignition SW ON 12-GROUND : Always approx. 12 volts A 7-GROUND : Always continuity A 5-GROUND : Continuity with LH door open A 10-GROUND: Approx. 12 volts with ignition key in cylinder A 2-GROUND : 0 Volts for 4 - 8 seconds with ignition SW ON and 12 volts 4 - 8 seconds after ignition SW ON Testing and Inspection Daytime Running Lamp Relay: Testing and Inspection Terminal Identification INSPECT DAYTIME RUNNING LIGHT RELAY CIRCUIT Disconnect the connector from the relay and inspect the connector on the wire harness side. If circuit is as specified, perform inspections. Page 362 CHART 24 Page 2076 Step 1 Step 2 Page 4433 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Testing and Inspection Brake Warning Indicator: Testing and Inspection INSPECT BRAKE WARNING LIGHT a. Disconnect the connectors from the level warning switch and parking brake switch. b. Connect terminals on the wire harness side connector of the level warning switch connector. c. Turn the ignition switch ON and check that the warning light lights up. If the warning light does not light up, test the bulb. Page 4336 Steps 2 - 3 INSPECTION PROCEDURE Page 4537 Step 1 Page 3773 Rear Seat Belt Extender Applications Page 4308 Steps 1 - 2 Page 3138 d. Torque the front and/or rear adjusting cam nuts. Torque: 130 Nm (1,325 kgf-cm, 96 ft. lbs.) Measuring Point Reference 5. INSPECT TOE-IN Toe-In: If the toe-in is not within the specified value, adjust the rack ends. Page 4010 Applicable Warranty*: This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Repair Procedure 1. Remove Wiper Arms, Plastic Cowl Cover and Wiper Motor (store wiper links up against bottom of windshield). NOTE: Mark wiper arm linkage attached to wiper motor and wiper motor splined shaft prior to removing the 12 mm retaining nut. 2. Spray Acrysol(TM) under entire lip of 1/2" pinch weld and wipe dry with a clean paper towel. FOLLOW DIRECTIONS ON SIDE OF CAN CAREFULLY. Dry open seam with compressed air prior to applying sealer. NOTE: Do not use a red shop towel to wipe surfaces because shop towels are contaminated with silicone. 3. Apply a small bead of Kent High Tech(TM) Clear Seam Sealer to underside front edge of the pinch weld from fender to fender as shown. 4. Apply Kent High Tech(TM) Clear Seam Sealer on all spot welds located on the floor of cowl panel. 5. Apply Kent High Tech(TM) Clear Seam Sealer around outside base of hood safety stops, and seal outside corner, under the "L" bracket as shown. Page 3392 Wheel Bearing: Diagrams Page 2921 The battery is now being tested. The progress bar fills in across the screen while testing. 12. Read or print the battery test results (press the PRINT soft key to print). Battery Inspection Results Once the test completes, proceed with one of the 5 procedures below according to the BATTERY CONDITION results. 1. Battery Condition: "GOOD BATTERY" Return the battery to service. 2. Battery Condition: "GOOD-RECHARGE" Fully charge the battery using the GR8 Battery Diagnostic Station (P/N 00002-MCGR8) and return it to service. 3. Battery Condition: "CHARGE & RETEST" Fully charge the battery using the GR8 Battery Diagnostic Station (P/N 00002-MCGR8) and retest. NOTE: Failure to fully charge the battery before retesting may cause false readings. 4. Battery Condition: "REPLACE BATTERY" Replace the battery. NOTE: A REPLACE BATTERY result may also mean a poor connection between the battery cables and the battery. Retest the battery using the out-of-vehicle test before replacing it. 5. Battery Condition: "BAD CELL-REPLACE" Replace the battery. The decision indicates a bad cell within the battery. CAUTION: ^ If "FROZEN BATTERY" is displayed as the test result, allow the battery to reach a temperature of 40°F (4°C) before retesting. ^ NEVER CHARGE A FROZEN BATTERY GASES MAY FORM, CRACKING THE CASE AND CAUSING BATTERY ACID TO LEAK. Page 80 Part 2 Of 2 (Except California Spec.) *1: A/T *2: M/T Page 2627 Shift Indicator: Connector Locations Page 1042 Water Pump: Diagrams WATER PUMP REPLACEMENT W/ RELATED COMPONENTS Part 1 of 3 Page 3233 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Page 3046 Junction Box / No. 1 Details Page 2977 Torque: 1.5 Nm (15 kg.cm, 13 in.lb) for 1.4 kW 3.8 Nm (39 kg.cm, 34 in.lb) for 3.8 kW b. Remove the O-ring from the field frame. HINT: At the time of reassembly, please refer to the following items. Use a new O-ring. c. Using a screwdriver hold the spring back and disconnect the brush from the brush holder. Disconnect the 4 brushes, and remove the brush holder. 5. REMOVE ARMATURE FROM FIELD FRAME REASSEMBLY Reassembly is in the reverse order of disassembly. HINT: Use high-temperature grease to lubricate the bearings, gears, return spring and steel ball when assembling the starter. REPLACEMENT 1. REPLACE FRONT BEARING a. Using SST, remove the bearing. SST 09286-46011 b. Using a press, press in a new bearing. Page 4926 Windshield Page 1595 CHART 24 Page 333 A/F and 02 Sensor Identification Page 4583 Seat Belt Reminder Lamp: Splice Locations Removal and Installation Steering Wheel: Service and Repair Removal and Installation COMPONENT REMOVAL REMOVE THESE PARTS a. Steering Wheel Pad b. Steering Wheel c. Upper And Lower Covers d. Spiral Cable INSTALLATION INSTALL THESE PARTS Wheels - Tire Inflation & Wheel Lug Torque Chart Tires: Technical Service Bulletins Wheels - Tire Inflation & Wheel Lug Torque Chart October 1, 1999 TIRE INFLATION & WHEEL LUG TORQUE REFERENCE CHART PG031-99 Introduction Proper tire inflation is important to maximize tire life and vehicle ride comfort. 2000 MY Toyota vehicles are available with a wide variety of wheel sizes and tire profiles. Prior to customer vehicle delivery, refer to the following table to identify the appropriate tire pressure setting. Adjust tire pressures accordingly. Applicable Vehicles All 2000 Models Tire Pressure Settings * Recommended tire inflation pressure under high load capacity. Description and Operation Camshaft Position Sensor: Description and Operation The Camshaft Position Sensor Camshaft position sensor (G signal) consists of a magnet, iron core and pickup coil. The G signal plate has 1 tooth, on its outer circumference and is mounted on the RH camshaft timing pulley. When the camshafts rotate, the protrusion on the signal plate and the air gap on the pickup coil change, causing fluctuations in the magnetic field and generating an electromotive force in the pickup coil. The NE signal plate has 34 teeth and is mounted on the crankshaft timing pulley. The NE signal sensor generates 34 signals at every engine revolution. The ECM detects the standard crankshaft angle based on the G signal and the actual crankshaft angle and the engine speed by the NE signal. Airbag(s) Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Airbag(s) Arming and Disarming CAUTION: * Work must be started 90 seconds after the ignition switch is turned to the "LOCK" position and the negative (-) terminal cable is disconnected from the battery. (The SRS is equipped with a back-up power source so that if work is started within 90 seconds of disconnecting the negative (-) terminal cable of the battery, the SRS may be deployed.) * When the negative (-) terminal cable is disconnected from the battery, the memory of the clock and audio system will be canceled. So before starting work, make a record of the contents memorized in the audio memory system. When work is finished, reset the audio systems as before and adjust the clock. To avoid erasing the memory of each memory system, never use a backup power supply from outside the vehicle. * Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during repairs. * Do not expose the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor directly to hot air or flames. AIR BAG SYSTEM DISARMING The Air Bag/Supplemental Restraint System (SRS) incorporates a backup energy source that maintains sufficient deployment voltage for up to 90 seconds after the ignition is turned Off and the battery has been disconnected. Before disconnecting battery, note radio station settings, since all vehicle memory will be lost. Never use a backup power source from outside the vehicle. 1. Turn ignition to Lock, then disconnect battery ground cable. 2. Wait at least 90 seconds after disconnection before beginning service or diagnostic procedures. AIR BAG SYSTEM ARMING 1. Ensure ignition is in Lock position. 2. Connect battery ground cable. 3. Wait at least 10 seconds before turning ignition from Lock position. 4. Turn ignition to ACC or On position and ensure SRS lamp lights, then goes off after approximately six seconds. If lamp remains lit, an SRS condition is indicated. Refer to Restraint Systems, Air Bag Systems, Testing And Inspection. See: Restraint Systems/Air Bag Systems/Testing and Inspection Page 1168 Refer to Reset Procedure 2 for the vehicles with Electronically Controlled Automatic Transmissions: Reset Procedure 1 1. Connect the Toyota Diagnostic Tester to the vehicle. 2. Reset the ECM (PCM). Refer to the procedures below. Page 3509 Specified amount: 600 ± 50 g (21.16 ± 1.76 oz.) 2. DISCONNECT SUCTION TUBE AND LIQUID TUBE FROM COOLING UNIT FITTINGS Torque: Liquid tube: 14 Nm (140 kg.cm, 10 ft.lb) Suction tube: 32 Nm (330 kg.cm, 24 ft.lb) NOTE: Cap the open fittings immediately to keep moisture or dirt out of the system. HINT: At the time of installation, please refer to the following item. Lubricate 2 new O-rings with compressor oil and install the tubes. 3. REMOVE 2 GROMMETS 4. REMOVE DRAIN PIPE GROMMET 5. REMOVE THESE PARTS: a. Glove compartment door b. Glove compartment door reinforcement c. Lower No.2 finish panel d. No.4 heater to register duct 6. REMOVE COOLING UNIT a. Disconnect the connectors. b. Remove the 3 screws, bolt and the cooling unit. INSTALLATION Installation is in the reverse order of removal Symptom Related Diagnostic Procedures Stop Light System Page 3608 Replacement Requirements Impact Sensor: Service and Repair Replacement Requirements REPLACEMENT REQUIREMENTS In the following cases, replace the front airbag sensor. - If the SRS has been deployed in a collision. (Replace both the left and right airbag sensors.) - If the front airbag sensor has been found to be faulty in troubleshooting. - If the front airbag sensor has been found to be faulty during checking items. - If the front airbag sensor has been dropped. CAUTION: Be sure to follow the correct procedure for removal and installation of the front airbag sensor. Page 2642 Junction Box / No. 3 Fuse and Fusible Link Locations Page 1778 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 3101 Interior J/B # 1 Page 4566 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 4998 6. Mask-off wiper motor opening. 7. Attach Kent(TM) 12" extension tube (P/N 90175) to the nozzle on the can of Leak-Chek(TM) (P/N 50087). NOTE: Direct Leak-Chek(TM) spray material approximately 1 inch above seam. Spray force is very strong - make several test passes before actually spraying material into seam. 8. Spray Leak-Chek(TM) through the wiper motor opening. a. Spray material inside upper cowl, beginning in lower corner, and continuing toward the centerline of vehicle. b. Remove wand from the wiper motor opening and insert it into larger cowl openings on the right hand side. Continue spraying material along entire seam until seam is filled from R/F fender to L/F fender area. Spray Leak-Chek(TM) into seam a total of 3 times, allowing Leak-Chek(TM) to flash dry for 30-45 minutes between applications. (Drying time increases as outside temperature decreases.) 9. After final application of Leak-Chek(TM) has been allowed to dry for approximately one hour, flood area with water for 5-10 minutes. NOTE: Hold garden hose at top right front corner of windshield and point hose downward toward lower right hand corner of windshield as shown. 10. Check inside cab behind Heater/Air Conditioner box for evidence of water leakage during water leak check. 11. Carefully inspect "T" joint on right and left sides (close to heater motor box, and brake booster) for evidence of water leaks. 12. If no leaks are found, cowl area leak repair is complete. Reinstall wiper motor, cowl trim panel, wiper arms, and hood. Wiper Arm Torque: 20 N.m (205 kgf.cm, 15 ft.lbf) If water leaks are still present and are coming in from the cowl area, remove right front fender and proceed as follows: 13. Seal around entire perimeter of "L" bracket with Kent High Tech(TM) Clear Seam Sealer (see drawing for location of "L" bracket). 14. Using a flashlight, look through the 2" x 3" rectangular hole on side of vertical cowl panel and locate vertical seam that connects side of cowl to front cowl. Page 4370 ABS Light: Testing and Inspection CIRCUIT DESCRIPTION If the ECU detects trouble, it lights the ABS warning light while at the same time prohibiting ABS control. At this time, the ECU records a DTC in memory. After removing the short pin of the DLC1, connect terminals Tc and E1 of the DLC1 to make the ABS warning light blink and output the DTC. WIRING DIAGRAM Step 1 Locations Knock Sensor: Locations Page 3230 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Description and Operation Brake Switch - TCC: Description and Operation Stop Light Switch Signal Engine This signal is used to detect when the brakes have been applied. The STP signal voltage is the same as the voltage supplied to the stop lights. The STP signal is used mainly to control the fuel cut-off engine speed (The fuel cut-off engine speed is reduced slightly when the vehicle is braking.). Automatic Transaxle The purpose of this circuit is to prevent the engine from stalling, while driving in lock-up condition, when brakes are suddenly applied. When the brake pedal is operated, this switch sends a signal to ECM. Then the ECM cancels operation of the lock-up clutch while braking is in progress. Specifications Compression Check: Specifications Compression Pressure ........................................................................................................................ ..................................................... 1,200 kPa or More Minimum Pressure .......................................... ....................................................................................................................................................... 1,000 kPa Difference Between Each Cylinder ..................................................................................... .......................................................................... 100 kPa or Less Page 3722 Before installation of the fluorocarbon resin tape, it is necessary to pre-release the colored film about 5 mm for each side. (Not fully released.) B. By pulling up the seat belt, put the fluorocarbon resin tape through the hole of the shoulder belt anchor. Match the shoulder belt anchor to the center of the tape. C. Remove the upper side colored film from the fluorocarbon resin tape, and securely affix the tape to the outside of the shoulder belt anchor. D. Remove the lower side colored film from the fluorocarbon resin tape, and securely affix the tape to the outside of the shoulder belt anchor. NOTE: ^ Be sure to affix the fluorocarbon tape securely along all edges. ^ Pay attention not to make any wrinkles or slack in the fluorocarbon resin tape. E. Remove the clip. F. By pulling the seat belt up and down several times, as shown in the illustration, securely affix the fluorocarbon resin tape and confirm the smoothness of the belt movement. Page 4041 10. Check inside cab behind Heater/Air Conditioner box for evidence of water leakage during water leak check. 11. Carefully inspect "T" joint on right and left sides (close to heater motor box, and brake booster) for evidence of water leaks. 12. If no leaks are found, cowl area leak repair is complete. Reinstall wiper motor, cowl trim panel, wiper arms, and hood. Wiper Arm Torque: 20 N.m (205 kgf.cm, 15 ft.lbf) If water leaks are still present and are coming in from the cowl area, remove right front fender and proceed as follows: 13. Seal around entire perimeter of "L" bracket with Kent High Tech(TM) Clear Seam Sealer (see drawing for location of "L" bracket). 14. Using a flashlight, look through the 2" x 3" rectangular hole on side of vertical cowl panel and locate vertical seam that connects side of cowl to front cowl. If seam is not sealed properly, clean vertical and horizontal seam area with Acrysol(TM) cleaner. Use an air hose to dry all seams before applying sealer. NOTE: Hole is located behind fender. 15. Attach a 12 to 18 inch length of plastic tubing to tip of Kent High Tech(TM) Clear Seam Sealer. 16. Seal entire vertical joint with High Tech(TM) clear seam sealer. Allow sealer to dry according to instructions on tube. NOTE: Seams are inside boxed area and accessed through the square hole as shown. 17. Flood cowl area with water to confirm that there are no cowl seam leaks into cab. If water leaks are still present and there are no cowl area seam leaks, reinstall front fender and inspect for water entry along lower edge of interior door trim panel; then proceed as follows: 18. Remove door trim panel. 19. Flood R/F door glass area (spray water at door glass, belt-molding area). 20. Inspect sealer between plastic sheeting (moisture barrier) and metal door panel for voids/skips in sealer. If there are voids/skips between the plastic sheet and the door panel, it will need to be resealed. Page 1907 CAUTION: Put a shop towel under the delivery pipe. Slowly loosen the union bolt. e. Install SST (pressure gauge) to the delivery pipe with the 2 gaskets and SST (union and union bolt). SST 09268-45012 Torque: 34.3 Nm (350 kg.cm, 25 ft.lb) f. Wipe off any splattered gasoline. g. Connect a TOYOTA hand-held tester to the DLC3. (See step 1) h. Reconnect the negative (-) terminal cable to the battery. i. Turn the ignition switch ON. j. Measure the fuel pressure. Fuel pressure: 265-304 kPa (2.7-3.1 kg/Sq.cm,38 - 44 psi) If pressure is high, replace the fuel pressure regulator. If pressure is low, check the fuel hoses, fuel hose connections, fuel pump, fuel filter and fuel pressure regulator. k. Disconnect the TOYOTA hand-held tester from the DLC3. l. Reinstall the No.2 timing belt cover with the 6 bolts. Torque: 9 Nm (90 kg.cm, 80 in.lb) m. Start the engine. n. Disconnect the vacuum sensing hose from the fuel pressure regulator, and plug the hose end. o. Measure the fuel pressure at idle. Fuel pressure: 265 - 304 kPa (2.7 - 3.1 kg/Sq.cm, 38 - 44 psi) p. Reconnect the vacuum sensing hose to the fuel pressure regulator. q. Measure the fuel pressure at idle. Fuel pressure: 226 - 265 kPa (2.3 - 2.7 kg/Sq.cm, 33 - 38 psi) If pressure is not as specified, check the vacuum sensing hose and fuel pressure regulator and fuel pressure regulator. r. Stop the engine. s. Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped. Fuel pressure: 147 kPa (1.5 kg/Sq.cm, 21 psi) or more If pressure is not as specified, check the fuel pump, pressure regulator and/or injectors. t. After checking fuel pressure, disconnect the negative (-) terminal cable from the battery and carefully remove the SST to prevent gasoline from splashing. SST 09268-45012 Page 1521 Engine Control Module: Pinout Values and Diagnostic Parameters Connectors (California Spec.) Part 1 Of 2 (California Spec.) Page 4819 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Diagrams Component Tests and General Diagnostics Key Reminder Switch: Component Tests and General Diagnostics Ignition Switch and Key Unlock Warning Switch INSPECTION 1. INSPECT IGNITION SWITCH CONTINUITY If continuity is not as specified, replace the switch. 2. INSPECT KEY UNLOCK WARNING SWITCH CONTINUITY If continuity is not as specified, replace the switch. 3. Key Unlock Warning System: INSPECT INTEGRATION RELAY OPERATION Page 3399 Wheel Bearing: Service and Repair Disassembly and Reassembly DISASSEMBLY Description and Operation Camshaft Position Sensor: Description and Operation The Camshaft Position Sensor Camshaft position sensor (G signal) consists of a magnet, iron core and pickup coil. The G signal plate has 1 tooth, on its outer circumference and is mounted on the RH camshaft timing pulley. When the camshafts rotate, the protrusion on the signal plate and the air gap on the pickup coil change, causing fluctuations in the magnetic field and generating an electromotive force in the pickup coil. The NE signal plate has 34 teeth and is mounted on the crankshaft timing pulley. The NE signal sensor generates 34 signals at every engine revolution. The ECM detects the standard crankshaft angle based on the G signal and the actual crankshaft angle and the engine speed by the NE signal. Page 632 9. INSTALL TIMING BELT TENSIONER a) Temporarily install the tensioner with the 2 bolts. b) Alternately tighten the 2 bolts. Torque: 27 Nm (280 kgf-cm, 20 ft. lbs.) c) Remove the 1.27 mm hexagon wrench from the tensioner. 10. CHECK VALVE TIMING a) Turn the crankshaft, and align the timing marks of the crankshaft timing pulley and oil pump body. NOTICE: Always turn the crankshaft clockwise. b) Check that the timing marks of the RH and LH timing pulleys with the timing marks of the No.3 timing belt cover as shown in the illustration. If the marks do not align, remove the timing belt and reinstall it. c) Remove the crankshaft pulley bolt. 11. INSTALL TIMING BELT GUIDE Install the guide, facing the cup side outward. Page 2052 Page 2859 Vacuum Brake Booster: Service and Repair REMOVAL 1. REMOVE MASTER CYLINDER 2. DISCONNECT VACUUM HOSE FROM BRAKE BOOSTER 3. REMOVE RETURN SPRING 4. REMOVE CLIP AND CLEVIS PIN 5. REMOVE BRAKE BOOSTER a. Remove the clevis from the push rod. b. Remove the 4 booster installation nuts. c. Remove the booster and gasket. INSTALLATION 1. INSTALL BRAKE BOOSTER a. Install the booster and a new gasket. b. Install the clevis to the operating rod. c. Install and torque the booster installation nuts. Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.) d. Install the clevis pin into the clevis and brake pedal, and install the clip to the clevis pin. e. Install the pedal return spring. 2. ADJUST LENGTH OF BOOSTER PUSH ROD a. Install a new gasket on the master cylinder. Page 4343 Steps 3 - 4 INSPECTION PROCEDURE Testing and Inspection Ignition Cable: Testing and Inspection ON-VEHICLE INSPECTION INSPECT HIGH-TENSION CORDS a. Remove the air cleaner hose. b. Disconnect the high-tension cords at the rubber boot. Do not pull on the high-tension cords. NOTE: Pulling on or bending the cords may damage the conductor inside. c. Using an ohmmeter, measure the high-tension cord resistance. Maximum resistance: 25 kohms per cord If the resistance is greater than maximum, check the terminals. If necessary, replace the high-tension cord. Page 4504 Splice Point J: Indicates a wiring Splice Point (Codes are "E"for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I 5 is indicated by the shaded section. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. N: Page No. How to Read Ground Points How to Read Ground Points Page 1576 CHART 1 Page 3226 Page 1762 Transmission Position Switch/Sensor: Service and Repair ON-VEHICLE REPAIR 1. DISCONNECT 2 OIL COOLER PIPES 2. DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 3. REMOVE PARK/NEUTRAL POSITION SWITCH a. Pry off the lock washer and remove the nut. b. Remove the bolt and pull out the park/neutral position switch. 4. INSTALL AND ADJUST PARK/NEUTRAL POSITION SWITCH Torque: Nut: 6.9 Nm (70 kgf-cm, 61 inch lbs.) Bolt: 13 Nm (130 kgf-cm, 9 ft. lbs.) 5. CONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 6. CONNECT 2 OIL COOLER PIPES Page 3118 Engine Compartment Instrument Panel Locations Page 2694 Step 2 Step 3 INSPECTION PROCEDURE Troubleshooting in accordance with the chart for each trouble symptom. Page 3908 Keyless Entry Transmitter: Technical Service Bulletins Keyless Entry - Transmitter Programming & Identification ELECTRICAL EL008-02 REVISED December 20, 2002 Title: WIRELESS TRANSMITTER & PROGRAMMING GUIDE Models: All Applicable TSB REVISION NOTICE: Page 4510 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Page 1705 Oxygen Sensor: Technical Service Bulletins Engine Controls - O2 Sensor Monitor Threshold Values SPECIAL SERVICE TOOLS SS002-03 December 17, 2003 Title O2S TEST RESULTS (MODE 05) Models All '96 - '03, '04 Corolla, ECHO, Matrix, Sienna & Scion xA & xB Introduction This Service Bulletin contains Oxygen Sensor (O2S) Monitor threshold values for all models from 1996 to 2003 and some 2004 models. Starting in 2004, the O2S Monitor threshold values can be found in the repair manual. These values are used when analyzing the O2S test results to determine the O2S condition. Applicable Vehicles ^ All 1996 - 2003 model year Toyota vehicles. ^ 2004 model year Corolla, ECHO, Matrix and Sienna vehicles. ^ 2004 model year Scion xA and xB vehicles. Function Description Checking O2S Test Results To view O2S test results, the O2S Monitor must be completed and the test results must be checked within the same key cycle. If the ignition key is cycled OFF, the O2S test results will be set to the minimum or maximum limits, and all test results will be erased. The O2S test results are stored in the ECU (SAE term: Powertrain Control Module/PCM) when the monitor is completed. The test results are static and will not change once the monitor is complete. The process for checking 02S test results is described in the following three basic steps: 1. Completing the O2S Readiness Monitor. 2. Accessing O2S Test Results. 3. Comparing O2S Test Results to Failure Thresholds. Required SSTs NOTE: Additional Diagnostic Tester Kits, Program Cards or other SSTs may be ordered by calling SPX-OTC at 1-800-933-8335. Warranty Information Completing O2S Readiness Monitor 1. Clear any stored Diagnostic Trouble Codes (DTCs) using the Toyota Diagnostic Tester. Connector Locations Key Reminder Switch: Connector Locations Page 1305 Oxygen Sensor: Locations Air-Fuel Ratio (A/F) Sensor Description and Operation Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor The crankshaft position sensor, which detects the engine speed and crankshaft angle signal (NE signal), has been installed on the oil pump body. The NE signal plate has 34 teeth. The NE signal sensor generates 34 signals at every engine revolution. The ECM detects the standard crankshaft angle based on the G signal, and the actual crankshaft angle and the engine speed by the NE signal. Page 3267 Remove the 4 bolts. 5. DISCONNECT RH AND LH TIE ROD ENDS 6. DISCONNECT INTERMEDIATE NO. 2 SHAFT 7. DISCONNECT PRESSURE FEED AND RETURN TUBES Using SST, disconnect the tube. SST 09631-22020 8. REMOVE PS GEAR ASSEMBLY a. Remove the bolt and nut from the bracket. b. Remove the 2 set bolts and nut. 9. REMOVE BRACKET AND GROMMET INSTALLATION 1. INSTALL GROMMET AND BRACKET 2. INSTALL PS GEAR ASSEMBLY a. Torque the gear assembly set bolt. Torque: 167 Nm (1,700 kgf-cm, 123 ft. lbs.) b. Torque the gear assembly set bolt and nut. Torque: 191 Nm (1,950 kgf-cm, 141 ft. lbs.) c. Torque the bolt and nut to the bracket. Torque: 167 Nm (1,700 kgf-cm, 123 ft. lbs.) 3. CONNECT PRESSURE FEED AND RETURN TUBES Using SST, connect the tube. SST 09631-22020 Pressure feed tube: Torque: 36 Nm (365 kgf-cm, 26 ft. lbs.) Return tube: Torque: 40 Nm (405 kgf-cm, 29 ft. lbs.) HINT: ^ Use a torque wrench with a fulcrum length of 300 mm (11.81 inch). ^ This torque value is effective in case that SST is parallel to a torque wrench. Page 248 Key Reminder Switch: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Description and Operation Evaporative Vapor Pressure Sensor: Description and Operation Evaporative Emissions System The vapor pressure sensor and VSV for vapor pressure sensor are used to detect abnormalities in the evaporative emission control system. The ECM decides whether there is an abnormality in the evaporative emission control system based on the vapor pressure sensor signal. Page 340 Page 1495 Page 405 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Description and Operation Acceleration/Deceleration Sensor: Description and Operation Deceleration Sensor This sensor detects deceleration on the vehicle. The sensor signal is used in ABS control. If the sensor functions abnormally, the ABS warning light comes on but the ABS still operates. Page 784 * For vehicle capacity weight. ** For reduced loads (1 to 4 passengers). *** For trailer towing. Locations Page 236 Junction Box / No. 3 Page 2171 Specifications Thermostat: Specifications Valve Opening Temperature 80 - 84 deg C Valve Lift 8.5 mm at 95 deg C or More Page 4663 Page 3137 c. How to read adjustment chart. 1. Find the wheel alignment standard value applicable for the particular model. 2. Mark the selected standard value on the adjustment chart. Example: Camber: 0°10' (0.17°) Caster: 1°40' (1.67°) 3. Mark the alignment value measured when the vehicle was non-loaded on the adjustment chart. Example: Camber: -0°10'(-0.17°) Caster: 1°40' (1.67°) 4. As shown in the chart, read the distance from the measured value to the standard value, and adjust the front and/or rear adjusting cams accordingly. Example: Front cam: -(Shorter) 2.8 Rear cam: -(Shorter) 2.8 Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Crankshaft Pulley Torque .................................................................................................................... ................................................................................................... 300 Nm Service and Repair Wheel Cylinder: Service and Repair For information regarding the service and repair of this component and the system that it is a part of, please refer to Drum Brake System; Service and Repair. Page 1707 ^ O2S TEST RESULTS A list of the available oxygen sensors will be displayed. 2. Select the desired oxygen sensor and press Enter. NOTE: The monitor result of the A/F sensor will not be displayed. If you select "Bank 1-Sensor 1" or Bank 2-Sensor 1" for a vehicle equipped with an A/F sensor, the Diagnostic Tester will display "No parameter to display." 3. Compare the test results with the values listed in the Failure Threshold Chart. * Although this procedure references the Toyota Diagnostic Tester, the O2S test results can be checked using a generic OBD II scantool. Refer to your OBD II scantool operator's manual for specific procedures. Comparing O2S Test Results to Failure Thresholds 1. Determine the correct O2S Failure Threshold Chart for your vehicle by looking in the "O2S Application Table," in this bulletin. 2. Select appropriate year, model, and engine for specified O2S Failure Threshold Chart. 3. Compare O2S test results with the specified O2S Failure Threshold Chart. It may be necessary to convert O2S test results to a specific measurement unit using the conversion factor that is supplied in the specified table. See example. Example: Page 1266 ^ O2S TEST RESULTS A list of the available oxygen sensors will be displayed. 2. Select the desired oxygen sensor and press Enter. NOTE: The monitor result of the A/F sensor will not be displayed. If you select "Bank 1-Sensor 1" or Bank 2-Sensor 1" for a vehicle equipped with an A/F sensor, the Diagnostic Tester will display "No parameter to display." 3. Compare the test results with the values listed in the Failure Threshold Chart. * Although this procedure references the Toyota Diagnostic Tester, the O2S test results can be checked using a generic OBD II scantool. Refer to your OBD II scantool operator's manual for specific procedures. Comparing O2S Test Results to Failure Thresholds 1. Determine the correct O2S Failure Threshold Chart for your vehicle by looking in the "O2S Application Table," in this bulletin. 2. Select appropriate year, model, and engine for specified O2S Failure Threshold Chart. 3. Compare O2S test results with the specified O2S Failure Threshold Chart. It may be necessary to convert O2S test results to a specific measurement unit using the conversion factor that is supplied in the specified table. See example. Example: Page 2350 ^ 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 3079 D: Indicates related system. Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V). Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, 1H2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green O = Orange P = Pink R = Red SB = Sky Blue V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Page 3371 1. REPLACE EYE BUSHING Using SST and a press, replace the bushing. SST 09550-10013 (09252-10010, 09553-10010) HINT: 2WD (Except PreRunner): When installing the bushing, as shown in the illustration. 2. REPLACE LEAF SPRING a. Bend to open the spring clip. 1. Using a chisel and hammer, pry up the spring clip. b. Remove the center bolt. 1. Hold the spring near the center bolt in a vise and remove the center bolt. c. Replace the spring clip. 1. Drill off the head of the rivet and drive it out. Page 1885 Fuel Injector: Pressure, Vacuum and Temperature Specifications Pressure Drop Pressure Drop Pressure Drop 1 Drop per 12 Minutes Page 177 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection COMPONENTS INSPECTION 1. DRAIN ENGINE COOLANT 2. DISCONNECT UPPER RADIATOR HOSE FROM WATER OUTLET 3. REMOVE NO.2 TIMING BELT COVER 4. REMOVE FUEL PIPE Remove the 2 union bolt, 4 gaskets and fuel pipe. Capacity Specifications Engine Oil: Capacity Specifications Engine Oil With filter .............................................................................................................................................. .......................................................... 5.7 Qts.(5.4L) Without filter ....................................................... ............................................................................................................................................ 5.4 Qts.(5.1L) Page 1086 INSTALLATION Installation is in the reverse order of removal. Page 2751 a. Prepare the wooden plate to hold the pistons. b. Place the plate between the pistons and insert a pad at one side. c. Use compressed air to remove the pistons alternately from the cylinder. CAUTION: Do not place your fingers in front of the pistons when using compressed air. 3. REMOVE PISTON SEALS Using a screwdriver, remove the 4 seals from the cylinder. INSPECTION 1. MEASURE PAD LINING THICKNESS Standard thickness: 11.5 mm (0.453 inch) Minimum thickness: 1.0 mm (0.039 inch) 2. MEASURE DISC THICKNESS Standard thickness: 22.0 mm (0.866 inch) Minimum thickness: 20.0 mm (0.787 inch) 3. MEASURE DISC RUNOUT a. Tighten the disc with the 3 hub nuts. b. Using a dial indicator, measure the disc runout at a position 10 mm (0.39 inch) from the outside edge. Maximum disc runout: 0.07 mm (0.0028 inch) If the runout is greater than the maximum, replace the disc or grind it on a "On-Car" brake lathe. HINT: Before measuring the runout, confirm that the front bearing play is within the specification. 4. IF NECESSARY, ADJUST DISC RUNOUT a. Remove the hub nuts and disc. Reinstall the disc rotating 1/6 of a turn from its original position on the hub. Install and torque the hub nuts. Remeasure the disc runout. Make a note of the runout and the disc's position on the hub. b. Repeat (a) until the disc has been installed on the 4 remaining hub position. If the minimum runout recorded in (a) and (b) is less than the maximum disc runout, install the disc in that position. If the minimum runout recorded in (a) and (b) is greater than the maximum disc runout, replace the disc and repeat step 3. REASSEMBLY Reassembly is in the reverse order of disassembly. Page 3779 Front Seat Belt Extender Applications Page 4291 6. Mask-off wiper motor opening. 7. Attach Kent(TM) 12" extension tube (P/N 90175) to the nozzle on the can of Leak-Chek(TM) (P/N 50087). NOTE: Direct Leak-Chek(TM) spray material approximately 1 inch above seam. Spray force is very strong - make several test passes before actually spraying material into seam. 8. Spray Leak-Chek(TM) through the wiper motor opening. a. Spray material inside upper cowl, beginning in lower corner, and continuing toward the centerline of vehicle. b. Remove wand from the wiper motor opening and insert it into larger cowl openings on the right hand side. Continue spraying material along entire seam until seam is filled from R/F fender to L/F fender area. Spray Leak-Chek(TM) into seam a total of 3 times, allowing Leak-Chek(TM) to flash dry for 30-45 minutes between applications. (Drying time increases as outside temperature decreases.) 9. After final application of Leak-Chek(TM) has been allowed to dry for approximately one hour, flood area with water for 5-10 minutes. NOTE: Hold garden hose at top right front corner of windshield and point hose downward toward lower right hand corner of windshield as shown. 10. Check inside cab behind Heater/Air Conditioner box for evidence of water leakage during water leak check. 11. Carefully inspect "T" joint on right and left sides (close to heater motor box, and brake booster) for evidence of water leaks. 12. If no leaks are found, cowl area leak repair is complete. Reinstall wiper motor, cowl trim panel, wiper arms, and hood. Wiper Arm Torque: 20 N.m (205 kgf.cm, 15 ft.lbf) If water leaks are still present and are coming in from the cowl area, remove right front fender and proceed as follows: 13. Seal around entire perimeter of "L" bracket with Kent High Tech(TM) Clear Seam Sealer (see drawing for location of "L" bracket). 14. Using a flashlight, look through the 2" x 3" rectangular hole on side of vertical cowl panel and locate vertical seam that connects side of cowl to front cowl. Page 3380 2. DISCONNECT SHOCK ABSORBER FROM LOWER SUSPENSION ARM a. Remove the shock absorber lower nut and washer. NOTICE: Do not remove the bolt. Torque: 135 Nm (1,400 kgf-cm, 101 ft. lbs.) HINT: At the time of installation, after stabilizing the suspension, torque the nut. b. With lowering the lower suspension arm, remove the bolt and disconnect the shock absorber. 3. REMOVE SHOCK ABSORBER WITH COIL SPRING Remove the 3 nuts and shock absorber with the coil spring. Torque: 64 Nm (650 kgf-cm, 47 ft. lbs.) INSTALLATION Installation is in the reverse order of removal. Disassembly and Reassembly DISASSEMBLY Page 1565 Engine Bank Identification Page 2433 Differential Lock: Electrical Diagrams Front Wheel Fastener: Service and Repair Front REPLACEMENT HINT: PreRunner is the model described below. RZN191L-TRPDKAB, RZN196L-CRPDKAB, VZN195L-CRPDKAB 1. REMOVE FRONT WHEEL 2. REMOVE BRAKE CALIPER AND DISC 3. REMOVE HUB BOLT Using SST, remove the hub bolt. SST 09650-17011 4. INSTALL HUB BOLT a. Install a washer and nut to a new hub bolt as shown in the illustration. b. Using a hammer handle or an equivalent to hold, install the bolt by torquing the nut. 5. INSTALL BRAKE DISC AND CALIPER 6. INSTALL FRONT WHEEL Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.) 7. DEPRESS BRAKE PEDAL SEVERAL TIMES Page 2093 Specifications Valve Clearance: Specifications Valve Clearance (Cold) Intake ................................................................................................................................................... ................................. 0.13-0.23 mm (0.006-0.009 in) Exhaust ............................................................ ..................................................................................................................... 0.27-0.37 mm (0.011-0.014 in) Page 2281 Step 4 Service and Repair Power Steering Bleeding: Service and Repair BLEEDING 1. CHECK FLUID LEVEL 2. JACK UP FRONT OF VEHICLE AND SUPPORT IT WITH STANDS 3. TURN STEERING WHEEL With the engine stopped, turn the wheel slowly from lock to lock several times. 4. LOWER VEHICLE 5. START ENGINE Run the engine at idle for a few minutes. 6. TURN STEERING WHEEL a. With the engine idling, turn the wheel to left or right full lock and keep it there for 2-3 seconds, then turn the wheel to the opposite full lock and keep it there for 2-3 seconds. b. Repeat (a) several times. 7. STOP ENGINE 8. CHECK FOR FOAMING OR EMULSIFICATION If the system has to be bled twice specifically because of foaming or emulsification, check for fluid leaks in the system. 9. CHECK FLUID LEVEL Page 4618 Junction Box / No. 3 Testing and Inspection Power Mirror Switch: Testing and Inspection INSPECT MIRROR SWITCH CONTINUITY Left Side Left Side: Page 667 A/C Clamp Remover for removing special air condition line clamps. Applicable: 1998 and newer Toyota models with the new style A/C clamps. Comparable to Toyota Tool numbers 09870-00015 and 09870-00025. - Made in USA - Fits both Toyota AC Clamps, used on high and low pressure lines. - Applicable to: 1998 and newer Toyota models - Stainless Steel release pins - Identification and Instructions are laser marked on the handle Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Testing and Inspection Windshield Washer Switch: Testing and Inspection INSPECT FRONT WIPER AND WASHER SWITCH CONTINUITY W/ Mist w/ MIST: Page 1286 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 2435 Page 2316 Transmission Position Switch/Sensor: Service and Repair ON-VEHICLE REPAIR 1. DISCONNECT 2 OIL COOLER PIPES 2. DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 3. REMOVE PARK/NEUTRAL POSITION SWITCH a. Pry off the lock washer and remove the nut. b. Remove the bolt and pull out the park/neutral position switch. 4. INSTALL AND ADJUST PARK/NEUTRAL POSITION SWITCH Torque: Nut: 6.9 Nm (70 kgf-cm, 61 inch lbs.) Bolt: 13 Nm (130 kgf-cm, 9 ft. lbs.) 5. CONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 6. CONNECT 2 OIL COOLER PIPES Page 4690 W/ Tachometer W/o Tachometer HINT: Connect the test leads so that the current from the ohmmeter can flow according to the above order. This circuit includes the diode. If resistance value is not as specified, replace the receiver gauge. Page 347 CHART 8 CHART 9 Page 3117 Junction Box / No. 1 Details Page 1183 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 697 Check that the engine can be started with the shift lever only in the N or P position, but not in other positions. If it is not as stated above, carry out the following adjustment procedure. 1. Loosen the park/neutral position switch bolt and set the shift lever to the N position. 2. Align the groove and neutral basic line. 1. Hold the switch in position and tighten the bolt. Torque: 13 Nm (130 kg.cm, 10 ft.lb) For continuity inspection of the park/neutral position switch. i. Check the idle speed. Connect OBD II scan tool or TOYOTA hand-held tester to the DLC 3 and inspect the idle speed. idle speed (in N position and air conditioner OFF): 3RZ-FE: 700 ± 50 rpm 5VZ-FE: 700 ± 50 rpm Page 1233 5. REMOVE ECT SENSOR a. Disconnect the ECT sensor connector. b. Using a 19 mm dean socket wrench, remove the ECT sensor and gasket. 6. INSPECT ECT SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: Refer to the graph If the resistance is not as specified, replace the ECT sensor. 7. REINSTALL ECT SENSOR a. Install a new gasket to the ECT sensor. b. Using a 19 mm deep socket, install the ECT sensor. Torque: 20 Nm (200 kg.cm, 14 ft.lb) c. Connect the ECT sensor connector. 8. REINSTALL FUEL PIPE Install the fuel pipe with 4 new gaskets and the 2 union bolts. Torque: 34.3 Nm (350 kg. cm, 25 ft.lb) 9. REINSTALL NO.2 TIMING BELT COVER 10. RECONNECT UPPER RADIATOR HOSE TO WATER OUTLET 11. REFILL WITH ENGINE COOLANT Page 4239 NOTE:The vehicle paint code is on the certification label which can be located on the drivers side door jamb or the lower section of the "B" pillar. Page 1586 CHART 16 CHART 17 Page 3848 5. Disconnect the pretensioner connector as shown in the illustration. c. Extra cab: Disconnect the pretensioner connector. 1. Remove the door scuff plate. 2. Remove the back panel upper garnish. 3. Remove the back panel trim. 4. Remove the rear seat cushions. 5. Remove the front and rear seat outer belt shoulder anchors. 6. Remove the lock handle. 7. Remove the front and rear seat outer belt floor anchors. 8. Remove the quarter trim. 9. Remove the retractor of front seat outer belt. 10. Disconnect the pretensioner connector as shown in the illustration. d. Install the SST. 1. Buckle the front seat belt and check that there is no looseness and slack in the front seat inner belt and front seat outer belt. 2. Connect the 2 SST, then connect them to the seat belt pretensioner. SST 09082-00700,09082-00740 NOTE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. Page 3214 Junction Box / No. 1 Page 431 Camshaft Position Sensor: Testing and Inspection INSPECT CAMSHAFT POSITION SENSOR a. Disconnect the sensor connector. b. Using an ohmmeter, measure the resistance between the terminals. Resistance: cold 835 - 1,400 ohms Hot 1,060 - 1,645 ohms If the resistance is not as specified, replace the sensor. c. Reconnect the camshaft position sensor connector. Description and Operation Acceleration/Deceleration Sensor: Description and Operation Deceleration Sensor This sensor detects deceleration on the vehicle. The sensor signal is used in ABS control. If the sensor functions abnormally, the ABS warning light comes on but the ABS still operates. Page 1487 Data Link Connector: Testing and Inspection Check the DLC 3 The vehicle's ECM uses the ISO 9141-2 communication protocol. The terminal arrangement of DLC 3 complies with SAE J1962 and matches the ISO 9141-2 format. HINT: - If your display shows UNABLE TO CONNECT TO VEHICLE when you have connected the cable of the OBD II scan tool or TOYOTA hand-held tester to the DLC 3, turned the ignition switch ON and operated the scan tool, there is a problem on the vehicle side or tool side. - If communication is normal when the tool is connected to another vehicle, inspect the DLC 3 on the original vehicle. - If communication is still not possible when the tool is connected to another vehicle, the problem is probably in the tool itself, so consult the Service Department listed in the tool's instruction manual. Page 2597 Transmission Position Switch/Sensor: Service and Repair ON-VEHICLE REPAIR 1. DISCONNECT 2 OIL COOLER PIPES 2. DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 3. REMOVE PARK/NEUTRAL POSITION SWITCH a. Pry off the lock washer and remove the nut. b. Remove the bolt and pull out the park/neutral position switch. 4. INSTALL AND ADJUST PARK/NEUTRAL POSITION SWITCH Torque: Nut: 6.9 Nm (70 kgf-cm, 61 inch lbs.) Bolt: 13 Nm (130 kgf-cm, 9 ft. lbs.) 5. CONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 6. CONNECT 2 OIL COOLER PIPES Locations Vehicle Lifting: Locations Page 2819 2. DISCONNECT CONNECTOR Pull out the release bar, and disconnect the connector. 3. DISCONNECT BRAKE LINES Using SST, disconnect the 5 brake lines from the ABS actuator. SST 09023-00100 Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.) 4. REMOVE ABS ACTUATOR ASSEMBLY Remove the bolt, 2 nuts and ABS actuator assembly. Torque: 19 Nm (195 kgf-cm, 14 ft. lbs.) 5. REMOVE ABS ACTUATOR Using a T25 torx wrench, remove the 3 bolts and ABS actuator from actuator bracket. Torque: 9.0 Nm (91.8 kgf-cm, 80 inch lbs.) INSTALLATION Installation is in the reverse order of removal. HINT: After installation, fill the brake reservoir with brake fluid, bleed brake system and check for leaks. See: Brake Bleeding Page 1182 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 2615 WIRING DIAGRAM Page 4911 Back Window Glass: Overhaul DISASSEMBLY 1. REMOVE STOPPER 2. REMOVE FIX FRAMES 3. REMOVE SLIDE GLASS Pull apart the channels and remove the 2 slide glass at the center area of the glass channel. 4. REMOVE NON-SLIDE GLASS a. Pull apart the channels and remove the fix frame, as shown in the illustration. b. Pull apart the channels and remove the non-slide glass,as shown in the illustration. HINT: Apply soapy water to the contact surface of the weatherstrip and glass channel flange. Page 504 WIRING DIAGRAM Page 1295 CHART 26 Page 672 Brake Fluid: Testing and Inspection Check for fluid leakage from actuator or hydraulic lines. Page 3336 FRONT UPPER BALL JOINT REPLACEMENT AND OVERHAUL W/ RELATED COMPONENTS Fuel System - Fuel Injector Cleaning Procedure Fuel Injector: Technical Service Bulletins Fuel System - Fuel Injector Cleaning Procedure PRODUCT GENERAL INFORMATION PG011-05 REVISED October 13, 2005 Title: FUEL INJECTOR CLEANING Models: '90 - '06 Toyota & Scion Models With Port Electronic Fuel Injection TSB REVISION NOTICE: ^ June 9, 2006: In the Required Tools & Material section, part numbers have been updated (TYG S-Line Device and Toyota Adaptor Pak), and the note with ordering information has been updated. Previous versions of this TSB should be discarded. Introduction Due to fuel quality concerns, some Toyota and Scion vehicles with Port Electronic Fuel Injection may experience clogged or blocked fuel injectors. The following procedure has been developed to clean the fuel injectors. Applicable Vehicles: ^ All 1990 - 2006 Toyota and Scion models equipped with Port Electronic Fuel Vehicles Injection (EFI). Required Tools & Material Warranty Information Repair Procedure 1. If the fuel injector nozzles are visibly blocked or if the injectors do NOT pass the fuel injector volume test, complete the fuel injector power flush using the following instructions: A. Before an injector cleaning is performed, it is recommended that the following items be cleaned with Toyota Throttle Plate Cleaner (P/N 00289-1TP00): ^ Idle air control device ^ Throttle plate (both sides if possible) ^ Throttle body B. Bring the engine to operating temperature. C. Disconnect the fuel pump electrical connector. Page 1017 d. Reconnect and install the high-tension cords as shown in the illustration. Page 374 Oxygen Sensor: Mechanical Specifications HEATED OXYGEN SENSOR Torque: ................................................................................................................................................ ................................. 20 N.m (200 kgf.cm, 14 ft.lbf) AIR-FUEL RATIO (A/F) SENSOR Torque: ................................................................................................................................................ ................................. 20 N.m (200 kgf.cm, 14 ft.lbf) Page 1422 Compression Check: Testing and Inspection INSPECTION HINT: If there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure. 1. WARM UP AND STOP ENGINE Allow the engine to warm up to normal operating temperature. 2. REMOVE SPARK PLUGS 3. CHECK CYLINDER COMPRESSION PRESSURE a) Insert a compression gauge into the spark plug hole. b) Fully open the throttle. c) While cranking the engine, measure the compression pressure. HINT: Always use a fully charged battery to obtain engine speed of 250 rpm or more. d) Repeat steps a) through c) for each cylinder. NOTICE: This measurement must be done in as short a time as possible. Compression pressure: 1,200 kPa (12.2 kgf/cm2, 174 psi) or more Minimum pressure: 1,000 kPa (10.2 kgf/cm2, 145 psi) Difference between each cylinder: 100 kPa (1.0 kgf/cm2, 15 psi) or less e) If the cylinder compression in 1 or more cylinders is low, pour a small amount of engine oil into the cylinder through the spark plug hole and repeat steps a) through c) for cylinders with low compression. If adding oil helps the compression, it is likely that the piston rings and/or cylinder bore are worn or damaged. - If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket. 4. REINSTALL SPARK PLUGS Page 1248 Knock Sensor: Testing and Inspection Capacity Specifications Refrigerant: Capacity Specifications Charge Volume 600 +/- 50 g Page 3907 Wireless Transmitter Identification Page 1282 CHART 15 Page 3904 Application Chart Page 719 c. Connect SST, as shown below. SST 09640-10010 (09641-01010, 09641-01030, 09641-01060) NOTICE: Check, that the valve of the SST is in the open position. d. Bleed the power steering system. e. Start the engine and run it at idle. f. Turn the steering wheel from lock to lock several times to boost fluid temperature. Fluid temperature: 80°C (176°F) g. With the engine idling, close the valve of the SST and observe the reading on the SST. Minimum fluid pressure: 8,336 kPa (85 kgf/cm2, 1,209 psi) NOTICE: Do not keep the valve closed for more than 10 seconds. Do not let the fluid temperature become too high. h. With the engine idling, open the valve fully. i. Measure the fluid pressure at engine speeds of 1,000 rpm and 3,000 rpm. Difference fluid pressure: 490 kPa (5 kgf/cm2, 71 psi) or less NOTICE: Do not turn the steering wheel. Service and Repair Transmission Temperature Sensor/Switch: Service and Repair With SR5 ON-VEHICLE INSPECTION 1. DISCONNECT ATF TEMPERATURE SENSOR CONNECTOR 2. DISCONNECT OIL COOLER PIPE a. Remove the 3 bolts and clamps. b. Disconnect the oil cooler pipe. 3. REMOVE OIL COOLER ELBOW 4. REMOVE ATF TEMPERATURE SENSOR a. Remove the ATF temperature sensor. b. Remove the O-ring from the ATF temperature sensor. 5. INSTALL ATF TEMPERATURE SENSOR a. Coat a new O-ring with ATF and install it to the ATF temperature sensor. b. Install the ATF temperature sensor. Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.) 6. INSTALL OIL COOLER ELBOW 7. CONNECT OIL COOLER PIPE a. Connect the oil cooler pipe Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.) b. Install the 3 clamps and bolts. 8. CONNECT ATF TEMPERATURE SENSOR NOTICE: Be careful not to twist the wire harness. Page 4888 Passenger's Switch (Window Unlock) Passenger's Switch (Window Unlock) Passenger's Switch (Window Lock) Passenger's Switch (Window lock) If continuity is not as specified, replace the switch. INSPECT POWER WINDOW SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 4238 Testing and Inspection EFI Main Relay: Testing and Inspection 1. REMOVE EFI MAIN RELAY (Marking: EFI) 2. INSPECT EFI MAIN RELAY a. Inspect the relay continuity. 1. Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. 2. Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. b. Inspect the relay operation. 1. Apply battery positive voltage across terminals 1 and 2. 2. Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. 3. REINSTALL EFI MAIN RELAY Page 4598 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Page 3655 Impact Sensor: Testing and Inspection Replacement Requirements REPLACEMENT REQUIREMENTS In the following cases, replace the front airbag sensor. - If the SRS has been deployed in a collision. (Replace both the left and right airbag sensors.) - If the front airbag sensor has been found to be faulty in troubleshooting. - If the front airbag sensor has been found to be faulty during checking items. - If the front airbag sensor has been dropped. CAUTION: Be sure to follow the correct procedure for removal and installation of the front airbag sensor. Page 1807 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 4394 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Page 3707 Page 4331 f. Read the blinking pattern of the CRUISE MAIN indicator light. g. After performing the check, turn the main switch OFF. HINT: When 2 or more signals are input to the ECU, the lowest numbered code will be displayed first. FORD Made HINT: 1. For check No.1 - No.2: Turn the ignition switch ON. 2. For check No.3: - Turn ignition switch ON. - Shift to D position. 3. For check No.4: - Jack up the vehicle. - Start the engine. - Shift to D position. a. Press the control switch to SET/COAST or RES/ACC position and hold it down or hold it up "1". b. Press the main switch ON "2". c. Check that the CRUISE MAIN indicator light blinks twice or 3 times repeatedly after 3 seconds. d. Turn the SET/COAST or RES/ACC switch OFF. e. Operate each switch as listed in the table. Page 1803 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Page 3139 6. ADJUST TOE-IN AND WHEEL ANGLE HINT: First, check or adjust the lengths of the rack ends, then adjust the toe-in. Rack end length difference: 1.5 mm (0.059 inch) or less a. Remove the 2 clips. b. Loosen the tie rod end lock nuts. c. Turn the right and left rack ends by an equal amount to adjust the toe-in. HINT: Try to adjust the toe-in to the center of the specified value. d. Make sure that the lengths of the right and left rack ends are the same. Rack end length difference: 1.5 mm (0.059 inch) or less e. Tighten the tie rod end lock nuts. Torque: 55 Nm (560 kgf-cm, 41 ft. lbs.) f. Place the boots on the seats and install the clips. HINT: Make sure that the boots are not twisted. g. Inspect the wheel angle. Turn the steering wheel fully and measure the turning angle. Wheel Turning Angle: If the right and left wheel turning angles differ from the specified value, readjust the toe-win and wheel angle within the specified value. At this time, the right and left error lengths of the rack end may be less than 1.5 mm (0.059 inch). Page 1269 Page 2590 Step 5 INSPECTION PROCEDURE Supercharger - Squeak/Rattle Noises From Idler Pulley Supercharger: All Technical Service Bulletins Supercharger - Squeak/Rattle Noises From Idler Pulley REF.: 3.4L V6 SUPERCHARGER NO.: SC001-00 DATE: AUGUST 1, 2000 MODEL: 4Runner, Tacoma, T100, and Tundra with 3.4L V6. SUPERCHARGER DRIVE-BELT IDLER PULLEY Due to a possible out-of-tolerance condition on the idler pulley shaft, some pulleys may have bearings that spin on the inner shaft and may cause a squeaking or rattling noise. The supercharger may be perfectly fine and the source of the noise may simply be the idler pulley PART NUMBER INFORMATION PRODUCTION EFFECTIVE: Supercharger Assemblies with Serial Numbers from: 10481 to: 10990 CHECK PROCEDURE: This condition can be verified by removing the supercharger drive belt and checking the movement of the pulley on the shaft The pulley should not slide fore and aft on the shaft. INSTALLATION PROCEDURE: Loosen the drive belt. Remove the idler plate assembly. Retain all the hardware. Remove the idler pulley sub-assembly from the idler plate assembly. Replace it with the supplied new idler pulley sub-assembly. Replace the idler plate assembly and all of the hardware. The tightening torques are shown in the table. Reinstall and tension the drive belt to 120-ft lbs. for a new belt or 80 ft lbs. for a used belt (any belt used for more than 10 minutes). WARRANTY INFORMATION:* * The idler pulley assembly is warrantable only for 12 months from the point-of-first-sale. If the supercharger assembly was dealer installed, then TRD matches the balance of the new vehicle powertrain warranty. Testing and Inspection Air Conditioning Switch: Testing and Inspection INSPECTION 1. INSPECT A/C INDICATOR OPERATION a. Connect the positive (+) lead from the battery to terminal 6 and the negative (-) lead to terminal 4. b. Push the A/C button in and then check that the indicator lights up. If operation is not as specified, replace the switch. 2. INSPECT DIMMING OPERATION a. Connect positive (+) lead from the battery to terminal 6 and negative (-) lead to terminal 4 and 1. b. Connect the positive (+) lead from the battery to terminal 3 and then check that the indicator dims. If operation is not as specified, replace the switch. 3. INSPECT A/C SWITCH CONTINUITY If operation is not as specified, replace the switch or test the bulb. Page 1865 Mass Air Flow Meter: Testing and Inspection INSPECTION 1. INSPECT MAF METER RESISTANCE Using an ohmmeter, measure the resistance between terminals THA and E2. If the resistance is not as specified, replace the MAF meter. Temperature Resistance at -20 °C (-4 °F) 13.6 - 18.4 Kohms at -20 °C (68 °F) 2.2 - 2.7 Kohms at -60 °C (140 °F) 0.5 - 0.7 Kohms 2. INSPECT MAF METER OPERATION a. Connect the MAF meter connector. b. Using a voltmeter, connect the positive (+) tester probe to terminal VG, and negative (-) tester probe to terminal E2G. c. Turn the ignition switch ON. d. Blow air into the MAF meter, and check that the voltage fluctuates. If operation is not as specified, replace the MAF meter. e. Turn the ignition switch OFF. f. Disconnect the MAF meter connector. Diagram Information and Instructions Shift Interlock: Diagram Information and Instructions Key to Diagrams Key to Diagrams A: System Title. B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: (1) Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. Page 3752 Seat Belt Page 1270 Page 1720 CHART 11 Page 4164 Warning: Auto Magic © Special Cleaner Concentrate is a corrosive material. Appropriate personal protection equipment must be worn to protect persons performing the contamination removal procedure. Please refer to the precautions on the product prior to use. Caution: Consult local or state regulations regarding the handling, use, and disposal of Auto Magic © Special Cleaner Concentrate prior to use. Under no circumstances should contamination removal be performed in direct sunlight or contamination removal solution be allowed to dry on vehicle surfaces, as staining of plastic, rubber, or painted parts may result. Repair Procedure 1. Move vehicle out of direct sunlight. Initially rinse with cool water then wash with liquid car wash detergent. Rinse again thoroughly with fresh water. 2. Dilute the mixture to a 1:8 ratio for painted surfaces. Use the recommended dilution ratio when applying to any other surface. Apply the diluted cleaner so that it evenly covers the affected area. Use an appropriate mitt or sponge to agitate the surface. 3. Thoroughly rinse vehicle with fresh water. 4. Inspect vehicle carefully both visually and by feel to determine if all iron particles have been removed. Repeat the wash several times if necessary to achieve complete removal. 5. Dry vehicle with a soft terry cloth towel and apply a non-abrasive non-silicone glaze to obtain a high-gloss finish. Page 3266 Part 3 Of 3 HINT: PreRunner is the model described below. RZN191 L-TRPDKAB, RZN196L-CRPDKAB, VZN195L-CRPDKAB NOTICE: Remove the steering wheel assembly before the steering gear removal, because there is possibility of breaking of the spiral cable. 1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 2. REMOVE STEERING WHEEL PAD 3. REMOVE STEERING WHEEL 4. REMOVE ENGINE UNDER COVER Page 2352 3. MEASURE TORQUE CONVERTER CLUTCH SLEEVE RUNOUT Temporarily mount the torque converter clutch to the drive plate. Set up a dial indicator. Maximum runout: 0.30 mm (0.0118 inch) If runout is not within the specification, try to correct by reorienting the installation of the torque converter switch Page 4448 Junction Box / No. 3 Page 4653 Page 3477 Compressor Clutch: Service and Repair Disassembly and Reassembly DISASSEMBLY 1. REMOVE PRESSURE PLATE a. Using SST and a socket wrench, remove the shaft bolt. Torque: 13.2 Nm (135 kg.cm, 9 ft.lb) b. Install SST on the pressure palate. SST 07112-66040 c. Using SST and socket wrench, remove the pressure plate. d. Remove the shims from the pressure palate. Page 4299 Applicable Warranty*: This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Repair Procedure 1. Remove Wiper Arms, Plastic Cowl Cover and Wiper Motor (store wiper links up against bottom of windshield). NOTE: Mark wiper arm linkage attached to wiper motor and wiper motor splined shaft prior to removing the 12 mm retaining nut. 2. Spray Acrysol(TM) under entire lip of 1/2" pinch weld and wipe dry with a clean paper towel. FOLLOW DIRECTIONS ON SIDE OF CAN CAREFULLY. Dry open seam with compressed air prior to applying sealer. NOTE: Do not use a red shop towel to wipe surfaces because shop towels are contaminated with silicone. 3. Apply a small bead of Kent High Tech(TM) Clear Seam Sealer to underside front edge of the pinch weld from fender to fender as shown. 4. Apply Kent High Tech(TM) Clear Seam Sealer on all spot welds located on the floor of cowl panel. 5. Apply Kent High Tech(TM) Clear Seam Sealer around outside base of hood safety stops, and seal outside corner, under the "L" bracket as shown. Page 3279 a. Using a screw extractor, remove the 2 seats from the control valve housing. b. Using a plastic hammer and sliding handle, lightly tap in 2 new seats. NOTICE: Before installing the union seat, remove dust sticking to the control valve housing. REASSEMBLY NOTICE: When using a vise, do not overtighten it. 1. COAT WITH POWER STEERING FLUID OR MOLYBDENUM DISULFIDE LITHIUM BASE GREASE 2. INSTALL SPACER AND OIL SEAL a. Coat a new oil seal lip with power steering fluid. b. Using SST, press in the oil seal and spacer. SST 09951-60010 (09951-00330, 09951-00490, 09952-06010), 09951-70010 (09951-07360) NOTICE: ^ Make sure to install the oil seal facing the correct direction. ^ Take care that the oil seal does not got reversed as you install it. Diagram Information and Instructions Seat Belt Reminder Lamp: Diagram Information and Instructions Key to Diagrams Key to Diagrams A: System Title. B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: (1) Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. Locations Transmission Speed Sensor: Locations CIRCUIT DESCRIPTION The speed sensor for ABS detects the wheel speed and sends the appropriate signals to the ABS ECU. The ECU converts these signals into a pulse signal and outputs it to the combination meter. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. Page 4542 Step 3 Testing and Inspection Turn Signal Switch: Testing and Inspection INSPECT TURN SIGNAL SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 1509 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2102 Junction Box / No. 3 Fuse and Fusible Link Locations Page 367 CHART 27 Page 2278 WIRING DIAGRAM Page 788 Wheel Bearing: Diagrams Page 4563 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Page 1306 Heated Oxygen Sensor Page 1417 Spark Plug: Testing and Inspection INSPECT SPARK PLUGS a. Disconnect the 3 high-tension cords. b. Remove the 3 ignition coils. c. Using a 16 mm plug wrench, remove the 6 spark plugs. d. Clean the spark plugs. If the electrode has traces of wet carbon, allow it to dry and then clean with a spark plug cleaner. Air pressure: Below 588 kPa (6 kg/Sq.cm, 85 psi) Duration: 20 seconds or less HINT: If there are traces of oil, remove it with gasoline before using the spark plug cleaner. e. Visually check the spark plug for thread damage and insulator damage. If abnormal, replace the spark plug. Recommended spark plug: DENSO made K16TR11 NGK made BKR5EKB-11 Steering/Suspension - Ball Joint Inspection Ball Joint: Technical Service Bulletins Steering/Suspension - Ball Joint Inspection PRODUCT GENERAL INFORMATION PG027-02 December 4, 2002 Title: SUSPENSION BALL JOINT INSPECTION Models: See Applicable Models Introduction This bulletin describes the inspection method and free play specification figures for suspension ball joints. The on-vehicle inspection methods have been standardized. Applicable Vehicles Warranty Information Page 4595 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 1340 Vehicle Speed Sensor: Description and Operation CIRCUIT DESCRIPTION The speed sensor for ABS detects the wheel speed and sends the appropriate signals to the ABS ECU. The ECU converts these signals into a pulse signal and outputs it to the combination meter. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. Page 1574 Locations Body - Acid Rain Paint Damage Prevention/Repair Paint: All Technical Service Bulletins Body - Acid Rain Paint Damage Prevention/Repair TITLE: ACID RAIN PAINT FINISH DAMAGE - PREVENTION & REPAIR SECTION: EXTERIOR BULLETIN # 165 MODELS: ALL TOYOTA LEXUS and SCION DATE: MARCH 2008 Condition & Cause 'Acid Rain' is the result of rainwater and other forms of airborne moisture mixing with atmospheric impurities, often referred to as industrial fallout. The mixing forms varying degrees of corrosive acidic compounds that can settle on exposed surfaces. Depending on geographic location, concentration level, and length of exposure; vehicle paint finish damage can occur. Horizontal surfaces such as roof, hood, and trunk panels are most vulnerable. Prevention of Finish Damage While Toyota, Lexus, and Scion paint finishes are engineered to look great and provide long-term durability, if not cared for properly they can sustain damage as a result of acid rain exposure. Exposure can occur at any time in the life-cycle of a vehicle, be it transport, storage, or consumer use. Dealers should refer to the Toyota Warranty Policy and Procedures Manual, Policy No.2.3 for information on Storage and Protection of New Vehicles. Detailed information is also provided on proper finish care in the Owner's Manual of all models. In brief, following washing and wax application recommendations should keep paint looking good. Inspection & Repair Acid rain damage can usually be identified visually and by touch. Stains look similar to hard-water spotting however, advanced stages of damage result in etching and depressions from the corrosive effect. Lightly rubbing a finger across a suspected acid rain stain may help to confirm etching. University of Toyota e-learning course E257- Vehicle Delivery Quality- Paint Finish Repair, provides detailed information on paint finish types, damage assessment methods, and repair techniques. And, Collision Repair & Refinish T101 and L101 'Paint Finish Repair' provide hands-on training. There is no substitute for a good training experience. Visit (www.crrtraining.com) for more information about hands-on training. Page 1367 Crankshaft Position Sensor: Testing and Inspection INSPECT CRANKSHAFT POSITION SENSOR a. Remove the sensor connector. b. Using an ohmmeter, measure the resistance between the terminals. Resistance: Cold 1,630 - 2,740 ohms Hot 2,065 - 3,225 ohms c. Reinstall the sensor. Page 3768 Part Number Information Owner Instructions Failure to follow the recommendations indicated below could result in reduced effectiveness of the seat belt restraint system in case of vehicle collision, causing personal injury. The Seat Belt Extender must not be used: a. By anyone other than for whom it was provided (name recorded on seat belt extender). b. In any vehicle and/or seat position other than the one for which it was provided. c. When the Seat Belt Extender is provided for rear seat positions (with automatic locking retractor), make sure the retractor is locked when in use. If your seat belt cannot be fastened securely because it is not long enough, a personalized Seat Belt Extender is available from your Toyota dealer free of charge. Please contact your local Toyota dealer so that the dealer can order the proper required length for the extender. Bring the heaviest coat you expect to wear for proper measurement and selection of length. Additional ordering information is available at your Toyota dealer. CAUTION: When using the Seat Belt Extender, observe the following. Failure to follow these instructions could result in reduced effectiveness of the seat belt restraint system in case of vehicle accident, increasing the chance of personal injury. ^ Never use the Seat Belt Extender if you can COMFORTABLY fasten the seat belt without it. ^ The Seat Belt Extender must never be used with any child safety seats. ^ Remember that the extender provided for you may not be safe when used on a different vehicle, or for another person or at a different seating position than the one originally intended for. Page 4659 Shift Indicator: Fuse and Fusible Link Locations Relay Box / No. 2 Lower Valve Body Valve Body: Locations Lower Valve Body Page 2454 Part 2 Of 2 REAR AXLE SHAFT REPLACEMENT AND OVERHAUL W/ RELATED COMPONENTS Page 1059 Coolant: Fluid Type Specifications Coolant Type "Toyota Long Life Coolant" or Equivelant Coolant Do Not use alcohol type antifreezs or plain water alone. Page 2116 Transmission Mode Indicator - A/T: Testing and Inspection CIRCUIT DESCRIPTION The ECM memory contains the shift programs for the NORMAL and POWER patterns, 2 position, L position and the lock-up patterns. Following the programs corresponding to the signals from the pattern select switch, the park/neutral position and other various sensors, the ECM switches the solenoid valves ON and OFF, and controls the transmission gear change and the lock-up clutch operation. Page 2709 2. DISCONNECT CONNECTOR Pull out the release bar, and disconnect the connector. 3. DISCONNECT BRAKE LINES Using SST, disconnect the 5 brake lines from the ABS actuator. SST 09023-00100 Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.) 4. REMOVE ABS ACTUATOR ASSEMBLY Remove the bolt, 2 nuts and ABS actuator assembly. Torque: 19 Nm (195 kgf-cm, 14 ft. lbs.) 5. REMOVE ABS ACTUATOR Using a T25 torx wrench, remove the 3 bolts and ABS actuator from actuator bracket. Torque: 9.0 Nm (91.8 kgf-cm, 80 inch lbs.) INSTALLATION Installation is in the reverse order of removal. HINT: After installation, fill the brake reservoir with brake fluid, bleed brake system and check for leaks. See: Brake Bleeding Connector Locations Stop Light: Connector Locations Page 5010 Wiper Motor: Testing and Inspection Low Speed: INSPECT WIPER MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 5 and the negative (-) lead from the battery to the motor body or terminal 4, and check that the motor operates at low speed. If operation is not as specified, replace the motor. High Speed: INSPECT WIPER MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 3 and the negative (-) lead from the battery to the motor body or terminal 4, and check that the motor operates at high speed. If operation is not as specified, replace the motor. Stopping at Stop Position: INSPECT WIPER MOTOR OPERATION a. Operate the motor at low speed and stop the motor operation anywhere except at the stop position by disconnecting positive (+) lead from terminal 5. b. Connect terminals 1 and 5. Page 4390 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Description and Operation Throttle Position Sensor: Description and Operation Throttle Position Sensor The throttle position sensor is mounted in the throttle body and detects the throttle valve opening angle. When the throttle valve is fully closed, a voltage of approximately 0.3 - 1 .0 V is applied to terminal VTA of the ECM. The voltage applied to terminals VTA of the ECM increases in proportion to the opening angle of the throttle valve and becomes approximately 2.7 - 5.2 V when the throttle valve is fully opened. The ECM ledges the vehicle driving conditions from these signals input from terminals VTA and uses them as one of the conditions to decide the air- fuel ratio correction, power increase correction and fuel-cut control etc. Page 1046 Page 4261 Right Side Right Side: If continuity is not as specified, replace the switch. Page 611 Valve Clearance: Testing and Inspection INSPECTION HINT: Inspect and adjust the valve clearance when the engine is cold. 1. REMOVE INTAKE AIR CONNECTOR 2. REMOVE CYLINDER HEAD COVERS 3. SET NO.1 CYLINDER TO TDC/COMPRESSION a) Turn the crankshaft pulley, and align its groove with timing mark "0" of the No.1 timing belt cover. b) Check that the timing marks (1 dot) of the camshaft drive and driven gears are in straight line on the cylinder heads surface as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) and align the marks. 4. INSPECT VALVE CLEARANCE a) Check only the valves indicated in the illustration. 1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft. 2) Record out of specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim. Valve clearance (Cold): Description and Operation Mass Air Flow Meter: Description and Operation Mass Air Flow Meter The mass air flow meter uses a platinum hot wire. The hot wire air flow meter consists of a platinum hot wire, thermistor and a control circuit installed in a plastic housing. The hot wire air flow meter works on the principle that the hot wire and thermistor located in the intake air bypass of the housing detect any changes in the intake air temperature. The hot wire is maintained at the set temperature by controlling the current flow through the hot wire. This current flow is then measured as the output voltage of the mass air flow meter. The circuit is constructed so that the platinum hot wire and thermistor provide a bridge circuit, with the power transistor controlled so that the potential of A and B remains equal to maintain the set temperature. Page 4564 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Page 2367 Transmission Speed Sensor: Description and Operation CIRCUIT DESCRIPTION The speed sensor for ABS detects the wheel speed and sends the appropriate signals to the ABS ECU. The ECU converts these signals into a pulse signal and outputs it to the combination meter. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. Testing and Inspection Oil Filter: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Engine Lubrication; Testing and Inspection. Page 550 Alignment: Specifications NOTE: RZN161L: 4WD Regular Cab, Short Wheelbase with 3RZ-FE engine RZN171L: 4WD Extra Cab, Extra Long Wheelbase with 3RZ-FE engine RZN191L: 2WD PreRunner Regular Cab, Short Wheelbase with 3RZ-FE engine RZN196L: 2WD PreRunner Extra Cab, Extra Long Wheelbase with 3RZ-FE engine VZN170L: 4WD Extra Cab, Extra Long Wheelbase with 5VZ-FE engine VZN195L: 2WD PreRunner Extra Cab, Extra Long Wheelbase with 5VZ-FE engine INSPECTION HINT: PreRunner is the model described below. RZN191L-TRPDKAB, RZN196L-CRPDKAB, VZN195L-CRPDKAB 1. MEASURE VEHICLE HEIGHT Vehicle Height: Measuring points: A: Ground clearance of spindle center. B: Ground clearance of front adjusting cam bolt center. C: Ground clearance of leaf spring front hanger pin bolt center. D: Ground clearance of rear axle shaft center. NOTICE: Before inspecting the wheel alignment, adjust the vehicle height to the specified value. If the vehicle height is not the specified value, try to adjust it by pushing down on or lifting the body. DENSO Made Clutch Switch: Testing and Inspection DENSO Made Clutch Switch Circuit CIRCUIT DESCRIPTION When the clutch pedal is depressed, the clutch switch sends a signal to the cruise control ECU. When the signal is input to the cruise control ECU during cruise control driving, the cruise control ECU cancels cruise control. Wiring Diagram Page 3122 Junction Box / No. 1 Details Page 2641 Junction Box / No. 3 Page 1479 Data Link Connector: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Page 3068 Auxiliary Power Outlet: Locations Component Locations Page 1515 Engine Control Module: Description and Operation DESCRIPTION The Engine Control Module (ECM) controls all phases of electrical engine operation. In order to accomplish this control, the ECM relies on the input from a variety of engine operation sensors. The ECM compares input signals with those stored in memory to determine what steps should be taken to achieve maximum performance, fuel economy, and meet emission standards. The ECM outputs the necessary signals to the fuel system, ignition system, emission control systems, etc.. Page 4773 Dome Lamp: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Specifications Timing Belt: Specifications Timing Belt Replacement Interval .................................................................................................................................................. 90,000 mi. or 72 months Timing Belt Cover Torque .................................................................................................................... ........................................................................ 9 Nm Service and Repair Fuel Pressure Release: Service and Repair 1. BEFORE WORKING ON FUEL SYSTEM, DISCONNECT NEGATIVE (-) TERMINAL CABLE FROM BATTERY HINT: Any diagnostic trouble code retained by the computer will be erased when the negative (-) terminal cable is removed from the battery. Therefore, if necessary, read the diagnosis before removing the negative (-) terminal cable from the battery. 2. DO NOT SMOKE OR WORK NEAR AN OPEN FLAME WHEN WORKING ON FUEL SYSTEM 3. KEEP GASOLINE AWAY FROM RUBBER OR LEATHER PARTS 4. FUEL SYSTEM a. When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe these procedures: 1. Disconnect the fuel pump connector. 2. Start the engine. After the engine has stopped on its own, turn the ignition switch OFF. 3. Put a container under the connection. 4. Slowly loosen the connection. 5. Disconnect the connection. 6. Plug the connection with a rubber plug. b. When connecting the union bolt on the high pressure pipe union, observe these procedures: 1. Always use 2 new gaskets. 2. Tighten the union bolt by hand. 3. Tighten the union bolt to the specified torque. Torque: 34.3 Nm (350 kg.cm, 25 ft.lb) Page 3144 d. Torque the front and/or rear adjusting cam nuts. Torque: 130 Nm (1,325 kgf-cm, 96 ft. lbs.) Measuring Point Reference 5. INSPECT TOE-IN Toe-In: If the toe-in is not within the specified value, adjust the rack ends. Page 4729 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 1450 4. REINSTALL NO.2 TIMING BELT COVER Page 3085 Auxiliary Power Outlet: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Page 4508 Page 2375 RETAINER SPECIFICATIONS Page 1389 If the CO/HC concentration does not comply with regulations, troubleshoot in the order given. 1) Check the A/F sensor or heated oxygen sensor operation. 2) See the table for possible causes, and then inspect and correct the applicable causes if necessary. Page 2103 Relay Box / No. 2 Ground Locations Page 4244 Removable Roof Page 3313 - When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool) Perform the operation in a place away from electrical noise. SST 09082-00700 - When deploying an airbag, perform the operation at least 10 m (33 ft) away from the steering wheel pad. - The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment. - Use gloves and safety glasses when handling a steering wheel pad with the deployed airbag. - Always wash your hands with water after completing the operation. - Do not apply water, etc. to a steering wheel pad with the deployed airbag. DEPLOYMENT WHEN DISPOSING OF STEERING WHEEL PAD WITH AIRBAG DEPLOYED IN COLLISION CAUTION: - The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment. - When moving a vehicle for scrapping which has a steering wheel pad with the deployed airbag, use gloves and safety glasses. - Use gloves and safety glasses when handling a steering wheel pad with deployed airbag. - Always wash your hands with water after completing the operation. - Do not apply water, etc. to a steering wheel pad with deployed airbag. 1. Remove the steering wheel pad from the steering wheel. 2. Place the steering wheel pad in a vinyl bag, tie the end tightly and dispose of it in the same way as other general parts disposal. Steering Wheel Airbag Disposal HINT: When scrapping vehicle equipped with an SRS or disposing of a steering wheel pad (with airbag), always first deploy the air bag in accordance with the procedure described. If any abnormality occurs with the airbag deployment, contact the SERVICE DEPT. of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION: - Never dispose of a steering wheel pad which has an undeployed airbag. - The airbag produces a sizeable exploding sound when it deploys, so perform the operation out-ofdoors and where it will not create a nuisance to nearby residents. - When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool). Perform the operation in a place away from electrical noise. SST 09082-00700 - When deploying an airbag, perform the operation at least 10 m (33 ft) away from the steering wheel pad. Page 2006 4. REINSTALL NO.2 TIMING BELT COVER Page 397 D: Indicates related system. Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V). Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, 1H2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green O = Orange P = Pink R = Red SB = Sky Blue V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Key to Diagrams Key to Diagrams A: System Title. B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: (1) Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. Removal and Installation Brake Caliper: Service and Repair Removal and Installation REMOVAL 1. REMOVE FRONT WHEEL Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.) 2. DISCONNECT FLEXIBLE HOSE Remove the union bolt and 2 gaskets from the caliper, then disconnect the flexible hose from the caliper. Torque: 30 Nm (310 kgf-cm, 22 ft. lbs.) HINT: At the time of installation, install the flexible hose lock securely in the lock hole in the caliper. Page 3562 If circuit is as specified, try replacing the amplifier with a new one. If the circuit is not as specified, inspect the circuits connected to other parts. Page 3937 Page 2340 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Page 2308 Step 4 Locations Vehicle Speed Sensor: Locations CIRCUIT DESCRIPTION The speed sensor for ABS detects the wheel speed and sends the appropriate signals to the ABS ECU. The ECU converts these signals into a pulse signal and outputs it to the combination meter. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. Component Inspection Idle Air Control Valve: Testing and Inspection Component Inspection INSPECT IAC VALVE OPERATION a. Connect the positive (+) lead from the battery to terminal +B and negative (-) lead to terminal RSC, and check that the valve is closed. b. Connect the positive (+) lead from the battery to terminal +B and negative (-) lead to terminal RSO, and check that the valve is open. If operation is not as specified, replace the IAC valve. Page 2680 Transmission Position Switch/Sensor: Service and Repair ON-VEHICLE REPAIR 1. DISCONNECT 2 OIL COOLER PIPES 2. DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 3. REMOVE PARK/NEUTRAL POSITION SWITCH a. Pry off the lock washer and remove the nut. b. Remove the bolt and pull out the park/neutral position switch. 4. INSTALL AND ADJUST PARK/NEUTRAL POSITION SWITCH Torque: Nut: 6.9 Nm (70 kgf-cm, 61 inch lbs.) Bolt: 13 Nm (130 kgf-cm, 9 ft. lbs.) 5. CONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 6. CONNECT 2 OIL COOLER PIPES Page 2233 Shift Indicator: Locations Component Locations 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. Description and Operation Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor The crankshaft position sensor, which detects the engine speed and crankshaft angle signal (NE signal), has been installed on the oil pump body. The NE signal plate has 34 teeth. The NE signal sensor generates 34 signals at every engine revolution. The ECM detects the standard crankshaft angle based on the G signal, and the actual crankshaft angle and the engine speed by the NE signal. Page 4720 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source How to Read Power Source Service and Repair Transmission Temperature Sensor/Switch: Service and Repair With SR5 ON-VEHICLE INSPECTION 1. DISCONNECT ATF TEMPERATURE SENSOR CONNECTOR 2. DISCONNECT OIL COOLER PIPE a. Remove the 3 bolts and clamps. b. Disconnect the oil cooler pipe. 3. REMOVE OIL COOLER ELBOW 4. REMOVE ATF TEMPERATURE SENSOR a. Remove the ATF temperature sensor. b. Remove the O-ring from the ATF temperature sensor. 5. INSTALL ATF TEMPERATURE SENSOR a. Coat a new O-ring with ATF and install it to the ATF temperature sensor. b. Install the ATF temperature sensor. Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.) 6. INSTALL OIL COOLER ELBOW 7. CONNECT OIL COOLER PIPE a. Connect the oil cooler pipe Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.) b. Install the 3 clamps and bolts. 8. CONNECT ATF TEMPERATURE SENSOR NOTICE: Be careful not to twist the wire harness. Page 2240 Junction Box / No. 3 Page 3902 Page 81 Engine Control Module: Description and Operation DESCRIPTION The Engine Control Module (ECM) controls all phases of electrical engine operation. In order to accomplish this control, the ECM relies on the input from a variety of engine operation sensors. The ECM compares input signals with those stored in memory to determine what steps should be taken to achieve maximum performance, fuel economy, and meet emission standards. The ECM outputs the necessary signals to the fuel system, ignition system, emission control systems, etc.. Page 3070 Connector Locations Page 1919 a. Check the fuel lines for cracks or leakage, and all connections for deformation. b. Check the fuel tank vapor vent system hoses and connections for looseness, sharp bends or damage. c. Check the fuel tank for deformation, cracks, fuel leakage or tank band looseness. d. Check the filler neck for damage or fuel leakage. e. Hose and pipe connections are as shown in the illustration. If a problem is found, repair or replace the parts as necessary. Body - Water Leaks to The Interior Wiper Arm: All Technical Service Bulletins Body - Water Leaks to The Interior BODY BO026-00 Title: WATER LEAK FIELD-FIX REPAIR INSTRUCTIONS Models: '97 - '04 Tacoma October 27, 2000 TSB Revision Notice: ^ January 12, 2005: Applicable Vehicles has been updated to include 2004 model year. ^ August 25, 2003: VIN and Applicable Model Information has changed, and repair procedure has been expanded and clarified. ^ October 27, 2000: This TSB updates B0016-98 dated June 12, 1998. B016-98 is now obsolete and should be discarded. Previous versions of this TSB should be discarded. Introduction Use the following field-fix procedures if water is present on the floor carpeting and it can be confirmed that the water is leaking into the cab from either the upper cowl or side cowl seam, or moisture barrier behind the door trim panel. Applicable Vehicles 1997 - 2004 model year Tacoma vehicles. Required Materials Warranty Information Page 3632 Clockspring Assembly / Spiral Cable: Testing and Inspection Replacement Requirements REPLACEMENT REQUIREMENTS In the following cases, replace the steering wheel pad, steering wheel or spiral cable CAUTION: Be sure to follow the correct procedure for removal and installation of the steering wheel pad. Page 2919 4. Press the NEXT soft key (if applicable) when the HELLO screen appears to proceed to the Main Menu. 5. Choose BATTERY TEST and press the SELECT soft key. 6. Select IN VEHICLE and press the NEXT soft key. 7. Select MODEL and press the NEXT soft key. NOTE: ^ "MODEL" or "STOCK # " MUST be used to receive a warranty code if the tester determines that the battery is bad. ^ "MODEL" and "STOCK#" are linked to custom algorithms and are the most accurate testing procedures. Page 1984 d. Reconnect the sensor connector. 3. M/T: INSPECT DASHPOT (DP) a. Allow the engine to warm up to normal operating temperature. b. Check the idle speed. Idle speed: 700 + 50 rpm c. Remove the cap, filter and separator from the DP. d. Maintain the engine speed at 2,500 rpm or more. e. Plug the VTV, hole with your finger. f. Release the throttle valve. g. Check the DP is set. DP setting speed: 1,800 - 2,200 rpm h. If the setting speed is not as specified, adjust it with the DP adjusting screw. i. Remove your finger from the hole and check that the engine returns to the idle speed in approx. 1 second. j. Reinstall the DP separator, filter and cap. HINT: Install the filter with the coarser surface facing the atmospheric side (outward). 4. INSPECT THROTTLE OPENER a. Allow the engine to warm up to normal operating temperature. b. Check the idle speed. Idle speed: 700 + 50 rpm Removal and Installation Wheel Bearing: Service and Repair Removal and Installation REMOVAL Page 88 Part 2 Of 2 (California Spec.) *1: Only for A/T *2: The ECM terminal voltage is fixed regardless of the output voltage from the sensor. Connectors (Except California Spec.) Page 2524 Step 3 Page 349 CHART 11 Page 1103 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection COMPONENTS INSPECTION 1. DRAIN ENGINE COOLANT 2. DISCONNECT UPPER RADIATOR HOSE FROM WATER OUTLET 3. REMOVE NO.2 TIMING BELT COVER 4. REMOVE FUEL PIPE Remove the 2 union bolt, 4 gaskets and fuel pipe. Page 1824 Evaporative Vapor Pressure Sensor: Testing and Inspection Vapor Pressure Sensor 1. INSPECT POWER SOURCE VOLTAGE OF VAPOR PRESSURE SENSOR a. Disconnect the vapor pressure sensor connector. b. Turn the ignition switch ON. c. Using a voltmeter, measure the voltage between connector terminals VC and E2 of the wiring harness side. Voltage: 4.5 - 5.5 V d. Turn the ignition switch OFF. e. Reconnect the vapor pressure sensor connector. 2. INSPECT POWER OUTPUT OF VAPOR PRESSURE SENSOR a. Turn the ignition switch ON. b. Disconnect the vacuum hose from the vapor pressure sensor. c. Connect a voltmeter to terminals PTNK and E2 of the ECM, and measure the output voltage under ambient atmospheric pressure. 1. Apply vacuum (2.0 kpa, 15 mmHg, 0.59 in.Hg) to the vapor pressure sensor. Voltage: 1.3 - 2.1 V 2. Release the vacuum from the vapor pressure sensor. Voltage: 3.0 - 3.6 V 3. Apply pressure (1.5 kPa, 15 gf/Sq.cm, 0.22 psi) to the vapor pressure sensor. Voltage: 4.2 - 4.8 V d. Reconnect the vacuum hose to the vapor pressure sensor. Testing and Inspection Temperature Gauge: Testing and Inspection INSPECT ENGINE COOLANT TEMPERATURE RECEIVER GAUGE OPERATION a. Disconnect the connector from the sender gauge. b. Turn the ignition switch ON and check that the receiver gauge needle indicates COOL. c. Ground terminal on the wire harness side connector through a 3.4 W test bulb. d. Turn the ignition switch ON, and check that the bulb lights up and the receiver gauge needle moves to the hot side. If operation is as specified, replace the sender gauge. Then, recheck the system. If operation is not as specified, measure the receiver gauge resistance. INSPECT ENGINE COOLANT TEMPERATURE RECEIVER GAUGE RESISTANCE Measure the resistance between terminals. Page 1899 c. Remove the 2 bolts, and pull out the pressure regulator. d. Remove the O-ring from the pressure regulator. INSTALLATION 1. INSTALL FUEL PRESSURE REGULATOR a. Apply a light coat of gasoline to a new O-ring, and install it to the pressure regulator. b. Attach the pressure regulator to the LH delivery pipe. c. Check that the pressure regulator rotates smoothly. NOTE: If it does not rotate smoothly, the O-ring may be pinched, so remove the pressure regulator and repeat steps (a) to (c) above. d. Install the pressure regulator with the 2 bolts. Torque: 8 Nm (80 kg.cm, 71 in.lb) e. Install the engine wire with the bolt. 2. CONNECT FUEL RETURN HOSE TO FUEL PRESSURE REGULATOR NOTE: Be sure to insert the hose up to the stopper and clip It. 3. INSTALL INTAKE AIR CONNECTOR ASSEMBLY 4. INSTALL AIR CLEANER HOSE 5. CHECK FOR FUEL LEAKS Page 4764 Dome Lamp: Harness Locations Page 4638 Key Reminder Switch: Description and Operation Current always flows to TERMINAL 12 of the integration relay through the DOME fuse. 1. SEAT BELT WARNING SYSTEM When the ignition SW is turned ON, current flows from the GAUGE fuse to TERMINAL 6 of the integration relay. At the same time, current flows to TERMINAL A 2 of the relay from the GAUGE fuse through the seat belt warning light. This current activates the integration relay and, for approx. 4-8 seconds, the current flowing through the warning light flows from TERMINAL A 2 of the relay to TERMINAL A 7 to GROUND, causing the warning light to light up. At the same time as the warning light lights up, a buckle SW ON signal is input to TERMINAL A 3 of the integration relay, the current flowing from TERMINAL 12 of the integration relay flows to TERMINAL A 7 to GROUND and the seat belt warning buzzer sounds for approx. 4 - 8 seconds. However, if the seat belt is put ON (Buckle SW OFF) during this period (while the buzzer is sounding), a signal input to TERMINAL A 3 of the integration relay stops and the current flowing from TERMINAL 12 of the integration relay to TERMINAL A 7 to GROUND is cut, causing the buzzer to stop. 2. KEY REMINDER SYSTEM With the ignition key inserted in the key cylinder (Unlock warning SW ON), the ignition SW still oft and front LH door open (Door courtesy SW ON), a signal is input to TERMINAL A 10, A 5 of the integration relay, the integration relay operates and current flows from TERMINAL 6 of the relay to TERMINAL A 7 to GROUND and the key reminder buzzer sounds. Page 2805 a. Prepare the wooden plate to hold the pistons. b. Place the plate between the pistons and insert a pad at one side. c. Use compressed air to remove the pistons alternately from the cylinder. CAUTION: Do not place your fingers in front of the pistons when using compressed air. 3. REMOVE PISTON SEALS Using a screwdriver, remove the 4 seals from the cylinder. INSPECTION 1. MEASURE PAD LINING THICKNESS Standard thickness: 11.5 mm (0.453 inch) Minimum thickness: 1.0 mm (0.039 inch) 2. MEASURE DISC THICKNESS Standard thickness: 22.0 mm (0.866 inch) Minimum thickness: 20.0 mm (0.787 inch) 3. MEASURE DISC RUNOUT a. Tighten the disc with the 3 hub nuts. b. Using a dial indicator, measure the disc runout at a position 10 mm (0.39 inch) from the outside edge. Maximum disc runout: 0.07 mm (0.0028 inch) If the runout is greater than the maximum, replace the disc or grind it on a "On-Car" brake lathe. HINT: Before measuring the runout, confirm that the front bearing play is within the specification. 4. IF NECESSARY, ADJUST DISC RUNOUT a. Remove the hub nuts and disc. Reinstall the disc rotating 1/6 of a turn from its original position on the hub. Install and torque the hub nuts. Remeasure the disc runout. Make a note of the runout and the disc's position on the hub. b. Repeat (a) until the disc has been installed on the 4 remaining hub position. If the minimum runout recorded in (a) and (b) is less than the maximum disc runout, install the disc in that position. If the minimum runout recorded in (a) and (b) is greater than the maximum disc runout, replace the disc and repeat step 3. REASSEMBLY Reassembly is in the reverse order of disassembly. Page 4814 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Page 752 Fuse: Application and ID Engine Room R/B # 2 Page 3769 To connect the extender to the seat belt, insert the tab into the seat belt buckle so that the "PRESS" signs on the buckle-release buttons of the extender and the seat belt are both facing outward as shown. You will hear a click when the tab locks into the buckle. When releasing the seat belt, press on the buckle-release button on the extender, not on the seat belt. This helps prevent damage to the vehicle interior and extender itself. When not in use, remove the extender and store in the vehicle for future use. Page 3106 Junction Box / No. 1 Details Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid Drain and refill ..................................................................................................................................... ........................................................................ 1.7 Qt Page 4795 If continuity is not as specified, replace the switch. Page 1174 Splice Point J: Indicates a wiring Splice Point (Codes are "E"for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I 5 is indicated by the shaded section. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. N: Page No. How to Read Ground Points How to Read Ground Points Page 1376 7. REMOVE WATER BYPASS PIPE AND KNOCK SENSOR WIRE 8. REMOVE KNOCK SENSORS Using SST, remove the knock sensor. SST 09817-16011 9. INSPECT KNOCK SENSORS Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor. 10. REINSTALL KNOCK SENSORS Using SST, install the knock sensor. SST 09817-16011 Torque: 39 Nm (400 kg.cm, 29 ft.lb) 11. REINSTALL WATER BYPASS PIPE AND KNOCK SENSOR WIRE 12. REINSTALL INTAKE MANIFOLD ASSEMBLY 13. REINSTALL FUEL PRESSURE REGULATOR 14. REINSTALL INTAKE AIR CONNECTOR ASSEMBLY 15. REINSTALL NO.2 TIMING BELT COVER 16. REINSTALL AIR CLEANER HOSE 17. REFILL WITH ENGINE COOLANT Page 50 Junction Box / No. 1 Details Page 892 Drive Belt: Service and Repair REMOVAL 1. REMOVE PS PUMP DRIVE BELT 2. REMOVE ENGINE UNDER COVER 3. LOOSEN IDLE PULLEY LOCK NUT Torque: 39 Nm (400 kg.cm, 29 ft.lb) 4. REMOVE COMPRESSOR DRIVE BELT Loosen drive belt tension by adjusting bolt and remove the drive belt. INSTALLATION 1. TIGHTEN IDLE PULLEY LOCK NUT TEMPORALLY Torque: 2.5 Nm (25 kg.cm, 22 in.lb) 2. INSTALL DRIVE BELT 3. USING ADJUSTING BOLT, ADJUST DRIVE BELT TENSION Drive belt tension New belt: 160 ± 25 lb Used belt: 100 ± 25 lb 4. TIGHTEN IDLE PULLEY LOCK NUT Torque: 39 Nm (400 kg.cm, 29 ft.lb) 5. INSTALL PS PUMP DRIVE BELT 6. INSTALL ENGINE UNDER COVER Body - Paintless Dent Repair Information Paint: All Technical Service Bulletins Body - Paintless Dent Repair Information TITLE: PAINTLESS DENT REPAIR SECTION: EXTERIOR BULLETIN # 146 MODELS: TOYOTA, SCION AND LEXUS DATE: SEPTEMBER 2006 Toyota has developed the following guidelines for the use of "Paintless Dent Repair (PDR) procedures on all Toyota, Scion and Lexus vehicles. PDR is used to reduce the cost of repairing minor dents and to avoid color match and refinish issues that may arise. Be sure to choose your PDR service provider carefully and always review their professional qualifications to ensure they are up to date on the latest PDR techniques and procedures. Repair Precautions ^ Always refer to the specific vehicle schematic (available from your PDR provider) for locations where PDR is possible. ^ Pay close attention to the locations of accessories and subassemblies that may utilize wire harnesses or drain hoses, etc. ^ PDR is often complicated by panel contour, placement of reinforcements, and location of electrical and mechanical components. ^ PDR Technicians should be aware of and take the necessary precautions to prevent damage to electrical and mechanical components while performing PDR repairs. General Repair Guidelines ^ The PDR process should only be considered when the exterior paint surface is not broken or cracked. A 30X power hand held microscope (available from most body shop jobbers) should be used to determine if the paint surface shows evidence of cracking. ^ Pushing and prying on the back side of body panels can disrupt the factory rust and corrosion protective coatings. PDR technicians must take steps to prevent corrosion coating damage or restore it with approved equivalent materials. PDR service companies performing PDR repairs should be knowledgeable and capable of restoring corrosion protective coatings damaged during PDR repairs. PLEASE ROUTE THIS BULLETIN TO YOUR COLLISION REPAIR CENTER MANAGER AND COLLISION REPAIR TECHNICIANS ^ Prying, pushing, or pulling on body panels may cause stretching beyond the flexible limits of the paint coatings causing delamination (paint coating separation) or micro-cracking. These conditions may not be immediately detectable (use a 30X magnifying hand-held microscope to inspect for cracks). Important: The PDR process uses special tools to access otherwise inaccessible areas. Drilling of holes, prying away or cutting reinforcements or welded structural components to gain access to perform a PDR is strictly prohibited and, if done, may void the manufacturer's corrosion protection warranty. ^ Using blocks or wedges between window moldings and door glass (for tool access) is also prohibited. This process can damage window moldings and reduce the factory designed-in pressure of the inner belt molding on the base of the door glass. ^ Window guard protectors must be used to protect window glass during PDR operations. Specific Repair Guidelines ^ Panels with multiple dents, including hail damage, may be considered for PDR as long as the original panel integrity (strength) is maintained. If a panel exhibits any evidence of loss of strength due to the number of dents, the panel should not be considered for PDR. If after performing a PDR repair the panel exhibits evidence of loss of strength, the panel must be repaired using conventional body shop processes. ^ Round/oval dents may be removed if they are 2 inches or more away from panel edges or body lines and are no larger than the diameter of a soft ball. ^ Creases that are up to 4 long may be considered for removal. Note: Sharp creases cannot be removed using PDR. ^ Dents or protrusions, of up to 6mm, from the reverse side, on hoods, trunks, fenders, and quarter panels may be considered, but extreme caution must Drivetrain - Revised Rear Axle Oil Seal/Installation Seals and Gaskets: Technical Service Bulletins Drivetrain - Revised Rear Axle Oil Seal/Installation DRIVELINE & DIFFERENTIAL DL002-03 August 6, 2003 Title: REAR AXLE SEAL DESIGN CHANGE Models: '01 - '02 Sequoia, '95 - '02 Tacoma & '00 - '02 Tundra Introduction The rear axle seal lip design has been changed from a flat face type to an angled face type. A different SST seal driver is required to install the seal properly and prevent damaging the oil seal during the installation process. NOTE: Use of SST part number 09951-00610 (Replacer 6-4) as listed in the Repair Manual to install the newly designed rear axle seal can damage the seal assembly causing it to leak. Repair Manual update on Technical Information System (TIS) is in process. Applicable Vehicles ^ 2001 - 2002 model year Sequoia vehicles. ^ 1995 - 2002 model year Tacoma vehicles. ^ 2000 - 2002 model year Tundra vehicles. Parts Information Required SSTs NOTE: Additional SSTs may be ordered by calling SPX/OTC at 1-800-933-8335. Required Tools & Material Warranty Information Identification Procedure Page 2979 If the depth of wear is greater than the maximum, replace the contact plate. c. Remove the terminal kit parts. 1. Using SST, loosen the terminal nuts. SST 09810-38140 2. Terminal C: Remove the terminal nut, wave washer, terminal insulator (outside), O-ring, terminal bolt, contact plate and terminal insulator (inside). 3. Terminal 30: Remove the terminal nut, wave washer, terminal insulator (outside), packing, O-ring, terminal bolt, contact plate, terminal insulator (inside) and insulation paper. d. Temporarily install these new terminal 30 kit parts: 1. Insulation paper 2. Terminal insulator (inside) NOTE: Be careful to install the terminal insulator (inside) in the correct direction. 3. Contact plate 4. Terminal bolt 5. O-ring 6. Packing and terminal insulator (outside) Install the packing to the terminal insulator, and install them. HINT: Match the protrusion of the insulator with the indentation of the housing. 7. Wave washer 8. Terminal nut Description and Operation Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor The crankshaft position sensor, which detects the engine speed and crankshaft angle signal (NE signal), has been installed on the oil pump body. The NE signal plate has 34 teeth. The NE signal sensor generates 34 signals at every engine revolution. The ECM detects the standard crankshaft angle based on the G signal, and the actual crankshaft angle and the engine speed by the NE signal. Page 2432 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Page 828 Compression Check: Testing and Inspection INSPECTION HINT: If there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure. 1. WARM UP AND STOP ENGINE Allow the engine to warm up to normal operating temperature. 2. REMOVE SPARK PLUGS 3. CHECK CYLINDER COMPRESSION PRESSURE a) Insert a compression gauge into the spark plug hole. b) Fully open the throttle. c) While cranking the engine, measure the compression pressure. HINT: Always use a fully charged battery to obtain engine speed of 250 rpm or more. d) Repeat steps a) through c) for each cylinder. NOTICE: This measurement must be done in as short a time as possible. Compression pressure: 1,200 kPa (12.2 kgf/cm2, 174 psi) or more Minimum pressure: 1,000 kPa (10.2 kgf/cm2, 145 psi) Difference between each cylinder: 100 kPa (1.0 kgf/cm2, 15 psi) or less e) If the cylinder compression in 1 or more cylinders is low, pour a small amount of engine oil into the cylinder through the spark plug hole and repeat steps a) through c) for cylinders with low compression. If adding oil helps the compression, it is likely that the piston rings and/or cylinder bore are worn or damaged. - If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket. 4. REINSTALL SPARK PLUGS Page 717 Power Steering Fluid: Fluid Type Specifications Lubricant Lubricant Type Automatic Transmission Fluid Dexron II or Dexron III Recall 01E041000: Trailer Wire Harness Converter Defect Trailer Connector: Recalls Recall 01E041000: Trailer Wire Harness Converter Defect Equipment Description: Trailer towing wire harness converters which integrates the vehicle's tail lights, brake lights, and turn signal lights with those equipped on the trailer. Manufactured between May 1, 1999, and August 31, 2000, these converters were sold for installation on 1999-2000 Toyota Tundra and Tacoma vehicles. Affected part numbers are: PT207-34000, PT207-34002, PT207-04981, and PT214-04985. In the Tundra vehicles, the circuitry utilized in the converter was inadequate to properly manage vehicle and/or trailer-side voltage spikes. If the converter is exposed to a voltage spike, it may cause an electrical short or open circuit within the converter. Tacoma vehicles, due to deficient waterproofing and improper installation location of the converter, which is mounted in the lower portion of the tailgate cavity of the vehicle, an electrical short circuit will occur if water enters the converter housing. An electrical short or open circuit can cause a fault in the converter and a non-operational condition of the trailer lights. A vehicle crash can occur, possibly resulting in personal injury or death, if the vehicle is driven without operational trailer lights. Dealers will notify the customers and install a redesigned trailer towing wire harness converter free of charge. Owner notification is expect to begin August 2001. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Toyota at 1-800-331-4331. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Diagrams Page 4980 Applicable Warranty*: This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Repair Procedure 1. Remove Wiper Arms, Plastic Cowl Cover and Wiper Motor (store wiper links up against bottom of windshield). NOTE: Mark wiper arm linkage attached to wiper motor and wiper motor splined shaft prior to removing the 12 mm retaining nut. 2. Spray Acrysol(TM) under entire lip of 1/2" pinch weld and wipe dry with a clean paper towel. FOLLOW DIRECTIONS ON SIDE OF CAN CAREFULLY. Dry open seam with compressed air prior to applying sealer. NOTE: Do not use a red shop towel to wipe surfaces because shop towels are contaminated with silicone. 3. Apply a small bead of Kent High Tech(TM) Clear Seam Sealer to underside front edge of the pinch weld from fender to fender as shown. 4. Apply Kent High Tech(TM) Clear Seam Sealer on all spot welds located on the floor of cowl panel. 5. Apply Kent High Tech(TM) Clear Seam Sealer around outside base of hood safety stops, and seal outside corner, under the "L" bracket as shown. Page 4942 INSPECT REAR WIPER AND WASHER SWITCH CONTINUITY If continuity is not as specified, replace the switch. INSPECT WASHER LINKED OPERATION a. Connect the positive (+) lead from the battery to terminal 16 and the negative (-) lead to terminal 2. b. Connect the positive (+) lead from the voltmeter to terminal 7 and the negative (-) lead to terminal 2. c. Push in the washer switch, and check that the voltage changes as shown in the table. If operation is not as specified, replace the wiper and washer switch. Page 1687 Page 2997 Auxiliary Power Outlet: Locations Component Locations Description and Operation Camshaft Position Sensor: Description and Operation The Camshaft Position Sensor Camshaft position sensor (G signal) consists of a magnet, iron core and pickup coil. The G signal plate has 1 tooth, on its outer circumference and is mounted on the RH camshaft timing pulley. When the camshafts rotate, the protrusion on the signal plate and the air gap on the pickup coil change, causing fluctuations in the magnetic field and generating an electromotive force in the pickup coil. The NE signal plate has 34 teeth and is mounted on the crankshaft timing pulley. The NE signal sensor generates 34 signals at every engine revolution. The ECM detects the standard crankshaft angle based on the G signal and the actual crankshaft angle and the engine speed by the NE signal. Page 2969 Standard Spring Installed Load Standard spring Installed load: Minimum Spring Installed Load Minimum spring installed load: If the installed load is less than minimum, replace the brush springs. 7. INSPECT BRUSH HOLDER Check the brush holder insulation. Using an ohmmeter, check that there is no continuity between the positive (+) and negative (-) brush holders. If there is continuity, repair or replace the brush holder. 8. INSPECT CLUTCH AND GEAR a. Check the gear teeth on the pinion gear, idler gear and clutch assembly for wear or damage. If damaged, replace the gear or clutch assembly. If damaged, also check the ring gear of the flywheel/drive plate for wear or damage. b. Check the clutch pinion gear. Hold the starter clutch and rotate the pinion gear counterclockwise, and check that it turns freely. Try to rotate the pinion gear clockwise and check that it locks. If necessary, replace the clutch assembly. 9. INSPECT MAGNETIC SWITCH a. Check the pull-in coil for open circuit. Page 4660 Shift Indicator: Ground Locations Page 3658 Impact Sensor: Service and Repair Airbag Sensor Connectors DISCONNECTION a. While holding both flank sides of the outer, slide the outer to the direction shown by an arrow. b. Lock of the connectors is released, then disconnect the connectors. HINT: Make sure to hold both flank sides of the outer. If holding the top and bottom sides, it will obstruct disconnection. CONNECTION a. Align the male connector (of the side of sensor) and female connector in the same direction as shown in the illustration and fit in them without rubbing. b. As they are fitted in, the outer slides rearward. Press it until the outer returns to its original position again. If fitting stops half way, connectors will separate. c. Make sure to insert until they are locked. After fitting in, pull them slightly to check that they are locked. (When locked, make sure that the outer returns to its original position and sound at the time of fitting in can be heard.) HINT: Do not fit in while holding the outer. - When fitting in, the outer slides. Do not touch it. ABS/TCS - Zero Point Calibration Information Steering Angle Sensor: Technical Service Bulletins ABS/TCS - Zero Point Calibration Information T-SB-0020-08 March 25, 2008 Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment Service Category Brake Section Brake Control/Dynamic Control System Market USA Applicability Introduction The purpose of this TSB is to provide information on when and how to perform the zero point calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting the battery is a necessary step for performing the zero point calibration. Warranty Information Required Tools & Equipment ^ Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE). ^ The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the service procedures listed in this bulletin. Preliminary Information Perform this procedure if any of these repairs have been performed on the vehicle: ^ Wheel alignment has been adjusted. ^ Any chassis components have been removed/installed or replaced. Diagram Information and Instructions Key Reminder Switch: Diagram Information and Instructions Key to Diagrams Key to Diagrams A: System Title. B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: (1) Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. Page 2339 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 510 Step 1 Page 1022 Spark Plug: Specifications Torque Specification Spark Plug x Cylinder Head ................................................................................................................ ......................................................................... 18 Nm Page 3270 Part 2 Of 3 Page 4696 Page 4344 Brake Switch (Cruise Control): Testing and Inspection FORD Made CIRCUIT DESCRIPTION When the brake is on, battery positive voltage normally applies through the STOP fuse and stop light switch to terminal STP-of the ECU, and the ECU turns the cruise control off. A fail-safe function is provided so that cancel functions normally, even if there is a malfunction in the stop light signal circuit. If the harness connected to terminal STP-has an open circuit, terminal STP-will have battery positive voltage and the cruise control will be turned off. Also, when the brake is on, the magnetic clutch is cut mechanically by the stop light switch, turning the cruise control off. Wiring Diagram Description and Operation Brake Switch - TCC: Description and Operation Stop Light Switch Signal Engine This signal is used to detect when the brakes have been applied. The STP signal voltage is the same as the voltage supplied to the stop lights. The STP signal is used mainly to control the fuel cut-off engine speed (The fuel cut-off engine speed is reduced slightly when the vehicle is braking.). Automatic Transaxle The purpose of this circuit is to prevent the engine from stalling, while driving in lock-up condition, when brakes are suddenly applied. When the brake pedal is operated, this switch sends a signal to ECM. Then the ECM cancels operation of the lock-up clutch while braking is in progress. Page 3221 D: Indicates related system. Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V). Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, 1H2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green O = Orange P = Pink R = Red SB = Sky Blue V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Airbag(s) Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Airbag(s) Arming and Disarming CAUTION: * Work must be started 90 seconds after the ignition switch is turned to the "LOCK" position and the negative (-) terminal cable is disconnected from the battery. (The SRS is equipped with a back-up power source so that if work is started within 90 seconds of disconnecting the negative (-) terminal cable of the battery, the SRS may be deployed.) * When the negative (-) terminal cable is disconnected from the battery, the memory of the clock and audio system will be canceled. So before starting work, make a record of the contents memorized in the audio memory system. When work is finished, reset the audio systems as before and adjust the clock. To avoid erasing the memory of each memory system, never use a backup power supply from outside the vehicle. * Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during repairs. * Do not expose the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor directly to hot air or flames. AIR BAG SYSTEM DISARMING The Air Bag/Supplemental Restraint System (SRS) incorporates a backup energy source that maintains sufficient deployment voltage for up to 90 seconds after the ignition is turned Off and the battery has been disconnected. Before disconnecting battery, note radio station settings, since all vehicle memory will be lost. Never use a backup power source from outside the vehicle. 1. Turn ignition to Lock, then disconnect battery ground cable. 2. Wait at least 90 seconds after disconnection before beginning service or diagnostic procedures. AIR BAG SYSTEM ARMING 1. Ensure ignition is in Lock position. 2. Connect battery ground cable. 3. Wait at least 10 seconds before turning ignition from Lock position. 4. Turn ignition to ACC or On position and ensure SRS lamp lights, then goes off after approximately six seconds. If lamp remains lit, an SRS condition is indicated. Refer to Restraint Systems, Air Bag Systems, Testing And Inspection. See: Restraint Systems/Air Bag Systems/Testing and Inspection Page 756 Interior Fuse Box Interior Panel Fuse Details Description and Operation Air Bag Deactivation Switch: Description and Operation PASSENGER AIRBAG MANUAL ON-OFF SWITCH Passenger airbag manual on-off switch is mounted on the center cluster finish panel. By turning the passenger airbag manual on-off switch to OFF with the ignition key, the passenger airbag system can be disabled. Also, in order to notify the passenger that the passenger airbag is disabled, OFF indicator inside the switch will light up. Page 712 Engine Oil: Service and Repair REPLACEMENT CAUTION: Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants, which may cause skin cancer. - Care should be taken, therefore, when changing engine, oil to minimize the frequency and length of time your skin is exposed to used engine oil. Protective clothing and gloves that cannot be penetrated by oil should be worn. The skin should be thoroughly washed with soap and water, or use water-less hand cleaner, to remove any used engine oil. Do not use gasoline, thinners, or solvents. - In order to preserve the environment, used oil and used oil filters must be disposed of only at designated disposal sites. 1. DRAIN ENGINE OIL a) Remove the oil filler cap. b) Remove the oil dipstick. c) Remove the oil drain plug and drain the oil into a container. 2. REPLACE OIL FILTER a) Using SST, remove the oil filter (located on left side of the cylinder block). SST 09228-07501 b) Clean the filter contact surface on the filter mounting. c) Apply clean engine oil to the gasket of a new oil filter. d) Tighten the filter by hand until the gasket contacts the seat of the filter mounting. Then using SST, give it an additional 3/4 turn to seat the filter. SST 09228-07501 3. REFILL WITH ENGINE OIL a) Clean and install the oil drain plug with a new gasket. b) Fill the engine with new oil. Oil capacity: c) Reinstall the oil filler cap. 4. START ENGINE AND CHECK FOR LEAKS 5. RECHECK ENGINE LEVEL Page 1060 Coolant: Testing and Inspection INSPECTION 1. CHECK ENGINE COOLANT LEVEL AT RESERVOIR TANK The engine coolant level should be between the "LOW" and "FULL" lines. When the engine is cold. If low, check for leaks and add "TOYOTA Long Life Coolant" or equivalent up to the "FULL" line. 2. CHECK ENGINE COOLANT QUALITY a) Remove the radiator cap. CAUTION: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure. b) There should not be any excessive deposits of rust or scale around the radiator cap or water outlet filler hole, and the coolant should be free from oil. If they are excessively dirty, clean the coolant passages and replace the coolant. c) Reinstall the radiator cap. Page 3293 Steering Wheel: Description and Operation Steering Wheel Pad (With Airbag) The inflater and bag of the SRS are stored in the steering wheel pad and cannot be disassembled. The inflater contains a squib, igniter charge and gas generant, etc., and inflates the bag when instructed by the airbag sensor assembly. Page 1708 A. The Diagnostic Tester displays 17" as a value of the Time $81" (see illustration). B. Find the Conversion Factor value of Time $81" in the O2S Failure Threshold chart. 0.3906 is specified for Time $81 in this chart. C. Multiply "17" in step "A" by 0.3906 (Conversion Factor) in step "B." 17 x 0.3906 = 6.6% D. If the answer is within the Standard Value of TEST LIMIT, the Time $81" can be confirmed to be normal. NOTE: ^ "LOW SW V" indicates the O2S voltage when the O2S status changes from rich to lean. ^ "HIGH SW V" indicates the O2S voltage when the O2S status changes from lean to rich. ^ If the O2S voltage is lower than "LOW SW V," the O2S status is lean. ^ If the O2S voltage is higher than "HIGH SW V," the O2S status is rich. NOTE: Before the O2S Monitor completes or after the ignition switch is turned OFF, the Diagnostic Tester displays the viewable upper limit or a lower limit of the test value (example: 0 V, 1.275 V, Os [seconds], 10.2s, 0 and 255). Specifications Clutch Fluid: Specifications Fluid Type FMVSS 116 DOT 3 Brake Fluid Component Inspection Control Assembly: Testing and Inspection Component Inspection INSPECT BLOWER SPEED CONTROL SWITCH CONTINUITY If continuity is not as specified, replace the heater control assembly or test the bulb. Page 2048 Crankshaft Position Sensor: Service and Repair REPLACEMENT 1. REMOVE ENGINE UNDER COVER 2. REMOVE CRANKSHAFT POSITION SENSOR a. Disconnect the sensor connector. b. Remove the bolt and sensor. Torque: 7.8 Nm (80 kg.cm, 69 in.lb) 3. REINSTALL NEW CRANKSHAFT POSITION SENSOR a. Install the sensor with the bolt. b. Connect the sensor connector. 4. REINSTALL ENGINE UNDER COVER Page 3327 Inspection Information On-Vehicle Inspection NOTE: ^ Be sure to check the table for the applicable inspection type based on the vehicle model. ^ Refer to the table for the standard free play values. 1. Inspect Lower Ball Joint Free Play Page 451 Air Bag Deactivation Switch: Testing and Inspection 1. INSPECT PASSENGER AIRBAG MANUAL ON-OFF SWITCH CONTINUITY HINT: Release the airbag activation prevention mechanism of the passenger airbag manual on-off switch connector on the air- bag sensor assembly side. If continuity is not as specified, replace the switch. 2. INSPECT PASSENGER AIRBAG MANUAL ON-OFF INDICATOR OPERATION a. Check that continuity exists between 5 and 6. b. Connect the positive (+) lead from the battery to terminal 1 and negative (-) lead to terminal 2. c. Check that the indicator light lights up. If the operation is not as specified, replace the indicator. 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 4355 Steps 3 - 4 INSPECTION PROCEDURE Page 4194 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 398 Splice Point J: Indicates a wiring Splice Point (Codes are "E"for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I 5 is indicated by the shaded section. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. N: Page No. How to Read Ground Points How to Read Ground Points Page 2331 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Page 1731 CHART 23 Front Shock Absorber Suspension Strut / Shock Absorber: Service and Repair Front Shock Absorber Removal and Installation REMOVAL HINT: PreRunner is the model described below. RZN191L-TRPDKAB, RZNI96L-CRPDKAB, VZN195L-CRPDKAB 1. REMOVE FRONT WHEEL Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.) Page 2914 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 243 Splice Point J: Indicates a wiring Splice Point (Codes are "E"for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I 5 is indicated by the shaded section. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. N: Page No. How to Read Ground Points How to Read Ground Points Page 556 Alignment: Service and Repair NOTICE: For Zero Point Calibration information, please refer to: TSB T-SB-0020-8 (3/25/08). NOTE: RZN161L: 4WD Regular Cab, Short Wheelbase with 3RZ-FE engine RZN171L: 4WD Extra Cab, Extra Long Wheelbase with 3RZ-FE engine RZN191L: 2WD PreRunner Regular Cab, Short Wheelbase with 3RZ-FE engine RZN196L: 2WD PreRunner Extra Cab, Extra Long Wheelbase with 3RZ-FE engine VZN170L: 4WD Extra Cab, Extra Long Wheelbase with 5VZ-FE engine VZN195L: 2WD PreRunner Extra Cab, Extra Long Wheelbase with 5VZ-FE engine INSPECTION HINT: PreRunner is the model described below. RZN191L-TRPDKAB, RZN196L-CRPDKAB, VZN195L-CRPDKAB 1. MEASURE VEHICLE HEIGHT Vehicle Height: Measuring points: A: Ground clearance of spindle center. B: Ground clearance of front adjusting cam bolt center. C: Ground clearance of leaf spring front hanger pin bolt center. D: Ground clearance of rear axle shaft center. NOTICE: Before inspecting the wheel alignment, adjust the vehicle height to the specified value. If the vehicle height is not the specified value, try to adjust it by pushing down on or lifting the body. Page 2536 Junction Box / No. 3 Page 1523 Part 1 Of 2 (Except California Spec.) Page 3369 Suspension Spring ( Coil / Leaf ): Service and Repair Rear Leaf Spring REMOVAL HINT: PreRunner is the model described below. RZN191L-TRPDKAB, RZN196L-CRPDKAB, VZN195L-CRPDKAB 1. SUPPORT BODY WITH SAFETY STANDS a. Jack up and support the body on safety stands. b. Lower the axle housing until the leaf spring tension is free, and keep it at this position. 2. REMOVE REAR WHEEL Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.) 3. 4WD: DISCONNECT PARKING BRAKE CABLE Capacity Specifications Coolant: Capacity Specifications Drain and Refill Drain and Refill Capacity (with manual transmission) 10.3 qt (US) Capacity (with automatic transmission) 10.0 qt (US) Page 4386 Removal and Installation Brake Master Cylinder: Service and Repair Removal and Installation REMOVAL 1. DISCONNECT LEVEL WARNING SWITCH CONNECTOR 2. TAKE OUT FLUID WITH SYRINGE NOTICE: Do not let brake fluid remain on a painted surface. Wash it off immediately. 3. DISCONNECT BRAKE LINES Using SST, disconnect the 5 brake lines. SST 09023-00100 Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.) Page 4759 Dome Lamp: Connector Locations Page 78 Part 2 Of 2 (California Spec.) *1: Only for A/T *2: The ECM terminal voltage is fixed regardless of the output voltage from the sensor. Connectors (Except California Spec.) Page 600 Spark Plug: Specifications Torque Specification Spark Plug x Cylinder Head ................................................................................................................ ......................................................................... 18 Nm Page 666 Hose/Line HVAC: Tools and Equipment A/C Clamp Remover AST tool# TOY 200 Restraints - Seat Belt Tongue Plate Stopper Replacement Seat Belt: All Technical Service Bulletins Restraints - Seat Belt Tongue Plate Stopper Replacement T-SB-0258-08 September 2, 2008 Seat Belt Tongue Plate Stopper Replacement Service Category Vehicle Interior Section Seat Belt Market USA Applicability TSB SUPERSESSION NOTICE The information contained in this TSB supersedes TSB No. BO017-07. ^ Applicability has been updated to include 2008 model year vehicles. TSB No. BO017-07 is Obsolete and any printed versions should be discarded. Be sure to review the entire content of this service bulletin before proceeding. Introduction For situations where only the seat belt stopper is broken a new service part has been developed to eliminate the need to replace the entire seat belt assembly. Follow the installation procedure below to utilize this new part. Page 3218 Key Reminder Switch: Splice Locations Page 2644 Page 2826 HINT: When the brakes are applied, the position will move down about 0.8 mm (0.03 inch). Even at this time, the piston should not make contact with or move the load sensing spring. b. In this position, check the rear brake pressure. If the measured value is not within the standard, replace the valve body. Page 3035 Junction Box / No. 1 Details Description and Operation Brake Switch - TCC: Description and Operation Stop Light Switch Signal Engine This signal is used to detect when the brakes have been applied. The STP signal voltage is the same as the voltage supplied to the stop lights. The STP signal is used mainly to control the fuel cut-off engine speed (The fuel cut-off engine speed is reduced slightly when the vehicle is braking.). Automatic Transaxle The purpose of this circuit is to prevent the engine from stalling, while driving in lock-up condition, when brakes are suddenly applied. When the brake pedal is operated, this switch sends a signal to ECM. Then the ECM cancels operation of the lock-up clutch while braking is in progress. Page 4432 Cigarette Lighter: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Page 3281 NOTICE: Use SST 09922-10010 in the direction shown in the illustration. HINT: Use a torque wrench with a fulcrum length of 345 mm (13.58 inch). c. Using a punch and hammer, stake the rack housing. 6. AIR TIGHTNESS TEST a. Install SST to the unions of the rack housing. SST 09631-12071 b. Apply 53 kPa (400 mm Hg, 15.75 inch Hg) of vacuum for about 30 seconds. c. Check that there is no change in the vacuum. If there is change in the vacuum, check the installation of the oil seals. 7. INSTALL CONTROL VALVE ASSEMBLY a. Coat the teflon rings with power steering fluid. b. To prevent oil seal lip damage, wind vinyl tape on the serrated part of the control valve shaft. c. Push the valve assembly into the control valve housing. NOTICE: Be careful not to damage the teflon rings and oil seal lip. d. Coat a new O-ring with power steering fluid, and install it to the bearing guide nut. e. Using SST, torque the nut. Page 2503 c. Install the 2 removed bearing outer races to the spider. d. Using SST, push out the bearing from the yoke. SST 09332-25010 e. Clamp the outer bearing race in a vise and tap off the yoke with a hammer. HINT: Remove the bearing on the opposite side in the same procedure. 5. SELECT SPIDER BEARING Select the bearing according to whether or not there is a drill mark on the yoke section. 6. INSTALL SPIDER BEARING a. Apply MP grease to a new spider and bearings. NOTICE: Be careful not to apply too much grease. b. Align the matchmarks on the yoke and shaft. c. Fit the spider into the yoke. Page 1246 Page 4919 b. Remove the lock handle from the quarter window glass. c. Remove the 2 hinges from the quarter window glass. INSTALLATION Installation is in the reverse order of removal. Page 1754 INSPECTION 1. INSPECT HEATER RESISTANCE OF HEATED OXYGEN SENSOR a. Disconnect the sensor connector. b. Using an ohmmeter,measure the resistance between terminals +B and HT. Resistance: at 20 °C (68 °F) 11 - 16 ohms at 800 °C (1,472 °F) 23 - 32 ohms If the resistance is not as specified, replace the sensor. Torque: 20 Nm (200 kg.cm, 14 ft.lb) c. Reconnect the oxygen sensor connector. 2. Bank 1 Sensor 1: INSPECT OPERATION OF HEATED OXYGEN SENSOR 3. Bank 1 Sensor 2: INSPECT OPERATION OF HEATED OXYGEN SENSOR Page 2553 Harness Locations Page 4077 Air Bag(s) Arming and Disarming: Service and Repair Release Method of Airbag Activation Prevention Mechanism Page 2676 Step 2 Step 3 INSPECTION PROCEDURE Page 1504 Engine Control Module: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Page 1771 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Page 3975 Front Bumper Cover / Fascia: Technical Service Bulletins Paint - Refinishing Bumper Cover PAINT PA003-02 REVISED June 4, 2002 Title REFINISHING REPLACEMENT BUMPER COVERS Models All '83 - '05 Models TSB REVISION NOTICE: ^ February 14, 2005: Applicable Vehicles now includes 2004 - 2005 model years. Previous versions of this TSB should be discarded. Introduction In cases where a bumper cover is being replaced a special preparation process is necessary to assure the refinish is customer acceptable. This bulletin provides the recommended refinishing procedure for new bumper covers. Applicable Vehicles ^ All 1983 - 2005 model year Toyota vehicles. Required Tools & Material Note:Please visit www.3m.comlautomotive to find the nearest store that sells 3M automotive products. Warranty Information Refinishing Procedure 1. Mix a solution of mild soap (car wash soap with no wax additives) and clean water. Note: Carefully follow mixing instructions on the soap container. Too much soap or too much water may cause surface contamination or rinsing difficulty. Speed Sensor, Front Wheel Speed Sensor: Service and Repair Speed Sensor, Front REMOVAL REMOVE SPEED SENSOR a. Disconnect the speed sensor connector. b. Remove the 2 (4WD, pre runner) or 4 (2WD) clamp bolts holding the sensor harness from the steering knuckle, upper arm and side rail. Torque: Upper arm: 8.0 Nm (82 kgf-cm, 71 inch lbs.) Side rail: 13 Nm (130 kgf-cm, 9 ft. lbs.) c. Remove the speed sensor installation bolt from the steering knuckle. Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.) NOTICE: At the time of installation, please refer to the following items. ^ There are no foreign objects on the sensor or the part of the knuckle to which the sensor is to be installed. ^ The sensor is installed flat against the knuckle when you tighten the bolt. When installing the resin clips, use new ones. INSTALLATION Installation is in the reverse order of removal. NOTICE: After installation, check the speed sensor signal. Page 1888 Fuel Injector: Testing and Inspection 1. INSPECT INJECTOR RESISTANCE Using an ohmmeter, measure the resistance between the terminals. Resistance: Approx. 13.8 ohms at 20 °C (68 °F) If the resistance is not as specified, replace the injector. 2. INSPECT INJECTOR INJECTION CAUTION: Keep injector clear of sparks during the test. a. Disconnect the fuel inlet pipe from the fuel tube. b. Connect SST (attachment and hose) to the fuel tube. SST 09268-41047 (09268-52011) c. Connect the fuel return hose, SST (union) and SST (hose) to the fuel pressure regulator. SST 09268-41047 (09268-41091) d. Connect SST (hose) to the injector. SST 09268-41047 e. Put the injector into the graduated cylinder. HINT: Install a suitable vinyl hose onto the injector to prevent gasoline from splashing out. f. Connect a TOYOTA hand-held tester to the DLC3. Page 4401 d. Disconnect the negative (-) lead from the battery to terminal 10. e. Check that the chime stops sounding. f. Connect the negative (-) lead from the battery to terminal 10. g. Connect the positive (+) lead from the battery to terminal 6. h. Check that the chime stops sounding. If operation is not as specified, replace the relay. INSPECT INTEGRATION RELAY CIRCUIT a. Remove the relay from the junction block No.1 and inspect the connectors on the junction block side. Page 3201 Repair Procedure 1. Disconnect the cable from the negative (-) battery terminal for MORE THAN two (2) seconds. 2. Reconnect the cable to the negative (-) battery terminal. 3. Perform the applicable zero point calibration of the yaw rate sensor and/or the steering angle sensor. HINT Refer to the applicable TSB or Repair Manual for the zero point calibration procedure. 4. Re-initialize all applicable systems available on the vehicle (power window sunroof power lift door etc.). Page 1775 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Page 2174 Locations Relay Box: Locations Relay Box / No. 2 Page 894 Assenmacher Specialty Tools 1-800-525-2943 Page 1005 c. When connecting the flare nut on the high pressure pipe union, observe these procedures: 1. Apply a light coat of engine oil to the flare and tighten the flare nut by hand. 2. Using SST, tighten the flare nut to the specified torque. SST 09631-22020 Torque: 28 Nm (285 kg.cm, 21 ft.lb) HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). d. Observe these precautions when removing and installing the injectors. 1. Never reuse the O-ring. 2. When placing a new O-ring on the injector, take care not to damage it in any way. 3. Coat a new O-ring with spindle oil or gasoline before installing-never use engine, gear or brake oil. e. Install the injector to the delivery pipe and intake manifold, as shown in the illustration. f. Check that there are no fuel leaks after doing maintenance anywhere on the fuel system. 1. Connect a TOYOTA hand-held tester to the DLC3. Component Locations Clock: Component Locations Page 1301 CHART 30 Page 3827 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Testing and Inspection Evaporator Temperature Sensor / Switch: Testing and Inspection Thermistor 1. REMOVE GLOVE COMPARTMENT DOOR 2. INSPECT THERMISTOR RESISTANCE a. Disconnect the connector b. Measure resistance between terminals 2 and 5. Standard resistance: 1,500 Ohms at 25 °C (77 °F) If resistance is not as specified, proceed next inspection. INSPECT THERMISTOR RESISTANCE a. Place the thermistor in cold water, and while changing the temperature of the water, measure resistance at the connector and at the same time, measure temperature of the water with a thermometer. b. Compare the 2 readings on the chart. If resistance value is not as specified, replace the thermistor. Page 3040 Junction Box / No. 1 Details Page 4517 Key Reminder Switch: Description and Operation Current always flows to TERMINAL 12 of the integration relay through the DOME fuse. 1. SEAT BELT WARNING SYSTEM When the ignition SW is turned ON, current flows from the GAUGE fuse to TERMINAL 6 of the integration relay. At the same time, current flows to TERMINAL A 2 of the relay from the GAUGE fuse through the seat belt warning light. This current activates the integration relay and, for approx. 4-8 seconds, the current flowing through the warning light flows from TERMINAL A 2 of the relay to TERMINAL A 7 to GROUND, causing the warning light to light up. At the same time as the warning light lights up, a buckle SW ON signal is input to TERMINAL A 3 of the integration relay, the current flowing from TERMINAL 12 of the integration relay flows to TERMINAL A 7 to GROUND and the seat belt warning buzzer sounds for approx. 4 - 8 seconds. However, if the seat belt is put ON (Buckle SW OFF) during this period (while the buzzer is sounding), a signal input to TERMINAL A 3 of the integration relay stops and the current flowing from TERMINAL 12 of the integration relay to TERMINAL A 7 to GROUND is cut, causing the buzzer to stop. 2. KEY REMINDER SYSTEM With the ignition key inserted in the key cylinder (Unlock warning SW ON), the ignition SW still oft and front LH door open (Door courtesy SW ON), a signal is input to TERMINAL A 10, A 5 of the integration relay, the integration relay operates and current flows from TERMINAL 6 of the relay to TERMINAL A 7 to GROUND and the key reminder buzzer sounds. Page 4626 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source How to Read Power Source Page 2901 Step 4 INSPECTION PROCEDURE Page 316 Page 1043 Part 2 of 3 Page 4292 If seam is not sealed properly, clean vertical and horizontal seam area with Acrysol(TM) cleaner. Use an air hose to dry all seams before applying sealer. NOTE: Hole is located behind fender. 15. Attach a 12 to 18 inch length of plastic tubing to tip of Kent High Tech(TM) Clear Seam Sealer. 16. Seal entire vertical joint with High Tech(TM) clear seam sealer. Allow sealer to dry according to instructions on tube. NOTE: Seams are inside boxed area and accessed through the square hole as shown. 17. Flood cowl area with water to confirm that there are no cowl seam leaks into cab. If water leaks are still present and there are no cowl area seam leaks, reinstall front fender and inspect for water entry along lower edge of interior door trim panel; then proceed as follows: 18. Remove door trim panel. 19. Flood R/F door glass area (spray water at door glass, belt-molding area). 20. Inspect sealer between plastic sheeting (moisture barrier) and metal door panel for voids/skips in sealer. If there are voids/skips between the plastic sheet and the door panel, it will need to be resealed. A. Using a heat gun, heat the butyl tape securing the plastic sheet to make removal easier. B. Use Kent Acrysol to clean the door panel and plastic sheet. NOTE: ^ Follow the directions provided by the cleaning agent. ^ To ensure proper sealing of the plastic sheeting, it is important that the door panel and plastic sheeting is extremely clean. C. Use 3M 8.0 mm butyl tape (P/N 08610) to reattach the plastic sheet to the door panel. Make sure there is a continuos solid bead sealing the plastic sheet to the door panel. 21. Inspect drain-back holes (small slits in metal door panel, near bottom of sealer) to determine if holes are covered by sealer material. If sealer covers drain-back holes (small slits in metal door panel) carefully pull up a portion of plastic sheet, clean out drain-back holes and Page 4228 Page 3812 Junction Box / No. 3 Page 1437 Mass Air Flow Meter: Service and Repair REMOVAL 1. REMOVE AIR CLEANER CASE a. Disconnect the air cleaner hose. b. Disconnect the MAF meter connector. c. Remove the 3 bolts and air cleaner case. 2. REMOVE MAF METER a. Remove the 2 screws and MAF meter. b. Remove the O-ring from the MAF meter. INSTALLATION 1. INSTALL MAF METER a. Install the O-ring to the MAF meter. b. Install the MAF meter with the 2 screws. 2. INSTALL AIR CLEANER CASE a. Install the air cleaner case with the 3 bolts. b. Connect the MAF meter connector. c. Connect the air cleaner hose. Page 4625 Splice Point J: Indicates a wiring Splice Point (Codes are "E"for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I 5 is indicated by the shaded section. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. N: Page No. How to Read Ground Points How to Read Ground Points Service and Repair Fuel Pressure Release: Service and Repair 1. BEFORE WORKING ON FUEL SYSTEM, DISCONNECT NEGATIVE (-) TERMINAL CABLE FROM BATTERY HINT: Any diagnostic trouble code retained by the computer will be erased when the negative (-) terminal cable is removed from the battery. Therefore, if necessary, read the diagnosis before removing the negative (-) terminal cable from the battery. 2. DO NOT SMOKE OR WORK NEAR AN OPEN FLAME WHEN WORKING ON FUEL SYSTEM 3. KEEP GASOLINE AWAY FROM RUBBER OR LEATHER PARTS 4. FUEL SYSTEM a. When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe these procedures: 1. Disconnect the fuel pump connector. 2. Start the engine. After the engine has stopped on its own, turn the ignition switch OFF. 3. Put a container under the connection. 4. Slowly loosen the connection. 5. Disconnect the connection. 6. Plug the connection with a rubber plug. b. When connecting the union bolt on the high pressure pipe union, observe these procedures: 1. Always use 2 new gaskets. 2. Tighten the union bolt by hand. 3. Tighten the union bolt to the specified torque. Torque: 34.3 Nm (350 kg.cm, 25 ft.lb) Page 4382 D: Indicates related system. Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V). Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, 1H2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green O = Orange P = Pink R = Red SB = Sky Blue V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Page 2586 WIRING DIAGRAM Page 1651 Engine Control Module: Pinout Values and Diagnostic Parameters Connectors (California Spec.) Part 1 Of 2 (California Spec.) Locations Page 1853 2. Turn the ignition switch ON and push TOYOTA hand-held tester main switch ON. NOTE: Do not start the engine. 3. Select the ACTIVE TEST mode on the TOYOTA hand-held tester. 4. Please refer to the TOYOTA hand-held tester operator's manual for further details. 5. If you have no TOYOTA hand-held tester, connect the positive (+) and negative (-) leads from the battery to the fuel pump connector. 6. Pinch the fuel return hose. The pressure in the high pressure line will rise to approx. 400 kPa (4 kg/Sq.cm, 57 psi). In this state, check to see that there are no leaks from any part of the fuel system. NOTE: Always pinch the hose. Avoid bending as it may cause the hose to crack. 7. Turn the ignition switch OFF. 8. Disconnect the TOYOTA hand-held tester from the DLC3. Testing and Inspection Daytime Running Lamp Relay: Testing and Inspection Terminal Identification INSPECT DAYTIME RUNNING LIGHT RELAY CIRCUIT Disconnect the connector from the relay and inspect the connector on the wire harness side. If circuit is as specified, perform inspections. Page 578 Idle Speed: Testing and Inspection INSPECTION 1. INITIAL CONDITIONS a) Engine at normal operating temperature b) Air cleaner installed c) All pipes and hoses of air induction system connected d) All accessories switched OFF e) All vacuum lines properly connected f) SFI system wiring connectors fully plugged g) Ignition timing checked correctly h) Transmission in neutral position i) A/C switch is OFF 2. CONNECT TOYOTA HANDHELD TESTER OR OBDII SCAN TOOL 3. INSPECT IDLE SPEED a) Race the engine speed at 1,000 rpm for approx. 5 seconds. b) Check the idle speed. Idle speed: 700 ± 50 rpm If the idle speed is not as specified, check the IAC valve and air intake system. 4. DISCONNECT TOYOTA HANDHELD TESTER OR OBDII SCAN TOOL Page 1828 Leak Detection Solenoid: Testing and Inspection VSV FOR VAPOR PRESSURE SENSOR 1. REMOVE VSV a. Disconnect the connector and 2 vacuum hoses. b. Remove the bolt and VSV. 2. INSPECT VSV a. Inspect the VSV for open circuit. Using an ohmmeter, check that there is continuity between the terminals. Resistance: 37 - 44 ohms at 20 °C (68 °F) If there is no continuity, replace the VSV. b. Inspect the VSV for ground. Using an ohmmeter, check that there is no continuity between each terminal and the body. Page 3480 a. Set the dial indicator to the pressure plate of the magnetic clutch. b. Connect the magnetic clutch lead wire to the positive (+) terminal of the battery. c. Check the clearance between the pressure plate and rotor when connecting the negative (-) terminal to the battery. Standard clearance: 0.5 ± 0.15 mm (0.020 ± 0.0059 in.) If the clearance is not within the standard clearance, adjust the clearance using shims to obtain the standard clearance. Shim thickness: 0.1 mm (0.004 in.) 0.3 mm (0.012 in.) 0.5 mm (0.020 in.) Page 455 Impact Sensor: Description and Operation FRONT AIRBAG SENSOR The front airbag sensor is mounted inside each of the aprons. The sensor unit is a mechanical type. When the sensor detects deceleration force above a predetermined limit, contact is made in the sensor, sending a signal to the airbag sensor assembly. The sensor cannot be disassembled. Testing and Inspection Backup Lamp Relay: Testing and Inspection INSPECT BACK-UP LIGHT RELAY CONTINUITY If continuity is not as specified, replace the relay. Page 2237 Connector Locations Page 3008 D: Indicates related system. Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V). Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, 1H2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green O = Orange P = Pink R = Red SB = Sky Blue V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. 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 3476 2. STOP ENGINE 3. DISCONNECT NEGATIVE (-) TERMINAL CABLE FROM BATTERY 4. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM 5. REMOVE ENGINE UNDER COVER 6. DISCONNECT DISCHARGE AND SUCTION HOSES Remove the 2 bolts and disconnect the both hoses. NOTE: Cap the open fitting immediately to keep moisture or dirt out of the system. 7. REMOVE DRIVE BELT 8. REMOVE PS PUMP SET BOLT AND NUT 9. REMOVE COMPRESSOR a. Disconnect the connector. b. Remove the 4 bolts and compressor. INSTALLATION 1. INSTALL COMPRESSOR a. Install the compressor with 4 bolts. Torque: 25 Nm (250 kg.cm, 18 ft.lb) b. Connect the connector. 2. CONNECT DISCHARGE AND SUCTION HOSES Connect the both hoses with the 2 bolts. Torque: 10 Nm (100 kg.cm, 7 ft.lb) NOTE: Hose should be connected immediately after the caps have been removed. HINT: Lubricate 2 new O-rings with compressor oil and install the hoses. 3. INSTALL AND CHECK DRIVE BELT 4. INSTALL ENGINE UNDER COVER 5. INSTALL PS PUMP SET BOLT AND NUT Torque: 43 Nm (440 kg.cm, 32 ft.lb) 6. CONNECT NEGATIVE (-) TERMINAL CABLE TO BATTERY 7. EVACUATE AIR FROM REFRIGERATION SYSTEM 8. CHARGE SYSTEM WITH REFRIGERANT Specified amount: 600 ± 50 g (21.16 ± 1.76 oz.) 9. INSPECT FOR LEAKAGE OF REFRIGERANT Using a gas leak detector, check for leakage of refrigerant. If there is leakage, check the tightening torque at the joints. 10. INSPECT A/C OPERATION Page 3901 Page 1276 CHART 7 Diagrams Axle Shaft: Diagrams Part 1 Of 2 Page 612 b) Turn the crankshaft 2/3 of a revolution (240°), and check only the valves indicated in the illustration. Measure the valve clearance. (See step (a)) c) Turn the crankshaft a further 2/3 of a revolution (240°), and check only the valves indicated in the illustration. Measure the valve clearance. (See step (a)) 5. ADJUST VALVE CLEARANCE a) Remove the adjusting shim. 1) Turn the camshaft so that the cam lobe for the valve to be adjusted faces up. 2) Turn the valve lifter with a screwdriver so that the notches are perpendicular to the camshaft. 3) Using SST (A), press down the valve lifter and place SST (B) between the camshaft and valve lifter. Remove SST (A). SST 09248-55040 (09248-05410, 09248-05420) Page 4506 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Testing and Inspection Antenna Relay: Testing and Inspection Auto Antenna Models: INSPECT ANTENNA MOTOR CONTROL RELAY CIRCUIT Disconnect the connector from the relay and inspect the connector on wire harness side, as shown in the chart below. Testing and Inspection Washer Fluid Level Indicator: Testing and Inspection INSPECT WASHER LEVEL WARNING LIGHT a. Disconnect the connectors from the level warning switch and parking brake switch. b. Connect terminals on the wire harness side connector of the level warning switch connector. c. Remove the CHARGE fuse and turn the ignition switch ON, and check that the warning light comes on. If the warning light does not light up, test the bulb. Page 1716 CHART 5 CHART 6 Page 1600 CHART 27 Component Locations Shift Indicator: Component Locations Page 2734 Loosen/Tighten Bleeder Plug 3. CONNECT VINYL TUBE TO BRAKE CALIPER OR WHEEL CYLINDER BLEEDER PLUG Insert the other end of the tube in a half-full container of brake fluid. HINT: Begin air bleeding from the wheel cylinder with the longest hydraulic line. 4. BLEED BRAKE LINE a. Slowly depress the brake pedal several times. b. While an assistant depresses the pedal, loosen the bleeder plug until fluid starts to run out. Then tighten the bleeder plug. c. Repeat this procedure until there are no more air bubbles in the fluid. Torque: (bleeder plug) 11 Nm (110 kgf-cm, 8 ft. lbs.) 5. REPEAT PROCEDURE FOR EACH WHEEL ON-VEHICLE INSPECTION HINT: Pre runner is the described below. RZN191L-TRPDKAB, RZN196L-CRPDKAB, VZN195L-RPDKAB 1. SET REAR AXLE LOAD Rear axle load (includes vehicle weight): 2. INSTALL LSP & BV GAUGE (SST) AND BLEED AIR SST 09709-29018 3. RAISE FRONT BRAKE PRESSURE TO 7,845 kPa (80 kgf/cm2, 1,138 psi) AND CHECK REAR BRAKE PRESSURE Rear Brake Pressure: Page 3830 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Testing and Inspection Seat Belt Buckle Switch: Testing and Inspection INSPECT BUCKLE SWITCH CONTINUITY a. Check that continuity exists between terminals on the switch side connector with the switch ON (belt unfastened). b. Check that no continuity exists between terminals on the switch side connector with the switch OFF (belt fastened). If operation is not as specified, replace the seat belt inner. Page 680 Coolant: Fluid Type Specifications Coolant Type "Toyota Long Life Coolant" or Equivelant Coolant Do Not use alcohol type antifreezs or plain water alone. Page 3609 Air Bag Harness: Testing and Inspection INSPECTION HINT: The SRS wire harness is integrated with the instrument panel wire harness assembly. All the connectors in the system are a standard yellow color. 1. VEHICLES NOT INVOLVED IN COLLISION Do a diagnostic system check. * 2. VEHICLES INVOLVED IN COLLISION a. Do a diagnostic system check. * b. Check breaks in all wires of the SRS wire harness, and exposed conductors. c. Check to see if the SRS wire harness connectors are cracked or chipped. * Refer to SRS Warning Light Check, and How to Display and Read Diagnostic Codes See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Displaying & Reading Trouble Codes Page 2064 f. Adjust the electrode gap. Carefully bend the outer electrode to obtain the correct electrode gap. Correct electrode gap: 1.1 mm (0.043 in.) g. Using a 16 mm plug wrench, reinstall the spark plugs. Torque: 18 Nm (180 kg.cm, 13 ft.lb) h. Reinstall the 3 ignition coils. i. Reconnect the 3 high-tension cords. Page 1299 CHART 28 Page 58 Refer to Reset Procedure 1 for the vehicles with Electronically Controlled Automatic Transmissions: Page 645 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 3133 Repair Procedure 1. Disconnect the cable from the negative (-) battery terminal for MORE THAN two (2) seconds. 2. Reconnect the cable to the negative (-) battery terminal. 3. Perform the applicable zero point calibration of the yaw rate sensor and/or the steering angle sensor. HINT Refer to the applicable TSB or Repair Manual for the zero point calibration procedure. 4. Re-initialize all applicable systems available on the vehicle (power window sunroof power lift door etc.). Testing and Inspection Antenna Relay: Testing and Inspection Auto Antenna Models: INSPECT ANTENNA MOTOR CONTROL RELAY CIRCUIT Disconnect the connector from the relay and inspect the connector on wire harness side, as shown in the chart below. Page 77 Engine Control Module: Connector Views Connectors (California Spec.) Part 1 Of 2 (California Spec.) Page 1703 Engine Bank Identification Page 682 Coolant: Service and Repair REPLACEMENT 1. DRAIN ENGINE COOLANT a) Remove the radiator cap. CAUTION: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure. b) Loosen the drain plugs, and drain the engine coolant. c) Close the drain plugs. 2. REFILL WITH ENGINE COOLANT a) Slowly fill the system with engine coolant. ^ Use of improper coolants may damage engine cooling system. ^ Use "TOYOTA Long Life Coolant" or equivalent and mix it with plain water according to the manufacturer's directions. ^ Use of the coolant which includes more than 50% (freezing protection down to -35°C (-31°F)) or 60% (freezing protection down to -50°C (-58°F)) of ethylene-glycol is recommended, but not more than 70%. NOTICE: ^ Do not use an alcohol type engine coolant. ^ The engine coolant should be mixed with demineralized water or distilled water. Capacity: b) Reinstall the radiator cap. c) Start the engine, and bleed the cooling system. d) If necessary, refill engine coolant into the reservoir until it is "FULL" line. 3. CHECK ENGINE COOLANT FOR LEAKS Page 4932 Torque: 20 N.m (205 kgf.cm, 15ft.lbf) 14. INSTALL COWL LOUVER 15. INSTALL FRONT PILLAR GARNISHES 16. INSTALL ASSIST GRIPS 17. INSTALL SUN VISORS AND HOLDERS 18. INSTALL INNER REAR VIEW MIRROR Page 1256 Page 1480 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Page 4193 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 3635 Clockspring Assembly / Spiral Cable: Service and Repair Deployment and Disposal Airbag Deployment When Scrapping Vehicle HINT: When scrapping vehicle equipped with an SRS or disposing of a steering wheel pad (with airbag), always first deploy the airbag in accordance with the procedure described. If any abnormality occurs with the airbag deployment, contact the SERVICE DEPT. of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION: - Never dispose of a steering wheel pad which has an undeployed airbag. - The airbag produces a sizeable exploding sound when it deploys, so perform the operation out-of-doors and where it will not create a nuisance to nearby residents. - When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool). Perform the operation in a place away from electrical noise. SST 09082-00700 - When deploying an airbag, perform the operation at least 10 m (33 ft) away from the steering wheel pad. - The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment. - Use gloves and safety glasses when handling a steering wheel pad with the deployed airbag. - Always wash your hands with water after completing the operation. - Do not apply water, etc. to a steering wheel pad with the deployed airbag. HINT: Have a battery ready as the power source to deploy the airbag. a. Check functioning of the SST. CAUTION: When deploying the airbag, always use the specified SST: SRS Airbag Deployment Tool. SST 09082-00700 Description and Operation Camshaft Position Sensor: Description and Operation The Camshaft Position Sensor Camshaft position sensor (G signal) consists of a magnet, iron core and pickup coil. The G signal plate has 1 tooth, on its outer circumference and is mounted on the RH camshaft timing pulley. When the camshafts rotate, the protrusion on the signal plate and the air gap on the pickup coil change, causing fluctuations in the magnetic field and generating an electromotive force in the pickup coil. The NE signal plate has 34 teeth and is mounted on the crankshaft timing pulley. The NE signal sensor generates 34 signals at every engine revolution. The ECM detects the standard crankshaft angle based on the G signal and the actual crankshaft angle and the engine speed by the NE signal. Locations Knock Sensor: Locations Page 4447 Junction Box / No. 3 Body - Water Leaks to The Interior Cowl: Customer Interest Body - Water Leaks to The Interior BODY BO026-00 Title: WATER LEAK FIELD-FIX REPAIR INSTRUCTIONS Models: '97 - '04 Tacoma October 27, 2000 TSB Revision Notice: ^ January 12, 2005: Applicable Vehicles has been updated to include 2004 model year. ^ August 25, 2003: VIN and Applicable Model Information has changed, and repair procedure has been expanded and clarified. ^ October 27, 2000: This TSB updates B0016-98 dated June 12, 1998. B016-98 is now obsolete and should be discarded. Previous versions of this TSB should be discarded. Introduction Use the following field-fix procedures if water is present on the floor carpeting and it can be confirmed that the water is leaking into the cab from either the upper cowl or side cowl seam, or moisture barrier behind the door trim panel. Applicable Vehicles 1997 - 2004 model year Tacoma vehicles. Required Materials Warranty Information Page 4173 Page 3534 Specified amount: 600 ± 50 g (21.16 ± 1.76 oz.) 5. INSPECT FOR LEAKAGE OF REFRIGERANT Using a gas leak detector, check for leakage of refrigerant. 6. INSPECT AIR CONDITIONING OPERATION Page 87 Engine Control Module: Pinout Values and Diagnostic Parameters Connectors (California Spec.) Part 1 Of 2 (California Spec.) Page 2130 Step 1 Step 2 Page 4983 reinstall plastic sheet against metal door panel. Confirm that there are no voids between sealer and plastic sheet and between sealer and metal door panel. 22. Flood all areas with water to confirm that there are no leaks into cab area. 23. If no leaks are present, reinstall door trim panel. Page 4929 4. POSITION GLASS a. Place the glass in the correct position. b. Check that all contacting parts of the glass rim are perfectly even and do not make contact with the spacers. c. Place reference marks between the glass and body. d. Remove the glass. 5. CLEAN CONTACT SURFACE OF GLASS Using a cleaner, clean the contact surface which is black-colored area around the entire glass rim. NOTE: Do not touch the glass face after cleaning it. 6. COAT CONTACT SURFACE OF BODY WITH PRIMER "M" Using a brush, coat Primer M to the exposed part of body on the vehicle side. NOTE: Let the primer coating dry for 3 minutes or more. - Do not coat Primer M to the adhesive. - Do not keep any of the opened Primer M for later use. 7. COAT CONTACT SURFACE OF GLASS WITH PRIMER "G" Page 4431 Diagrams Description and Operation Idle Up Control Valve: Description and Operation Intake Air Control Valve The rotary solenoid type IAC valve is located on the throttle body and intake air bypassing the throttle valve is directed to the IAC valve through a passage. In this way the intake air volume bypassing the throttle valve is regulated, controlling the engine speed. The ECM operates only the IAC valve to perform idle-up and provide feedback for the target idling speed. Page 2980 e. Temporarily install these new terminal C kit parts: 1. Terminal insulator (inside) NOTE: Be careful to install the terminal insulator (inside) in the correct direction. 2. Contact plate 3. Terminal bolt 4. O-ring 5. Terminal insulator (outside) 6. Wave washer 7. Terminal nut f. Temporarily tighten the terminal nuts. g. Tighten the terminal nuts. 1. Put a wooden block on the contact plate and press it down with a hand press. Dimensions of wooden block: 20 x 37 x 40 mm (0.79 x 1.46 x 1.57 in.) Press force: 981 N (100 kg, 221 lb) NOTE: Check the diameter of the hand press ram. Then calculate the gauge pressure of the press when 981 N (100 kg, 221 lb) of force is applied. Gauge Pressure - If the contact plate is not pressed down with the specified pressure, the contact plate may tilt due to coil deformation or the tightening of the nut. Front Page 3939 Page 3030 Interior J/B # 1 Page 3746 Inspect the entire length of webbing for damage and replace the assembly if needed. Be careful NOT to damage the webbing during repair. 3. Install the NEW tongue plate stopper A. Install a NEW tongue plate stopper in the hole of the webbing. NOTE Be sure to install the stopper in the correct direction as shown in the illustration. B. Pinch the tongue plate stopper into the webbing using the tool shown in Figure 3 or use a small "C" clamp. NOTE To prevent damage to the plastic tongue plate stopper when using a "C" clamp device, use light to moderate clamping force when crimping the two halves of the tongue plate stopper together. HINT Press the adjustment screw locating the male and female parts of the tongue plate stopper parallel to each other. Page 1197 Part 2 Of 2 (California Spec.) *1: Only for A/T *2: The ECM terminal voltage is fixed regardless of the output voltage from the sensor. Connectors (Except California Spec.) Removal and Installation Compressor Clutch: Service and Repair Removal and Installation COMPONENTS REMOVAL 1. RUN ENGINE AT IDLE SPEED WITH A/C ON FOR APPROX. 10 MINUTES WITH A/C ON Page 989 Fuel Pressure: Specifications Volume Specification Information not supplied by the manufacturer. Speed Sensor, Front Wheel Speed Sensor: Service and Repair Speed Sensor, Front REMOVAL REMOVE SPEED SENSOR a. Disconnect the speed sensor connector. b. Remove the 2 (4WD, pre runner) or 4 (2WD) clamp bolts holding the sensor harness from the steering knuckle, upper arm and side rail. Torque: Upper arm: 8.0 Nm (82 kgf-cm, 71 inch lbs.) Side rail: 13 Nm (130 kgf-cm, 9 ft. lbs.) c. Remove the speed sensor installation bolt from the steering knuckle. Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.) NOTICE: At the time of installation, please refer to the following items. ^ There are no foreign objects on the sensor or the part of the knuckle to which the sensor is to be installed. ^ The sensor is installed flat against the knuckle when you tighten the bolt. When installing the resin clips, use new ones. INSTALLATION Installation is in the reverse order of removal. NOTICE: After installation, check the speed sensor signal. Page 4516 Page 4776 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 3849 3. Move the SST to at least 10 m (33 ft) away from the front of the vehicle. 4. Close all the doors and windows of the vehicle. NOTE: Take care not to damage the SST wire harness. 5. Connect the SST red clip to the battery positive (+) terminal and the black clip to the negative (-) terminal. e. Activate the seat belt pretensioner. 1. Confirm that no one is inside the vehicle or within 10 m (33 ft) area around of the vehicle. 2. Press the SST activation switch and activate the seat belt pretensioner. HINT: The seat belt pretensioner operates simultaneously as the LED of the SST activation switch lights up. f. Dispose of front seat outer belt (with seat belt pretensioner). CAUTION: The front seat outer belt is very hot when the seat belt pretensioner is activated, so leave it alone for at least 30 minutes after activation. - Use gloves and safety glasses when handling a front seat outer belt with activated seat belt pretensioner. - Always wash your hands with water after completing the operation. - Do not apply water, etc. to a front seat outer belt with activated seat belt pretensioner. HINT: When scrapping a vehicle, activate the seat belt pretensioner and scrap the vehicle with activated front seat outer belt still installed. 2. ACTIVATION WHEN DISPOSING OF FRONT SEAT OUTER BELT ONLY NOTE: When disposing of the front seat outer belt (with seat belt pretensioner) only, never use the customer's vehicle to activate the seat belt pretensioner. - Be sure to follow the procedure given on the next page when activating the seat belt pretensioner. HINT: Have a battery ready as the power source when activating the seat belt pretensioner. a. Remove the front seat outer belt. HINT: Cut the belt near the seat belt retractor. b. Check functioning of SST. (See step 1-(a)) SST 09082-00700,09082-00740 Page 2614 Overdrive Indicator Lamp: Testing and Inspection O/D Main Switch & O/D OFF Indicator Light Circuit CIRCUIT DESCRIPTION The O/D main switch is a momentary type switch. When pressing the O/D OFF main switch, the O/D OFF indicator light lights up and ECM prohibit shifting to O/D, and when pressing it again, the O/D OFF indicator light goes off and ECM allows shifting to O/D. Turning the IG switch OFF will reset the O/D OFF indicator light. Trailer Harness - Updated Design/Diagnostics Trailer Adapter Kit: Technical Service Bulletins Trailer Harness - Updated Design/Diagnostics ACCESSORIES AX006-02 October 18, 2002 Title: TRAILER WIRE HARNESS Models: 4Runner, Highlander, land Cruiser, RAV4, Sienna, Tacoma & Tundra Introduction Beginning in 2000, the accessory trailer wire harness supplier was changed and a new design was adopted which incorporated in-line fuses in the tow wire harness in addition to the vehicle fuse. This bulletin identifies the fuse location to supplement dealer diagnostics troubleshooting. In the future please reference the accessory trailer wire harness Owner's Guide for the vehicle specific diagnostic procedures. As a general note please place the towing wire harness Owner's Guide in glove box after every DIO installation. Applicable Vehicles ^ 4Runner, Highlander, Land Cruiser, RAV4, Sienna, Tacoma, and Tundra vehicles using the Accessory Towing Receiver Hitch and factory Towing Receiver Hitch option. (See table below for applicable model years.) Accessory Wire Harness Kit Information Warranty Information Page 549 Repair Procedure 1. Disconnect the cable from the negative (-) battery terminal for MORE THAN two (2) seconds. 2. Reconnect the cable to the negative (-) battery terminal. 3. Perform the applicable zero point calibration of the yaw rate sensor and/or the steering angle sensor. HINT Refer to the applicable TSB or Repair Manual for the zero point calibration procedure. 4. Re-initialize all applicable systems available on the vehicle (power window sunroof power lift door etc.). Page 1081 Radiator: Testing and Inspection ON-VEHICLE INSPECTION 1. REMOVE RADIATOR CAP CAUTION: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot, as fluid and steam can be out under pressure. 2. INSPECT RADIATOR CAP NOTICE: ^ If the radiator cap has contaminations, always rinse it with water. ^ Before using a radiator cap tester, wet the relief valve and pressure valve with engine coolant or water. Using a radiator cap tester, pump the tester and measure the relief valve opening pressure. Standard opening pressure: 74 - 103 kPa (0.75 - 1.05 kgf/cm2, 10.7 - 14.9 psi) Minimum opening pressure: 59 kPa (0.6 kgf/cm2, 8.5 psi) HINT: Use the tester's maximum reading as the opening pressure. If the opening pressure is less than minimum, replace the radiator cap. 3. INSPECT COOLING SYSTEM FOR LEAKS a) Fill the radiator with coolant and attach a radiator cap tester. b) Warm up the engine. c) Pump it to 118 kPa (1.2 kgf/cm2, 17.1 psi), and check that the pressure does not drop. If the pressure drops, check the hoses, radiator or water pump for leaks. If no external leaks are found, check the heater core, cylinder block and head. 4. REINSTALL RADIATOR CAP Page 1631 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Page 1034 b) Turn the crankshaft 2/3 of a revolution (240°), and check only the valves indicated in the illustration. Measure the valve clearance. (See step (a)) c) Turn the crankshaft a further 2/3 of a revolution (240°), and check only the valves indicated in the illustration. Measure the valve clearance. (See step (a)) 5. ADJUST VALVE CLEARANCE a) Remove the adjusting shim. 1) Turn the camshaft so that the cam lobe for the valve to be adjusted faces up. 2) Turn the valve lifter with a screwdriver so that the notches are perpendicular to the camshaft. 3) Using SST (A), press down the valve lifter and place SST (B) between the camshaft and valve lifter. Remove SST (A). SST 09248-55040 (09248-05410, 09248-05420) Description and Operation Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Sensor A thermistor that is built into the engine coolant temperature sensor changes the resistance value according to the engine coolant temperature. The lower the engine coolant temperature sensor, the greater the thermistor resistance value, and the higher the engine coolant temperature sensor temperature, the lower the thermistor resistance value. The engine coolant temperature sensor is connected to the ECM. The 5 V power source voltage in the ECM is applied to the engine coolant temperature sensor from the terminal THA via a resistor R. That is, the resistor R and the engine coolant temperature sensor are connected in series. When the resistance value of the engine coolant temperature sensor changes in accordance with changes in the engine coolant temperature, the potential at terminal THA also changes. Based on this signal, the ECM increases the fuel injection volume to improve driveability during cold engine operation. Description and Operation Transmission Mode Indicator - A/T: Description and Operation The ECM memory contains the shift programs for the NORMAL and POWER patterns, 2 position, L position and the lock-up patterns. Following the programs corresponding to the signals from the pattern select switch, the park/neutral position and other various sensors, the ECM switches the solenoid valves ON and OFF, and controls the transmission gear change and the lock-up clutch operation. Page 4001 Applicable Warranty*: This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Repair Procedure 1. Remove Wiper Arms, Plastic Cowl Cover and Wiper Motor (store wiper links up against bottom of windshield). NOTE: Mark wiper arm linkage attached to wiper motor and wiper motor splined shaft prior to removing the 12 mm retaining nut. 2. Spray Acrysol(TM) under entire lip of 1/2" pinch weld and wipe dry with a clean paper towel. FOLLOW DIRECTIONS ON SIDE OF CAN CAREFULLY. Dry open seam with compressed air prior to applying sealer. NOTE: Do not use a red shop towel to wipe surfaces because shop towels are contaminated with silicone. 3. Apply a small bead of Kent High Tech(TM) Clear Seam Sealer to underside front edge of the pinch weld from fender to fender as shown. 4. Apply Kent High Tech(TM) Clear Seam Sealer on all spot welds located on the floor of cowl panel. 5. Apply Kent High Tech(TM) Clear Seam Sealer around outside base of hood safety stops, and seal outside corner, under the "L" bracket as shown. Page 2924 10. Select the appropriate model and press the NEXT soft key. 11. Select OEM battery type and press the NEXT soft key. 12. Choose the correct battery (model number and CCA) and press the NEXT soft key. The battery will be tested before charging will occur. The progress bar fills in across the screen while testing. Page 2041 Camshaft Position Sensor: Testing and Inspection INSPECT CAMSHAFT POSITION SENSOR a. Disconnect the sensor connector. b. Using an ohmmeter, measure the resistance between the terminals. Resistance: cold 835 - 1,400 ohms Hot 1,060 - 1,645 ohms If the resistance is not as specified, replace the sensor. c. Reconnect the camshaft position sensor connector. Electrical - SRS And HV Wiring Repairs Wiring Harness: Technical Service Bulletins Electrical - SRS And HV Wiring Repairs TITLE: SRS & HV WIRING REPAIRS SECTION: ELECTRICAL BULLETIN # 156 MODELS: ALL TOYOTA LEXUS and SCION MODELS DATE: AUGUST 2007 There are no approved repairs to Supplemental Restraint System (SRS) or High Voltage (HV) wiring or connectors. SRS system wiring and connectors are color coded yellow and HV wiring is orange however vehicle-specific wiring diagrams are the best source for identifying wiring in these circuits. Wiring diagrams are available through the Technical Information System (TIS) www.techinfo.toyota.com. If SRS or HV wiring or connectors are suspected of damage they should be inspected thoroughly. Damaged wiring and/or connectors require replacement of the affected harness. Follow all precautions and procedures outlined in model-specific repair manuals for replacing SRS wiring or components. Only Certified Hybrid Service Technicians are qualified to replace HV system wiring and components. Page 1121 Part 2 of 3 Page 1624 3. Start the engine and warm it up to normal operating temperatures before test-driving. 4. Perform a thorough test drive with several accelerations from a stop with "light throttle" application until proper transmission shifting is verified. Reset Procedure 2 1. Disconnect the negative battery cable for 5 minutes. 2. Reconnect battery cable. 3. Start the engine and warm it up to normal operating temperatures before test-driving. 4. Perform a thorough test drive with several accelerations from a stop with "light throttle" application until proper transmission shifting is verified. Page 2645 Splice Locations Page 1799 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Page 3738 Before installation of the fluorocarbon resin tape, it is necessary to pre-release the colored film about 5 mm for each side. (Not fully released.) B. By pulling up the seat belt, put the fluorocarbon resin tape through the hole of the shoulder belt anchor. Match the shoulder belt anchor to the center of the tape. C. Remove the upper side colored film from the fluorocarbon resin tape, and securely affix the tape to the outside of the shoulder belt anchor. D. Remove the lower side colored film from the fluorocarbon resin tape, and securely affix the tape to the outside of the shoulder belt anchor. NOTE: ^ Be sure to affix the fluorocarbon tape securely along all edges. ^ Pay attention not to make any wrinkles or slack in the fluorocarbon resin tape. E. Remove the clip. F. By pulling the seat belt up and down several times, as shown in the illustration, securely affix the fluorocarbon resin tape and confirm the smoothness of the belt movement. Component Tests and General Diagnostics Audible Warning Device: Component Tests and General Diagnostics Automatic Light Control Automatic Light Control System Light-On Warning System: INSPECT INTEGRATION RELAY OPERATION a. Connect the positive (+) lead from the battery to terminal 12 and the negative (-) lead to terminal 7. b. Connect the positive (+) lead from the battery to terminal 4 and the negative (-) lead to terminal 5. c. Check that the buzzer does not sound when terminal 4 or 5 is connected to the positive (+) lead. d. Check that the buzzer does not sound when disconnecting terminal 4 or 5. If operation is not as specified, replace the relay. Ignition Switch and Key Unlock Warning Key Unlock Warning System: INSPECT INTEGRATION RELAY OPERATION a. Connect the positive (+) lead from the battery to terminal 12. b. Connect the negative (-) lead from the battery to terminals 5,7 and 10. c. Check the chime sounds. Page 1449 Camshaft Position Sensor: Service and Repair COMPONENTS REPLACEMENT 1. REMOVE NO.2 TIMING BELT COVER 2. REMOVE CAMSHAFT POSITION SENSOR a. Disconnect the sensor connector. b. Remove the bolt and sensor. 3. REINSTALL NEW CAMSHAFT POSITION SENSOR a. Install a new sensor with the bolt. Torque: 7.8 Nm (80 kg.cm, 69 in.lb) b. Connect the sensor connector. Page 4634 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 4185 For additional information about color matching Toyota vehicles refer to the repainting section of the Toyota Fundamental Painting procedure manual (part # 00400-BR024) or contact your regional office to obtain information about Toyota Collision Repair and Refinish Training Programs. Page 557 2. INSTALL CAMBER-CASTER-KING PIN GAUGE OR POSITION VEHICLE ON WHEEL ALIGNMENT TESTER Follow the specific instructions of the equipment manufacturer. 3. INSPECT CAMBER, CASTER AND STEERING AXIS INCLINATION Camber, caster and steering axis inclination: RZN161L Model RZN1171L Model RZN191L model RZN196L model VZN170L model Page 1564 Testing and Inspection Parking Brake Lever: Testing and Inspection ON-VEHICLE INSPECTION HINT: Pre-runner is the described below. RZN191L-TRPDKAB, RZN196L-RPDKAB, VZN195L-CRPDKAB 1. CHECK PARKING BRAKE LEVER TRAVEL Pull the parking brake lever all the way up, and count the number of clicks. Parking brake lever travel at 196 N (20 kgf, 44.1 lbs): 12 - 18 clicks 2. 2WD: IF NECESSARY, ADJUST PARKING BRAKE HINT: Before adjusting the parking brake, make sure that the rear brake shoe clearance has been adjusted. a. Loosen the lock nut. b. Tighten the adjusting nut until the travel is correct. Then tighten the lock nut. c. After adjusting the parking brake, confirm that the rear brakes are not dragging. 3. 4WD and pre runner: IF NECESSARY, ADJUST PARKING BRAKE HINT: Before adjusting the parking brake, make sure that the rear brake shoe clearance has been adjusted. a. Tighten 1 of the adjusting nuts of the intermediate lever while loosening the other one until the travel is correct. Tighten the 2 adjusting nuts. b. After adjusting the parking brake, confirm that the bellcrank stopper screw comes into contact with the backing plate. Page 3794 Seat Belt Reminder Buzzer: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. System Diagnosis Air/Fuel Mixture: Testing and Inspection INSPECTION HINT: This check is used only to determine whether or not the idle CO/HC complies with regulations. 1. INITIAL CONDITIONS a) Engine at normal operating temperature b) Air cleaner installed c) All pipes and hoses of air induction system connected d) All accessories switched OFF e) All vacuum lines properly connected f) SFI system wiring connectors fully plugged g) Ignition timing checked correctly h) Transmission in neutral position i) Tachometer and CO/HC meter calibrated by hand 2. START ENGINE 3. RACE ENGINE AT 2,500 RPM FOR APPROX. 180 SECONDS 4. INSERT CO/HC METER TESTING PROBE AT LEAST 40 cm (1.3 ft) INTO TAILPIPE DURING IDLING 5. IMMEDIATELY CHECK CO/HC CONCENTRATION AT IDLE AND/OR 2,500 RPM Complete the measuring within 3 minutes. HINT: When doing the 2 mode (2,500 rpm and idle) test, follow the measurement order prescribed by the applicable local regulations Testing and Inspection Air Conditioning Switch: Testing and Inspection INSPECTION 1. INSPECT A/C INDICATOR OPERATION a. Connect the positive (+) lead from the battery to terminal 6 and the negative (-) lead to terminal 4. b. Push the A/C button in and then check that the indicator lights up. If operation is not as specified, replace the switch. 2. INSPECT DIMMING OPERATION a. Connect positive (+) lead from the battery to terminal 6 and negative (-) lead to terminal 4 and 1. b. Connect the positive (+) lead from the battery to terminal 3 and then check that the indicator dims. If operation is not as specified, replace the switch. 3. INSPECT A/C SWITCH CONTINUITY If operation is not as specified, replace the switch or test the bulb. Page 4666 Connector Locations Page 2998 Page 2256 WIRING DIAGRAM Step 1 Page 332 Engine Bank Identification Page 2587 Step 1 Step 2 Page 296 Camshaft Position Sensor: Testing and Inspection INSPECT CAMSHAFT POSITION SENSOR a. Disconnect the sensor connector. b. Using an ohmmeter, measure the resistance between the terminals. Resistance: cold 835 - 1,400 ohms Hot 1,060 - 1,645 ohms If the resistance is not as specified, replace the sensor. c. Reconnect the camshaft position sensor connector. Page 1258 A/F and 02 Sensor Identification Page 4389 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Page 4036 If seam is not sealed properly, clean vertical and horizontal seam area with Acrysol(TM) cleaner. Use an air hose to dry all seams before applying sealer. NOTE: Hole is located behind fender. 15. Attach a 12 to 18 inch length of plastic tubing to tip of Kent High Tech(TM) Clear Seam Sealer. 16. Seal entire vertical joint with High Tech(TM) clear seam sealer. Allow sealer to dry according to instructions on tube. NOTE: Seams are inside boxed area and accessed through the square hole as shown. 17. Flood cowl area with water to confirm that there are no cowl seam leaks into cab. If water leaks are still present and there are no cowl area seam leaks, reinstall front fender and inspect for water entry along lower edge of interior door trim panel; then proceed as follows: 18. Remove door trim panel. 19. Flood R/F door glass area (spray water at door glass, belt-molding area). 20. Inspect sealer between plastic sheeting (moisture barrier) and metal door panel for voids/skips in sealer. If there are voids/skips between the plastic sheet and the door panel, it will need to be resealed. A. Using a heat gun, heat the butyl tape securing the plastic sheet to make removal easier. B. Use Kent Acrysol to clean the door panel and plastic sheet. NOTE: ^ Follow the directions provided by the cleaning agent. ^ To ensure proper sealing of the plastic sheeting, it is important that the door panel and plastic sheeting is extremely clean. C. Use 3M 8.0 mm butyl tape (P/N 08610) to reattach the plastic sheet to the door panel. Make sure there is a continuos solid bead sealing the plastic sheet to the door panel. 21. Inspect drain-back holes (small slits in metal door panel, near bottom of sealer) to determine if holes are covered by sealer material. If sealer covers drain-back holes (small slits in metal door panel) carefully pull up a portion of plastic sheet, clean out drain-back holes and Page 51 Engine Compartment Instrument Panel Locations Body - Acid Rain Paint Damage Prevention/Repair Paint: All Technical Service Bulletins Body - Acid Rain Paint Damage Prevention/Repair TITLE: ACID RAIN PAINT FINISH DAMAGE - PREVENTION & REPAIR SECTION: EXTERIOR BULLETIN # 165 MODELS: ALL TOYOTA LEXUS and SCION DATE: MARCH 2008 Condition & Cause 'Acid Rain' is the result of rainwater and other forms of airborne moisture mixing with atmospheric impurities, often referred to as industrial fallout. The mixing forms varying degrees of corrosive acidic compounds that can settle on exposed surfaces. Depending on geographic location, concentration level, and length of exposure; vehicle paint finish damage can occur. Horizontal surfaces such as roof, hood, and trunk panels are most vulnerable. Prevention of Finish Damage While Toyota, Lexus, and Scion paint finishes are engineered to look great and provide long-term durability, if not cared for properly they can sustain damage as a result of acid rain exposure. Exposure can occur at any time in the life-cycle of a vehicle, be it transport, storage, or consumer use. Dealers should refer to the Toyota Warranty Policy and Procedures Manual, Policy No.2.3 for information on Storage and Protection of New Vehicles. Detailed information is also provided on proper finish care in the Owner's Manual of all models. In brief, following washing and wax application recommendations should keep paint looking good. Inspection & Repair Acid rain damage can usually be identified visually and by touch. Stains look similar to hard-water spotting however, advanced stages of damage result in etching and depressions from the corrosive effect. Lightly rubbing a finger across a suspected acid rain stain may help to confirm etching. University of Toyota e-learning course E257- Vehicle Delivery Quality- Paint Finish Repair, provides detailed information on paint finish types, damage assessment methods, and repair techniques. And, Collision Repair & Refinish T101 and L101 'Paint Finish Repair' provide hands-on training. There is no substitute for a good training experience. Visit (www.crrtraining.com) for more information about hands-on training. Description and Operation Seat Belt Tensioner: Description and Operation Seat Belt Pretensioner The seat belt pretensioner system is a component of the front seat outer belt. The pretensioner contains a squib, gas generant, strip, etc., and operates in the event of a frontal collision. Page 519 Transmission Speed Sensor: Description and Operation CIRCUIT DESCRIPTION The speed sensor for ABS detects the wheel speed and sends the appropriate signals to the ABS ECU. The ECU converts these signals into a pulse signal and outputs it to the combination meter. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. Page 4095 Body/Interior - Trim Removal & Installation Exterior Moulding / Trim: Technical Service Bulletins Body/Interior - Trim Removal & Installation TITLE: TRIM REMOVAL & INSTALLATION SECTION: GENERAL BULLETIN #167 MODELS: ALL TOYOTA LEXUS and SCION DATE: JULY 2OO8 During collision repair and refinish operations it is often necessary to remove interior and exterior trim. Instructions and illustrations for removal and installation of trim can be found in the Interior and Exterior Panels/Trim section of model-specific Repair Manuals at www.techinfo.toyota.com. Collision repair professionals can view illustrations, step by step instructions, and helpful tips. Illustrations identify the type, quantity, and location of fasteners, as well as non-reusable items. This information can enhance productivity and reduce damage to reusable trim and fasteners. It is important to remove and install trim properly, as improper installation may result in poor fit and unwanted noises that may negatively impact quality and customer satisfaction. Most important, improperly installed interior trim may become projectiles during airbag deployment. The illustration is provided as an example of available information shown. Page 4474 W/ Tachometer W/o Tachometer If resistance value is not as specified, replace the receiver gauge. Specifications Brake Rotor/Disc: Specifications FRONT BRAKE Standard thickness .............................................................................................................................. ................................................ 22.0 mm (0.866 in.) Minimum thickness ............................................. ............................................................................................................................... 20.0 mm (0.787 in.) Maximum disc runout .......................................................................................................................... ............................................. 0.07 mm (0.0028 in.) Page 2204 Fluid Pump: Specifications Service Specifications Oil Pump Body Clearance Standard .............................................................................................................................................. .................. 0.07 - 0.15 mm (0.0028 - 0.0059 inch) Maximum ............................................................. .............................................................................................................................. 0.3 mm (0.012 inch) Tip Clearance Standard .............................................................................................................................................. .................. 0.11 - 0.14 mm (0.0043 - 0.0055 inch) Maximum ............................................................. .............................................................................................................................. 0.3 mm (0.012 inch) Side Clearance Standard .............................................................................................................................................. .................. 0.02 - 0.05 mm (0.0008 - 0.0020 inch) Maximum ............................................................. .............................................................................................................................. 0.1 mm (0.004 inch) Pump Body Bushing Inside Diameter, Maximum ........................................................................................................................... 38.19 mm (1.5035 inch) Stator Shaft Bushing Inside Diameter Front Side Maximum ........................................................................................................................... ........................................ 21.58 mm (0.8496 inch) Rear Side Maximum ............................................ ........................................................................................................................ 27.08 mm (1.0661 inch) Drive Gear and Driven Gear Thickness Mark 1 .................................................................................................................................................. ............................. 9.440 - 9.449 (0.3717 - 0.3720 Mark 2 .................................................................. ............................................................................................................ 9.450 - 9.459 (0.3720 0.3724) Mark 3 .................................................................................................................................... .......................................... 9.460 - 9.470 (0.3724 - 0.3728) Mark 4 .................................................... .......................................................................................................................... 9.471 - 9.480 (0.3720 - 0.3724) Mark 5 .................................................................................................................................. ............................................ 9.481 - 9.490 (0.3729 - 0.3736) Page 1053 Torque: 20 Nm (200 kgf-cm, 14 ft. lbs.) 2. CONNECT NO.2 OIL COOLER HOSE 3. INSTALL THERMOSTAT AND WATER INLET 4. INSTALL TIMING BELT Page 3644 Clockspring Assembly / Spiral Cable: Service and Repair Removal and Installation COMPONENT REMOVAL REMOVE THESE PARTS a. Steering Wheel Pad b. Steering Wheel c. Upper And Lower Covers d. Spiral Cable INSTALLATION INSTALL THESE PARTS Page 4044 4. Apply Kent High Tech(TM) Clear Seam Sealer on all spot welds located on the floor of cowl panel. 5. Apply Kent High Tech(TM) Clear Seam Sealer around outside base of hood safety stops, and seal outside corner, under the "L" bracket as shown. 6. Mask-off wiper motor opening. 7. Attach Kent(TM) 12" extension tube (P/N 90175) to the nozzle on the can of Leak-Chek(TM) (P/N 50087). NOTE: Direct Leak-Chek(TM) spray material approximately 1 inch above seam. Spray force is very strong - make several test passes before actually spraying material into seam. 8. Spray Leak-Chek(TM) through the wiper motor opening. a. Spray material inside upper cowl, beginning in lower corner, and continuing toward the centerline of vehicle. b. Remove wand from the wiper motor opening and insert it into larger cowl openings on the right hand side. Continue spraying material along entire seam until seam is filled from R/F fender to L/F fender area. Spray Leak-Chek(TM) into seam a total of 3 times, allowing Leak-Chek(TM) to flash dry for 30-45 minutes between applications. (Drying time increases as outside temperature decreases.) 9. After final application of Leak-Chek(TM) has been allowed to dry for approximately one hour, flood area with water for 5-10 minutes. Page 3300 Steering Wheel: Service and Repair Air Bag - Deployment and Disposal Deployment When Disposing of Steering Wheel Pad Only DISPOSAL HINT: When scrapping vehicle equipped with an SRS or disposing of a steering wheel pad (with airbag), always first deploy the air-bag in accordance with the procedure described below. If any abnormality occurs with the airbag deployment, contact the SERVICE DEPT of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION: - Never dispose of a steering wheel pad which has an undeployed airbag. - The airbag produces a sizeable exploding sound when it deploys, so perform the operation out-of-doors and where it will not create a nuisance to nearby residents. - When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool) Perform the operation in a place away from electrical noise. SST 09082-00700 - When deploying an airbag, perform the operation at least 10 m (33 ft) away from the steering wheel pad. - The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment. - Use gloves and safety glasses when handling a steering wheel pad with the deployed airbag. - Always wash your hands with water after completing the operation. - Do not apply water, etc. to a steering wheel pad with the deployed airbag. DEPLOYMENT WHEN DISPOSING OF STEERING WHEEL PAD ONLY NOTE: - When disposing of the steering wheel pad (with air-bag) only, never use the customers vehicle to deploy the airbag. - Be sure to follow the procedure given below when deploying the airbag. HINT: Have a battery ready as the power source to deploy the airbag. a. Remove the steering wheel pad. CAUTION: When removing the steering wheel pad, work must be started 90 seconds after the ignition switch is turned to the "LOCK" position and the negative (-) terminal cable is disconnected from the battery. - When storing the steering wheel pad, keep the upper surface of the pad facing upward. b. Remove the connector on the steering wheel pad rear surface. Page 3086 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Page 2461 b. Using SST and a hammer, install a new oil seal. SST 09950-60020 (09951-00710), 09950-70010 (09951-07150) c. Coat a new oil seal lip with MP grease. INSTALLATION Installation is in the reverse order of removal. HINT: After installation, bleed the brake system and check the ABS speed sensor signal. Page 1913 b. Inspect the relay operation. 1. Apply battery positive voltage across terminals 3 and 5. 2. Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. 3. Apply battery positive voltage across terminals 2 and 4. 4. Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. 3. REINSTALL CIRCUIT OPENING RELAY Testing and Inspection Backup Lamp Switch: Testing and Inspection INSPECT BACK-UP LIGHT SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 4635 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 969 17. SET NO.1 CYLINDER AT TDC/COMPRESSION a) Temporarily install the crankshaft pulley bolt to the crankshaft. b) Turn the crankshaft, and align the timing marks of the crankshaft timing pulley and oil pump body. NOTICE: Always turn the crankshaft clockwise. c) Check that the timing marks of the camshaft timing pulleys and No.3 timing belt cover are aligned. If not, turn the crankshaft pulley 1 revolution (360°). d) Remove the crankshaft pulley bolt. 18. IF REUSING TIMING BELT, CHECK INSTALLATION MARKS ON TIMING BELT Check that there are 3 installation marks and front mark on the timing belt. If the installation and front marks have disappeared, before removing the timing belt, place 3 new installation marks on the timing belt to match the timing marks of the timing pulleys, and place a new front mark on the timing belt. 19. REMOVE TIMING BELT TENSIONER Alternately loosen the 2 bolts, and remove them, the belt tensioner and dust boot. 20. REMOVE TIMING BELT 21. REMOVE RH CAMSHAFT TIMING PULLEY a) Using SST, loosen the pulley bolt. SST 09960-10010 (09962-01000, 09963-01000) b) Remove the bolt, knock pin and timing pulley. Page 2647 Page 1260 Applicable Vehicles Locations Fuse Block: Locations Relay Box / No. 2 Page 3382 SST 09727-30021 NOTICE: ^ To avoid damage to SST, set SST arms to allow clearance to hold a 8-roll coil between them. ^ Do not compress the coil spring more than necessary. ^ Do not use an impact wrench. It will damage the SST. b. Remove suspension support center nut. c. Remove the 3 retainers, 2 cushions, suspension support and coil spring. INSPECTION INSPECT SHOCK ABSORBER Compress and extend the shock absorber rod and check that there is no abnormal resistance or unusual operation sounds. If there is any abnormality, replace the shock absorber with a new one. NOTICE: When discarding the shock absorber, see DISPOSAL. DISPOSAL 1. FULLY EXTEND SHOCK ABSORBER ROD 2. DRILL HOLE TO DISCHARGE GAS FROM CYLINDER Using a drill, make a hole in the cylinder as shown in the illustration to discharge the gas inside. CAUTION: The discharged gas is harmless, but be careful of chips which may fly up when drilling. REPLACEMENT 1. REMOVE BUSHING Using SST and a press, remove the bushing. SST 09506-35010, 09632-36010 Page 3636 1. Connect the red clip of the SST to the battery positive (+) terminal and the black clip to the battery negative (-) terminal. HINT: Do not connect the yellow connector which will be connected with the supplemental restraint system. 2. Press the SST activation switch, and check that the LED of the SST activation switch lights up. CAUTION: If the LED lights up when the activation switch is not being pressed, SST malfunction is probable, so definitely do not use the SST. 3. Disconnect the SST from the battery. b. Install the SST. CAUTION: Check that there is no looseness in the steering wheel and steering wheel pad. 1. Remove the steering column lower cover. Remove the 3 screws and steering column lower cover as shown in the illustration. 2. Disconnect the airbag connector of the spiral cable. 3. Connect the connector of the SST to the airbag connector of the spiral cable. SST 09082-00700 NOTE: To avoid damaging the connector of the SST and wire harness, do not lock the secondary lock of the twin lock. Page 559 c. How to read adjustment chart. 1. Find the wheel alignment standard value applicable for the particular model. 2. Mark the selected standard value on the adjustment chart. Example: Camber: 0°10' (0.17°) Caster: 1°40' (1.67°) 3. Mark the alignment value measured when the vehicle was non-loaded on the adjustment chart. Example: Camber: -0°10'(-0.17°) Caster: 1°40' (1.67°) 4. As shown in the chart, read the distance from the measured value to the standard value, and adjust the front and/or rear adjusting cams accordingly. Example: Front cam: -(Shorter) 2.8 Rear cam: -(Shorter) 2.8 O/D Cancel Signal Circuit Overdrive Indicator Lamp: Testing and Inspection O/D Cancel Signal Circuit CIRCUIT DESCRIPTION While driving uphill with cruise control activated, in order to minimize gear shifting and provide smooth cruising O/D may be prohibited temporarily under some conditions. The cruise control ECU sends O/D cut signals to the ECM as necessary and the ECM cancels O/D shifting until these signals are discontinued. WIRING DIAGRAM System Diagnosis Air/Fuel Mixture: Testing and Inspection INSPECTION HINT: This check is used only to determine whether or not the idle CO/HC complies with regulations. 1. INITIAL CONDITIONS a) Engine at normal operating temperature b) Air cleaner installed c) All pipes and hoses of air induction system connected d) All accessories switched OFF e) All vacuum lines properly connected f) SFI system wiring connectors fully plugged g) Ignition timing checked correctly h) Transmission in neutral position i) Tachometer and CO/HC meter calibrated by hand 2. START ENGINE 3. RACE ENGINE AT 2,500 RPM FOR APPROX. 180 SECONDS 4. INSERT CO/HC METER TESTING PROBE AT LEAST 40 cm (1.3 ft) INTO TAILPIPE DURING IDLING 5. IMMEDIATELY CHECK CO/HC CONCENTRATION AT IDLE AND/OR 2,500 RPM Complete the measuring within 3 minutes. HINT: When doing the 2 mode (2,500 rpm and idle) test, follow the measurement order prescribed by the applicable local regulations Page 1729 CHART 22 Page 403 Vehicle Speed Sensor: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Page 2192 Check that the engine can be started with the shift lever only in the N or P position, but not in other positions. If it is not as stated above, carry out the following adjustment procedure. 1. Loosen the park/neutral position switch bolt and set the shift lever to the N position. 2. Align the groove and neutral basic line. 1. Hold the switch in position and tighten the bolt. Torque: 13 Nm (130 kg.cm, 10 ft.lb) For continuity inspection of the park/neutral position switch. i. Check the idle speed. Connect OBD II scan tool or TOYOTA hand-held tester to the DLC 3 and inspect the idle speed. idle speed (in N position and air conditioner OFF): 3RZ-FE: 700 ± 50 rpm 5VZ-FE: 700 ± 50 rpm Page 302 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection COMPONENTS INSPECTION 1. DRAIN ENGINE COOLANT 2. DISCONNECT UPPER RADIATOR HOSE FROM WATER OUTLET 3. REMOVE NO.2 TIMING BELT COVER 4. REMOVE FUEL PIPE Remove the 2 union bolt, 4 gaskets and fuel pipe. Page 4256 LH RH INSPECT DOOR KEY LOCK AND UNLOCK SWITCH CONTINUITY If continuity is not as specified, replace the switch. If continuity is not as specified, replace the switch. Page 4957 Windshield Washer Spray Nozzle: Adjustments ADJUSTMENT ADJUST WASHER NOZZLE Using a tool like the one shown in the figure, change the direction of the nozzle hole to adjust the point where washer fluid hits the windshield. Page 977 15. INSTALL NO.2 TIMING BELT COVER a) Check that the timing belt cover gasket has no cracks or peeling, etc. If the gasket does have cracks or peeling, etc., replace it using these steps. 1) Using a screwdriver and gasket scraper, remove all the old gasket material. 2) Thoroughly clean all components to remove all the loose material. 3) Remove the backing paper from a new gasket and install the gasket evenly to the part of the belt cover shaded black in the illustration. b) Install the timing belt cover with the 6 bolts. Torque: 9 Nm (90 kgf-cm, 80 inch lbs.) c) Connect the 4 high-tension cord clamps and camshaft position sensor connector to the timing belt cover. 16. INSTALL OIL DIPSTICK AND GUIDE a) Install a new O-ring to the dipstick guide. b) Apply soapy water to the O-ring. c) Install the oil dipstick and guide to the cylinder block. d) Install the bolt to the generator bracket. Torque: 8 Nm (80 kgf-cm, 71 inch lbs.) 17. INSTALL A/C COMPRESSOR BRACKET Torque: 47 Nm (479 kgf-cm, 35 ft. lbs.) 18. TEMPORARILY INSTALL FAN WITH FLUID COUPLING AND FAN PULLEYS 19. INSTALL NO.2 FAN SHROUD 20. INSTALL AND ADJUST DRIVE BELT FOR GENERATOR 21. TIGHTEN FAN WITH FLUID COUPLING AND FAN PULLEYS Torque: 5.4 Nm (54 kgf-cm, 48 inch lbs.) 22. CONNECT A/C COMPRESSOR TO ENGINE a) Install the A/C compressor with the 4 bolts. Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.) b) Install the drive belt. c) Connect the A/C compressor connector. 23. CONNECT PS PUMP TO ENGINE a) Temporarily install the PS pump with the bolt and nut. b) Install the drive belt. c) Tighten the bolt and nut. Torque: 43 Nm (440 kgf-cm,31 ft. lbs.) d) Install the PS pressure tube clamp with the bolt. e) Connect the 2 PS air hoses to the air intake chamber and resonator. 24. CONNECT UPPER RADIATOR HOSE 25. FILL ENGINE WITH COOLANT 26. START ENGINE CHECK FOR LEAKS 27. INSTALL ENGINE UNDER COVER 28. PERFORM ROAD TEST Check for abnormal noise, shock, slippage, correct shift points and smooth operation. 29. RECHECK ENGINE COOLANT LEVEL Wheels - Tire Inflation & Wheel Lug Torque Chart Wheel Fastener: Technical Service Bulletins Wheels - Tire Inflation & Wheel Lug Torque Chart October 1, 1999 TIRE INFLATION & WHEEL LUG TORQUE REFERENCE CHART PG031-99 Introduction Proper tire inflation is important to maximize tire life and vehicle ride comfort. 2000 MY Toyota vehicles are available with a wide variety of wheel sizes and tire profiles. Prior to customer vehicle delivery, refer to the following table to identify the appropriate tire pressure setting. Adjust tire pressures accordingly. Applicable Vehicles All 2000 Models Tire Pressure Settings * Recommended tire inflation pressure under high load capacity. Page 3238 a. Connect the positive (+) lead from the battery to terminal 12. b. Connect the negative (-) lead from the battery to terminals 5,7 and 10. c. Check the chime sounds. d. Disconnect the negative (-) lead from the battery to terminal 10. e. Check that the chime stops sounding. f. Connect the negative (-) lead from the battery to terminal 10. g. Connect the positive (+) lead from the battery to terminal 6. h. Check that the chime stops sounding. If operation is not as specified, replace the relay. 4. INSPECT INTEGRATION RELAY CIRCUIT a. Remove the relay from the junction block No.1 and inspect the connectors on the junction block side. Page 4662 Shift Indicator: Locations Component Locations Page 2591 Overdrive Switch: Testing and Inspection O/D Cancel Signal Circuit CIRCUIT DESCRIPTION While driving uphill with cruise control activated, in order to minimize gear shifting and provide smooth cruising O/D may be prohibited temporarily under some conditions. The cruise control ECU sends O/D cut signals to the ECM as necessary and the ECM cancels O/D shifting until these signals are discontinued. WIRING DIAGRAM Page 1207 Fuel Pump Relay: Testing and Inspection 1. REMOVE CIRCUIT OPENING RELAY 2. INSPECT CIRCUIT OPENING RELAY a. Inspect the relay continuity. 1. Using an ohmmeter, check that there is no continuity between terminals 1 and 2. If there is continuity, replace the relay. 2. Check that there is continuity between terminals 2 and 4. If there is no continuity, replace the relay. 3. Check that there is continuity between terminals 5 and 5. If there is no continuity, replace the relay. Page 1312 Oxygen Sensor: Testing and Inspection Heated Oxygen Sensor Heated Oxygen Sensor COMPONENTS Pressure Specification Fuel Pressure: Specifications Fuel Pressure No Vacuum 38 to 44 psi Page 4439 Page 3308 c. Deploy the airbag. 1. Check that no one is inside the vehicle or within 10 m (33 ft) area around the vehicle. 2. Press the SST activation switch and deploy the airbag. HINT: The airbag deploys simultaneously as the LED of the SST activation switch lights up. d. Dispose of steering wheel pad (with airbag). CAUTION: The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment. - Use gloves and safety glasses when handling a steering wheel pad with the deployed airbag. - Always wash your hands with water after completing the operation. - Do not apply water, etc. to a steering wheel pad with the deployed airbag. 1. When scrapping a vehicle, deploy the airbag and scrap the vehicle with the steering wheel pad still installed. 2. When moving a vehicle for scrapping which has a steering wheel pad with deployed airbag, use gloves and safety glasses. Deployment When Disposing of Steering Wheel Pad DISPOSAL HINT: When scrapping vehicle equipped with an SRS or disposing of a front passenger airbag assembly, always first deploy the airbag in accordance with the procedure described below. If any abnormality occurs with the airbag deployment, contact the SERVICE DEPT. of the TOYOTA MOTOR SALES, U.S.A., INC. CAUTION: - Never dispose of a front passenger airbag assembly which has an undeployed airbag. - The airbag produces a sizeable exploding sound when it deploys, so perform the operation out-of-doors and where it will not create a nuisance to nearby residents. - When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool). Perform the operation in a place away from electrical noise. - When deploying an airbag, perform the operation at least 10 m (33 ft) away from the front passenger airbag assembly. - The front passenger airbag assembly is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment. - Use gloves and safety glasses when handling a front passenger airbag assembly with the deployed airbag. - Always wash your hands with water after completing the operation. - Do not apply water, etc. to a front passenger airbag assembly with the deployed airbag. DISPOSE HORN BUTTON ASSY(WHEN DISPOSING OF AIRBAG ASSEMBLY DEPLOYMENT METHOD)[45130/ 98-75] NOTE: - When disposing of the steering wheel pad (with air- bag) only, never use the customers vehicle to deploy the airbag. - Be sure to follow the procedure given below when deploying the airbag. Page 4387 Testing and Inspection Fuel Gauge: Testing and Inspection INSPECT FUEL RECEIVER GAUGE OPERATION a. Disconnect the connector from the sender gauge. b. Turn the ignition switch ON, check that the receiver gauge needle indicates EMPTY c. Connect terminals 2 and 3 on the wire harness side connector through a 3.4 W test bulb. d. Turn the ignition switch ON, check that the bulb lights up and the receiver gauge needle moves toward FULL side. HINT: Because of the silicon oil in the gauge, it will take a short time for needle to stabilize. If operation is not as specified, inspect the receiver gauge resistance. INSPECT FUEL RECEIVER GAUGE RESISTANCE Measure the resistance between terminals. Page 1566 A/F and 02 Sensor Identification Page 2387 Collision / Non-Collision Inspections Seat Belt Tensioner: Testing and Inspection Collision / Non-Collision Inspections INSPECTION 1. PRETENSIONER IS NOT ACTIVATED a. Perform a diagnostic system check. b. Perform a visual check which includes the following items with the front seat outer belt removed from the vehicle. - Regular cab: Check for cuts and cracks in, or marked discoloration on the retractor cover. - Extra cab: Check for cuts and cracks in, or marked discoloration on the quarter trim. - Check for cuts and cracks in wire harness, and for chipping in connectors. - Check for deformation of the quarter panel. Page 216 Air Conditioning Switch: Service and Repair REMOVAL REMOVE A/C SWITCH a. Cover the switch with a cloth. b. Using pliers, pull out the switch. INSTALLATION Installation is in the reverse order of removal. Page 4088 Headliner: Service and Repair Roof Headlining (Regular Cab) REMOVAL 1. REMOVE ASSIST GRIPS 2. REMOVE SUN VISORS AND HOLDERS 3. REMOVE INNER REAR VIEW MIRROR 4. REMOVE ROOM LIGHT 5. REMOVE FRONT DOOR SCUFF PLATES 6. REMOVE COWL SIDE TRIMS 7. REMOVE DOOR OPENING TRIMS 8. REMOVE FRONT SEAT OUTER BELT SHOULDER ANCHORS Remove the 2 bolts and front seat outer belt shoulder anchors. Torque: 43 N.m (440 kgf.cm, 32 ft.lbf) 9. REMOVE QUARTER TRIM BOARD a. Using a screwdriver, remove the quarter trim board. HINT: Tape the screwdriver tip before use. NOTE: Paying enough attention remove the clip on the quarter trim board shown in the illustration. Otherwise, the quarter trim board or the front pillar garnish might be broken. b. Employ the same manner described above to the other side. 10. REMOVE FRONT PILLAR GARNISHES 11. REMOVE ROOF HEADLINING a. Using a clip remover, remove the 2 clips. b. Remove the roof headlining. INSTALLATION Installation is in the reverse order of removal. Page 1066 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection COMPONENTS INSPECTION 1. DRAIN ENGINE COOLANT 2. DISCONNECT UPPER RADIATOR HOSE FROM WATER OUTLET 3. REMOVE NO.2 TIMING BELT COVER 4. REMOVE FUEL PIPE Remove the 2 union bolt, 4 gaskets and fuel pipe. Page 3025 Junction Box / No. 1 Details Page 2305 WIRING DIAGRAM Component Locations Shift Indicator: Component Locations Page 4427 Splice Point J: Indicates a wiring Splice Point (Codes are "E"for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I 5 is indicated by the shaded section. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. N: Page No. How to Read Ground Points How to Read Ground Points Page 765 Junction Box / No. 1 Details Testing and Inspection Parking Brake Warning Switch: Testing and Inspection INSPECT PARKING BRAKE SWITCH CONTINUITY a. Check that continuity exists between terminals with the switch ON (switch pin released). b. Check that no continuity exists between terminals with the switch OFF (switch pin pushed in). If operation is not as specified, replace the switch. Testing and Inspection Oil Pressure Sender: Testing and Inspection INSPECT LOW OIL PRESSURE SWITCH a. Disconnect the connector from the switch. b. Check that continuity exists between terminal and ground with the engine stopped. c. Check that no continuity exists between terminal and ground with the engine running. HINT: Oil pressure should be over 49 kPa (0.5 kg/sq.cm, 7.1 psi). If operation is not as specified, replace the switch. Testing and Inspection Power Window Circuit Breaker: Testing and Inspection INSPECT CIRCUIT BREAKER OPERATION a. Disconnect the connector from the master switch. b. Connect the positive (+) lead from the battery to terminal 3 and the negative (-) lead to terminal 4 on the wire harness side connector, and raise the window to full closed position. c. Continue to apply voltage and check that there is a circuit breaker operation noise within approximately 4 - 40 seconds. d. Reverse the polarity and check that the window begins to descend within approximately 60 seconds. If operation is not as specified, replace the motor Page 2098 Connector Locations Testing and Inspection Tachometer: Testing and Inspection INSPECT TACHOMETER (ON-VEHICLE) a. Connect a tune-up test tachometer, and start the engine. NOTE: Reversing the connection of the tachometer will damage the transistors and diodes inside. - When removing or installing the tachometer, be careful not to drop or subject it to heavy shocks. b. Compare the tester and tachometer indications. DC 13.5 V 20 °C at (68 °F) If error is excessive, replace the tachometer. Page 2289 7. INSTALL PARKING LOCK PAWL BRACKET Torque: 7.4 Nm (75 kgf-cm, 65 inch lbs.) HINT: Push the lock rod fully forward. - Check that the parking lock pawl operates smoothly. 8. INSTALL VALVE BODY Page 3067 Page 3521 4. REMOVE WATER VALVE Remove the bolt and water valve. INSTALLATION Installation is in the reverse order of removal. Page 3282 SST 09631-20060 Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.) NOTICE: Be careful not to damage the oil seal lip. f. Using a punch, stake the nut. 8. INSTALL CONTROL VALVE HOUSING WITH CONTROL VALVE ASSEMBLY a. Coat a new O-ring with power steering fluid, and install it to the valve housing. b. Align the matchmarks on the valve housing and rack housing, and install the valve housing with the valve assembly to the rack housing. c. Torque the 2 bolts. Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.) 9. INSTALL DUST COVER 10. INSTALL RACK GUIDE, RACK GUIDE SPRING AND RACK GUIDE SPRING CAP a. Apply sealant to 2 or 3 threads of the cap. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent b. Temporarily install the cap. 11. ADJUST TOTAL PRELOAD a. To prevent the steering rack teeth from damaging the oil seal lip, temporarily install the RH and LH rack ends. b. Torque the rack guide spring cap. Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.) c. Return the cap 19°. d. Using SST, turn the control valve shaft right and left 1 or 2 times. SST 09616-00010 e. Loosen the cap until the rack guide spring is not functioning. Page 1029 Compression Check: Testing and Inspection INSPECTION HINT: If there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure. 1. WARM UP AND STOP ENGINE Allow the engine to warm up to normal operating temperature. 2. REMOVE SPARK PLUGS 3. CHECK CYLINDER COMPRESSION PRESSURE a) Insert a compression gauge into the spark plug hole. b) Fully open the throttle. c) While cranking the engine, measure the compression pressure. HINT: Always use a fully charged battery to obtain engine speed of 250 rpm or more. d) Repeat steps a) through c) for each cylinder. NOTICE: This measurement must be done in as short a time as possible. Compression pressure: 1,200 kPa (12.2 kgf/cm2, 174 psi) or more Minimum pressure: 1,000 kPa (10.2 kgf/cm2, 145 psi) Difference between each cylinder: 100 kPa (1.0 kgf/cm2, 15 psi) or less e) If the cylinder compression in 1 or more cylinders is low, pour a small amount of engine oil into the cylinder through the spark plug hole and repeat steps a) through c) for cylinders with low compression. If adding oil helps the compression, it is likely that the piston rings and/or cylinder bore are worn or damaged. - If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket. 4. REINSTALL SPARK PLUGS Page 4557 Splice Point J: Indicates a wiring Splice Point (Codes are "E"for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I 5 is indicated by the shaded section. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. N: Page No. How to Read Ground Points How to Read Ground Points Page 3401 3. w/ Freewheel hub: REMOVE LOCK NUT AND ABS SPEED SENSOR ROTOR/SPACER a. Using a chisel and hammer, loosen the staked part of the lock nut. NOTICE: Be careful not to damage the bushing. b. Using SST, remove the lock nut. SST 09318-12010 c. Remove the ABS speed sensor rotor/spacer. NOTICE: Take care not to scratch the serration of the speed sensor rotor. 4. REMOVE AXLE HUB FROM STEERING KNUCKLE a. Remove the 4 bolts and shift the dust cover towards the hub side (outside). b. Using SST, remove the axle hub from the steering knuckle. SST 09710-30021 (09710-03051), 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04031, 09957-04010, 09958-04011) c. Remove the dust cover from the steering knuckle. d. w/o Free wheel hub (4WD only): Remove the bearing spacer and ABS speed sensor rotor/ spacer. 5. REMOVE OIL SEAL (OUTSIDE) Using a screwdriver, remove the oil seal (outside) from the steering knuckle. 6. REMOVE BEARING FROM STEERING KNUCKLE a. Using snap ring pliers, remove the snap ring. b. Using SST and a press, remove the bearing from the steering knuckle. SST 09950-60020 (09951-00810), 09950-70010 (09951-07150) REASSEMBLY DENSO Made Brake Switch (Cruise Control): Testing and Inspection DENSO Made CIRCUIT DESCRIPTION When the brake pedal is on depressed, battery positive voltage normally applies through the STOP fuse and stop light switch to terminal STP-of the ECU, and the ECU turns the cruise control off. A fail-safe function is provided so that cancel functions normally, even if there is a malfunction in the stop light signal circuit. If the harness connected to terminal STP-has an open circuit, terminal STP-will have battery positive voltage and the cruise control will be turned off. Also, when the brake is on, the magnetic clutch is cut mechanically by the stop light switch, turning the cruise control oft. (See operation of the magnetic clutch) Wiring Diagram Description and Operation Acceleration/Deceleration Sensor: Description and Operation Deceleration Sensor This sensor detects deceleration on the vehicle. The sensor signal is used in ABS control. If the sensor functions abnormally, the ABS warning light comes on but the ABS still operates. Page 4597 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 433 4. REINSTALL NO.2 TIMING BELT COVER Page 1459 Step 2 TOYOTA hand-held tester: Step 1 Description and Operation Brake Fluid Solenoid Valve Relay: Description and Operation ABS Solenoid Relay This relay supplies power to each ABS solenoid. After the ignition switch is turned ON, if the initial check is OK, the relay goes on. Page 4290 Applicable Warranty*: This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Repair Procedure 1. Remove Wiper Arms, Plastic Cowl Cover and Wiper Motor (store wiper links up against bottom of windshield). NOTE: Mark wiper arm linkage attached to wiper motor and wiper motor splined shaft prior to removing the 12 mm retaining nut. 2. Spray Acrysol(TM) under entire lip of 1/2" pinch weld and wipe dry with a clean paper towel. FOLLOW DIRECTIONS ON SIDE OF CAN CAREFULLY. Dry open seam with compressed air prior to applying sealer. NOTE: Do not use a red shop towel to wipe surfaces because shop towels are contaminated with silicone. 3. Apply a small bead of Kent High Tech(TM) Clear Seam Sealer to underside front edge of the pinch weld from fender to fender as shown. 4. Apply Kent High Tech(TM) Clear Seam Sealer on all spot welds located on the floor of cowl panel. 5. Apply Kent High Tech(TM) Clear Seam Sealer around outside base of hood safety stops, and seal outside corner, under the "L" bracket as shown. Service and Repair Front Fender Liner: Service and Repair FRONT FENDER APRON (ASSEMBLY) REMOVAL (With the radiator support removed.) 1. After removing the cowl top side panel, remove the front fender apron. INSTALLATION Page 1776 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Description and Operation Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor The crankshaft position sensor, which detects the engine speed and crankshaft angle signal (NE signal), has been installed on the oil pump body. The NE signal plate has 34 teeth. The NE signal sensor generates 34 signals at every engine revolution. The ECM detects the standard crankshaft angle based on the G signal, and the actual crankshaft angle and the engine speed by the NE signal. Page 255 Page 1033 Valve Clearance: Testing and Inspection INSPECTION HINT: Inspect and adjust the valve clearance when the engine is cold. 1. REMOVE INTAKE AIR CONNECTOR 2. REMOVE CYLINDER HEAD COVERS 3. SET NO.1 CYLINDER TO TDC/COMPRESSION a) Turn the crankshaft pulley, and align its groove with timing mark "0" of the No.1 timing belt cover. b) Check that the timing marks (1 dot) of the camshaft drive and driven gears are in straight line on the cylinder heads surface as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) and align the marks. 4. INSPECT VALVE CLEARANCE a) Check only the valves indicated in the illustration. 1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft. 2) Record out of specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim. Valve clearance (Cold): Page 4561 Page 479 Clutch Switch: Testing and Inspection FORD Made Clutch Switch Circuit CIRCUIT DESCRIPTION When the clutch pedal is depressed, the clutch switch sends a signal to the cruise control ECU. When the signal is input to the cruise control ECU during cruise control driving, the cruise control ECU cancels cruise control. Wiring Diagram Page 1562 Oxygen Sensor: Technical Service Bulletins Engine Controls - Bank 1/Bank 2 O2 Sensor identification ENGINE EG034-07 Title: ENGINE BANK 1 AND BANK 2 A/F AND O2 IDENTIFICATION Models: '93 - '08 Applicable Models June 28, 2007 The information contained in this TSB supercedes TSB No. EG037-04. TSB No. EG037-04 is now obsolete and should be discarded. Introduction This service bulletin provides information on the proper identification of engine bank 1 and engine bank 2 for correct A/F sensor and oxygen sensor replacement. This bulletin contains information that identifies engine bank 1 and engine bank 2 on the following engines: 1AZ-FE, 2AZ-FE, 2AZ-FE (PZEV), 1GR-FE, 2GR-FE, 2GR-FSE, 2JZ-GE, 1MZ-FE, 3MZ-FE, 1UR-FSE, 3UR-FE, 2UZ-FE, 3UZ-FE, 5VZ-FE, and 1ZZ-FE. ^ Bank 1 (B1) refers to the bank that includes cylinder No. 1. ^ Bank 2 (B2) refers to the bank opposite bank 1. ^ Sensor 1 (S1) refers to the sensor that is located before the catalytic converters. ^ Sensor 2 (S2) refers to the sensor that is located after the catalytic converters. Warranty Information Page 1049 Water Pump: Service and Repair Page 3535 Hose/Line HVAC: Tools and Equipment A/C Clamp Remover AST tool# TOY 200 Page 206 Wiring Diagram Step 1 Page 3721 A. Pull out the seat belt about 300 mm and attach a clip as shown in the illustration. HINT: Preventing the seat belt from retraction with a clip will make the following work easier. B. Put the Velcro tape (in the parts kit) through the hole of the shoulder belt anchor, brush-shaped side to the anchor. C. Pull both ends of the Velcro tape with your hand and shave off the dirt on the shoulder belt anchor by moving the Velcro tape several times as shown in the illustration. NOTE: Remove the dirt completely. Otherwise, the fluorocarbon resin tape may not adhere properly. 2. INSTALL FLUOROCARBON RESIN TAPE A. Place the fluorocarbon resin tape onto the seat belt as shown in the illustration. NOTE: Page 4195 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 3302 2. Using 3 wire harness, wind the wire harness at least 2 times each around the bolts installed on the left and right sides of the steering wheel pad. CAUTION: Tightly wind the wire harness around the bolts so that there is no slack. - If there is slackness in the wire harness, the steering wheel pad may come loose due to the shock when the airbag is deployed. This is highly dangerous. 3. Face the upper surface of the steering wheel pad upward. Separately tie the left and right sides of the steering wheel pad to the disc wheel through the hub nut holes. Position the steering wheel pad connector so that it hangs downward through a hub hole in the disc wheel. CAUTION: Make sure that the wire harness is tight. It is very dangerous when looseness in the wire harness results in the steering wheel pad coming free due to the shock from the airbag deploying. - Always tie down the steering wheel pad with the pad side facing upward. It is very dangerous if the steering wheel pad is tied down with the metal surface facing upward as the wire harness will be cut by the shock from the airbag deploying and the steering wheel pad will be thrown into the air. NOTE: The disc wheel will be marked by airbag deployment, so when disposing of the airbag use a redundant disc wheel d. Check functioning of the SST. Testing and Inspection Hazard Warning Switch: Testing and Inspection Turn Signal And Hazard Warning System Reference INSPECT HAZARD WARNING SWITCH CONTINUITY If continuity is not as specified, replace the switch. Specifications Exhaust Manifold: Specifications Exhaust Manifold Fasteners 40 Nm (30 ft.lb) Exhaust Manifold Heat Insulators (Except CA.) 8 Nm (71 in.lb) Page 2470 Wheel Bearing: Diagrams Page 2227 Junction Box / No. 1 Page 2089 Junction Box / No. 3 Page 1227 Camshaft Position Sensor: Service and Repair COMPONENTS REPLACEMENT 1. REMOVE NO.2 TIMING BELT COVER 2. REMOVE CAMSHAFT POSITION SENSOR a. Disconnect the sensor connector. b. Remove the bolt and sensor. 3. REINSTALL NEW CAMSHAFT POSITION SENSOR a. Install a new sensor with the bolt. Torque: 7.8 Nm (80 kg.cm, 69 in.lb) b. Connect the sensor connector. Page 973 4. INSTALL LH CAMSHAFT TIMING PULLEY a) Face the flange side of the timing pulley outward. b) Align the knock pin on the camshaft with the knock pin groove of the timing pulley, and slide on the timing pulley. c) Using SST, install the pulley bolt. SST 09960-10010 (09962-01000, 09963-01000) Torque: 110 Nm (1,100 kgf-cm, 81 ft. lbs.) 5. INSTALL RH CAMSHAFT TIMING PULLEY a) Face the flange side of the timing pulley outward. b) Align the knock pin on the camshaft with the knock pin groove of the timing pulley, and slide on the timing pulley. c) Using SST, install the pulley bolt. SST 09960-10010 (09962-01000, 09963-01000) Torque: 110 Nm (1,100 kgf-cm, 81 ft. lbs.) 6. SET NO.1 CYLINDER TO TDC/COMPRESSION a) Temporarily install the crankshaft pulley bolt to the crankshaft. b) Turn the crankshaft, and align the timing marks of the crankshaft timing pulley and oil pump body. c) Using SST, turn the camshaft pulley, align the timing marks of the timing pulley and No.3 timing belt cover. SST 09960-10010 (09962-01000, 09963-01000) Page 337 A. The Diagnostic Tester displays 17" as a value of the Time $81" (see illustration). B. Find the Conversion Factor value of Time $81" in the O2S Failure Threshold chart. 0.3906 is specified for Time $81 in this chart. C. Multiply "17" in step "A" by 0.3906 (Conversion Factor) in step "B." 17 x 0.3906 = 6.6% D. If the answer is within the Standard Value of TEST LIMIT, the Time $81" can be confirmed to be normal. NOTE: ^ "LOW SW V" indicates the O2S voltage when the O2S status changes from rich to lean. ^ "HIGH SW V" indicates the O2S voltage when the O2S status changes from lean to rich. ^ If the O2S voltage is lower than "LOW SW V," the O2S status is lean. ^ If the O2S voltage is higher than "HIGH SW V," the O2S status is rich. NOTE: Before the O2S Monitor completes or after the ignition switch is turned OFF, the Diagnostic Tester displays the viewable upper limit or a lower limit of the test value (example: 0 V, 1.275 V, Os [seconds], 10.2s, 0 and 255). Page 336 ^ O2S TEST RESULTS A list of the available oxygen sensors will be displayed. 2. Select the desired oxygen sensor and press Enter. NOTE: The monitor result of the A/F sensor will not be displayed. If you select "Bank 1-Sensor 1" or Bank 2-Sensor 1" for a vehicle equipped with an A/F sensor, the Diagnostic Tester will display "No parameter to display." 3. Compare the test results with the values listed in the Failure Threshold Chart. * Although this procedure references the Toyota Diagnostic Tester, the O2S test results can be checked using a generic OBD II scantool. Refer to your OBD II scantool operator's manual for specific procedures. Comparing O2S Test Results to Failure Thresholds 1. Determine the correct O2S Failure Threshold Chart for your vehicle by looking in the "O2S Application Table," in this bulletin. 2. Select appropriate year, model, and engine for specified O2S Failure Threshold Chart. 3. Compare O2S test results with the specified O2S Failure Threshold Chart. It may be necessary to convert O2S test results to a specific measurement unit using the conversion factor that is supplied in the specified table. See example. Example: Page 4395 Page 3591 - If the horn button contact plate of the steering wheel is deformed, never repair it. Always replace the steering wheel assembly with a new one. - There should be no interference between the steering wheel pad and steering wheel, and the clearance should be uniform all the way around when the new steering wheel pad is installed on the steering wheel. CAUTION: Be sure to follow the correct procedure for removal and installation of the steering wheel pad. REPLACEMENT REQUIREMENTS In the following cases, replace the steering wheel pad, steering wheel or spiral cable CAUTION: Be sure to follow the correct procedure for removal and installation of the steering wheel pad. AIRBAG HARNESS INSPECTION HINT: The SRS wire harness is integrated with the instrument panel wire harness assembly. All the connectors in the system are a standard yellow color. 1. VEHICLES NOT INVOLVED IN COLLISION Do a diagnostic system check. * 2. VEHICLES INVOLVED IN COLLISION a. Do a diagnostic system check. * b. Check breaks in all wires of the SRS wire harness, and exposed conductors. c. Check to see if the SRS wire harness connectors are cracked or chipped. * Refer to SRS Warning Light Check, and How to Display and Read Diagnostic Codes. AIRBAG SENSOR ASSEMBLY VEHICLE NOT INVOLVED IN COLLISION Check a diagnostic system. VEHICLE INVOLVED IN COLLISION WITH AIRBAG NOT DEPLOYED Check a diagnostic system. * A/T - Fluid Requirements Fluid - A/T: Technical Service Bulletins A/T - Fluid Requirements TRANSMISSION & CLUTCH TC001-02 May 24, 2002 Title: AUTOMATIC TRANSMISSION FLUID REQUIREMENTS Models: All '00 - '02 Models & '03 Corolla & Matrix Introduction Please refer to the table for correct application of Dexron(R) III (Dexron(R) II) and Toyota Type T-IV Automatic Transmission Fluids or equivalent. Parts Information Warranty Information Locations Page 84 Step 1 Step 2 Testing and Inspection Refrigerant Pressure Sensor / Switch: Testing and Inspection 1. SET ON MANIFOLD GAUGE SET 2. REMOVE GLOVE COMPARTMENT DOOR 3. DISCONNECT CONNECTOR FROM COOLING UNIT 4. SET VEHICLE IN THESE CONDITIONS: a. Running engine at 2,000 rpm b. Blower speed control switch at HI c. Temperature control lever MAX. COOL d. A/C switch ON 5. INSPECT PRESSURE SWITCH OPERATION a. Connect the positive (+) lead from the ohmmeter to terminal 1 and negative (-) lead to terminal 4. b. Check continuity between terminals when refrigerant pressure is changed, as shown in the illustration. If operation is not as specified, replace the pressure switch. Page 1292 CHART 24 Body - Water Leaks to The Interior Cowl: All Technical Service Bulletins Body - Water Leaks to The Interior BODY BO026-00 Title: WATER LEAK FIELD-FIX REPAIR INSTRUCTIONS Models: '97 - '04 Tacoma October 27, 2000 TSB Revision Notice: ^ January 12, 2005: Applicable Vehicles has been updated to include 2004 model year. ^ August 25, 2003: VIN and Applicable Model Information has changed, and repair procedure has been expanded and clarified. ^ October 27, 2000: This TSB updates B0016-98 dated June 12, 1998. B016-98 is now obsolete and should be discarded. Previous versions of this TSB should be discarded. Introduction Use the following field-fix procedures if water is present on the floor carpeting and it can be confirmed that the water is leaking into the cab from either the upper cowl or side cowl seam, or moisture barrier behind the door trim panel. Applicable Vehicles 1997 - 2004 model year Tacoma vehicles. Required Materials Warranty Information Page 2498 HINT: When replacing the propeller shaft, install new parts facing, as shown in the illustration. 1. 3-joint type: INSTALL CENTER SUPPORT BEARING ON INTERMEDIATE SHAFT Install the center support bearing and spacer. HINT: Install the center support bearing with the cutout toward the rear. 2. 3-joint type: INSTALL FLANGE ON INTERMEDIATE SHAFT a. Coat the splines of the intermediate shaft with MP grease. b. Place the flange on the shaft and align the matchmarks. HINT: If replacing either the center flange or intermediate shaft, reassemble them so that the front flange yoke of the intermediate shaft and the rear flange yoke of the propeller shaft are facing in the same direction. c. Install the spacer. Page 1645 Engine Control Module: Description and Operation DESCRIPTION The Engine Control Module (ECM) controls all phases of electrical engine operation. In order to accomplish this control, the ECM relies on the input from a variety of engine operation sensors. The ECM compares input signals with those stored in memory to determine what steps should be taken to achieve maximum performance, fuel economy, and meet emission standards. The ECM outputs the necessary signals to the fuel system, ignition system, emission control systems, etc.. Page 2078 Step 4 Page 4028 reinstall plastic sheet against metal door panel. Confirm that there are no voids between sealer and plastic sheet and between sealer and metal door panel. 22. Flood all areas with water to confirm that there are no leaks into cab area. 23. If no leaks are present, reinstall door trim panel. Page 1697 Page 2383 Valve Body: Locations Rear Upper Valve Body Page 2973 COMPONENTS REMOVAL Page 570 u. Remove the other union bolt, 3 gaskets and fuel pipe from the delivery pipes. v. Reinstall the fuel pipe with 4 new gaskets and the 2 union bolts. Torque: 34.3 Nm (350 kg.cm, 25 ft.lb) w. Reconnect the negative (-) terminal cable to the battery. x. Check for fuel leaks. 3. INSPECT FUEL PUMP RESISTANCE Using an ohmmeter, measure the resistance between terminals 4 and 5. Resistance: 0.2 - 3.0 ohms at 20 °C (68 °F) If the resistance is not specified, replace the fuel pump and/or lead wire. 4. INSPECT FUEL PUMP RESISTANCE Connect the positive (+) lead from the battery to terminal 4 of the connector, and the negative (-) lead to terminal 5. Check that the fuel pump operates. NOTE: These tests must be done quickly (within 10 seconds) to prevent the coil from burning out. - Keep the fuel pump as far away from the battery as possible. - Always do switching at the battery side. If operation is not as specified, replace the fuel pump and/or lead wire. Page 2032 7. REMOVE WATER BYPASS PIPE AND KNOCK SENSOR WIRE 8. REMOVE KNOCK SENSORS Using SST, remove the knock sensor. SST 09817-16011 9. INSPECT KNOCK SENSORS Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor. 10. REINSTALL KNOCK SENSORS Using SST, install the knock sensor. SST 09817-16011 Torque: 39 Nm (400 kg.cm, 29 ft.lb) 11. REINSTALL WATER BYPASS PIPE AND KNOCK SENSOR WIRE 12. REINSTALL INTAKE MANIFOLD ASSEMBLY 13. REINSTALL FUEL PRESSURE REGULATOR 14. REINSTALL INTAKE AIR CONNECTOR ASSEMBLY 15. REINSTALL NO.2 TIMING BELT COVER 16. REINSTALL AIR CLEANER HOSE 17. REFILL WITH ENGINE COOLANT Page 3750 Seat Belt Page 872 HINT: Apply SST (B) at a slight angle on the side marked with "9" or "7", at the position shown in the illustration. - When SST (B) is inserted too deeply, it will get pinched by the shim. To prevent it from being stuck, insert it gently from the intake side, at a slight angle. 4) Using a small screwdriver and magnetic finger, remove the adjusting shim. b) Determine the replacement adjusting shim size by following the Formula or Charts: 1) Using a micrometer, measure the thickness of the removed shim. 2) Calculate the thickness of a new shim so the valve clearance comes within the specified value. T Thickness of used shim A Measured valve clearance N Thickness of new shim Intake: N = T + (A - 0.18 mm (0.007 inch)) Exhaust: N = T + (A - 0.32 mm (0.013 inch)) Page 970 22. REMOVE LH CAMSHAFT TIMING PULLEY a) Using SST, loosen the pulley bolt. SST 09960-10010 (09962-01000, 09963-01000) b) Remove the bolt, knock pin and timing pulley. 23. REMOVE NO.2 IDLER PULLEY Remove the bolt and idler pulley. 24. REMOVE NO.1 IDLER PULLEY Using a 10 mm hexagon wrench, remove the pivot bolt, idler pulley and plate washer. 25. REMOVE CRANKSHAFT TIMING PULLEY Remove the timing pulley. HINT: If the pulley cannot be removed by hand, use SST and a service bolt to remove the timing pulley. SST 09950-50011 (09951-05010, 09952-05010, 09953-05020, 09954-05010) INSPECTION 1. INSPECT TIMING BELT NOTICE: Do not bend, twist or turn the timing belt inside out. - Do not allow the timing belt to come into contact with oil, water or steam. - Do not utilize timing belt tension when installing or removing the mount bolt of the camshaft timing pulley. Page 3770 Technical Service Bulletin # BO002-01 Date: 010126 Seat Belts - Extenders BODY BO002-01 January 26, 2001 Title: SEAT BELT EXTENDER Models: '99 - '01 Model Year TSB UPDATE NOTICE: The information contained in this TSB updates B0020-00 dated August 11, 2000. Revised text is underlined. Introduction Toyota customers who find it necessary to increase the length of their seal belts may obtain Seat Belt Extenders at no cost through their local Toyota dealer. ^ The extender is available in 6 inch, 9 inch, 12 inch, 15 inch and 18 inch lengths. ^ The extender is available only in black. ^ Owners are informed of the Seat Belt Extender availability through the Toyota Owner's Manual included in each vehicle. The customer (individual requiring the extender) must visit a Toyota dealership to have the required measurements made and to complete the Seat Belt Extender worksheet. The worksheet will allow the proper fitting and selection of a Seat Belt Extender for the customer. The dealership personnel should then determine the applicable part number and place a Critical Order through the TDN Parts Network. The dealership service department should complete the affixed Seat Belt Extender Customer Information Label and review the Owner Instruction Sheet" with the customer. The dealership should give a copy of the completed worksheet to the customer and keep the original in the customer's file. To assure utmost owner satisfaction, it is recommended that a dealership designate one person to coordinate all activities related to the Seat Belt Extender issue. It is recommended that dealerships do not stock Seat Belt Extenders due to the need for proper fitting to individual customers. This bulletin contains the following information: Procedure and Sample Label Application Charts Part Number Information Owner Instructions Seat Belt Extender Worksheet Applicable Vehicles ^ 1999 through 2001 model year Toyota vehicles. Page 1261 Testing and Inspection Headlamp Relay: Testing and Inspection INSPECT HEADLIGHT CONTROL RELAY CONTINUITY If continuity is not as specified, replace the relay. Glass - Windshield and Fixed Glass Bonding Windshield: Technical Service Bulletins Glass - Windshield and Fixed Glass Bonding COLLISION REPAIR INFORMATION CRIB127 TITLE: WINDSHIELD AND FIXED GLASS BONDING SECTION: EXTERIOR BULLETIN #127 MODELS: ALL TOYOTA & LEXUS DATE: MAY 2003 During windshield and fixed glass removal or replacement, it is crucial to follow proper installation procedures. These specific procedures are outlined in Toyota and Lexus model-specific repair manuals. The manuals provide detailed instructions and illustrations for removal and installation procedures for windshields, backlights and other fixed glass. Replacement Information The following recommendations are provided as supplemental in formation to model-specific Repair Manual documented procedures. ^ Technicians performing glass installations should be well trained andlor certified in glass installation methods. If training is needed, glass installation courses are available through I-CAR or through the National Glass Association (NGA). ^ Always inspect glass opening bonding surface for damage or corrosion that may negatively impact proper glass installation. ^ Consult manuals and disassemble as recommended for removal. ^ Cover interior and exterior panels and components to protect them from glass and bonding debris. ^ Remove glass making sure not to damage painted finishes. ^ Body filler materials should NOT be used on bond surfaces. ^ Apply a two-part epoxy primer to properly prepared bare metal on the bonding surface and allow to dry. ^ Test fit replacement glass. ^ Clean, prep, and prime glass as required by adhesive manufacturer. ^ Select proper urethane adhesive with an American National Standards Institute (ANSI) minimum lap-shear strength rating of 500-750 PSI. ^ Apply urethane bead to glass as specified (width and height) and set glass. ^ Vacuum or blow (with low pressure air) to clean debris from interior and air ducts and then re-assemble. Specifications Axle Nut: Specifications Front Wheel Hub Lock Nut 235 Nm (174 ft.lb) Page 1724 CHART 16 CHART 17 Page 1734 CHART 25 Page 2831 Load Compensator: Service and Repair Disassembly and Assembly DISASSEMBLY 1. REMOVE VALVE BRACKET a. Remove the nut, bolt and 2 plate washers. b. 2WD: Remove the 2 nuts and flexible hose bracket, and remove the valve bracket and set plate from the valve body. c. 4WD and Pre runner: Remove the 2 nuts, and remove the valve bracket and set plate from the valve body. Page 3358 Repair Procedure 1. Disconnect the cable from the negative (-) battery terminal for MORE THAN two (2) seconds. 2. Reconnect the cable to the negative (-) battery terminal. 3. Perform the applicable zero point calibration of the yaw rate sensor and/or the steering angle sensor. HINT Refer to the applicable TSB or Repair Manual for the zero point calibration procedure. 4. Re-initialize all applicable systems available on the vehicle (power window sunroof power lift door etc.). Page 2925 The charger starts charging upon completion of testing. The screen displays the status of charge. 13. Read or print the battery test results. P 1/4: BATTERY RESULTS P 2/4: STATE OF CHARGE (SOC) P 3/4: STATE OF HEALTH (SOH) P 4/4: WARRANTY CODE To print: Align the Midtronics IR Printer (P/N 00002-A0870, component of P/N 00002-V8150-KIT) in front of the IR port on the charger and select the PRINT soft key. Battery Charging Results Once the test completes, proceed with 1 of the 3 procedures below according to the BATTERY CONDITION results. 1. Battery Condition: "GOOD BATTERY" Return the battery to service. 2. Battery Condition: "REPLACE BATTERY" Replace the battery. Print the RESULTS screen for WARRANTY CODE by pressing the PRINT soft key. NOTE: A REPLACE BATTERY result may also mean a poor connection between the battery cables and the battery. Retest the battery using the out-of-vehicle test before replacing it. 3. Battery Condition: "BAD CELL-REPLACE" Replace the battery. The decision indicates a bad cell within the battery. Print the RESULTS screen for WARRANTY CODE by pressing the PRINT soft key. Vehicle - Towing Guide. Towing Information: Technical Service Bulletins Vehicle - Towing Guide. BULLETIN NUMBER: AX001-00 DATE: March 17, 2000 TITLE: TOYOTA "DINGHY" TOWING GUIDE MODELS: All Models INTRODUCTION The chart on the next page indicates which Toyota vehicles can be Dinghy towed (towed with four wheels on the ground) behind a Motorhome CAUTION: Dinghy towing a vehicle behind a Motorhome requires special towing equipment and accessories. Please see your Motorhome Manufacturer/Service Outlet for recommended towing equipment. Warranty Information WARRANTY INFORMATION APPLICABLE VEHICLES Electrode Gap Specification Spark Plug: Specifications Electrode Gap Specification Electrode Gap Correct Gap ......................................................................................................................................... ........................................................................ 1.1 mm Testing and Inspection Dimmer Switch: Testing and Inspection W/ Tachometer (DLX Grade M/T Vehicle) INSPECT LIGHT CONTROL RHEOSTAT a. Turn the rheostat knob OFF and check that no continuity exists between terminals (Rheostat knob turned to fully counterclockwise). b. Gradually, turn the rheostat knob from the dark side to bright side and check that the resistance decreases from 10 to 0 Ohm. (Rheostat knob turned to clockwise) If operation is not as specified, replace the rheostat. ELECTRICAL TYPE (W/ All A/T Vehicle and SR5 Grade M/T Vehicle): INSPECT LIGHT CONTROL RHEOSTAT a. Connect terminals 1 and 3 through a 3.4 W test bulb. b. Connect the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal 2. c. Turn the rheostat knob to fully counterclockwise and check that the test bulb goes out. d. Gradually turn the rheostat knob to clockwise and check that the test bulb brightness changes from dark to bright. If operation is not as specified, replace the rheostat. Page 4925 Windshield Page 873 Testing and Inspection Brake Hose/Line: Testing and Inspection Check for fluid leakage from actuator or hydraulic lines. Page 3798 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Specifications Wheel Bearing: Specifications On models with serviceable wheel bearings, use a Lithium Multipurpose Grease. Page 2047 Crankshaft Position Sensor: Testing and Inspection INSPECT CRANKSHAFT POSITION SENSOR a. Remove the sensor connector. b. Using an ohmmeter, measure the resistance between the terminals. Resistance: Cold 1,630 - 2,740 ohms Hot 2,065 - 3,225 ohms c. Reinstall the sensor. Service and Repair Universal Joint: Service and Repair SPIDER BEARING REPLACEMENT NOTICE: Be careful not to grip the propeller shaft tube too tightly in a vise as this will cause deformation. 1. PLACE MATCHMARKS ON SHAFT AND YOKE 2. TMC made: REMOVE SNAP RING a. Using a brass bar and hammer, slightly tap in the bearing outer races. b. Using 2 screwdrivers, remove the 4 snap rings from the grooves. 3. DANA made: REMOVE SNAP RING a. Using a brass bar and hammer, slightly tap in the bearing outer races. b. Using needle nose pliers, remove the 4 snap rings from the grooves. 4. REMOVE SPIDER BEARING a. Using SST, push out the bearing from the propeller shaft. SST 09332-25010 HINT: Sufficiently raise the part indicated by "A" so that it does not come into contact with the bearing. b. Clamp the bearing outer race in a vise and tap off the propeller shaft with a hammer. HINT: Remove the bearing on the opposite side in the same procedure. Page 2084 Testing and Inspection Hazard Warning Switch: Testing and Inspection Turn Signal And Hazard Warning System Reference INSPECT HAZARD WARNING SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 4890 e. Check that the current increases to approximately 14.5 A or more when the window stops going down. HINT: The circuit breaker opens for some 4 - 40 seconds after the window stops going down, so that the check must be done before the circuit breaker operates. If operation is as specified, replace the master switch. Page 4140 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 569 CAUTION: Put a shop towel under the delivery pipe. Slowly loosen the union bolt. e. Install SST (pressure gauge) to the delivery pipe with the 2 gaskets and SST (union and union bolt). SST 09268-45012 Torque: 34.3 Nm (350 kg.cm, 25 ft.lb) f. Wipe off any splattered gasoline. g. Connect a TOYOTA hand-held tester to the DLC3. (See step 1) h. Reconnect the negative (-) terminal cable to the battery. i. Turn the ignition switch ON. j. Measure the fuel pressure. Fuel pressure: 265-304 kPa (2.7-3.1 kg/Sq.cm,38 - 44 psi) If pressure is high, replace the fuel pressure regulator. If pressure is low, check the fuel hoses, fuel hose connections, fuel pump, fuel filter and fuel pressure regulator. k. Disconnect the TOYOTA hand-held tester from the DLC3. l. Reinstall the No.2 timing belt cover with the 6 bolts. Torque: 9 Nm (90 kg.cm, 80 in.lb) m. Start the engine. n. Disconnect the vacuum sensing hose from the fuel pressure regulator, and plug the hose end. o. Measure the fuel pressure at idle. Fuel pressure: 265 - 304 kPa (2.7 - 3.1 kg/Sq.cm, 38 - 44 psi) p. Reconnect the vacuum sensing hose to the fuel pressure regulator. q. Measure the fuel pressure at idle. Fuel pressure: 226 - 265 kPa (2.3 - 2.7 kg/Sq.cm, 33 - 38 psi) If pressure is not as specified, check the vacuum sensing hose and fuel pressure regulator and fuel pressure regulator. r. Stop the engine. s. Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped. Fuel pressure: 147 kPa (1.5 kg/Sq.cm, 21 psi) or more If pressure is not as specified, check the fuel pump, pressure regulator and/or injectors. t. After checking fuel pressure, disconnect the negative (-) terminal cable from the battery and carefully remove the SST to prevent gasoline from splashing. SST 09268-45012 Page 3910 Difficulties during Remote Keyless Entry Transmitter Programming can arise due to confusion between Toyota Factory Wireless systems and Toyota Port/Dealer installed systems. This bulletin will assist in identifying the system/correct remote transmitters for each vehicle, and provide the location of the most accurate programming procedure for each system. Applicable Vehicles ^ All applicable Toyota vehicles. Warranty Information System Identification Page 2943 a. Remove the 4 screws and rectifier holder. b. Remove the 4 rubber insulators. 5. REMOVE PULLEY a. Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque. SST O9820-63010 Torque: 39 Nm (400 kg.cm, 29 ft.lb) b. Check that SST (A) is secured to the rotor shaft. c. As shown in the illustration, mount SST (C) in a vise, and install the generator with SST (A) and (B) to SST (C). d. To loosen the pulley nut, turn SST (A) in the direction shown in the illustration. Page 2938 a. Check the stator for open circuit. Using an ohmmeter, check that there is continuity between the coil leads. If there is no continuity, replace the drive end frame assembly. b. Check the stator for ground. Using an ohmmeter, check that there is no continuity between the coil lead and drive end frame. If there is continuity, replace the drive end frame assembly. 3. INSPECT BRUSHES Using a scale, measure the exposed brush length. Standard exposed length: 9.5 - 11.5 mm (0.374 - 0.453 in.) Minimum exposed length: 1.5 mm (0.059 in.) If the exposed length is less than minimum, replace the brushes. 4. INSPECT RECTIFIERS (RECTIFIER HOLDER) Page 4512 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 203 f. Read the blinking pattern of the CRUISE MAIN indicator light. g. After performing the check, turn the main switch OFF. HINT: When 2 or more signals are input to the ECU, the lowest numbered code will be displayed first. Page 622 Timing Belt: Service and Repair Part 1 Of 2 Page 4780 Testing and Inspection Headlamp Dimmer Switch: Testing and Inspection INSPECT LIGHT CONTROL SWITCH CONTINUITY If continuity is not as specified, replace the switch. INSPECT HEADLIGHT DIMMER SWITCH CONTINUITY Page 919 Engine Oil: Fluid Type Specifications Engine Oil Type GRADE ..................................................................................................................................... API SJ Energy-Conserving or ILSAC multigrade engine oil All temperatures ............................................ ..................................................................................................................................................... SAE 5W-30 Above 0° F ............................................................................................................................... ................................................................................. 10W-30 Page 1575 O2S Application Table O2S Failure Threshold Charts Page 3088 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Locations Fuel Pressure Regulator: Locations Lower Ball Joint: Service and Repair Lower REMOVAL 1. REMOVE FRONT WHEEL Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.) 2. DISCONNECT TIE ROD END a. Loosen the 4 bolts. Torque: 80 Nm (820 kgf-cm, 59 ft. lbs.) HINT: Do not remove the bolts. b. Remove the cotter pin and nut from the tie rod end. Torque: 90 Nm (930 kgf-cm, 67 ft. lbs.) HINT: At the time of installation, if the holes for the cotter pin are not aligned, tighten the nut further up to 60°. Page 3145 6. ADJUST TOE-IN AND WHEEL ANGLE HINT: First, check or adjust the lengths of the rack ends, then adjust the toe-in. Rack end length difference: 1.5 mm (0.059 inch) or less a. Remove the 2 clips. b. Loosen the tie rod end lock nuts. c. Turn the right and left rack ends by an equal amount to adjust the toe-in. HINT: Try to adjust the toe-in to the center of the specified value. d. Make sure that the lengths of the right and left rack ends are the same. Rack end length difference: 1.5 mm (0.059 inch) or less e. Tighten the tie rod end lock nuts. Torque: 55 Nm (560 kgf-cm, 41 ft. lbs.) f. Place the boots on the seats and install the clips. HINT: Make sure that the boots are not twisted. g. Inspect the wheel angle. Turn the steering wheel fully and measure the turning angle. Wheel Turning Angle: If the right and left wheel turning angles differ from the specified value, readjust the toe-win and wheel angle within the specified value. At this time, the right and left error lengths of the rack end may be less than 1.5 mm (0.059 inch). O/D Main Switch & O/D OFF Indicator Light Circuit Overdrive Switch: Testing and Inspection O/D Main Switch & O/D OFF Indicator Light Circuit CIRCUIT DESCRIPTION The O/D main switch is a momentary type switch. When pressing the O/D OFF main switch, the O/D OFF indicator light lights up and ECM prohibit shifting to O/D, and when pressing it again, the O/D OFF indicator light goes off and ECM allows shifting to O/D. Turning the IG switch OFF will reset the O/D OFF indicator light. Page 624 4. DISCONNECT PS PUMP FROM ENGINE a) Disconnect the 2 PS air hoses from the air intake chamber and resonator. b) Remove the bolt holding the PS pressure tube clamp to the frame. c) Remove the drive belt. d) Remove the bolt and nut, and disconnect the PS pump from the engine. 5. DISCONNECT A/C COMPRESSOR FROM ENGINE a) Disconnect the A/C compressor connector. b) Remove the drive belt. c) Remove the 4 bolts, and disconnect the A/C compressor from the engine. 6. LOOSEN FAN WITH FLUID COUPLING AND FAN PULLEYS 7. REMOVE DRIVE BELT FOR GENERATOR 8. REMOVE NO.2 FAN SHROUD 9. REMOVE FAN WITH FLUID COUPLING AND FAN PULLEYS 10. REMOVE A/C COMPRESSOR BRACKET Remove the 5 bolts and A/C compressor bracket. 11. REMOVE OIL DIPSTICK AND GUIDE Remove the bolt, oil dipstick, guide and O-ring. 12. REMOVE NO.2 TIMING BELT COVER a) Disconnect the 4 high-tension cord clamps from the timing belt cover. b) Remove the 6 bolts and timing belt cover. c) Disconnect the camshaft position sensor connector. Page 3818 D: Indicates related system. Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V). Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, 1H2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green O = Orange P = Pink R = Red SB = Sky Blue V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Testing and Inspection Stop Light Switch: Testing and Inspection Stop Light System INSPECTION 1. w/o Cruise Control: INSPECT STOP LIGHT SWITCH CONTINUITY If continuity is not as specified, replace the switch. 2. W/ Cruise Control: INSPECT STOP LIGHT SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 1559 Page 2929 HINT: Check the indicator as shown in the illustration. 4. CHECK BATTERY TERMINALS, FUSIBLE LINK AND FUSES a. Check that the battery terminals are not loose or corroded. If the terminals are corroded, clean the terminals. b. Check the H-fuses, M-fuse and fuses for continuity. Page 2228 Junction Box / No. 3 Page 1691 7. REMOVE WATER BYPASS PIPE AND KNOCK SENSOR WIRE 8. REMOVE KNOCK SENSORS Using SST, remove the knock sensor. SST 09817-16011 9. INSPECT KNOCK SENSORS Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor. 10. REINSTALL KNOCK SENSORS Using SST, install the knock sensor. SST 09817-16011 Torque: 39 Nm (400 kg.cm, 29 ft.lb) 11. REINSTALL WATER BYPASS PIPE AND KNOCK SENSOR WIRE 12. REINSTALL INTAKE MANIFOLD ASSEMBLY 13. REINSTALL FUEL PRESSURE REGULATOR 14. REINSTALL INTAKE AIR CONNECTOR ASSEMBLY 15. REINSTALL NO.2 TIMING BELT COVER 16. REINSTALL AIR CLEANER HOSE 17. REFILL WITH ENGINE COOLANT Page 3216 Key Reminder Switch: Fuse and Fusible Link Locations Relay Box / No. 2 Page 4445 Clock: Connector Locations Testing and Inspection Headlamp Dimmer Switch: Testing and Inspection INSPECT LIGHT CONTROL SWITCH CONTINUITY If continuity is not as specified, replace the switch. INSPECT HEADLIGHT DIMMER SWITCH CONTINUITY Page 967 4. DISCONNECT PS PUMP FROM ENGINE a) Disconnect the 2 PS air hoses from the air intake chamber and resonator. b) Remove the bolt holding the PS pressure tube clamp to the frame. c) Remove the drive belt. d) Remove the bolt and nut, and disconnect the PS pump from the engine. 5. DISCONNECT A/C COMPRESSOR FROM ENGINE a) Disconnect the A/C compressor connector. b) Remove the drive belt. c) Remove the 4 bolts, and disconnect the A/C compressor from the engine. 6. LOOSEN FAN WITH FLUID COUPLING AND FAN PULLEYS 7. REMOVE DRIVE BELT FOR GENERATOR 8. REMOVE NO.2 FAN SHROUD 9. REMOVE FAN WITH FLUID COUPLING AND FAN PULLEYS 10. REMOVE A/C COMPRESSOR BRACKET Remove the 5 bolts and A/C compressor bracket. 11. REMOVE OIL DIPSTICK AND GUIDE Remove the bolt, oil dipstick, guide and O-ring. 12. REMOVE NO.2 TIMING BELT COVER a) Disconnect the 4 high-tension cord clamps from the timing belt cover. b) Remove the 6 bolts and timing belt cover. c) Disconnect the camshaft position sensor connector. Page 3340 c. Using SST, disconnect the tie rod end from the steering knuckle. SST 09610-20012 3. REMOVE LOWER BALL JOINT a. Remove the cotter pin and nut from the lower ball joint. Torque: 140 Nm (1,450 kgf-cm, 103 ft. lbs.) HINT: At the time of installation, if the holes for the cotter pin are not aligned, tighten the nut further up to 60°. b. Using SST, disconnect the lower ball joint from the lower suspension arm. SST 09628-62011 HINT: At the time of installation, face the cotter pin hole of the lower ball joint forward. c. Remove the 4 bolts. d. With lifting the upper suspension arm and steering knuckle, remove the lower ball joint. HINT: At the time of installation, after removing the lower ball joint, support the upper suspension arm and steering knuckle securely. INSPECTION INSPECT LOWER BALL JOINT FOR ROTATION CONDITION a. As shown in the illustration, flip the ball joint stud back and forth 5 times before installing the nut. b. Using a torque wrench, turn the nut continuously 1 turn each 2-4 seconds and take the torque reading on the 5th turn. Turning torque: 0.1-2.5 Nm (11-25 kgf-cm, 1-22 inch lbs.) INSTALLATION Installation is in the reverse order of removal. HINT: After installation, check the front wheel alignment. Page 1502 Page 1711 Page 1426 Valve Clearance: Testing and Inspection INSPECTION HINT: Inspect and adjust the valve clearance when the engine is cold. 1. REMOVE INTAKE AIR CONNECTOR 2. REMOVE CYLINDER HEAD COVERS 3. SET NO.1 CYLINDER TO TDC/COMPRESSION a) Turn the crankshaft pulley, and align its groove with timing mark "0" of the No.1 timing belt cover. b) Check that the timing marks (1 dot) of the camshaft drive and driven gears are in straight line on the cylinder heads surface as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) and align the marks. 4. INSPECT VALVE CLEARANCE a) Check only the valves indicated in the illustration. 1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft. 2) Record out of specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim. Valve clearance (Cold): Page 2393 15. A340F: INSTALL OIL PIPE Using a plastic hammer, install the pipe into position. NOTICE: Be careful not to bend or damage the pipe. - Make sure that the oil pipe or magnet do not interfere with the oil pan. 16. A340E: INSTALL OIL STRAINER a. Install 2 new gaskets. b. Install the oil strainer with the 3 bolts. Torque: 10 Nm (100 kgf-cm, 7 ft. lbs.) c. Clamp solenoid wire. 17. A340F: INSTALL OIL STRAINER a. Install 2 new gaskets in the oil strainer case. Page 4710 Page 4769 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source How to Read Power Source Page 3326 Page 3796 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Cooling System - Radiator Cap Inspection Procedure Radiator Cap: Technical Service Bulletins Cooling System - Radiator Cap Inspection Procedure ENGINE EG014-05 Title: RADIATOR CAP INSPECTION Models: All Toyota Models March 28, 2005 Introduction The procedure for inspecting the radiator cap has been revised. Please refer to the following procedures when inspecting the radiator cap on all Toyota models. Applicable Vehicles ^ All Toyota and Scion models. Required Equipment Warranty Information Page 1653 Part 1 Of 2 (Except California Spec.) Pressure Specification Fuel Pressure: Specifications Fuel Pressure No Vacuum 38 to 44 psi Page 834 2. Place the intake camshaft at 90° angle of timing mark (1 dot mark) on the cylinder head. 3. Apply MP grease to a new oil seal lip. 4. Install the oil seal to the camshaft. 5. Remove any old packing (FIPG) material. 6. Apply seal packing to the No.1 bearing cap as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent 7. Install the 5 bearing caps in their proper locations. 8. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts. 9. Install and uniformly tighten the 10 bearing cap bolts, in several passes. Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.) d. Install the exhaust camshaft of the LH cylinder head. 1. Apply new engine oil to the thrust portion and journal of the camshaft. Testing and Inspection Ignition Cable: Testing and Inspection ON-VEHICLE INSPECTION INSPECT HIGH-TENSION CORDS a. Remove the air cleaner hose. b. Disconnect the high-tension cords at the rubber boot. Do not pull on the high-tension cords. NOTE: Pulling on or bending the cords may damage the conductor inside. c. Using an ohmmeter, measure the high-tension cord resistance. Maximum resistance: 25 kohms per cord If the resistance is greater than maximum, check the terminals. If necessary, replace the high-tension cord. Page 1531 Idle Air Control Valve: Testing and Inspection On-Vehicle Inspection 1. INSPECT IAC VALVE OPERATION a. Initial conditions: - Engine at normal operating temperature - Idle speed checked correctly - Transmission in neutral position - A/C switch OFF b. Using SST, connect terminals TE1 and E1 of the DLC1 SST 09843-18020 c. After engine speed is kept at approx. 1,000 rpm for 5 seconds, check that it returns to the idle speed. If the engine speed operation is not as specified, check the IAC valve, wiring and ECM. d. Remove the SST from the DLC1. SST 09843-18020 2. INSPECT IAC VALVE RESISTANCE NOTE: "Cold" and "Hot" In the following sentences express the temperature of the coils themselves. "Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F). a. Disconnect the IAC valve connector. b. Using an ohmmeter, measure the resistance between terminal +B and other terminals (RSC, RSO). Resistance: Cold 17.0 - 25.0 ohms Hot 21.5 - 29.5 ohms If the resistance is not as specified replace the IAC valve. c. Reconnect the IAC valve connector. 3. INSPECT AIR ASSIST SYSTEM a. Initial conditions: - Engine at normal operating temperature - Idle speed checked correctly - Transmission in neutral position - A/C switch OFF Page 1125 INSPECTION 1. INSPECT WATER PUMP a) Visually check the drain hole for coolant leakage. If leakage is found, replace the water pump. If engine coolant has leaked onto the timing belt, replace the timing belt. b) Turn the pulley, and check that the water pump bearing moves smoothly and quietly. If necessary, replace the water pump. 2. INSPECT FLUID COUPLING a) Remove the 4 nuts and fan from the fluid coupling. b) Check that the fluid coupling is not damaged and that no silicon oil leaks. Page 444 Knock Sensor: Testing and Inspection SRS/Interior - Seat Cover Replacement Caution Side Air Bag: Technical Service Bulletins SRS/Interior - Seat Cover Replacement Caution BODY BO014-05 Title: SEAT COVER REPLACEMENT FOR SIDE AIRBAG EQUIPPED VEHICLES Models: '98 - '06 All Models November 10, 2005 TSB UPDATE NOTICE: The information contained in this TSB supercedes TSB No. B0025-97. TSB No. B0025-97 is now obsolete and should be discarded. Introduction Beginning in 1998, Toyota introduced side airbags as optional equipment. Toyota does NOT recommend replacement of original seat covers* with non-Toyota leather or other seat cover materials on vehicles due to the following: ^ Seat covers NOT recommended by Toyota may affect side airbag performance, in general or in part, during an accident. ^ Modifications that negatively affect side airbag performance can result in severe occupant injuries. ^ Seat covers are an integral part of this safety system. Replacing fabric seat covers* with non-Toyota leather or other seat cover materials may compromise the effectiveness of this safety system. ^ The design of the seat is complex, integrating safety and strength with comfort and luxury. *NOTE: Toyota original seat covers that were NOT designed for side airbag equipped seats cannot be used due to the effect on proper airbag performance. Toyota strongly discourages modifying original equipment seats that have optional side airbags. Additionally, Toyota strongly advises against the installation or use of aftermarket seat covers, which could impair the performance of the side airbags in the event of an accident. Applicable Vehicles ^ All 1998 - 2006 model year Toyota and Scion vehicles equipped with side airbags. Warranty Information Page 2478 HINT: PreRunner is the model described below. RZN191L-TRPDKAB, RZN196L-CRPDKAB, VZN195L-CRPDKAB 1. 4WD: REMOVE OIL SEAL (INSIDE) a. Clamp the axle hub in a soft jaw vise. HINT: Close vise until it holds hub bolts. Do not tighten further. b. Using a screwdriver, remove the oil seal (inside). 2. PreRunner: REMOVE GREASE CAP a. Clamp the axle hub in a soft jaw vise. HINT: Close vise until it holds hub bolts. Do not tighten further. b. Using a screwdriver, remove the grease cap. Page 2652 Shift Indicator: Pinout Values and Diagnostic Parameters E 2 ELECTRONICALLY CONTROLLED TRANSMISSION SOLENOID 1, 2, 3-GROUND : Approx. 13 Ohm P 1 PARK/NEUTRAL POSITION SW 4-GROUND : Approx. 12 volts with ignition SW ON (Floor A/T), ACC (Column A/T) position O 4-A, S 4-B O/D MAIN SW A-1-A-3,B-5-B-10 : Open with O/D main SW at ON position Closed with O/D main SW at OFF position S 5-A,B STOP LIGHT SW A-1-A-2,B-1-B-2 : Closed with brake pedal depressed E 5-A, E 6-B, E 7-C, E 8-D ENGINE CONTROL MODULE S1-E1 : 9 - 14 volts S2,SL-E1 : 0 - 1.5 volts STP-E1 : 7.5 - 14 volts with brake pedal depressed : 0 - 1.5 volts with brake pedal released THW-E2 : 0.2 - 1.0 volts with coolant temp. 80 °C (176 °F) OIL-E2 : 4 - 5 volts with fluid temp. 20 °C (68 °F) VTA-E2 : 0.3 - 0.6 volts with throttle valve fully closed : 3.2 - 4.9 volts with throttle valve fully open VC-E2 : 4.5 - 5.5 volts OD1-E1 : 4.5 - 5.5 volts ODMS-E1 : 9 - 14 volts O/D main SW turned ON : 0 volts O/D main SW turned OFF SP1-E1 : Pulse generation with vehicle moving 2-E1 : 10 - 14 volts with shift lever at 2 position : 0-2 volts with shift lever at except 2 position L-E1 : 10 - 14 volts with shift lever at L position : 0 - 2 volts with shift lever at except L position OILW-E1 : 0.1 - 4.9 volts +B-E1 : 9 - 14 volts BATT-E1 : 9 - 14 volts Page 256 Key Reminder Switch: Description and Operation Current always flows to TERMINAL 12 of the integration relay through the DOME fuse. 1. SEAT BELT WARNING SYSTEM When the ignition SW is turned ON, current flows from the GAUGE fuse to TERMINAL 6 of the integration relay. At the same time, current flows to TERMINAL A 2 of the relay from the GAUGE fuse through the seat belt warning light. This current activates the integration relay and, for approx. 4-8 seconds, the current flowing through the warning light flows from TERMINAL A 2 of the relay to TERMINAL A 7 to GROUND, causing the warning light to light up. At the same time as the warning light lights up, a buckle SW ON signal is input to TERMINAL A 3 of the integration relay, the current flowing from TERMINAL 12 of the integration relay flows to TERMINAL A 7 to GROUND and the seat belt warning buzzer sounds for approx. 4 - 8 seconds. However, if the seat belt is put ON (Buckle SW OFF) during this period (while the buzzer is sounding), a signal input to TERMINAL A 3 of the integration relay stops and the current flowing from TERMINAL 12 of the integration relay to TERMINAL A 7 to GROUND is cut, causing the buzzer to stop. 2. KEY REMINDER SYSTEM With the ignition key inserted in the key cylinder (Unlock warning SW ON), the ignition SW still oft and front LH door open (Door courtesy SW ON), a signal is input to TERMINAL A 10, A 5 of the integration relay, the integration relay operates and current flows from TERMINAL 6 of the relay to TERMINAL A 7 to GROUND and the key reminder buzzer sounds. Page 789 FRONT AXLE HUB REPLACEMENT AND OVERHAUL W/ RELATED COMPONENTS Page 2359 Step 2 Step 3 INSPECTION PROCEDURE Page 171 Repair Procedure 1. Disconnect the cable from the negative (-) battery terminal for MORE THAN two (2) seconds. 2. Reconnect the cable to the negative (-) battery terminal. 3. Perform the applicable zero point calibration of the yaw rate sensor and/or the steering angle sensor. HINT Refer to the applicable TSB or Repair Manual for the zero point calibration procedure. 4. Re-initialize all applicable systems available on the vehicle (power window sunroof power lift door etc.). Body - Water Leaks to The Interior Wiper Arm: Customer Interest Body - Water Leaks to The Interior BODY BO026-00 Title: WATER LEAK FIELD-FIX REPAIR INSTRUCTIONS Models: '97 - '04 Tacoma October 27, 2000 TSB Revision Notice: ^ January 12, 2005: Applicable Vehicles has been updated to include 2004 model year. ^ August 25, 2003: VIN and Applicable Model Information has changed, and repair procedure has been expanded and clarified. ^ October 27, 2000: This TSB updates B0016-98 dated June 12, 1998. B016-98 is now obsolete and should be discarded. Previous versions of this TSB should be discarded. Introduction Use the following field-fix procedures if water is present on the floor carpeting and it can be confirmed that the water is leaking into the cab from either the upper cowl or side cowl seam, or moisture barrier behind the door trim panel. Applicable Vehicles 1997 - 2004 model year Tacoma vehicles. Required Materials Warranty Information Page 4412 Junction Box / No. 1 Page 2824 Load Compensator: Testing and Inspection ON-VEHICLE INSPECTION HINT: Pre runner is the described below. RZN191L-TRPDKAB, RZN196L-CRPDKAB, VZN195L-RPDKAB 1. SET REAR AXLE LOAD Rear axle load (includes vehicle weight): 2. INSTALL LSP & BV GAUGE (SST) AND BLEED AIR SST 09709-29018 3. RAISE FRONT BRAKE PRESSURE TO 7,845 kPa (80 kgf/cm2, 1,138 psi) AND CHECK REAR BRAKE PRESSURE Rear Brake Pressure: HINT: The brake pedal should not be depressed twice and/or returned while setting to the specified pressure. Read the value of rear brake pressure 2 seconds after adjusting the specified fluid pressure. If the brake pressure is incorrect, adjust the fluid pressure. Locations Testing and Inspection Headlamp Relay: Testing and Inspection INSPECT HEADLIGHT CONTROL RELAY CONTINUITY If continuity is not as specified, replace the relay. Page 2215 Step 1 Step 2 Page 2005 Camshaft Position Sensor: Service and Repair COMPONENTS REPLACEMENT 1. REMOVE NO.2 TIMING BELT COVER 2. REMOVE CAMSHAFT POSITION SENSOR a. Disconnect the sensor connector. b. Remove the bolt and sensor. 3. REINSTALL NEW CAMSHAFT POSITION SENSOR a. Install a new sensor with the bolt. Torque: 7.8 Nm (80 kg.cm, 69 in.lb) b. Connect the sensor connector. O/D Main Switch & O/D OFF Indicator Light Circuit Overdrive Switch: Testing and Inspection O/D Main Switch & O/D OFF Indicator Light Circuit CIRCUIT DESCRIPTION The O/D main switch is a momentary type switch. When pressing the O/D OFF main switch, the O/D OFF indicator light lights up and ECM prohibit shifting to O/D, and when pressing it again, the O/D OFF indicator light goes off and ECM allows shifting to O/D. Turning the IG switch OFF will reset the O/D OFF indicator light. Page 2053 Knock Sensor: Description and Operation Knock Sensor Each knock sensor is fitted to the right bank and left bank of the cylinder block to detect engine knocking. This sensor contains a piezoelectric element which generates a voltage when it becomes deformed, which occurs when the cylinder block vibrates due to knocking. If engine knocking occurs, ignition timing is retarded to suppress it. Page 1952 b. Inspect the relay operation. 1. Apply battery positive voltage across terminals 3 and 5. 2. Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. 3. Apply battery positive voltage across terminals 2 and 4. 4. Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. 3. REINSTALL CIRCUIT OPENING RELAY Page 976 12. INSTALL NO.1 TIMING BELT COVER AND STARTER WIRE BRACKET a) Check that the timing belt cover gaskets have cracks or peeling, etc. If the gasket does have cracks or peeling, etc., replace it using these steps. Using a screwdriver and gasket scraper, remove all the old gasket material. - Thoroughly clean all components to remove all the loose material. - Remove the backing paper from a new gasket and install the gasket evenly to the part of the belt cover shaded back in the illustration. b) Install the timing belt cover with the 4 bolts. Torque: 9 Nm (90 kgf-cm, 80 inch lbs.) c) Install the starter wire bracket with the 2 bolts. 13. INSTALL CRANKSHAFT PULLEY a) Align the pulley set key with the key groove of the pulley, and slide the pulley. b) Using SST, install a new bolt. SST 09213-54015 (90119-08216), 09330-00021 Torque: 300 Nm (3,000 kgf-cm, 217 ft. lbs.) 14. INSTALL FAN BRACKET a) Install the fan bracket with the bolt and nut. b) Install the PS pump adjusting strut with the nut. Page 2551 Page 966 Part 2 Of 2 REMOVAL 1. REMOVE ENGINE UNDER COVER 2. DRAIN ENGINE COOLANT 3. DISCONNECT UPPER RADIATOR HOSE SRS/Interior - Seat Cover Replacement Caution Seat Cover: Technical Service Bulletins SRS/Interior - Seat Cover Replacement Caution BODY BO014-05 Title: SEAT COVER REPLACEMENT FOR SIDE AIRBAG EQUIPPED VEHICLES Models: '98 - '06 All Models November 10, 2005 TSB UPDATE NOTICE: The information contained in this TSB supercedes TSB No. B0025-97. TSB No. B0025-97 is now obsolete and should be discarded. Introduction Beginning in 1998, Toyota introduced side airbags as optional equipment. Toyota does NOT recommend replacement of original seat covers* with non-Toyota leather or other seat cover materials on vehicles due to the following: ^ Seat covers NOT recommended by Toyota may affect side airbag performance, in general or in part, during an accident. ^ Modifications that negatively affect side airbag performance can result in severe occupant injuries. ^ Seat covers are an integral part of this safety system. Replacing fabric seat covers* with non-Toyota leather or other seat cover materials may compromise the effectiveness of this safety system. ^ The design of the seat is complex, integrating safety and strength with comfort and luxury. *NOTE: Toyota original seat covers that were NOT designed for side airbag equipped seats cannot be used due to the effect on proper airbag performance. Toyota strongly discourages modifying original equipment seats that have optional side airbags. Additionally, Toyota strongly advises against the installation or use of aftermarket seat covers, which could impair the performance of the side airbags in the event of an accident. Applicable Vehicles ^ All 1998 - 2006 model year Toyota and Scion vehicles equipped with side airbags. Warranty Information Page 2239 Junction Box / No. 1 Page 4540 WIRING DIAGRAM Page 2657 WIRING DIAGRAM Step 1 Page 1546 Page 4013 reinstall plastic sheet against metal door panel. Confirm that there are no voids between sealer and plastic sheet and between sealer and metal door panel. 22. Flood all areas with water to confirm that there are no leaks into cab area. 23. If no leaks are present, reinstall door trim panel. Specifications Removable Roof Page 85 Step 3 Step 4 Step 5 Step 6 Page 2967 Standard Undercut Depth Standard undercut depth: Minimum undercut depth: 0.2 mm (0.008 in.) If the undercut depth is less than minimum, correct it with a hacksaw blade. 3. INSPECT FIELD COIL a. Check the field coil for open circuit. Using an ohmmeter, check that there is continuity between the lead wire and field coil brush lead. If there is no continuity, replace the field frame. b. 1.4 kW: Check the field coil for ground. Using an ohmmeter, check that there is no continuity between the field coil end and field frame. If there is continuity, repair or replace the field frame. 4. 1.8 kW: INSPECT SHUNT COIL FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between terminal (A) and (B). Standard resistance: 1.4 - 1.9 Ohm at 20°C (68 °F) If the resistance is not as specified, repair or replace the field frame. Page 1296 Description and Operation Mass Air Flow Meter: Description and Operation Mass Air Flow Meter The mass air flow meter uses a platinum hot wire. The hot wire air flow meter consists of a platinum hot wire, thermistor and a control circuit installed in a plastic housing. The hot wire air flow meter works on the principle that the hot wire and thermistor located in the intake air bypass of the housing detect any changes in the intake air temperature. The hot wire is maintained at the set temperature by controlling the current flow through the hot wire. This current flow is then measured as the output voltage of the mass air flow meter. The circuit is constructed so that the platinum hot wire and thermistor provide a bridge circuit, with the power transistor controlled so that the potential of A and B remains equal to maintain the set temperature. Specifications Idle Speed: Specifications Idle Speed 700 +/- 50 rpm Page 3259 NOTICE: Remove the rack from the steering pinion housing side of the rack housing, as shown. INSPECTION NOTICE: When using a vise, do not overtighten it. 1. INSPECT STEERING RACK a. Using a dial indicator, check the rack for runout and for teeth wear and damage. Maximum runout: 0.30 mm (0.0118 inch) b. Check the back surface for wear and damage. 2. INSPECT BEARING a. Check the needle roller bearing for pitmarks or damage. If faulty, replace the rack housing. b. Apply molybdenum disulfide lithium base grease to the inside of the bearing. 3. IF NECESSARY, REPLACE BUSHING a. Using a screwdriver, loosen the 3 claws of the bushing, and remove the bushing from the rack housing. b. Coat a new bushing with molybdenum disulfide lithium base grease. c. Install the bushing into the rack housing, making sure to align with the 3 holes. 4. INSPECT BEARING Check the bearing rotation condition and check for abnormal noise. If the bearing is worn or damaged, replace the steering pinion assembly. 5. IF NECESSARY, REPLACE OIL SEAL Page 1591 CHART 22 Page 3737 A. Pull out the seat belt about 300 mm and attach a clip as shown in the illustration. HINT: Preventing the seat belt from retraction with a clip will make the following work easier. B. Put the Velcro tape (in the parts kit) through the hole of the shoulder belt anchor, brush-shaped side to the anchor. C. Pull both ends of the Velcro tape with your hand and shave off the dirt on the shoulder belt anchor by moving the Velcro tape several times as shown in the illustration. NOTE: Remove the dirt completely. Otherwise, the fluorocarbon resin tape may not adhere properly. 2. INSTALL FLUOROCARBON RESIN TAPE A. Place the fluorocarbon resin tape onto the seat belt as shown in the illustration. NOTE: Locations Transmission Speed Sensor: Locations CIRCUIT DESCRIPTION The speed sensor for ABS detects the wheel speed and sends the appropriate signals to the ABS ECU. The ECU converts these signals into a pulse signal and outputs it to the combination meter. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. Page 4997 Applicable Warranty*: This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Repair Procedure 1. Remove Wiper Arms, Plastic Cowl Cover and Wiper Motor (store wiper links up against bottom of windshield). NOTE: Mark wiper arm linkage attached to wiper motor and wiper motor splined shaft prior to removing the 12 mm retaining nut. 2. Spray Acrysol(TM) under entire lip of 1/2" pinch weld and wipe dry with a clean paper towel. FOLLOW DIRECTIONS ON SIDE OF CAN CAREFULLY. Dry open seam with compressed air prior to applying sealer. NOTE: Do not use a red shop towel to wipe surfaces because shop towels are contaminated with silicone. 3. Apply a small bead of Kent High Tech(TM) Clear Seam Sealer to underside front edge of the pinch weld from fender to fender as shown. 4. Apply Kent High Tech(TM) Clear Seam Sealer on all spot welds located on the floor of cowl panel. 5. Apply Kent High Tech(TM) Clear Seam Sealer around outside base of hood safety stops, and seal outside corner, under the "L" bracket as shown. Page 5015 W/ Intermittent w/ INTERMITTENT: If continuity is not as specified, replace the switch. INSPECT INTERMITTENT OPERATION a. Turn the wiper switch to INT position. b. Turn the intermittent time control switch to FAST position. c. Connect the positive (+) lead from the battery to terminal 16 and the negative (-) lead to terminal 2. d. Connect the positive (+) lead from the voltmeter to terminal 7 and the negative (-) lead to terminal 2, check that the meter needle indicates battery positive voltage. If operation is not as specified, replace the wiper and washer switch. Page 3262 a. To prevent the steering rack teeth from damaging the oil seal lip, temporarily install the RH and LH rack ends. b. Using SST, torque the rack guide spring cap. SST 09631-10021 Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.) c. Using SST, while gradually loosening the rack guide spring cap, measure and adjust the preload. SST 09612-24014 (09616-10010), 09631-10021 Preload (turning): 1.3 Nm (13 kgf-cm, 11.3 inch lbs.) or less 9. INSTALL RACK GUIDE SPRING CAP LOCK NUT a. Apply sealant to 2 or 3 threads of the nut. Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent b. Using SST to stop the rack guide spring cap rotating, and using SST, torque the nut. SST 09631-10021, 09922-10010 Torque: 50 Nm (513 kgf-cm, 37 ft. lbs.) NOTICE: Use SST 09922-10010 in the direction shown in the illustration. HINT: Use a torque wrench with a fulcrum length of 345 mm (13.58 inch). c. Recheck the total preload. Preload (turning): 1.3 Nm (13 kgf-cm, 11.3 inch lbs.) or less d. Remove the RH and LH rack ends. 10. INSTALL RACK HOUSING NO.2 BRACKET AND GROMMET a. Align the matchmarks on the bracket and rack housing. b. Torque the bolt. Torque: 61 Nm (620 kgf-cm, 45 ft. lbs.) 11. INSTALL RH AND LH CLAW WASHERS AND RACK ENDS a. Install a new washer, and temporarily tighten the rack end. HINT: Align the claws of the washer with the steering rack grooves. b. Using a spanner to hold the steering rack steady, and using SST, torque the rack end. SST 09922-10010 Torque: 61 Nm (621 kgf-cm, 45 ft. lbs.) Page 3765 Warranty Information Procedure 1. Owner requests a Seat Belt Extender from dealer. 2. Dealer verifies the need for a Seat Belt Extender and obtains a current copy of this TSB and copies the Worksheet. 3. Dealer measures the customer and completes the Worksheet. Dealer determines the correct part number and places a Critical Order for the part through the TDN Parts Network or Dealer Daily. 4. Dealer receives Seat Belt Extender and calls the customer in to check fit of the part. 5. If the Seat Belt Extender fit is good, dealership personnel completes the Customer Information Label on the part, explains usage of the part, and gives the customer a copy of the completed Worksheet. 6. Dealer places copy of the completed Worksheet in the customer's records. Sample Seat Belt Extender Customer Information Label Page 4452 #2 HINT: Troubleshoot the clock according to the table below. Testing and Inspection Parking Brake Warning Switch: Testing and Inspection INSPECT PARKING BRAKE SWITCH CONTINUITY a. Check that continuity exists between terminals with the switch ON (switch pin released). b. Check that no continuity exists between terminals with the switch OFF (switch pin pushed in). If operation is not as specified, replace the switch. Page 3780 Rear Seat Belt Extender Applications Part Number Information Page 1532 b. Using SST; connect terminals TE1 and E1 of the DLC1. SST 09843-18020 c. After the engine speed is kept at 900 - 1,300 rpm for 10 seconds, check that it returns to the idle speed. d. Stop the engine. e. Disconnect the air assist hose from the IAC valve, and plug it. f. Start the engine and check that the idle speed reaches 500 rpm or below (the engine may stall). If the idle does not reach 500 rpm or below, check for a leak between the air assist hoses, pipe and injectors. g. Remove the SST from the DLC1. SST 09843-18020 h. Reconnect the air assist hose to the IAC valve. Page 2029 Knock Sensor: Description and Operation Knock Sensor Each knock sensor is fitted to the right bank and left bank of the cylinder block to detect engine knocking. This sensor contains a piezoelectric element which generates a voltage when it becomes deformed, which occurs when the cylinder block vibrates due to knocking. If engine knocking occurs, ignition timing is retarded to suppress it. Page 3905 Page 4772 Page 1077 W/ Tachometer W/o Tachometer HINT: Connect the test leads so that the current from the ohmmeter can flow according to the above order. This circuit includes the diode. If resistance value is not as specified, replace the receiver gauge. Page 3865 Impact Sensor: Description and Operation FRONT AIRBAG SENSOR The front airbag sensor is mounted inside each of the aprons. The sensor unit is a mechanical type. When the sensor detects deceleration force above a predetermined limit, contact is made in the sensor, sending a signal to the airbag sensor assembly. The sensor cannot be disassembled. Page 1198 Part 1 Of 2 (Except California Spec.) Page 3072 Relay Box / No. 2 Ground Locations Page 4762 Dome Lamp: Fuse and Fusible Link Locations Relay Box / No. 2 Locations Page 188 Steps 3 - 4 INSPECTION PROCEDURE Supercharger - Squeak/Rattle Noises From Idler Pulley Supercharger: Customer Interest Supercharger - Squeak/Rattle Noises From Idler Pulley REF.: 3.4L V6 SUPERCHARGER NO.: SC001-00 DATE: AUGUST 1, 2000 MODEL: 4Runner, Tacoma, T100, and Tundra with 3.4L V6. SUPERCHARGER DRIVE-BELT IDLER PULLEY Due to a possible out-of-tolerance condition on the idler pulley shaft, some pulleys may have bearings that spin on the inner shaft and may cause a squeaking or rattling noise. The supercharger may be perfectly fine and the source of the noise may simply be the idler pulley PART NUMBER INFORMATION PRODUCTION EFFECTIVE: Supercharger Assemblies with Serial Numbers from: 10481 to: 10990 CHECK PROCEDURE: This condition can be verified by removing the supercharger drive belt and checking the movement of the pulley on the shaft The pulley should not slide fore and aft on the shaft. INSTALLATION PROCEDURE: Loosen the drive belt. Remove the idler plate assembly. Retain all the hardware. Remove the idler pulley sub-assembly from the idler plate assembly. Replace it with the supplied new idler pulley sub-assembly. Replace the idler plate assembly and all of the hardware. The tightening torques are shown in the table. Reinstall and tension the drive belt to 120-ft lbs. for a new belt or 80 ft lbs. for a used belt (any belt used for more than 10 minutes). WARRANTY INFORMATION:* * The idler pulley assembly is warrantable only for 12 months from the point-of-first-sale. If the supercharger assembly was dealer installed, then TRD matches the balance of the new vehicle powertrain warranty. Page 2783 Brake Drum: Service and Repair For information regarding the service and repair of this component and the system that it is a part of, please refer to Drum Brake System; Service and Repair. Page 634 15. INSTALL NO.2 TIMING BELT COVER a) Check that the timing belt cover gasket has no cracks or peeling, etc. If the gasket does have cracks or peeling, etc., replace it using these steps. 1) Using a screwdriver and gasket scraper, remove all the old gasket material. 2) Thoroughly clean all components to remove all the loose material. 3) Remove the backing paper from a new gasket and install the gasket evenly to the part of the belt cover shaded black in the illustration. b) Install the timing belt cover with the 6 bolts. Torque: 9 Nm (90 kgf-cm, 80 inch lbs.) c) Connect the 4 high-tension cord clamps and camshaft position sensor connector to the timing belt cover. 16. INSTALL OIL DIPSTICK AND GUIDE a) Install a new O-ring to the dipstick guide. b) Apply soapy water to the O-ring. c) Install the oil dipstick and guide to the cylinder block. d) Install the bolt to the generator bracket. Torque: 8 Nm (80 kgf-cm, 71 inch lbs.) 17. INSTALL A/C COMPRESSOR BRACKET Torque: 47 Nm (479 kgf-cm, 35 ft. lbs.) 18. TEMPORARILY INSTALL FAN WITH FLUID COUPLING AND FAN PULLEYS 19. INSTALL NO.2 FAN SHROUD 20. INSTALL AND ADJUST DRIVE BELT FOR GENERATOR 21. TIGHTEN FAN WITH FLUID COUPLING AND FAN PULLEYS Torque: 5.4 Nm (54 kgf-cm, 48 inch lbs.) 22. CONNECT A/C COMPRESSOR TO ENGINE a) Install the A/C compressor with the 4 bolts. Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.) b) Install the drive belt. c) Connect the A/C compressor connector. 23. CONNECT PS PUMP TO ENGINE a) Temporarily install the PS pump with the bolt and nut. b) Install the drive belt. c) Tighten the bolt and nut. Torque: 43 Nm (440 kgf-cm,31 ft. lbs.) d) Install the PS pressure tube clamp with the bolt. e) Connect the 2 PS air hoses to the air intake chamber and resonator. 24. CONNECT UPPER RADIATOR HOSE 25. FILL ENGINE WITH COOLANT 26. START ENGINE CHECK FOR LEAKS 27. INSTALL ENGINE UNDER COVER 28. PERFORM ROAD TEST Check for abnormal noise, shock, slippage, correct shift points and smooth operation. 29. RECHECK ENGINE COOLANT LEVEL Page 3229 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Page 615 3) Select a new shim with a thickness as close as possible to the calculated values. HINT: Shims are available in 17 sizes in increments of 0.050 mm (0.0020 inch), from 2.500 mm (0.0984 inch) to 3.300 mm (0.1299 inch). O/D Main Switch & O/D OFF Indicator Light Circuit Overdrive Switch: Testing and Inspection O/D Main Switch & O/D OFF Indicator Light Circuit CIRCUIT DESCRIPTION The O/D main switch is a momentary type switch. When pressing the O/D OFF main switch, the O/D OFF indicator light lights up and ECM prohibit shifting to O/D, and when pressing it again, the O/D OFF indicator light goes off and ECM allows shifting to O/D. Turning the IG switch OFF will reset the O/D OFF indicator light. Page 3188 If necessary, replace the valve. NOTICE: Install a new valve with the same inscribed mark as the old one. Inscribed mark: A, B, C, D, E or F 4. INSPECT SPRING Using calipers, measure the free length of the spring. Minimum free length: 33.2 mm (1.307 inch) If it is not within specification, replace the spring. 5. IF NECESSARY, REPLACE OIL SEAL a. Using a screwdriver with vinyl tape wound around its tip, remove the oil seal. NOTICE: Be careful not to damage the bushing of the front housing. b. Coat a new oil seal lip with power steering fluid. c. Using SST, press in the oil seal. SST 09950-60010 (09951-00330), 09950-70010 (09951-07100) NOTICE: Make sure to install the oil seal facing the correct direction. REASSEMBLY Page 2224 Page 1313 INSPECTION 1. INSPECT HEATER RESISTANCE OF HEATED OXYGEN SENSOR a. Disconnect the sensor connector. b. Using an ohmmeter,measure the resistance between terminals +B and HT. Resistance: at 20 °C (68 °F) 11 - 16 ohms at 800 °C (1,472 °F) 23 - 32 ohms If the resistance is not as specified, replace the sensor. Torque: 20 Nm (200 kg.cm, 14 ft.lb) c. Reconnect the oxygen sensor connector. 2. Bank 1 Sensor 1: INSPECT OPERATION OF HEATED OXYGEN SENSOR 3. Bank 1 Sensor 2: INSPECT OPERATION OF HEATED OXYGEN SENSOR Page 1701 Applicable Vehicles Airbag(s) Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Airbag(s) Arming and Disarming CAUTION: * Work must be started 90 seconds after the ignition switch is turned to the "LOCK" position and the negative (-) terminal cable is disconnected from the battery. (The SRS is equipped with a back-up power source so that if work is started within 90 seconds of disconnecting the negative (-) terminal cable of the battery, the SRS may be deployed.) * When the negative (-) terminal cable is disconnected from the battery, the memory of the clock and audio system will be canceled. So before starting work, make a record of the contents memorized in the audio memory system. When work is finished, reset the audio systems as before and adjust the clock. To avoid erasing the memory of each memory system, never use a backup power supply from outside the vehicle. * Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during repairs. * Do not expose the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor directly to hot air or flames. AIR BAG SYSTEM DISARMING The Air Bag/Supplemental Restraint System (SRS) incorporates a backup energy source that maintains sufficient deployment voltage for up to 90 seconds after the ignition is turned Off and the battery has been disconnected. Before disconnecting battery, note radio station settings, since all vehicle memory will be lost. Never use a backup power source from outside the vehicle. 1. Turn ignition to Lock, then disconnect battery ground cable. 2. Wait at least 90 seconds after disconnection before beginning service or diagnostic procedures. AIR BAG SYSTEM ARMING 1. Ensure ignition is in Lock position. 2. Connect battery ground cable. 3. Wait at least 10 seconds before turning ignition from Lock position. 4. Turn ignition to ACC or On position and ensure SRS lamp lights, then goes off after approximately six seconds. If lamp remains lit, an SRS condition is indicated. Refer to Restraint Systems, Air Bag Systems, Testing And Inspection. See: Restraint Systems/Air Bag Systems/Testing and Inspection Page 5008 If seam is not sealed properly, clean vertical and horizontal seam area with Acrysol(TM) cleaner. Use an air hose to dry all seams before applying sealer. NOTE: Hole is located behind fender. 15. Attach a 12 to 18 inch length of plastic tubing to tip of Kent High Tech(TM) Clear Seam Sealer. 16. Seal entire vertical joint with High Tech(TM) clear seam sealer. Allow sealer to dry according to instructions on tube. NOTE: Seams are inside boxed area and accessed through the square hole as shown. 17. Flood cowl area with water to confirm that there are no cowl seam leaks into cab. If water leaks are still present and there are no cowl area seam leaks, reinstall front fender and inspect for water entry along lower edge of interior door trim panel; then proceed as follows: 18. Remove door trim panel. 19. Flood R/F door glass area (spray water at door glass, belt-molding area). 20. Inspect sealer between plastic sheeting (moisture barrier) and metal door panel for voids/skips in sealer. If there are voids/skips between the plastic sheet and the door panel, it will need to be resealed. A. Using a heat gun, heat the butyl tape securing the plastic sheet to make removal easier. B. Use Kent Acrysol to clean the door panel and plastic sheet. NOTE: ^ Follow the directions provided by the cleaning agent. ^ To ensure proper sealing of the plastic sheeting, it is important that the door panel and plastic sheeting is extremely clean. C. Use 3M 8.0 mm butyl tape (P/N 08610) to reattach the plastic sheet to the door panel. Make sure there is a continuos solid bead sealing the plastic sheet to the door panel. 21. Inspect drain-back holes (small slits in metal door panel, near bottom of sealer) to determine if holes are covered by sealer material. If sealer covers drain-back holes (small slits in metal door panel) carefully pull up a portion of plastic sheet, clean out drain-back holes and Testing and Inspection Starter Relay: Testing and Inspection INSPECTION 1. REMOVE STARTER RELAY (Marking: ST) 2. INSPECT STARTER RELAY a. Inspect the relay continuity. 1. Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. 2. Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. b. Inspect the relay operation. 1. Apply battery positive voltage across terminals 1 and 2. Page 4039 Warranty Information Applicable Warranty*: This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Repair Procedure 1. Remove Wiper Arms, Plastic Cowl Cover and Wiper Motor (store wiper links up against bottom of windshield). NOTE: Mark wiper arm linkage attached to wiper motor and wiper motor splined shaft prior to removing the 12 mm retaining nut. 2. Spray Acrysol(TM) under entire lip of 1/2" pinch weld and wipe dry with a clean paper towel. FOLLOW DIRECTIONS ON SIDE OF CAN CAREFULLY. Dry open seam with compressed air prior to applying sealer. NOTE: Do not use a red shop towel to wipe surfaces because shop towels are contaminated with silicone. 3. Apply a small bead of Kent High Tech(TM) Clear Seam Sealer to underside front edge of the pinch weld from fender to fender as shown. 4. Apply Kent High Tech(TM) Clear Seam Sealer on all spot welds located on the floor of cowl panel. Page 3976 2. Scrub the bumper covers with the soap and water solution, making sure all difficult-to-reach areas are thoroughly cleaned. 3. Rinse the entire bumper cover with clean deionized water, making sure all difficult-to-reach areas are thoroughly rinsed. 4. Dry the surface with a clean towel before water dries on the surface. Clean, dry compressed air from an oil-less compressor may be substituted for drying with a towel. 5. Degrease the surface with a wax, grease, and silicone remover. Note: Lacquer thinner or brake cleaner will NOT remove silicone. You MUST use a wax, grease, and silicone remover. Carefully follow application instructions on the container label. Fish eyes or other paint irregularities may result from not following instructions. 6. Apply a generous amount of sanding paste with a gray 3M ScotchBrite pad. Only a gray pad should be used during the sanding process. Sand the entire bumper cover surface. Be sure all difficult-to-reach areas are thoroughly sanded. 7. Clean the entire bumper cover with car wash soap and water. Be sure all difficult-to-reach areas are thoroughly cleaned. 8. Rinse the entire bumper with clean deionized water. Be sure all difficult-to-reach areas are thoroughly rinsed. 9. Degrease the surface with an anti-static plastic parts cleaner and a white body shop towel or paper towel. Note: Never use a red shop towel to wipe the surface (contains silicone). 10. Assure the bumper is firmly held in place to a steady fixture. 11. Apply a plastic parts adhesion promoter to the surface, according to the manufacturer's recommendations. 12. Apply plastic parts primer to the surface, according to the paint manufacturer's recommendations. 13. Since bumpers are made of flexible plastic urethane material, use a two-part urethane finish paint system with plasticizer (flex agent) for all bumper and cladding repairs. Apply the appropriate top coat to the surface, according to the paint manufacturer's recommendations. 14. If heat is applied to cure the paint, assure the surface temperature does not exceed 80°C (176°F.) For additional information concerning the refinish process for plastic bumpers/cladding, please contact your respective refinish paint manufacturer's local representative. Description and Operation Mass Air Flow Meter: Description and Operation Mass Air Flow Meter The mass air flow meter uses a platinum hot wire. The hot wire air flow meter consists of a platinum hot wire, thermistor and a control circuit installed in a plastic housing. The hot wire air flow meter works on the principle that the hot wire and thermistor located in the intake air bypass of the housing detect any changes in the intake air temperature. The hot wire is maintained at the set temperature by controlling the current flow through the hot wire. This current flow is then measured as the output voltage of the mass air flow meter. The circuit is constructed so that the platinum hot wire and thermistor provide a bridge circuit, with the power transistor controlled so that the potential of A and B remains equal to maintain the set temperature. Page 1154 Applicable Warranty*: This repair is covered under the Federal Emissions Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in service date. *Warranty application is limited to correction of a problem based upon a customer's specific complaint. Page 3004 Harness Locations Page 2975 Starter Motor: Service and Repair Disassembly and Reassembly DISASSEMBLY 1. REMOVE FIELD FRAME AND ARMATURE a. Remove the nut, and disconnect the lead wire from the magnetic switch terminal. Torque: 5.9 Nm (60 kg.cm, 52 in.lb) b. Remove the 2 through bolts. Torque: 5.9 Nm (60 kg.cm, 52 in.lb) for 1.4 kW 9.3 Nm (95 kg.cm, 82 in.lb) for 1.8 kW c. Pull out the field frame with the armature from the magnetic switch assembly. HINT: At the time of reassembly, please refer to the following items. Align the protrution of the field frame with the cutout of the magnetic switch. d. Remove the O-ring. HINT: At the time of reassembly, please refer to the following items. Use a new O-ring. Page 4345 Steps 1 - 2 Page 809 * For vehicle capacity weight. ** For reduced loads (1 to 4 passengers). *** For trailer towing. Locations Knock Sensor: Locations Page 990 Fuel Pressure: Testing and Inspection 1. CHECK FUEL PUMP OPERATION a. Connect a TOYOTA hand-held tester to the DLC3. b. Turn the ignition switch ON and push TOYOTA hand-held tester main switch ON. NOTE: Do not start the engine. c. Select the ACTIVE TEST mode on the TOYOTA hand-held tester. d. Please refer to the TOYOTA hand-held tester operator's manual for further details. e. If you have no TOYOTA hand-held tester, connect the positive (+) and negative (-) leads from the battery to the fuel pump connector. (See step 4) f. Check that there is pressure in the fuel inlet hose from the fuel filter. HINT: If there is fuel pressure, you will hear the sound of fuel flowing. If there is no pressure, check the M-fuse, fuses, EFI main relay,fuel pump, ECM and wiring connections. g. Turn the ignition switch OFF. h. Disconnect the TOYOTA hand-held tester from the DLC3. 2. CHECK FUEL PRESSURE a. Check the battery positive voltage is above 12 V. b. Disconnect the negative (-) terminal cable from the battery. c. Remove the 6 bolts, and disconnect the No.2 timing belt cover. d. Remove the union bolt holding the fuel pipe to the delivery pipe and gasket. Page 3190 NOTICE: Be careful the direction of the gasket. 8. INSTALL SIDE PLATE Align the holes of the plate and 2 straight pins. 9. INSTALL WAVE WASHER Install the washer so that its protrusions fit into the slots in the side plate. 10. INSTALL REAR HOUSING a. Coat 2 new O-rings with power steering fluid and install them to the housing. b. Torque the 2 bolts. Torque: 24 Nm (240 kgf-cm, 17 ft. lbs.) 11. INSTALL SPRING, FLOW CONTROL VALVE AND PRESSURE PORT UNION a. Install the valve facing the correct direction. b. Coat a new O-ring with power steering fluid and install it to the union. c. Torque the union. Torque: 83 Nm (850 kgf-cm, 62 ft. lbs.) 12. INSTALL BRACKET Torque the 2 bolts. Torque: 43 Nm (440 kgf-cm, 32 ft. lbs.) 13. INSTALL OIL RESERVOIR a. Coat a new O-ring with power steering fluid and install it to the oil reservoir. b. Install the oil reservoir with the 3 bolts. Torque: Front side bolt: 13 Nm (130 kgf-cm, 9 ft. lbs.) Rear side bolts: 24 Nm (240 kgf-cm, 17 ft. lbs.) 14. INSTALL VANE PUMP PULLEY Using SST to stop the pulley rotating, torque the nut. SST 09960-10010 (09962-01000, 09963-01000) Torque: 43 Nm (440 kgf-cm, 32 ft. lbs.) 15. MEASURE PS VANE PUMP ROTATING TORQUE Page 4383 Splice Point J: Indicates a wiring Splice Point (Codes are "E"for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I 5 is indicated by the shaded section. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. N: Page No. How to Read Ground Points How to Read Ground Points Page 4418 Page 2266 Step 1 Page 346 CHART 7 Component Locations Shift Indicator: Component Locations Page 1167 Refer to Reset Procedure 1 for the vehicles with Electronically Controlled Automatic Transmissions: Testing and Inspection Dimmer Switch: Testing and Inspection W/ Tachometer (DLX Grade M/T Vehicle) INSPECT LIGHT CONTROL RHEOSTAT a. Turn the rheostat knob OFF and check that no continuity exists between terminals (Rheostat knob turned to fully counterclockwise). b. Gradually, turn the rheostat knob from the dark side to bright side and check that the resistance decreases from 10 to 0 Ohm. (Rheostat knob turned to clockwise) If operation is not as specified, replace the rheostat. ELECTRICAL TYPE (W/ All A/T Vehicle and SR5 Grade M/T Vehicle): INSPECT LIGHT CONTROL RHEOSTAT a. Connect terminals 1 and 3 through a 3.4 W test bulb. b. Connect the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal 2. c. Turn the rheostat knob to fully counterclockwise and check that the test bulb goes out. d. Gradually turn the rheostat knob to clockwise and check that the test bulb brightness changes from dark to bright. If operation is not as specified, replace the rheostat. Locations Vehicle Speed Sensor: Locations CIRCUIT DESCRIPTION The speed sensor for ABS detects the wheel speed and sends the appropriate signals to the ABS ECU. The ECU converts these signals into a pulse signal and outputs it to the combination meter. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. Page 399 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source How to Read Power Source Page 3096 Junction Box / No. 1 Details Page 3099 Engine Room R/B # 2 Engine Room R/B # 2 Service and Repair Heated Glass Element: Service and Repair Defogger Wire Repair a. Clean the broken wire tips with a grease, wax and silicone remover. b. Place the masking tape along both sides of the wire to be repaired. c. Thoroughly mix the repair agent (Dupont paste No. 4817). d. Using a fine tip brush, apply a small amount to the wire. e. After a few minutes, remove the masking tape. f. Do not repair the defogger wire for at least 24 hours. Page 3825 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Page 4767 D: Indicates related system. Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V). Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, 1H2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green O = Orange P = Pink R = Red SB = Sky Blue V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Page 4011 6. Mask-off wiper motor opening. 7. Attach Kent(TM) 12" extension tube (P/N 90175) to the nozzle on the can of Leak-Chek(TM) (P/N 50087). NOTE: Direct Leak-Chek(TM) spray material approximately 1 inch above seam. Spray force is very strong - make several test passes before actually spraying material into seam. 8. Spray Leak-Chek(TM) through the wiper motor opening. a. Spray material inside upper cowl, beginning in lower corner, and continuing toward the centerline of vehicle. b. Remove wand from the wiper motor opening and insert it into larger cowl openings on the right hand side. Continue spraying material along entire seam until seam is filled from R/F fender to L/F fender area. Spray Leak-Chek(TM) into seam a total of 3 times, allowing Leak-Chek(TM) to flash dry for 30-45 minutes between applications. (Drying time increases as outside temperature decreases.) 9. After final application of Leak-Chek(TM) has been allowed to dry for approximately one hour, flood area with water for 5-10 minutes. NOTE: Hold garden hose at top right front corner of windshield and point hose downward toward lower right hand corner of windshield as shown. 10. Check inside cab behind Heater/Air Conditioner box for evidence of water leakage during water leak check. 11. Carefully inspect "T" joint on right and left sides (close to heater motor box, and brake booster) for evidence of water leaks. 12. If no leaks are found, cowl area leak repair is complete. Reinstall wiper motor, cowl trim panel, wiper arms, and hood. Wiper Arm Torque: 20 N.m (205 kgf.cm, 15 ft.lbf) If water leaks are still present and are coming in from the cowl area, remove right front fender and proceed as follows: 13. Seal around entire perimeter of "L" bracket with Kent High Tech(TM) Clear Seam Sealer (see drawing for location of "L" bracket). 14. Using a flashlight, look through the 2" x 3" rectangular hole on side of vertical cowl panel and locate vertical seam that connects side of cowl to front cowl. Page 1753 Oxygen Sensor: Testing and Inspection Heated Oxygen Sensor Heated Oxygen Sensor COMPONENTS 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 Specifications Valve Clearance: Specifications Valve Clearance (Cold) Intake ................................................................................................................................................... ................................. 0.13-0.23 mm (0.006-0.009 in) Exhaust ............................................................ ..................................................................................................................... 0.27-0.37 mm (0.011-0.014 in) Page 2381 ABS/TCS - Zero Point Calibration Information Steering Angle Sensor: Technical Service Bulletins ABS/TCS - Zero Point Calibration Information T-SB-0020-08 March 25, 2008 Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment Service Category Brake Section Brake Control/Dynamic Control System Market USA Applicability Introduction The purpose of this TSB is to provide information on when and how to perform the zero point calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting the battery is a necessary step for performing the zero point calibration. Warranty Information Required Tools & Equipment ^ Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE). ^ The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the service procedures listed in this bulletin. Preliminary Information Perform this procedure if any of these repairs have been performed on the vehicle: ^ Wheel alignment has been adjusted. ^ Any chassis components have been removed/installed or replaced. Specifications Compression Check: Specifications Compression Pressure ........................................................................................................................ ..................................................... 1,200 kPa or More Minimum Pressure .......................................... ....................................................................................................................................................... 1,000 kPa Difference Between Each Cylinder ..................................................................................... .......................................................................... 100 kPa or Less Page 4208 be used during this type of repair due to the higher potential of damaging the paint surface. Remember no broken paint. Page 3911 Page 3640 through the hub nut holes. Position the steering wheel pad connector so that it hangs downward through a hub hole in the disc wheel. CAUTION: Make sure that the wire harness is tight. It Is very dangerous when looseness In the wire harness results In the steering wheel pad coming free due to the shock from the airbag deploying. - Always tie down the steering wheel pad with the pad side facing upward. It Is very dangerous if the steering wheel pad Is tied down with the metal surface facing upward as the wire harness will be cut by the shock from the airbag deploying and the steering wheel pad will be thrown Into the air. NOTE: The disc wheel will be marked by airbag deployment, so when disposing of the airbag use a redundant disc wheel. c. Check functioning of the SST. SST 09082-00700 d. Install the SST. CAUTION: Place the disc wheel on the level ground. 1. Connect the connector of the SST to the steering wheel pad connector. SST 09082-00700 NOTE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. Also, secure some slack for the SST wire harness inside the disc wheel. 2. Move the SST to at least 10 m (33 ft) away from the steering wheel pad tied down on the disc wheel. Page 4596 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 2422 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source How to Read Power Source Page 924 Oil Cooler: Service and Repair REMOVAL 1. DRAIN ENGINE COOLANT 2. DISCONNECT OIL COOLER HOSES Disconnect the No.1 and No.2 oil cooler hoses. 3. REMOVE OIL COOLER Remove the bolt, relief valve, gaskets and oil cooler. Torque: 59 Nm (600 kgf-cm, 43 ft. lbs.) HINT: At the time of installation, please refer to the following items. Replace the O-ring with a new part. - Use a new gasket to the relief valve. INSPECTION 1. INSPECT OIL COOLER Check the oil cooler for damage or clogging. If necessary, replace the oil cooler. INSTALLATION Installation is in the reverse order of removal. Removal And Installation Evaporator Case: Service and Repair Removal And Installation COMPONENTS REMOVAL 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM HINT: At the time of installation, please refer to the following item. Evacuate air from refrigeration system. Charge system with refrigerant and inspect for leakage of refrigerant. Page 1633 Page 3051 Junction Box / No. 1 Details Page 2094 Shift Indicator: Locations Component Locations Page 760 Junction Box / No. 1 Details Page 1483 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 4556 D: Indicates related system. Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V). Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, 1H2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green O = Orange P = Pink R = Red SB = Sky Blue V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Page 1790 Transmission Position Switch/Sensor: Service and Repair ON-VEHICLE REPAIR 1. DISCONNECT 2 OIL COOLER PIPES 2. DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 3. REMOVE PARK/NEUTRAL POSITION SWITCH a. Pry off the lock washer and remove the nut. b. Remove the bolt and pull out the park/neutral position switch. 4. INSTALL AND ADJUST PARK/NEUTRAL POSITION SWITCH Torque: Nut: 6.9 Nm (70 kgf-cm, 61 inch lbs.) Bolt: 13 Nm (130 kgf-cm, 9 ft. lbs.) 5. CONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 6. CONNECT 2 OIL COOLER PIPES Page 2172 Clutch: Diagrams Service and Repair Fuel Pressure Release: Service and Repair 1. BEFORE WORKING ON FUEL SYSTEM, DISCONNECT NEGATIVE (-) TERMINAL CABLE FROM BATTERY HINT: Any diagnostic trouble code retained by the computer will be erased when the negative (-) terminal cable is removed from the battery. Therefore, if necessary, read the diagnosis before removing the negative (-) terminal cable from the battery. 2. DO NOT SMOKE OR WORK NEAR AN OPEN FLAME WHEN WORKING ON FUEL SYSTEM 3. KEEP GASOLINE AWAY FROM RUBBER OR LEATHER PARTS 4. FUEL SYSTEM a. When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe these procedures: 1. Disconnect the fuel pump connector. 2. Start the engine. After the engine has stopped on its own, turn the ignition switch OFF. 3. Put a container under the connection. 4. Slowly loosen the connection. 5. Disconnect the connection. 6. Plug the connection with a rubber plug. b. When connecting the union bolt on the high pressure pipe union, observe these procedures: 1. Always use 2 new gaskets. 2. Tighten the union bolt by hand. 3. Tighten the union bolt to the specified torque. Torque: 34.3 Nm (350 kg.cm, 25 ft.lb) Service Precautions Air Bag(s) Arming and Disarming: Service Precautions NOTE: TOYOTA trucks are equipped with SRS, which comprises a driver airbag and front passenger airbag. Failure to carry out service operations in the correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Further, if a mistake is made in servicing the SRS, it is possible that the SRS may fail to operate when required. Before performing servicing (including removal or installation of parts, inspection or replacement), be sure to read the following items carefully, then follow the correct procedures described in the repair manual. Malfunction symptoms of the SRS are difficult to confirm, so the DTCs become the most important source of information when troubleshooting. When troubleshooting the SRS, always inspect the DTCs before disconnecting the battery. Even in cases of a minor collision where the SRS does not deploy, the steering wheel pad, front passenger airbag assembly, airbag sensor assembly and front airbag sensor should be inspected. Never use SRS parts from another vehicle. When replacing parts, replace them with new parts. Never disassemble and repair the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor in order to reuse it. If the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor has been dropped, or if there are cracks, dents or other defects in the case, bracket or connector, replace them with new ones. Use a volt/ohmmeter with high impedance (10 K.Ohm/V minimum) for troubleshooting the system's electrical circuits. Information labels are attached to the periphery of the SRS components. Follow the instructions on the notes. After work on the SRS is completed, perform the SRS warning light check. If the vehicle is equipped with a mobile communication system, refer to the precaution in the Introduction system. CAUTION: Work must be started 90 seconds after the ignition switch is turned to the "LOCK" position and the negative (-) terminal cable is disconnected from the battery (The SRS is equipped with a back-up power source so that if work is started within 90 seconds from disconnecting the negative (-) terminal cable of the battery, the SRS may be deployed.). When the negative (-) terminal cable is disconnected from the battery, the memory of the clock and audio system will be canceled. So before starting work, make a record of the contents memorized in the audio memory system. When work is finished, reset the audio systems as they were before and adjust the clock. However, it is not possible to make a record of the memory contents. So when the work is finished, it will be necessary to explain this fact to the customer, and ask the customer to adjust the features and reset the memory. To avoid erasing the memory in each memory system, never use a back-up power supply from outside the vehicle. Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during repairs. Do not expose the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor directly to hot air or flames. Page 4078 An airbag activation prevention mechanism is built into the connector for the squib circuit of the SRS. When release of the airbag activation prevention mechanism is directed in the troubleshooting procedure, as shown in the illustration of the connectors on the next pages, insert paper which has the same thickness as the male terminal between the terminal and the short spring. CAUTION: Never release the airbag activation prevention mechanism on the squib connector. NOTE: - Do not release the airbag activation prevention mechanism unless specifically directed by the troubleshooting procedure. - If the inserted paper is too thick the terminal and short spring may be damaged, so always use paper with the same thickness as the male terminal. Page 204 Cruise Control Switch: Testing and Inspection Main Switch Circuit (Cruise Control Switch) DENSO Made CIRCUIT DESCRIPTION When the cruise control main switch is turned off, the cruise control does not operate. Wiring Diagram Page 4234 Page 1092 5. Before installing the radiator cap tester, use the applicable radiator cap adaptor provided in the following SST kits in conjunction with the radiator cap tester: ^ SST P/N 09230-00030-01 (09231-10080-01) or 09230-00020-01 (09231-10060-01) or 09230-00050-01 (09231-10110-01 6. When using the radiator cap tester, tilt it more than 30 degrees. 7. Pump the radiator cap tester several times, and check the maximum pressure. Pumping speed: 1 pump/second HINT: Stop pumping when the valve opens and read the gauge. The gauge must be within the standard values listed below when the pressure valve opens. The cap is considered OK when the pressure holds steady or falls very slowly, but holds within the standard values listed below for one minute. Specification: If the maximum pressure is less than the minimum standard value, replace the radiator cap sub-assembly. Type: N-cap, 108 kPa Page 3350 7. REMOVE NO. 1 AND NO. 2 SPRING BUMPERS Using SST, remove the No. 1 and No. 2 spring bumpers. SST 09922-10010 Torque: 23 Nm (235 kgf-cm, 17 ft. lbs.) HINT: At the time of installation, use a torque wrench with a fulcrum length of 345 mm (13.58 inch). INSTALLATION Installation is in the reverse order of removal. HINT: After installation, check the front wheel alignment. Page 1718 CHART 8 CHART 9 Page 2073 Step 2 Step 3 INSPECTION PROCEDURE Page 1470 Page 595 d. Reconnect and install the high-tension cords as shown in the illustration. Page 3753 Seat Belt: Testing and Inspection INSPECTION CAUTION: Replace the seat belt assembly (outer belt, inner belt, bolts, nuts or sill-bar) if it has been used in a severe impact. The entire assembly should be replaced even if damage is not obvious. 1. Except manual type: RUNNING TEST (IN SAFE AREA) a. Fasten the front seat belts. b. Drive the car at 10 mph (16 km/h) and slam on the brakes. Check that the belt locks and cannot be extended at this time. HINT: Conduct this test in a safe area. If the belt does not lock, remove the belt mechanism assembly and conduct the following static check. Also, whenever installing a new belt assembly, verify the proper operation before installation. 2. Driver's seat belt (ELR): STATIC TEST a. Make sure that the belt locks when pulled out quickly. b. Remove the locking retractor assembly. c. Tilt the retractor slowly. d. Make sure that the belt can be pulled out at a tilt of 15 degrees or less, and cannot be pulled out over 45 degrees of tilt. If a problem is found, replace the assembly. 3. Except driver's seat belt (ALR/ELR): STATIC TEST a. Make sure that the belt locks when pulled out quickly. b. Remove the locking retractor assembly. c. Pull out the whole belt and measure the length of the whole belt. Then retract the belt slightly and pull it out again d. Make sure that the belt cannot be extended further. If a problem is found, replace the assembly. Page 1596 CHART 25 Service and Repair Tape Player: Service and Repair Tape Player - Head Cleaning / MAINTENANCE A. Raise the cassette door with your finger. Next, using a pencil or like object, push in the guide. B. Using a cleaning pen or cotton applicator soaked in cleaner, clean the head surface, pinch rollers and capstans. Page 754 Engine Room Fuse Details Interior J/B # 1 Vehicle - Towing Guide. Towing Information: Technical Service Bulletins Vehicle - Towing Guide. BULLETIN NUMBER: AX001-00 DATE: March 17, 2000 TITLE: TOYOTA "DINGHY" TOWING GUIDE MODELS: All Models INTRODUCTION The chart on the next page indicates which Toyota vehicles can be Dinghy towed (towed with four wheels on the ground) behind a Motorhome CAUTION: Dinghy towing a vehicle behind a Motorhome requires special towing equipment and accessories. Please see your Motorhome Manufacturer/Service Outlet for recommended towing equipment. Warranty Information WARRANTY INFORMATION APPLICABLE VEHICLES Page 1719 CHART 10 Removal and Installation Wheel Bearing: Service and Repair Removal and Installation REMOVAL Page 4099 Roof Headlining (Extra Cab) Headliner: Service and Repair Roof Headlining (Extra Cab) REMOVAL 1. w/ Removable roof: REMOVE SUNSHADE TRIM 2. w/ Removable roof: REMOVE REMOVABLE ROOF LOCK HANDLE AND LOCK BASE 3. w/ Removable roof: REMOVE SLIDING ROOF OPENING TRIM 4. REMOVE ASSIST GRIPS 5. REMOVE SUN VISORS AND HOLDERS 6. REMOVE INNER REAR VIEW MIRROR 7. REMOVE ROOM LIGHT 8. REMOVE COWL SIDE TRIMS 9. REMOVE FRONT DOOR SCUFF PLATES 10. REMOVE DOOR OPENING TRIMS 11. REMOVE BACK PANEL UPPER GARNISH AND BACK PANEL TRIM a. Using a screwdriver, remove the garnish. HINT: Tape the screwdriver tip before use. b. Remove the 3 bolts and trim. Torque: 9.8 N.m (100 kgf.cm, 7 ft.lbf) 12. REMOVE BACK PANEL LOWER GARNISH Using a screwdriver, remove the garnish. HINT: Tape the screwdriver tip before use. 13. REMOVE REAR SEAT CUSHIONS Remove the 4 bolts and rear seat cushions. Torque: 9.8 N.m (100 kgf.cm, 7 ft.lbf) 14. REMOVE FRONT AND REAR SEAT OUTER BELT SHOULDER ANCHORS Page 3775 and the seat belt are both facing outward as shown. You will hear a click when the tab locks into the buckle. When releasing the seat belt, press on the buckle-release button on the extender not on the seat belt. This helps prevent damage to the vehicle interior and extender itself. When not in use, remove the extender and store in the vehicle for future use. Body - Tailgate Lock (Pop & Lock) Torque Change Tailgate Release Handle: Technical Service Bulletins Body - Tailgate Lock (Pop & Lock) Torque Change ACCESSORIES AX007-02 October 23, 2002 Title: TAILGATE LOCK (POP AND LOCK) TORQUE CHANGE Models: '95 Through Current Model Year Tacoma Introduction The torque specifications for the tailgate lock (pop and lock) assembly on 1995 through current model year Tacoma trucks have been changed as described below. Applicable Vehicles ^ 1995 through current model year Tacoma trucks. Parts Information Required Tools & Material Repair Procedure The revised nominal "handle mounting screw" torque specification has been reduced from 108 in..lbf to 48 in.lbf (Torque Range = 60 in.lbf to 36 in..lbf) and is effective immediately (reference DIO Installation Instructions, Rev A [5/31/02], Section II, step A.7.i.). The new nominal installation torque of 48 in..lbf (Torque Range = 60 in..lbf to 36 in..lbf), has been revised in the DIO Installation Instructions as of August 2, 2002. Warranty Information Page 3443 * For vehicle capacity weight. ** For reduced loads (1 to 4 passengers). *** For trailer towing. Page 371 CHART 30 Page 3536 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 835 2. Align the timing marks (1 dot mark) of the camshaft drive and driven gears. 3. Place the exhaust camshaft on the cylinder head. 4. Install the 4 bearing caps in their proper locations. 5. Apply a light coat of engine oil on the threads and under the heads of bearing cap bolts. 6. Install and uniformly tighten the 8 bearing cap bolts, in several passes. Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.) 7. Remove the service bolt. DENSO Made Clutch Switch: Testing and Inspection DENSO Made CIRCUIT DESCRIPTION When the clutch pedal is depressed, the clutch switch sends a signal to the cruise control ECU. When the signal is input to the cruise control ECU during cruise control driving, the cruise control ECU cancels cruise control. Wiring Diagram Page 355 CHART 20 Page 359 Page 552 VZN195L model If the steering axis inclination is not within the specified value, after the camber and caster have been correctly adjusted, recheck the steering knuckle and front wheel for bearing or looseness. 4. ADJUST CAMBER AND CASTER a. Loosen the front and/or rear adjusting cam nuts. b. Adjust the camber and caster by front and/or rear adjusting cams (See adjustment chart). HINT: Try to adjust the camber and caster to the center of the specified values. Page 2533 Page 1512 Part 2 Of 2 (California Spec.) *1: Only for A/T *2: The ECM terminal voltage is fixed regardless of the output voltage from the sensor. Connectors (Except California Spec.) Description and Operation Transmission Mode Indicator - A/T: Description and Operation The ECM memory contains the shift programs for the NORMAL and POWER patterns, 2 position, L position and the lock-up patterns. Following the programs corresponding to the signals from the pattern select switch, the park/neutral position and other various sensors, the ECM switches the solenoid valves ON and OFF, and controls the transmission gear change and the lock-up clutch operation. Locations Heater Control Assembly Locations Page 3112 Engine Compartment Instrument Panel Locations Locations Relay Box: Locations Relay Box / No. 2 Page 4718 D: Indicates related system. Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V). Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, 1H2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green O = Orange P = Pink R = Red SB = Sky Blue V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid Drain and refill ..................................................................................................................................... ........................................................................ 1.7 Qt Page 4392 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 1352 Mass Air Flow Meter: Service and Repair REMOVAL 1. REMOVE AIR CLEANER CASE a. Disconnect the air cleaner hose. b. Disconnect the MAF meter connector. c. Remove the 3 bolts and air cleaner case. 2. REMOVE MAF METER a. Remove the 2 screws and MAF meter. b. Remove the O-ring from the MAF meter. INSTALLATION 1. INSTALL MAF METER a. Install the O-ring to the MAF meter. b. Install the MAF meter with the 2 screws. 2. INSTALL AIR CLEANER CASE a. Install the air cleaner case with the 3 bolts. b. Connect the MAF meter connector. c. Connect the air cleaner hose. Page 1923 Fuel Supply Line: Service Precautions FUEL TANK AND LINE PRECAUTION - Always use new gaskets when replacing the fuel tank or component parts. - Apply the proper torque to all parts tightened. Page 3681 Airbag Sensor Assembly: Description and Operation AIRBAG SENSOR ASSEMBLY The airbag sensor assembly is mounted on the floor inside the center cluster. The airbag sensor assembly consists of a airbag sensor, safing sensor, diagnosis circuit, ignition control and drive circuit, etc. It receives signals from the airbag sensor assembly and judges whether the SRS must be activated or not and diagnosis system malfunctions. Page 1351 Mass Air Flow Meter: Testing and Inspection INSPECTION 1. INSPECT MAF METER RESISTANCE Using an ohmmeter, measure the resistance between terminals THA and E2. If the resistance is not as specified, replace the MAF meter. Temperature Resistance at -20 °C (-4 °F) 13.6 - 18.4 Kohms at -20 °C (68 °F) 2.2 - 2.7 Kohms at -60 °C (140 °F) 0.5 - 0.7 Kohms 2. INSPECT MAF METER OPERATION a. Connect the MAF meter connector. b. Using a voltmeter, connect the positive (+) tester probe to terminal VG, and negative (-) tester probe to terminal E2G. c. Turn the ignition switch ON. d. Blow air into the MAF meter, and check that the voltage fluctuates. If operation is not as specified, replace the MAF meter. e. Turn the ignition switch OFF. f. Disconnect the MAF meter connector. Page 2646 Harness Locations Page 2431 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 4435 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 3247 Steering Gear: Diagrams Power Steering Gear Part 1 Of 3 Page 3143 c. How to read adjustment chart. 1. Find the wheel alignment standard value applicable for the particular model. 2. Mark the selected standard value on the adjustment chart. Example: Camber: 0°10' (0.17°) Caster: 1°40' (1.67°) 3. Mark the alignment value measured when the vehicle was non-loaded on the adjustment chart. Example: Camber: -0°10'(-0.17°) Caster: 1°40' (1.67°) 4. As shown in the chart, read the distance from the measured value to the standard value, and adjust the front and/or rear adjusting cams accordingly. Example: Front cam: -(Shorter) 2.8 Rear cam: -(Shorter) 2.8 Page 3822 Page 458 Impact Sensor: Testing and Inspection Replacement Requirements REPLACEMENT REQUIREMENTS In the following cases, replace the front airbag sensor. - If the SRS has been deployed in a collision. (Replace both the left and right airbag sensors.) - If the front airbag sensor has been found to be faulty in troubleshooting. - If the front airbag sensor has been found to be faulty during checking items. - If the front airbag sensor has been dropped. CAUTION: Be sure to follow the correct procedure for removal and installation of the front airbag sensor. Page 4918 a. using a screwdriver,remove the cover. HINT:Tape the screwdriver tip below use. b. remove the 2 screws and lock handle. 7. REMOVE QUARTER TRIM a. Remove the screw and coat hook. b. Using a screwdriver, remove the quarter trim. NOTE: Paying enough attention remove the clip on the quarter trim shown in the illustration. Otherwise, the quarter trim or the front pillar garnish might be broken. HINT: Tape the screwdriver tip before use. 8. REMOVE QUARTER WINDOW GLASS a. Remove the 4 nuts and quarter window glass. Page 3709 Page 4627 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Page 3299 a. Spiral Cable b. Upper And Lower Column Covers c. Steering Wheel d. Steering Wheel Pad Page 186 Brake Switch (Cruise Control): Testing and Inspection FORD Made CIRCUIT DESCRIPTION When the brake is on, battery positive voltage normally applies through the STOP fuse and stop light switch to terminal STP-of the ECU, and the ECU turns the cruise control off. A fail-safe function is provided so that cancel functions normally, even if there is a malfunction in the stop light signal circuit. If the harness connected to terminal STP-has an open circuit, terminal STP-will have battery positive voltage and the cruise control will be turned off. Also, when the brake is on, the magnetic clutch is cut mechanically by the stop light switch, turning the cruise control off. Wiring Diagram Page 4499 Key Reminder Switch: Ground Locations Page 628 If there are any defects, as shown in the illustrations, check these points: 1) Premature parting Check for proper installation. Check the timing cover gasket for damage and proper installation. 2) If the belt teeth are cracked or damaged, check to see if either camshaft is locked. 3) If there is noticeable wear or cracks on the belt face, check to see if there are nicks on the side of the idler pulley lock and water pump. 4) If there is wear or damage on only one side of the belt, check the belt guide and the alignment of each pulley. 5) If there is noticeable wear on the belt teeth, check the timing cover for damage, correct gasket installation, and for foreign material on the pulley teeth. If necessary, replace the timing belt. 2. INSPECT IDLER PULLEYS a) Visually check the seal portion of the idler pulley for oil leakage. If leakage is found, replace the idler pulley. b) Check that the idler pulley turns smoothly. If necessary, replace the idler pulley. 3. INSPECT TIMING BELT TENSIONER a) Visually check the seal portion of the tensioner for oil leakage. HINT: If there is only the faintest trace of oil on the seal on the push rod side, the tensioner is all right. If leakage is found, replace the tensioner. Page 3021 Auxiliary Power Outlet: Electrical Diagrams Service Hints P 13, P 14 POWER OUTLET 2-GROUND : Approx. 12 volts with the ignition SW at ACC or ON position 1-GROUND : Always continuity Page 614 Page 1625 Electrical - SRS And HV Wiring Repairs Wiring Harness: Technical Service Bulletins Electrical - SRS And HV Wiring Repairs TITLE: SRS & HV WIRING REPAIRS SECTION: ELECTRICAL BULLETIN # 156 MODELS: ALL TOYOTA LEXUS and SCION MODELS DATE: AUGUST 2007 There are no approved repairs to Supplemental Restraint System (SRS) or High Voltage (HV) wiring or connectors. SRS system wiring and connectors are color coded yellow and HV wiring is orange however vehicle-specific wiring diagrams are the best source for identifying wiring in these circuits. Wiring diagrams are available through the Technical Information System (TIS) www.techinfo.toyota.com. If SRS or HV wiring or connectors are suspected of damage they should be inspected thoroughly. Damaged wiring and/or connectors require replacement of the affected harness. Follow all precautions and procedures outlined in model-specific repair manuals for replacing SRS wiring or components. Only Certified Hybrid Service Technicians are qualified to replace HV system wiring and components. Page 3730 Inspect the entire length of webbing for damage and replace the assembly if needed. Be careful NOT to damage the webbing during repair. 3. Install the NEW tongue plate stopper A. Install a NEW tongue plate stopper in the hole of the webbing. NOTE Be sure to install the stopper in the correct direction as shown in the illustration. B. Pinch the tongue plate stopper into the webbing using the tool shown in Figure 3 or use a small "C" clamp. NOTE To prevent damage to the plastic tongue plate stopper when using a "C" clamp device, use light to moderate clamping force when crimping the two halves of the tongue plate stopper together. HINT Press the adjustment screw locating the male and female parts of the tongue plate stopper parallel to each other. Page 4154 be used during this type of repair due to the higher potential of damaging the paint surface. Remember no broken paint. Page 1193 Step 1 Step 2 Testing and Inspection Evaporator Temperature Sensor / Switch: Testing and Inspection Thermistor 1. REMOVE GLOVE COMPARTMENT DOOR 2. INSPECT THERMISTOR RESISTANCE a. Disconnect the connector b. Measure resistance between terminals 2 and 5. Standard resistance: 1,500 Ohms at 25 °C (77 °F) If resistance is not as specified, proceed next inspection. INSPECT THERMISTOR RESISTANCE a. Place the thermistor in cold water, and while changing the temperature of the water, measure resistance at the connector and at the same time, measure temperature of the water with a thermometer. b. Compare the 2 readings on the chart. If resistance value is not as specified, replace the thermistor. Page 3781 Parts Information Owner Instructions OWNER INSTRUCTIONS: Failure to follow the recommendations indicated below could result in reduced effectiveness of the seat belt restraint system in case of vehicle collision, causing personal injury. The Seat Belt Extender must not be used: a. By anyone other than for whom it was provided (name recorded on seat belt extender). b. In any vehicle and/or seat position other than the one for which it was provided. c. When the Seat Belt Extender is provided for rear seat positions (with automatic locking retractor), make sure the retractor is locked when in use. If your seat belt cannot be fastened securely because it is not long enough, a personalized Seat Belt Extender is available from your Toyota dealer free of charge. Please contact your local Toyota dealer so that the dealer can order the proper required length for the extender. Bring the heaviest coat you expect to ABS/TCS - Zero Point Calibration Information Yaw Rate Sensor: Technical Service Bulletins ABS/TCS - Zero Point Calibration Information T-SB-0020-08 March 25, 2008 Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment Service Category Brake Section Brake Control/Dynamic Control System Market USA Applicability Introduction The purpose of this TSB is to provide information on when and how to perform the zero point calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting the battery is a necessary step for performing the zero point calibration. Warranty Information Required Tools & Equipment ^ Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE). ^ The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the service procedures listed in this bulletin. Preliminary Information Perform this procedure if any of these repairs have been performed on the vehicle: ^ Wheel alignment has been adjusted. ^ Any chassis components have been removed/installed or replaced. Page 2271 Step 3 Page 3688 3. REMOVE AIRBAG SENSOR ASSEMBLY a. Disconnect the connector. NOTE: Remove the connector with the sensor assembly installed. b. Using a torx wrench remove the 3 screws and airbag sensor assembly. Torx wrench: T40 (Part No.09042-00020 or locally manufactured tool) INSTALLATION NOTE: - Never use SRS parts from another vehicle. When replacing parts, replace with new parts. - Never reuse the airbag sensor assembly involved in a collision when the airbag has deployed. - Never repair a sensor in order to reuse it. 1. INSTALL AIRBAG SENSOR ASSEMBLY a. Using a torx wrench, install the airbag sensor assembly with the 3 screws. Torx wrench: T40 (Part No.09042-00020 or locally manufactured tool) Torque: 20 Nm (205 kg.cm, 15 ft.lb) b. Connect the connector. NOTE: Installation of the connector is done after the sensor assembly has been installed. - Make sure the sensor assembly is installed to the specified torque. - If the sensor assembly has been dropped, or there are cracks, dents or other defects in the case, bracket or connector, replace the sensor assembly with a new one. - When installing the airbag sensor assembly, take care that the SRS wiring does not interfere with other parts and is not pinched between other parts. - After installation, shake the sensor assembly to check that there is no looseness. 2. INSTALL REMOVED PARTS Page 1607 Oxygen Sensor: Mechanical Specifications HEATED OXYGEN SENSOR Torque: ................................................................................................................................................ ................................. 20 N.m (200 kgf.cm, 14 ft.lbf) AIR-FUEL RATIO (A/F) SENSOR Torque: ................................................................................................................................................ ................................. 20 N.m (200 kgf.cm, 14 ft.lbf) Service and Repair Transmission Temperature Sensor/Switch: Service and Repair With SR5 ON-VEHICLE INSPECTION 1. DISCONNECT ATF TEMPERATURE SENSOR CONNECTOR 2. DISCONNECT OIL COOLER PIPE a. Remove the 3 bolts and clamps. b. Disconnect the oil cooler pipe. 3. REMOVE OIL COOLER ELBOW 4. REMOVE ATF TEMPERATURE SENSOR a. Remove the ATF temperature sensor. b. Remove the O-ring from the ATF temperature sensor. 5. INSTALL ATF TEMPERATURE SENSOR a. Coat a new O-ring with ATF and install it to the ATF temperature sensor. b. Install the ATF temperature sensor. Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.) 6. INSTALL OIL COOLER ELBOW 7. CONNECT OIL COOLER PIPE a. Connect the oil cooler pipe Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.) b. Install the 3 clamps and bolts. 8. CONNECT ATF TEMPERATURE SENSOR NOTICE: Be careful not to twist the wire harness. Page 1363 4. REINSTALL NO.2 TIMING BELT COVER Exhaust System - Sulfur Smell Fuel: Technical Service Bulletins Exhaust System - Sulfur Smell ENGINE EG003-03 February 24, 2003 Title: SULFUR ODOR FROM EXHAUST Models: All Models Introduction Some owners of Toyota vehicles may experience a sulfur-like or "rotten egg" odor from the exhaust system. Sulfur is a natural component of crude oil from which gasoline is refined and the amount of sulfur can be decreased through the refining process. The amount of sulfur in fuel sold in California is regulated, however gasoline sold in other states can have substantially higher sulfur content. Sulfur content also varies considerably between gasoline brands and locations. Applicable Vehicles ^ All Models. Repair Procedure A sulfur odor emitted from the vehicle's tailpipe does not necessarily indicate that there is an issue with the engine's running condition, but is most likely directly related to the fuel. ^ If the vehicle is exhibiting an excessive sulfur odor, the following checks should be performed: ^ If the MIL light is ON, check for DTCs and repair as necessary. If no trouble is found after performing the above check, recommend the customer try a different source of fuel. Replacement of oxygen sensors, air/fuel ratio sensors or catalytic converters will not reduce the odor and will therefore not be considered warrantable. Warranty Information Page 4620 Key Reminder Switch: Ground Locations Page 4637 Page 2004 Camshaft Position Sensor: Testing and Inspection INSPECT CAMSHAFT POSITION SENSOR a. Disconnect the sensor connector. b. Using an ohmmeter, measure the resistance between the terminals. Resistance: cold 835 - 1,400 ohms Hot 1,060 - 1,645 ohms If the resistance is not as specified, replace the sensor. c. Reconnect the camshaft position sensor connector. Page 3275 a. Using an extension bar and socket wrench (24 mm), press out the rack and oil seal. NOTICE: Take care not to drop the rack. b. Remove the oil seal from the rack. 14. REMOVE OIL SEAL AND SPACER Using SST, press out the oil seal and spacer. SST 09950-60010 (09951-00360), 09950-70010 (09951-07360) INSPECTION 1. INSPECT STEERING RACK a. Using a dial indicator, check the rack for runout and for teeth wear and damage. Maximum runout: 0.3 mm (0.0118 inch) b. Check the back surface for wear and damage. 2. IF NECESSARY, REPLACE OIL SEAL AND BEARING a. Using SST, press out the oil seal and bearing from the control valve housing. SST 09950-60010 (09951-00260), 09950-70010 (09951-07150) b. Coat a new oil seal lip with power steering fluid. c. Using SST, press in the oil seal. SST 09950-60010 (09951-00180, 09951-00330, 09952-06010), 09950-70010 (09951-07150) Description and Operation Air Bag Deactivation Switch: Description and Operation PASSENGER AIRBAG MANUAL ON-OFF SWITCH Passenger airbag manual on-off switch is mounted on the center cluster finish panel. By turning the passenger airbag manual on-off switch to OFF with the ignition key, the passenger airbag system can be disabled. Also, in order to notify the passenger that the passenger airbag is disabled, OFF indicator inside the switch will light up. Page 187 Steps 1 - 2 Page 3705 Child Restraint Seat Top Strap Bracket Installation Obtain the exact year and vehicle model Toyota Owner's Manual before beginning installation. 1. Confirm with the customer which seat location(s) they will be installing the child restraint seat. The Owner's Manual seat section provides an illustration showing available top strap bracket location(s). The illustration page in the Owner's Manual is shown in this bulletin. NOTE: Determine which kit parts are needed for each specific child seat location, by referring information in this bulletin. 2. Remove a 20mm diameter area of the carpet or trim material above the bracket mounting location. In some vehicles, a 20mm circle is already pre-cut into the interior trim material. Once the interior trim material is removed, the nuts welded in by the factory should be visible. 3. If a 5mm or 15mm spacer is specified, remove the red lock washer from the Bracket Sub-Assembly (P/N 73709-12010) and remove the 10mm spacer. Assure the red lock washer is re-installed onto the bolt. If a 5mm spacer is needed, use the 15mm bolt from the CRS Kit (P/N 04731-22012). Description and Operation Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Sensor A thermistor that is built into the engine coolant temperature sensor changes the resistance value according to the engine coolant temperature. The lower the engine coolant temperature sensor, the greater the thermistor resistance value, and the higher the engine coolant temperature sensor temperature, the lower the thermistor resistance value. The engine coolant temperature sensor is connected to the ECM. The 5 V power source voltage in the ECM is applied to the engine coolant temperature sensor from the terminal THA via a resistor R. That is, the resistor R and the engine coolant temperature sensor are connected in series. When the resistance value of the engine coolant temperature sensor changes in accordance with changes in the engine coolant temperature, the potential at terminal THA also changes. Based on this signal, the ECM increases the fuel injection volume to improve driveability during cold engine operation. Page 4423 Harness Locations Page 2616 Step 1 Step 2 Page 3183 Power Steering Pump: Service and Repair Disassembly and Reassembly Part 1 Of 2 Page 318 Knock Sensor: Testing and Inspection Service and Repair Fuel Pressure Release: Service and Repair 1. BEFORE WORKING ON FUEL SYSTEM, DISCONNECT NEGATIVE (-) TERMINAL CABLE FROM BATTERY HINT: Any diagnostic trouble code retained by the computer will be erased when the negative (-) terminal cable is removed from the battery. Therefore, if necessary, read the diagnosis before removing the negative (-) terminal cable from the battery. 2. DO NOT SMOKE OR WORK NEAR AN OPEN FLAME WHEN WORKING ON FUEL SYSTEM 3. KEEP GASOLINE AWAY FROM RUBBER OR LEATHER PARTS 4. FUEL SYSTEM a. When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe these procedures: 1. Disconnect the fuel pump connector. 2. Start the engine. After the engine has stopped on its own, turn the ignition switch OFF. 3. Put a container under the connection. 4. Slowly loosen the connection. 5. Disconnect the connection. 6. Plug the connection with a rubber plug. b. When connecting the union bolt on the high pressure pipe union, observe these procedures: 1. Always use 2 new gaskets. 2. Tighten the union bolt by hand. 3. Tighten the union bolt to the specified torque. Torque: 34.3 Nm (350 kg.cm, 25 ft.lb) Page 4362 Cruise Control Switch: Testing and Inspection Main Switch Circuit (Cruise Control Switch) DENSO Made CIRCUIT DESCRIPTION When the cruise control main switch is turned off, the cruise control does not operate. Wiring Diagram Locations Cooling / Heating Units Page 354 CHART 18 CHART 19 Page 1071 Heater Control Valve: Service and Repair REMOVAL 1. DRAIN ENGINE COOLANT FROM RADIATOR HINT: It is not necessary to drain out all the coolant. 2. DISCONNECT WATER VALVE CONTROL CABLE FROM WATER VALVE HINT: At the time of installation, please refer to the following item. For installing the control cable, refer to "INSTALLATION" of HEATER CONTROL ASSEMBLY. 3. DISCONNECT WATER HOSES a. Using pliers, grip the claws of the clip and slide the clip along the hose. b. Disconnect the water hose. HINT: At the time of installation, please refer to the following item. Install the hose clip in the position, as shown in the illustration. Page 4668 Junction Box / No. 1 Page 3304 2. Move the SST to at least 10 m (33 ft) away from the steering wheel pad tied down on the disc wheel. f. Cover the steering wheel pad with a cardboard box or tires. - Covering method using a cardboard box: Cover the steering wheel pad with the cardboard box and weight the cardboard box down in 4 places with at least 190 N (20 kg, 44 lb). Size of cardboard box. Must exceed the following dimensions: X = 460 mm (18.11 in.) Y = 650 mm (25.59 in.) NOTE: When dimension Y of the cardboard box exceeds the diameter of the disc wheel with tire to which the steering wheel pad is tied, X should be the following size. X = 460 mm (18.11 in.) + width of tire - If a cardboard box smaller than the specified size is used, the cardboard box will be broken by the shock from the airbag deployment. - Covering method using tires: Place at least 3 tires without disc wheel on top of the disc wheel with tire to which the steering wheel pad is tied. Tire size: Must exceed the following dimension- Width: 185 mm (7.87 in.) Inner diameter: 360 mm (14.17 in.) CAUTION: Do not use tires with disc wheels. NOTE: The tires may be marked by the airbag deployment, so use the redundant tires. g. Deploy the airbag. 1. Connect the SST red clip to the battery positive (+) terminal and the black clip to the battery negative (-) terminal. Page 1334 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Page 3444 Wheel Fastener: Specifications Hub Nut ............................................................................................................................................... ................................................... 110 Nm (83 ft. lbs.) Page 2640 Junction Box / No. 1 Testing and Inspection Power Window Switch: Testing and Inspection INSPECT POWER WINDOW MASTER SWITCH CONTINUITY Driver's Switch (Window Unlock) Driver's Switch (Window Unlock) Driver's Switch (Window Lock) Driver's Switch (Window lock) Paint - Codes & Code Label Locations Paint: All Technical Service Bulletins Paint - Codes & Code Label Locations Bulletin Number: PA001-00 Group: PAINT Date: January 28, 2000 Title: 2000 MODEL YEAR PAINT CODES Models: All '00 Models Introduction: Attached for your reference is a list of all 2000 model year OEM paint codes. NOTE: The body color code is on the vehicle Certification Regulation Label, located on the left front door "B" Pillar or door rear lower surface. Applicable Vehicles: All 2000 Models. Warranty Information Page 2535 Junction Box / No. 1 Locations Relay Box: Locations Relay Box / No. 2 Page 3593 Repairs and Inspections Required After a Collision: Service and Repair Seat Belt System REPAIRS AND INSPECTIONS REQUIRED AFTER A COLLISION SEAT BELT SYSTEMS CAUTION: Replace the seat belt assembly (outer belt, inner belt, bolts, nuts or sill-bar) if it has been used in a severe impact. The entire assembly should be replaced even if damage is not obvious. 1. PRETENSIONER IS NOT ACTIVATED a. Perform a diagnostic system check. b. Perform a visual check which includes the following items with the front seat outer belt removed from the vehicle. - Check for cuts and cracks in, or marked discoloration on the quarter trim panel. - Check for cuts and cracks in wire harness, and for chipping in connectors. - Check for deformation of the center floor No.3 crossmember. NOTE: For removal and installation of the front seat outer belt. 2. PRETENSIONER IS ACTIVATED a. Perform a diagnostic system check. b. Perform a visual check which includes the following items with the front seat outer belt removed from the vehicle. - Check for deformation of the center floor No.3 crossmember. - Check for damage on the connector and wire harness. * Refer to SRS Warning Light Check, and How to Display and Read Diagnostic Trouble Codes. Page 4658 Junction Box / No. 3 Page 1674 5. REMOVE ECT SENSOR a. Disconnect the ECT sensor connector. b. Using a 19 mm dean socket wrench, remove the ECT sensor and gasket. 6. INSPECT ECT SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: Refer to the graph If the resistance is not as specified, replace the ECT sensor. 7. REINSTALL ECT SENSOR a. Install a new gasket to the ECT sensor. b. Using a 19 mm deep socket, install the ECT sensor. Torque: 20 Nm (200 kg.cm, 14 ft.lb) c. Connect the ECT sensor connector. 8. REINSTALL FUEL PIPE Install the fuel pipe with 4 new gaskets and the 2 union bolts. Torque: 34.3 Nm (350 kg. cm, 25 ft.lb) 9. REINSTALL NO.2 TIMING BELT COVER 10. RECONNECT UPPER RADIATOR HOSE TO WATER OUTLET 11. REFILL WITH ENGINE COOLANT Locations Transmission Speed Sensor: Locations CIRCUIT DESCRIPTION The speed sensor for ABS detects the wheel speed and sends the appropriate signals to the ABS ECU. The ECU converts these signals into a pulse signal and outputs it to the combination meter. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. Page 1095 Specification: If the maximum pressure is less than the minimum standard value, replace the radiator cap sub-assembly. Type: Compact Cap, 108 kPa 1. Remove coolant and any foreign material on rubber points "A," "B," and "C." 2. Check that points "A" and "B" are not deformed, cracked, or swollen. 3. Check that points "B" and "C" are not stuck together. 4. Apply engine coolant to point "B" before using the radiator cap tester. ^ Radiator Cap Tester: Snap-On/Sun P/N SVTS262A (or equivalent) 5. Before installing the radiator cap tester, use the applicable radiator cap adaptor provided in the following SST kits in conjunction with the radiator cap tester: ^ SST P/N 09230-00030-01 (09231-10080-01) or 09230-00020-01 (09231-10060-01) or 09230-00050-01 (09231-10110-01) 6. When using the radiator cap tester, tilt it more than 30 degrees. Page 4971 Applicable Warranty*: This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Repair Procedure 1. Remove Wiper Arms, Plastic Cowl Cover and Wiper Motor (store wiper links up against bottom of windshield). NOTE: Mark wiper arm linkage attached to wiper motor and wiper motor splined shaft prior to removing the 12 mm retaining nut. 2. Spray Acrysol(TM) under entire lip of 1/2" pinch weld and wipe dry with a clean paper towel. FOLLOW DIRECTIONS ON SIDE OF CAN CAREFULLY. Dry open seam with compressed air prior to applying sealer. NOTE: Do not use a red shop towel to wipe surfaces because shop towels are contaminated with silicone. 3. Apply a small bead of Kent High Tech(TM) Clear Seam Sealer to underside front edge of the pinch weld from fender to fender as shown. 4. Apply Kent High Tech(TM) Clear Seam Sealer on all spot welds located on the floor of cowl panel. 5. Apply Kent High Tech(TM) Clear Seam Sealer around outside base of hood safety stops, and seal outside corner, under the "L" bracket as shown. Page 3177 Power Steering Pump: Testing and Inspection For information regarding the Testing and Inspection of this component and the system that it is a part of, please refer to Steering; Testing and Inspection; Procedures Fluid Level and Pressure Inspection. Page 3871 Impact Sensor: Service and Repair Airbag Sensor Connectors DISCONNECTION a. While holding both flank sides of the outer, slide the outer to the direction shown by an arrow. b. Lock of the connectors is released, then disconnect the connectors. HINT: Make sure to hold both flank sides of the outer. If holding the top and bottom sides, it will obstruct disconnection. CONNECTION a. Align the male connector (of the side of sensor) and female connector in the same direction as shown in the illustration and fit in them without rubbing. b. As they are fitted in, the outer slides rearward. Press it until the outer returns to its original position again. If fitting stops half way, connectors will separate. c. Make sure to insert until they are locked. After fitting in, pull them slightly to check that they are locked. (When locked, make sure that the outer returns to its original position and sound at the time of fitting in can be heard.) HINT: Do not fit in while holding the outer. - When fitting in, the outer slides. Do not touch it. Page 2968 5. INSPECT BRUSHES Using vernier calipers, measure the brush length. Standard Length Standard length: Minimum Length Minimum length: If the length is less than minimum, replace the brush holder and field frame. 6. INSPECT BRUSH SPRINGS Check the brush spring load. Take the pull scale reading the instant the brush spring separates from the brush. Diagrams Back Window Glass Page 3431 3. w/ Freewheel hub: REMOVE LOCK NUT AND ABS SPEED SENSOR ROTOR/SPACER a. Using a chisel and hammer, loosen the staked part of the lock nut. NOTICE: Be careful not to damage the bushing. b. Using SST, remove the lock nut. SST 09318-12010 c. Remove the ABS speed sensor rotor/spacer. NOTICE: Take care not to scratch the serration of the speed sensor rotor. 4. REMOVE AXLE HUB FROM STEERING KNUCKLE a. Remove the 4 bolts and shift the dust cover towards the hub side (outside). b. Using SST, remove the axle hub from the steering knuckle. SST 09710-30021 (09710-03051), 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04031, 09957-04010, 09958-04011) c. Remove the dust cover from the steering knuckle. d. w/o Free wheel hub (4WD only): Remove the bearing spacer and ABS speed sensor rotor/ spacer. 5. REMOVE OIL SEAL (OUTSIDE) Using a screwdriver, remove the oil seal (outside) from the steering knuckle. 6. REMOVE BEARING FROM STEERING KNUCKLE a. Using snap ring pliers, remove the snap ring. b. Using SST and a press, remove the bearing from the steering knuckle. SST 09950-60020 (09951-00810), 09950-70010 (09951-07150) REASSEMBLY Windshield Wiper Blade - Maintenance and Cleaning Wiper Blade: Technical Service Bulletins Windshield Wiper Blade - Maintenance and Cleaning BODY BO030-01 Title: WINDSHIELD WIPER BLADE MAINTENANCE AND CLEANING Models: All Models December 7, 2001 Introduction The following procedures are recommended to maintain windshield wiper blade performance. Applicable Vehicles ^ All models. Warranty Information Maintenance, Cleaning and Use Recommendations for Windshield Wiper Maintenance, Cleaning and Use: 1. Scheduled Maintenance ^ Check wiper rubber blades every 4 - 6 months or 7,500 miles for wear, cracking and contamination. ^ Clean glass and rubber wiper blades if blades are not clearing glass adequately. If this does not correct the problem, then replace the rubber elements. 2. Cleaning Procedure ^ Wiper Rubber: Bugs, dirt, sap and road grime on blades will cause streaking. ^ Clean wiper rubber of road and environmental debris using cloth or paper towel soaked with windshield washer fluid or mild detergent. ^8DO NOT USE fuel, kerosene, or petroleum based products to clean rubber wiper blades. ^ Windshield: Bugs, road grime, sap and car wash wax treatments decrease wiper performance. ^ Rinse windshield with water and apply non-abrasive cleaner, such as Bon-Ami (www.faultless.com), with a sponge. NOTE: Make sure to use plenty of water with all powder based cleaners so the glass is not scratched. 3. Contributors to Poor Performance/Decreased Rubber Blade Life (require rubber replacement) ^ Dusty areas cause the rubber edge to wear quickly. ^ Sand and salt used for road conditioning during winter causes the edge to wear quickly, so areas with significant snowfall require more frequent wiper replacement. ^ Heat and time cause the rubber to become excessively "permanent set," so the rubber does not turn over, resulting in streaking and/or unwiped areas on the glass. ^ Rubber is easily cut or torn while using ice scrapers on the glass. ^ Rubber can be torn when pulling blades off a frozen windshield. Page 4642 If circuit is as specified, try replacing the relay with a new one. If circuit is not as specified, inspect the circuits connected to other parts. Page 1505 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Overdrive Direct Clutch Page 4715 Page 2409 Steps 3 - 4 INSPECTION PROCEDURE Service and Repair Fuel Pressure Release: Service and Repair 1. BEFORE WORKING ON FUEL SYSTEM, DISCONNECT NEGATIVE (-) TERMINAL CABLE FROM BATTERY HINT: Any diagnostic trouble code retained by the computer will be erased when the negative (-) terminal cable is removed from the battery. Therefore, if necessary, read the diagnosis before removing the negative (-) terminal cable from the battery. 2. DO NOT SMOKE OR WORK NEAR AN OPEN FLAME WHEN WORKING ON FUEL SYSTEM 3. KEEP GASOLINE AWAY FROM RUBBER OR LEATHER PARTS 4. FUEL SYSTEM a. When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe these procedures: 1. Disconnect the fuel pump connector. 2. Start the engine. After the engine has stopped on its own, turn the ignition switch OFF. 3. Put a container under the connection. 4. Slowly loosen the connection. 5. Disconnect the connection. 6. Plug the connection with a rubber plug. b. When connecting the union bolt on the high pressure pipe union, observe these procedures: 1. Always use 2 new gaskets. 2. Tighten the union bolt by hand. 3. Tighten the union bolt to the specified torque. Torque: 34.3 Nm (350 kg.cm, 25 ft.lb) Page 1247 Knock Sensor: Description and Operation Knock Sensor Each knock sensor is fitted to the right bank and left bank of the cylinder block to detect engine knocking. This sensor contains a piezoelectric element which generates a voltage when it becomes deformed, which occurs when the cylinder block vibrates due to knocking. If engine knocking occurs, ignition timing is retarded to suppress it. Page 766 Engine Compartment Instrument Panel Locations System Outline Audible Warning Device: Description and Operation System Outline With the ignition SW in ACC position, current flows to TERMINAL 8 of the integration relay. When the ignition SW is turned to ON position, current flows to TERMINAL 6 of the relay. When the light control SW is turned to TAIL or HEAD position, current is applied to TERMINAL 4 of the relay through the TAIL fuse. LIGHT REMINDER SYSTEM When the light control SW is in TAIL or HEAD position and the driver's door is opened (Door courtesy SW ON), as a result, the relay is activated and current flows from TERMINAL 4 of the relay to TERMINAL A 5 to TERMINAL 1 of the door courtesy SW LH to GROUND, sounding the light reminder buzzer. Page 4402 If circuit is as specified, try replacing the relay with a new one. If circuit is not as specified, inspect the circuits connected to other parts. b. Disconnect the connector from the integration relay and inspect the connectors on the wire harness side. Page 1514 Part 2 Of 2 (Except California Spec.) *1: A/T *2: M/T Page 1992 Throttle Position Sensor: Service and Repair Refer to Fuel Delivery and Air Induction / Throttle Body / Service and Repair, for removal and installation of this component. Locations Intake Air Temperature Sensor: Locations The Intake Air Temperature (IAT) Sensor is installed in the Mass Air Flow (MAF) Meter. Page 1845 Fuel Pressure: Specifications Volume Specification Information not supplied by the manufacturer. Recall 01E041000: Trailer Wire Harness Converter Defect Trailer Connector: All Technical Service Bulletins Recall 01E041000: Trailer Wire Harness Converter Defect Equipment Description: Trailer towing wire harness converters which integrates the vehicle's tail lights, brake lights, and turn signal lights with those equipped on the trailer. Manufactured between May 1, 1999, and August 31, 2000, these converters were sold for installation on 1999-2000 Toyota Tundra and Tacoma vehicles. Affected part numbers are: PT207-34000, PT207-34002, PT207-04981, and PT214-04985. In the Tundra vehicles, the circuitry utilized in the converter was inadequate to properly manage vehicle and/or trailer-side voltage spikes. If the converter is exposed to a voltage spike, it may cause an electrical short or open circuit within the converter. Tacoma vehicles, due to deficient waterproofing and improper installation location of the converter, which is mounted in the lower portion of the tailgate cavity of the vehicle, an electrical short circuit will occur if water enters the converter housing. An electrical short or open circuit can cause a fault in the converter and a non-operational condition of the trailer lights. A vehicle crash can occur, possibly resulting in personal injury or death, if the vehicle is driven without operational trailer lights. Dealers will notify the customers and install a redesigned trailer towing wire harness converter free of charge. Owner notification is expect to begin August 2001. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Toyota at 1-800-331-4331. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Page 4629 Page 1937 b. Using SST; connect terminals TE1 and E1 of the DLC1. SST 09843-18020 c. After the engine speed is kept at 900 - 1,300 rpm for 10 seconds, check that it returns to the idle speed. d. Stop the engine. e. Disconnect the air assist hose from the IAC valve, and plug it. f. Start the engine and check that the idle speed reaches 500 rpm or below (the engine may stall). If the idle does not reach 500 rpm or below, check for a leak between the air assist hoses, pipe and injectors. g. Remove the SST from the DLC1. SST 09843-18020 h. Reconnect the air assist hose to the IAC valve. Page 1786 Throttle Position Sensor: Service and Repair Refer to Fuel Delivery and Air Induction / Throttle Body / Service and Repair, for removal and installation of this component. Testing and Inspection Blower Motor Relay: Testing and Inspection INSPECT HEATER MAIN RELAY (Making: HTR) CONTINUITY If continuity is not as specified, replace the relay. Page 721 Power Steering Fluid: Service and Repair For information regarding the Service and Repair of this component and the system that it is a part of, please refer to Power Steering Bleeding. O/D Cancel Signal Circuit Overdrive Indicator Lamp: Testing and Inspection O/D Cancel Signal Circuit CIRCUIT DESCRIPTION While driving uphill with cruise control activated, in order to minimize gear shifting and provide smooth cruising O/D may be prohibited temporarily under some conditions. The cruise control ECU sends O/D cut signals to the ECM as necessary and the ECM cancels O/D shifting until these signals are discontinued. WIRING DIAGRAM Page 4403 Audible Warning Device: Pinout Values and Diagnostic Parameters I 15-A INTEGRATION RELAY 4-GROUND : Approx. 12 volts with light control SW at TAIL or HEAD position A-5-GROUND : Continuity with LH door open Page 1508 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 3789 Splice Point J: Indicates a wiring Splice Point (Codes are "E"for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I 5 is indicated by the shaded section. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. N: Page No. How to Read Ground Points How to Read Ground Points Page 2460 9. REPLACE OIL DEFLECTOR a. Using a brass bar and hammer, remove the hub bolts, oil deflector and gasket. b. Position a new gasket on the axle shaft and install a washer and nut to a new hub bolt, as shown in the illustration, and install the hub bolt by torquing the nut. 10. INSTALL REAR AXLE SHAFT IN BACKING PLATE a. Coat a new oil seal lip with MP grease. b. Install the backing plate and bearing retainer on the rear axle shaft. c. Using SST and a press, install the rear axle shaft into the backing plate. SST 09316-60011 (09316-00051) d. Using snap ring expander, install a new snap ring. 11. w/ ABS: INSTALL ABS SPEED SENSOR ROTOR AND BEARING RETAINER (DIFFERENTIAL SIDE) Using SST and a press, install a new sensor rotor and new bearing retainer to the axle shaft. SST 09316-60011 (09316-00051) Standard length: 122.2 ± 1.0 mm (4.811 ± 0.039 inch) 12. REPLACE OIL SEAL (INNER SIDE) a. Using SST, remove the oil seal. SST 09308-00010 Page 2100 Junction Box / No. 1 Page 1943 Idle Up Control Valve: Testing and Inspection INSPECTION 1. TURN AIR CONDITIONING SWITCH OFF 2. CHECK IDLE-UP a. Start engine and run it at idle. b. Fully turn the steering wheel. c. Check that the engine rpm decreases when the vacuum hose of the air control valve is pinched. d. Check that the engine rpm increases when the hose is released. Keyless Entry - Remote Transmitter Programming Guide Keyless Entry Transmitter: Technical Service Bulletins Keyless Entry - Remote Transmitter Programming Guide ELECTRICAL EL010-07 REVISED Title: WIRELESS TRANSMITTER & PROGRAMMING GUIDE Models: '90 - '08 Applicable Toyota November 9, 2007 TSB REVISION NOTICE: ^ November 10, 2007: A TSB reference has been updated in the Programming column of the Application Chart. Previous versions of this TSB should be discarded. TSB UPDATE NOTICE: The information contained in this TSB supersedes TSB No. EL008-02. TSB No. EL008-02 is now obsolete and should be discarded. Introduction Difficulties during Remote Keyless Entry (RKE) Transmitter Programming can arise due to confusion between Toyota Factory Wireless systems and Toyota Port/Dealer installed systems. This bulletin will assist in identifying the system/correct remote transmitters for each vehicle, and provide the location of the most accurate programming procedure for each system. Applicable Vehicles ^ 1990 - 2008 model year applicable Toyota vehicles. Warranty Information System Identification The Application Chart contains all of the necessary information to correctly identify the type of system installed, and where to go to get programming procedures for each vehicle. Should a vehicle having both VIP and Factory systems available (as identified in the Application Chart) be brought in without any remotes (or one non-working remote), use the following tips to help determine which type of wireless system (O.E. or PIO/DIO) the vehicle has. ^ Look at the Trim Level of the vehicle. Higher-grade vehicles will tend to have O.E. systems, while entry-grade vehicles will tend to have VIR For example, the 2001 Camry XLE has Factory WRKE, but the LE and CE grades have VIR ^ Look for a "Status Monitor" with a glass breakage sensor and an LED externally installed into the dashboard or on the center console. Most VIP systems will have this. ^ Locate the ECU (refer to the applicable vehicle VIP Manual installation instructions for location). Once located, refer to the part label. ^ Attempt to perform the factory wireless programming procedure to get a response from the vehicle. Select the "confirmation mode" and see if any "Lock/Unlock" response is received, if so, the vehicle has a factory system. Page 2376 CHECK BALL DIAMETERS Testing and Inspection Fuel Gauge Sender: Testing and Inspection INSPECT FUEL SENDER GAUGE RESISTANCE Measure the resistance between terminals 2 and 3. 68 L 57 L If resistance value is not as specified, replace the sender gauge. Page 3063 Page 3613 Airbag Sensor Assembly: Description and Operation AIRBAG SENSOR ASSEMBLY The airbag sensor assembly is mounted on the floor inside the center cluster. The airbag sensor assembly consists of a airbag sensor, safing sensor, diagnosis circuit, ignition control and drive circuit, etc. It receives signals from the airbag sensor assembly and judges whether the SRS must be activated or not and diagnosis system malfunctions. Page 3700 An airbag activation prevention mechanism is built into the connector for the squib circuit of the SRS. When release of the airbag activation prevention mechanism is directed in the troubleshooting procedure, as shown in the illustration of the connectors on the next pages, insert paper which has the same thickness as the male terminal between the terminal and the short spring. CAUTION: Never release the airbag activation prevention mechanism on the squib connector. NOTE: - Do not release the airbag activation prevention mechanism unless specifically directed by the troubleshooting procedure. - If the inserted paper is too thick the terminal and short spring may be damaged, so always use paper with the same thickness as the male terminal. Page 2267 Step 2 Step 3 INSPECTION PROCEDURE Page 3494 2. REMOVE CENTER CLUSTER FINISH PANEL a. Remove the A/C switch. b. Pull out the hater control knobs. c. Remove heater control name plate. d. Remove the 2 screws. e. Using a screwdriver, release the 4 fitting clips and pull out the panel, then disconnect the connector. HINT: Tape the screwdriver tip before use. Page 696 1. Loosen the nut on the control shaft lever. 2. Push the control shaft fully forward. 3. Return the control shaft lever 2 notches to N position. 4. Set the shift lever to N position. 5. While holding the shift lever lightly toward the R position side, adjust the control lever nut. 6. Tighten the control shaft lever nut. Torque: 13 Nm (130 kg.cm, 10 ft.lb) 7. Start the engine and make sure that the vehicle moves forward when shifting the lever from the N to D position and reverses when shifting it to the R position. g. Floor shift: Inspect and adjust the shift lever position. When shifting the shift lever from the N position to other positions, check that the lever can be shifted smoothly and accurately to each position and that the position indicator correctly indicates the position. If the indicator is not aligned with the correct position, carry out the following adjustment procedures. 1. Remove the nut on the shift lever. 2. Push the control shaft lever fully downward. 3. Return the control shaft lever 2 notches to N position. 4. Set the shift lever to N position. 5. While holding the shift lever lightly toward the R position side, adjust the control shaft lever nut. 6. Tighten the control shaft lever nut. Torque: 13 Nm (130 kg.cm, 10 ft.lb) 7. Start the engine and make sure that the vehicle moves forward when shifting the lever from the N to D position and reverses when shifting it to the R position. h. Inspect and adjust the park/neutral position. Page 1737 Page 3225 Page 2211 Step 1 Seat Belt Extender - Increases Belt Length Seat Belt Extension: Technical Service Bulletins Seat Belt Extender - Increases Belt Length BODY BO023-01 September 14, 2001 Title: SEAT BELT EXTENDER Models: '00 -'02 Model Year Introduction Toyota customers who find it necessary to increase the length of their seat belts may obtain Seat Belt Extenders at no cost through their local Toyota dealer. ^ The extender is available in 6 inch, 9 inch, 12 inch, 15 inch and 18 inch lengths. ^ The extender is available only in black. ^ Owners are informed of the Seat Belt Extender availability through the Toyota Owner's Manual included in each vehicle. The customer (individual requiring the extender) must visit a Toyota dealership to have the required measurements made and to complete the Seat Belt Extender Worksheet. The worksheet will allow the proper fitting and selection of a Seat Belt Extender for the customer. The dealership personnel should then determine the applicable part number and place a Critical Order through the TDN Parts Network or Dealer Daily. The dealership service department should complete the affixed Seat Belt Extender Customer Information Label on the part and review the Owner Instruction Sheet" with the customer. The dealership should give a copy of the completed worksheet to the customer and keep the original in the customer's file. To assure utmost owner satisfaction, it is recommended that a dealership designate one person to coordinate all activities related to the Seat Belt Extender issue. It is recommended that dealerships do NOT stock Seat Belt Extenders due to the need for proper fitting to individual customers. This bulletin contains the following information: Procedure and Sample Label Application Charts Part Number Information Owner Instructions Seat Belt Extender Worksheet Applicable Vehicles ^ 2000 through 2002 model year Toyota vehicles. Page 375 Oxygen Sensor: Locations Air-Fuel Ratio (A/F) Sensor Page 750 Junction Box / No. 1 Details Page 1713 O2S Application Table O2S Failure Threshold Charts Page 3795 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Page 1328 Splice Point J: Indicates a wiring Splice Point (Codes are "E"for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I 5 is indicated by the shaded section. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. N: Page No. How to Read Ground Points How to Read Ground Points Page 1482 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 1112 Page 3073 Page 2055 COMPONENTS INSPECTION 1. DRAIN ENGINE COOLANT 2. REMOVE AIR CLEANER HOSE 3. REMOVE NO.2 TIMING BELT COVER 4. REMOVE INTAKE AIR CONNECTOR ASSEMBLY 5. REMOVE FUEL PRESSURE REGULATOR 6. REMOVE INTAKE MANIFOLD ASSEMBLY Description and Operation Leak Detection Solenoid: Description and Operation Evaporative Emissions System The vapor pressure sensor and VSV for vapor pressure sensor are used to detect abnormalities in the evaporative emission control system. The ECM decides whether there is an abnormality in the evaporative emission control system based on the vapor pressure sensor signal. Page 3255 Part 2 Of 2 DISASSEMBLY NOTICE: When using a vise, do not overtighten it. Page 4351 Steps 1 - 3 Page 2190 Capacity: A340E: 1.6 liters (1.7 US qts, 1.4 Imp. qts) A340F: 2.0 liters (2.1 US qts, 1.8 Imp. qts) 4. Start the engine and shift the shift lever into all positions from P to L position and then shift into P position. 5. With the engine idling, check the fluid level. Add fluid up to the COOL level on the dipstick. 6. Check the fluid level at the normal operating temperature, 70 - 80 °C (158 - 176 °F), and add as necessary. NOTE: Do not overfill. d. Check the fluid leaks. Check for leaks in the transmission. If there are leaks, it is necessary to repair or replacements, FIPGs, oil seals, plugs or other parts. e. Inspect and adjust the throttle cable. 1. Check that the throttle valve is fully closed. 2. Check that the inner cable is not slack. 3. Measure the distance between the outer cable end and stopper on the cable. Standard distance: 0 - 1 mm (0 - 0.04 in.) If the distance is not standard, adjust the cable by the adjusting nuts. f. Column shift: Inspect and adjust the shift lever position. When shifting the shift lever from the N position to other positions, check that the lever can be shifted smoothly and accurately to each position and that the position indicator correctly indicates the position. If the indicator is not aligned with the correct position, carry out the following adjustment procedures. Page 3231 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 410 Vehicle Speed Sensor: Description and Operation CIRCUIT DESCRIPTION The speed sensor for ABS detects the wheel speed and sends the appropriate signals to the ABS ECU. The ECU converts these signals into a pulse signal and outputs it to the combination meter. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. Page 4594 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Page 2970 Using an ohmmeter, check that there is continuity between terminals 50 and C. If there is no continuity, check and replace the magnetic switch. b. Check the hold-in coil for open circuit. Using an ohmmeter, check that there is continuity between terminal 50 and the switch body. If there is no continuity, replace the magnetic switch. 10. INSPECT BEARING Turn the bearing by hand while applying inward force. If resistance is felt or the bearing sticks, replace the bearing. Page 1097 5. When using the radiator cap tester, tilt it more than 30 degrees. 6. Pump the radiator cap tester several times, and check the maximum pressure. Pumping speed: 1 pump/second HINT: Stop pumping when the valve opens and read the gauge. The gauge must be within the standard values listed below when the pressure valve opens. The cap is considered OK when the pressure holds steady or falls very slowly, but holds within the standard values listed below for one minute. Specification: If the maximum pressure is less than the minimum standard value, replace the radiator cap sub-assembly. Page 369 CHART 28 Page 4293 reinstall plastic sheet against metal door panel. Confirm that there are no voids between sealer and plastic sheet and between sealer and metal door panel. 22. Flood all areas with water to confirm that there are no leaks into cab area. 23. If no leaks are present, reinstall door trim panel. Service and Repair Transmission Temperature Sensor/Switch: Service and Repair With SR5 ON-VEHICLE INSPECTION 1. DISCONNECT ATF TEMPERATURE SENSOR CONNECTOR 2. DISCONNECT OIL COOLER PIPE a. Remove the 3 bolts and clamps. b. Disconnect the oil cooler pipe. 3. REMOVE OIL COOLER ELBOW 4. REMOVE ATF TEMPERATURE SENSOR a. Remove the ATF temperature sensor. b. Remove the O-ring from the ATF temperature sensor. 5. INSTALL ATF TEMPERATURE SENSOR a. Coat a new O-ring with ATF and install it to the ATF temperature sensor. b. Install the ATF temperature sensor. Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.) 6. INSTALL OIL COOLER ELBOW 7. CONNECT OIL COOLER PIPE a. Connect the oil cooler pipe Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.) b. Install the 3 clamps and bolts. 8. CONNECT ATF TEMPERATURE SENSOR NOTICE: Be careful not to twist the wire harness. Service and Repair Throttle Valve Cable/Linkage: Service and Repair ON-VEHICLE REPAIR 1. DISCONNECT THROTTLE CABLE a. Disconnect the cable from the throttle linkage. b. Disconnect the cable from the cable clamps in the engine compartment. c. Remove the bolt and disconnect the cable clamp from the torque converter clutch housing. 2. REMOVE VALVE BODY 3. REMOVE THROTTLE CABLE Remove the retaining bolt and pull out the throttle cable. 4. INSTALL THROTTLE CABLE If the throttle cable is new, perform the following operations a - c. a. Bend the cable so that there is radius of about 200 mm (7.87 inch). b. Pull the inner cable lightly until the resistance is slightly felt, and hold it there. c. Stake the stopper, 0.8 - 1.5 mm (0.031 - 0.059 inch) from the end of the outer cable. d. Install a new O-ring to the throttle cable. e. Pull the throttle cable and install the retaining bolt. Torque: 10 Nm (100 kgf-cm, 7 kgf-cm) 5. INSTALL VALVE BODY 6. CONNECT THROTTLE CABLE TO ENGINE 7. INSTALL DRAIN PLUG Torque: 20 Nm (205 kgf-cm, 15 ft. lbs.) 8. FILL ATF AND CHECK FLUID LEVEL 9. ADJUST THROTTLE CABLE Page 4644 Key Reminder Switch: Pinout Values and Diagnostic Parameters B 6 BUCKLE SW 1-2 : Open with driver's seat belt in use D 15 DOOR COURTESY SW LH 1-GROUND : Closed with LH door open I 15-A SEAT BELT WARNING RELAY [INTEGRATION RELAY] 6-GROUND : Approx. 12 volts with ignition SW ON 12-GROUND : Always approx. 12 volts A 7-GROUND : Always continuity A 5-GROUND : Continuity with LH door open A 10-GROUND: Approx. 12 volts with ignition key in cylinder A 2-GROUND : 0 Volts for 4 - 8 seconds with ignition SW ON and 12 volts 4 - 8 seconds after ignition SW ON Page 1178 Specifications Clutch: Specifications Overdrive Direct Clutch Clutch Drum Bushing Inside Diameter, Maximum .......................................................................................................................... 27.11 mm (1.0673 inch) Overdrive Direct Clutch Piston Stroke Supra ................................................................................................................................................... .................. 1.45 - 1.70 mm (0.0571 - 0.0669 inch) Others ................................................................. ................................................................................................... 1.85 - 2.15 mm (0.0728 - 0.0846 inch) Overdrive Planetary Gear Bushing, Maximum ................................................................................................................................ 11.27 mm (0.4437 inch) Planetary Pinion Gear Thrust Clearance Standard .............................................................................................................................................. .................. 0.20 - 0.60 mm (0.0079 - 0.0236 inch) Maximum ............................................................. .......................................................................................................................... 1.00 mm (0.0394 inch) Flange Thickness No. 16 .................................................................................................................................................. .............................................. 3.6 mm (0.142 inch) No. 17 .................................................................. .............................................................................................................................. 3.5 mm (0.138 inch) No. 18 ......................................................................................................................................... ....................................................... 3.4 mm (0.134 inch) No. 19 ......................................................... ....................................................................................................................................... 3.3 mm (0.130 inch) No. 20 .............................................................................................................................. .................................................................. 3.2 mm (0.126 inch) No. 21 .............................................. .................................................................................................................................................. 3.1 mm (0.122 inch) Overdrive Brake Piston Stroke Previa .................................................................................................................................................. .................. 1.32 - 1.62 mm (0.0520 - 0.0638 inch) Others ................................................................. ................................................................................................... 1.40 - 1.70 mm (0.0551 - 0.0669 inch) Flange Thickness No. 77 .................................................................................................................................................. .............................................. 3.3 mm (0.130 inch) No. 78 .................................................................. .............................................................................................................................. 3.5 mm (0.138 inch) No. 79 ......................................................................................................................................... ....................................................... 3.6 mm (0.142 inch) No. 80 ......................................................... ....................................................................................................................................... 3.7 mm (0.146 inch) No. 81 .............................................................................................................................. .................................................................. 3.8 mm (0.150 inch) No. 82 .............................................. .................................................................................................................................................. 3.9 mm (0.154 inch) None ......................................................................................................................... ......................................................................... 4.0 mm (0.157 inch) Direct Clutch Piston Stroke ............................................................................................................................................................. 1.37 - 1.60 mm (0.0359 - 0.0630 inch) Drum Bushing Inside Diameter ....................................................................................................................................................... 53.99 mm (2.1256 inch) Flange Thickness No. 33 .................................................................................................................................................. .............................................. 3.0 mm (0.118 inch) No. 32 .................................................................. .............................................................................................................................. 3.1 mm (0.122 inch) No. 31 ......................................................................................................................................... ....................................................... 3.2 mm (0.126 inch) No. 32 ......................................................... ....................................................................................................................................... 3.3 mm (0.130 inch) No. 29 .............................................................................................................................. .................................................................. 3.4 mm (0.134 inch) No. 28 .............................................. .................................................................................................................................................. 3.5 mm (0.138 inch) No. 27 ....................................................................................................................... ......................................................................... 3.6 mm (0.142 inch) No. 34 ....................................... ......................................................................................................................................................... 3.7 mm (0.146 inch) Forward Clutch Pack Clearance .......................................................................................................... ........................................................ 0.5 - 0.9 mm (0.020 - 0.035 inch) Drum Bushing Inside Diameter ....................................................................................................................................................... 24.08 mm (0.9480 inch) Flange Thickness No. 61 .................................................................................................................................................. .............................................. 3.0 mm (0.118 inch) No. 60 .................................................................. .............................................................................................................................. 3.2 mm (0.126 inch) No. 45 ......................................................................................................................................... ....................................................... 3.4 mm (0.134 inch) No. 62 ......................................................... ....................................................................................................................................... 3.6 mm (0.142 inch) No. 44 .............................................................................................................................. .................................................................. 3.8 mm (0.150 inch) No. 42 .............................................. .................................................................................................................................................. 4.0 mm (0.157 inch) No. 63 ....................................................................................................................... ......................................................................... 4.2 mm (0.165 inch) No. 64 ....................................... ......................................................................................................................................................... 4.4 mm (0.173 inch) Second Brake Pack Clearance .......................................................................................................................................................... 0.62 - 1.98 mm (0.0244 - 1.1780 inch) First and Reverse Brake Pack Clearance .......................................................................................................................................................... 0.60 - 1.12 mm (0.0236 - 0.0441 inch) Flange Thickness No. 50 .................................................................................................................................................. .............................................. 5.0 mm (0.197 inch) No. 51 .................................................................. .............................................................................................................................. 4.8 mm (0.189 inch) Testing and Inspection Starter Relay: Testing and Inspection INSPECTION 1. REMOVE STARTER RELAY (Marking: ST) 2. INSPECT STARTER RELAY a. Inspect the relay continuity. 1. Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. 2. Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. b. Inspect the relay operation. 1. Apply battery positive voltage across terminals 1 and 2. Page 2796 Loosen/Tighten Bleeder Plug 3. CONNECT VINYL TUBE TO BRAKE CALIPER OR WHEEL CYLINDER BLEEDER PLUG Insert the other end of the tube in a half-full container of brake fluid. HINT: Begin air bleeding from the wheel cylinder with the longest hydraulic line. 4. BLEED BRAKE LINE a. Slowly depress the brake pedal several times. b. While an assistant depresses the pedal, loosen the bleeder plug until fluid starts to run out. Then tighten the bleeder plug. c. Repeat this procedure until there are no more air bubbles in the fluid. Torque: (bleeder plug) 11 Nm (110 kgf-cm, 8 ft. lbs.) 5. REPEAT PROCEDURE FOR EACH WHEEL ON-VEHICLE INSPECTION HINT: Pre runner is the described below. RZN191L-TRPDKAB, RZN196L-CRPDKAB, VZN195L-RPDKAB 1. SET REAR AXLE LOAD Rear axle load (includes vehicle weight): 2. INSTALL LSP & BV GAUGE (SST) AND BLEED AIR SST 09709-29018 3. RAISE FRONT BRAKE PRESSURE TO 7,845 kPa (80 kgf/cm2, 1,138 psi) AND CHECK REAR BRAKE PRESSURE Rear Brake Pressure: Locations Transmission Speed Sensor: Locations CIRCUIT DESCRIPTION The speed sensor for ABS detects the wheel speed and sends the appropriate signals to the ABS ECU. The ECU converts these signals into a pulse signal and outputs it to the combination meter. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. Locations Knock Sensor: Locations Page 67 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Locations Testing and Inspection Headlamp Relay: Testing and Inspection INSPECT HEADLIGHT CONTROL RELAY CONTINUITY If continuity is not as specified, replace the relay. Page 1115 Thermostat: Service and Repair REMOVAL 1. DRAIN ENGINE COOLANT 2. DISCONNECT LOWER RADIATOR HOSE 3. REMOVE THERMOSTAT a) Remove the 3 nuts, water inlet and thermostat with gasket from the water pump. b) Remove the gasket from the thermostat. INSPECTION INSPECT THERMOSTAT HINT: Thermostat is numbered according to the valve opening temperature. Page 3317 Steering Wheel: Service and Repair Steering Wheel Off Center Procedures REPAIR PROCEDURES HINT: This is the repair procedure for steering off center. 1. INSPECT STEERING WHEEL OFF CENTER a. Apply masking tape on the top center of the steering wheel and steering column upper cover. b. Drive the vehicle in a straight line for 100 meters at a constant speed of 35 mph (56 km/h), and hold the steering wheel to maintain the course. c. Draw a line on the masking tape as shown in the illustration. d. Turn the steering wheel to its straight position. HINT: Refer to the upper surface of the steering wheel, steering spoke and SRS airbag line for the straight position. Page 1777 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 2342 Testing and Inspection Turn Signal Switch: Testing and Inspection INSPECT TURN SIGNAL SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 1730 Service Precautions Air Bag(s) Arming and Disarming: Service Precautions NOTE: TOYOTA trucks are equipped with SRS, which comprises a driver airbag and front passenger airbag. Failure to carry out service operations in the correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Further, if a mistake is made in servicing the SRS, it is possible that the SRS may fail to operate when required. Before performing servicing (including removal or installation of parts, inspection or replacement), be sure to read the following items carefully, then follow the correct procedures described in the repair manual. Malfunction symptoms of the SRS are difficult to confirm, so the DTCs become the most important source of information when troubleshooting. When troubleshooting the SRS, always inspect the DTCs before disconnecting the battery. Even in cases of a minor collision where the SRS does not deploy, the steering wheel pad, front passenger airbag assembly, airbag sensor assembly and front airbag sensor should be inspected. Never use SRS parts from another vehicle. When replacing parts, replace them with new parts. Never disassemble and repair the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor in order to reuse it. If the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor has been dropped, or if there are cracks, dents or other defects in the case, bracket or connector, replace them with new ones. Use a volt/ohmmeter with high impedance (10 K.Ohm/V minimum) for troubleshooting the system's electrical circuits. Information labels are attached to the periphery of the SRS components. Follow the instructions on the notes. After work on the SRS is completed, perform the SRS warning light check. If the vehicle is equipped with a mobile communication system, refer to the precaution in the Introduction system. CAUTION: Work must be started 90 seconds after the ignition switch is turned to the "LOCK" position and the negative (-) terminal cable is disconnected from the battery (The SRS is equipped with a back-up power source so that if work is started within 90 seconds from disconnecting the negative (-) terminal cable of the battery, the SRS may be deployed.). When the negative (-) terminal cable is disconnected from the battery, the memory of the clock and audio system will be canceled. So before starting work, make a record of the contents memorized in the audio memory system. When work is finished, reset the audio systems as they were before and adjust the clock. However, it is not possible to make a record of the memory contents. So when the work is finished, it will be necessary to explain this fact to the customer, and ask the customer to adjust the features and reset the memory. To avoid erasing the memory in each memory system, never use a back-up power supply from outside the vehicle. Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during repairs. Do not expose the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor directly to hot air or flames. Locations Knock Sensor: Locations Page 1329 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source How to Read Power Source Page 3909 ^ February 28, 2003: In Wireless Transmitter Identification section Figures 5, 9, 10,1 2, and 13 as shown are updated to include 2003 model year; Figure 11 updated to include 1999 and 2003 model year. ^ January 17, 2003: 2003 model year added to Solara in the Application Chart. ^ The information contained in this TSB supercedes TSB EL010-01, dated October 26, 2001. The previous TSB, EL010-01, should be discarded. Introduction Page 795 Wheel Bearing: Service and Repair Disassembly and Reassembly DISASSEMBLY Engine/Transmission Controls - Resetting ECM Memory Engine Control Module: Technical Service Bulletins Engine/Transmission Controls - Resetting ECM Memory TRANSMISSION & CLUTCH TC002-03 REVISED Title: ECM RESET MEMORY FUNCTION Models: '00 - '05 All Models June 10, 2003 TSB REVISION NOTICE: ^ December 20, 2004: Applicable Vehicles section has been updated - 2004 and 2005 model years added, models and model years updated for various models; and Reset Procedure 2 has been revised. ^ January 16, 2004: Tundra vehicles were added to the Applicable Vehicles chart. ^ December 17, 2003: T-100 vehicles were removed from the Applicable Vehicles chart. Previous versions of this TSB should be discarded. Introduction Whenever an automatic transmission is replaced, overhauled or individual components are replaced, use this procedure to clear Engine Control Module (ECM, SAE term: Powertrain Control Module, PCM) "Learned Values" to minimize subsequent performance concerns. CAUTION: Failure to follow the procedure below may lengthen the time to readjust the ECM "Learned Values," potentially resulting in performance concerns. Required SSTs Warranty Information Applicable Vehicles Page 3510 Evaporator Case: Service and Repair Disassembly and Reassembly DISASSEMBLY 1. REMOVE THESE PARTS: a. A/C amplifier. b. Wire harness. 2. REMOVE BLOWER RESISTOR Remove the 2 screws and blower resistor. 3. SEPARATE UPPER AND LOWER UNIT CASES a. Using a knife, cut off the each packing. b. Remove 3 clips and 3 screws. c. Separate the upper and lower unit case. 4. REMOVE EVAPORATOR FROM LOWER UNIT CASE HINT: At the time of reassembly, please refer to the following item. If evaporator is replaced, add compressor oil to evaporator. Add 40 - 50 cc (1.4-1.7 fl.oz.) Compressor oil: ND-OIL 8 or equivalent 5. REMOVE THERMISTOR Pull out the thermistor from evaporator. 6. REMOVE PRESSURE SWITCH FROM LIQUID TUBE Torque: 10 Nm (100 kg.cm, 7 ft.lb) HINT: Lock the switch mount on the tube with an opened wrench, being careful not to deform the tube and remove the switch. - At the time of reassembly, please refer to the following item. Lubricate a new O-ring with compressor oil and install the switch. 7. REMOVE EXPANSION VALVE Using a hexagon wrench, remove the 2 bolts and separate the expansion valve evaporator, liquid and suction tube. Torque: 5.4 Nm (55 kg.cm, 48 in.lb) HINT: At the time of reassembly, please refer to the following item. Lubricate 4 new O-rings with compressor oil and install the valve and tubes. REASSEMBLY Reassembly is in the reverse order of disassembly. Page 879 c. When connecting the flare nut on the high pressure pipe union, observe these procedures: 1. Apply a light coat of engine oil to the flare and tighten the flare nut by hand. 2. Using SST, tighten the flare nut to the specified torque. SST 09631-22020 Torque: 28 Nm (285 kg.cm, 21 ft.lb) HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). d. Observe these precautions when removing and installing the injectors. 1. Never reuse the O-ring. 2. When placing a new O-ring on the injector, take care not to damage it in any way. 3. Coat a new O-ring with spindle oil or gasoline before installing-never use engine, gear or brake oil. e. Install the injector to the delivery pipe and intake manifold, as shown in the illustration. f. Check that there are no fuel leaks after doing maintenance anywhere on the fuel system. 1. Connect a TOYOTA hand-held tester to the DLC3. Service and Repair Parking Pawl: Service and Repair ON-VEHICLE REPAIR 1. REMOVE VALVE BODY 2. REMOVE PARKING LOCK PAWL BRACKET 3. REMOVE SPRING FROM PARKING LOCK PAWL SHAFT 4. REMOVE PARKING LOCK PAWL AND SHAFT 5. INSTALL PARKING LOCK PAWL AND SHAFT 6. INSTALL SPRING TO PARKING LOCK PAWL SHAFT Page 1571 Page 437 Crankshaft Position Sensor: Testing and Inspection INSPECT CRANKSHAFT POSITION SENSOR a. Remove the sensor connector. b. Using an ohmmeter, measure the resistance between the terminals. Resistance: Cold 1,630 - 2,740 ohms Hot 2,065 - 3,225 ohms c. Reinstall the sensor. Page 2643 Relay Box / No. 2 Ground Locations Page 2995 Auxiliary Power Outlet: Ground Locations Page 1936 Idle Air Control Valve: Testing and Inspection On-Vehicle Inspection 1. INSPECT IAC VALVE OPERATION a. Initial conditions: - Engine at normal operating temperature - Idle speed checked correctly - Transmission in neutral position - A/C switch OFF b. Using SST, connect terminals TE1 and E1 of the DLC1 SST 09843-18020 c. After engine speed is kept at approx. 1,000 rpm for 5 seconds, check that it returns to the idle speed. If the engine speed operation is not as specified, check the IAC valve, wiring and ECM. d. Remove the SST from the DLC1. SST 09843-18020 2. INSPECT IAC VALVE RESISTANCE NOTE: "Cold" and "Hot" In the following sentences express the temperature of the coils themselves. "Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F). a. Disconnect the IAC valve connector. b. Using an ohmmeter, measure the resistance between terminal +B and other terminals (RSC, RSO). Resistance: Cold 17.0 - 25.0 ohms Hot 21.5 - 29.5 ohms If the resistance is not as specified replace the IAC valve. c. Reconnect the IAC valve connector. 3. INSPECT AIR ASSIST SYSTEM a. Initial conditions: - Engine at normal operating temperature - Idle speed checked correctly - Transmission in neutral position - A/C switch OFF Page 2134 Overdrive Switch: Testing and Inspection O/D Cancel Signal Circuit CIRCUIT DESCRIPTION While driving uphill with cruise control activated, in order to minimize gear shifting and provide smooth cruising O/D may be prohibited temporarily under some conditions. The cruise control ECU sends O/D cut signals to the ECM as necessary and the ECM cancels O/D shifting until these signals are discontinued. WIRING DIAGRAM Page 4816 Page 2656 Transmission Mode Indicator - A/T: Testing and Inspection CIRCUIT DESCRIPTION The ECM memory contains the shift programs for the NORMAL and POWER patterns, 2 position, L position and the lock-up patterns. Following the programs corresponding to the signals from the pattern select switch, the park/neutral position and other various sensors, the ECM switches the solenoid valves ON and OFF, and controls the transmission gear change and the lock-up clutch operation. Locations Intake Air Temperature Sensor: Locations The Intake Air Temperature (IAT) Sensor is installed in the Mass Air Flow (MAF) Meter. Paint - Refinishing Bumper Cover Paint: All Technical Service Bulletins Paint - Refinishing Bumper Cover PAINT PA003-02 REVISED June 4, 2002 Title REFINISHING REPLACEMENT BUMPER COVERS Models All '83 - '05 Models TSB REVISION NOTICE: ^ February 14, 2005: Applicable Vehicles now includes 2004 - 2005 model years. Previous versions of this TSB should be discarded. Introduction In cases where a bumper cover is being replaced a special preparation process is necessary to assure the refinish is customer acceptable. This bulletin provides the recommended refinishing procedure for new bumper covers. Applicable Vehicles ^ All 1983 - 2005 model year Toyota vehicles. Required Tools & Material Note:Please visit www.3m.comlautomotive to find the nearest store that sells 3M automotive products. Warranty Information Refinishing Procedure 1. Mix a solution of mild soap (car wash soap with no wax additives) and clean water. Note: Carefully follow mixing instructions on the soap container. Too much soap or too much water may cause surface contamination or rinsing difficulty. Page 2964 Starter Motor: Testing and Inspection ON-VEHICLE INSPECTION NOTE: Before changing the starter, check the following items again: - Connector connection - Accessory installation, e.g.: theft deterrent system TESTING NOTE: These tests must be done within 3 to 5 seconds to avoid burning out the coil. 1. DO PULL-IN TEST a. Disconnect the field coil lead wire from terminal C. b. Connect the battery to the magnetic switch as shown. Check that the clutch pinion gear moves outward. 2. DO HOLD-IN TEST With battery connected as above with the clutch pinion gear out, disconnect the negative (-) lead from terminal C. Check that the pinion gear remains out. 3. INSPECT CLUTCH PINION GEAR RETURN Disconnect the negative (-) lead from the switch body. Check that the clutch pinion gear returns inward. 4. DO NO-LOAD PERFORMANCE TEST Page 4040 5. Apply Kent High Tech(TM) Clear Seam Sealer around outside base of hood safety stops, and seal outside corner, under the "L" bracket as shown. 6. Mask-off wiper motor opening. 7. Attach Kent(TM) 12" extension tube (P/N 90175) to the nozzle on the can of Leak-Chek(TM) (P/N 50087). NOTE: Direct Leak-Chek(TM) spray material approximately 1 inch above seam. Spray force is very strong - make several test passes before actually spraying material into seam. 8. Spray Leak-Chek(TM) through the wiper motor opening. a. Spray material inside upper cowl, beginning in lower corner, and continuing toward the centerline of vehicle. b. Remove wand from the wiper motor opening and insert it into larger cowl openings on the right hand side. Continue spraying material along entire seam until seam is filled from R/F fender to L/F fender area. Spray Leak-Chek(TM) into seam a total of 3 times, allowing Leak-Chek(TM) to flash dry for 30-45 minutes between applications. (Drying time increases as outside temperature decreases.) 9. After final application of Leak-Chek(TM) has been allowed to dry for approximately one hour, flood area with water for 5-10 minutes. NOTE: Hold garden hose at top right front corner of windshield and point hose downward toward lower right hand corner of windshield as shown. ABS/TCS - Zero Point Calibration Information Steering Angle Sensor: Technical Service Bulletins ABS/TCS - Zero Point Calibration Information T-SB-0020-08 March 25, 2008 Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment Service Category Brake Section Brake Control/Dynamic Control System Market USA Applicability Introduction The purpose of this TSB is to provide information on when and how to perform the zero point calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting the battery is a necessary step for performing the zero point calibration. Warranty Information Required Tools & Equipment ^ Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE). ^ The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the service procedures listed in this bulletin. Preliminary Information Perform this procedure if any of these repairs have been performed on the vehicle: ^ Wheel alignment has been adjusted. ^ Any chassis components have been removed/installed or replaced. Page 4139 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 1547 Knock Sensor: Description and Operation Knock Sensor Each knock sensor is fitted to the right bank and left bank of the cylinder block to detect engine knocking. This sensor contains a piezoelectric element which generates a voltage when it becomes deformed, which occurs when the cylinder block vibrates due to knocking. If engine knocking occurs, ignition timing is retarded to suppress it. Page 4577 Page 202 f. Read the blinking pattern of the CRUISE MAIN indicator light. g. After performing the check, turn the main switch OFF. HINT: When 2 or more signals are input to the ECU, the lowest numbered code will be displayed first. FORD Made HINT: 1. For check No.1 - No.2: Turn the ignition switch ON. 2. For check No.3: - Turn ignition switch ON. - Shift to D position. 3. For check No.4: - Jack up the vehicle. - Start the engine. - Shift to D position. a. Press the control switch to SET/COAST or RES/ACC position and hold it down or hold it up "1". b. Press the main switch ON "2". c. Check that the CRUISE MAIN indicator light blinks twice or 3 times repeatedly after 3 seconds. d. Turn the SET/COAST or RES/ACC switch OFF. e. Operate each switch as listed in the table. Page 4377 Audible Warning Device: Connector Locations Child Restraint - Seat Top Strap Installation Technical Service Bulletin # BO010-02 Date: 020524 Child Restraint - Seat Top Strap Installation BODY BO010-02 May 24, 2002 Title: CHILD RESTRAINT SEAT TOP STRAP BRACKET INSTALLATION Models: '83 - '00 All Models Introduction Child restraint seat top strap bracket installation procedures are provided to supplement the Owner's Manual. Beginning with 2001 models, the top strap brackets are factory installed. NOTE: ^ The child restraint seat top strap assembly is not available as a service part. Contact the child restraint seat manufacturer for recommended top strap information, top strap to child restraint seat installation instructions, and top strap retailers. ^ The top strap brackets can only be installed on vehicles that have nuts welded in place by the factory. The locations of these nuts can be found in the Owner's Manual (for most 1983 and newer models.) Toyota does not recommend modifying vehicles that do not have nuts welded in place by the factory. Some Land Cruiser and RAV4 vehicles, prior to 2001 model year, may not have these nuts welded in by the factory. Applicable Vehicles ^ 1983 - 2000 model year vehicles, all models. Parts Information Warranty Information Installation Procedure/Reference Information Installation Procedure Page 3479 b. Using SST, remove the snap ring. SST 07114-84020 NOTE: At the time of reassembly, please refer to the following item. The snap ring should be installed so that its beveled side faces up. c. Remove the stator. REASSEMBLY Reassembly is in the reverse order of disassembly. HINT: After reassembly, check clearance of magnetic clutch. Removal and Installation Wheel Bearing: Service and Repair Removal and Installation REMOVAL Page 3772 Front Seat Belt Extender Applications Page 4038 Front Door Panel: By Symptom Technical Service Bulletin # BO026R-00 Date: 050112 Body - Water Leaks to The Interior BODY BO026-00 Title: WATER LEAK FIELD-FIX REPAIR INSTRUCTIONS Models: '97 - '04 Tacoma October 27, 2000 TSB Revision Notice: ^ January 12, 2005: Applicable Vehicles has been updated to include 2004 model year. ^ August 25, 2003: VIN and Applicable Model Information has changed, and repair procedure has been expanded and clarified. ^ October 27, 2000: This TSB updates B0016-98 dated June 12, 1998. B016-98 is now obsolete and should be discarded. Previous versions of this TSB should be discarded. Introduction Use the following field-fix procedures if water is present on the floor carpeting and it can be confirmed that the water is leaking into the cab from either the upper cowl or side cowl seam, or moisture barrier behind the door trim panel. Applicable Vehicles 1997 - 2004 model year Tacoma vehicles. Required Materials Page 928 Oil Filter: Tools and Equipment Toyota Oil Filter Wrench Set AST tool# TOY 300 This set includes our tool numbers TOY640, TOY730, and M0219. With the TOY300 you have every gas engine Toyota/Lexus model covered between 1980 and 2009. - Covers all Toyota and Lexus vehicles 1980-2009, based on factory filters. Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 This Kit Contains the Following Tools: TOY 640 - Toyota Oil Filter Wrench Page 4808 Horn: Fuse and Fusible Link Locations Relay Box / No. 2 Description and Operation SRS Warning Light: Description and Operation SRS WARNING LIGHT The SRS warning light is located on the combination meter. It goes on to alert the driver of trouble in the system when a malfunction is detected in the airbag sensor assembly self-diagnosis. In normal operating conditions when the ignition switch is turned to the ACC or ON position, the light goes on for about 6 seconds and then goes OFF. Page 3708 Page 1569 ^ O2S TEST RESULTS A list of the available oxygen sensors will be displayed. 2. Select the desired oxygen sensor and press Enter. NOTE: The monitor result of the A/F sensor will not be displayed. If you select "Bank 1-Sensor 1" or Bank 2-Sensor 1" for a vehicle equipped with an A/F sensor, the Diagnostic Tester will display "No parameter to display." 3. Compare the test results with the values listed in the Failure Threshold Chart. * Although this procedure references the Toyota Diagnostic Tester, the O2S test results can be checked using a generic OBD II scantool. Refer to your OBD II scantool operator's manual for specific procedures. Comparing O2S Test Results to Failure Thresholds 1. Determine the correct O2S Failure Threshold Chart for your vehicle by looking in the "O2S Application Table," in this bulletin. 2. Select appropriate year, model, and engine for specified O2S Failure Threshold Chart. 3. Compare O2S test results with the specified O2S Failure Threshold Chart. It may be necessary to convert O2S test results to a specific measurement unit using the conversion factor that is supplied in the specified table. See example. Example: Page 1287 CHART 21 Page 4588 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source How to Read Power Source Page 442 Page 3478 2. REMOVE ROTOR a. Using SST, remove the snap ring. SST 07114-84020 NOTE: At the time of reassembly, please refer to the following item. The snap ring should be installed so that beveled side faces up. b. Using a plastic hammer, tap the rotor off the shaft. NOTE: Be careful not to damage the pulley when tapping on the rotor. 3. REMOVE STATOR a. Disconnect the stator lead wire from the compressor housing. Page 4083 Headliner: Diagrams Roof Headlining (Regular Cab) Page 8 WARRANTY INFORMATION PROGRAMMING PROCEDURE AUTOMATIC (IGNITION-CONTROLLED) DOOR LOCKING/UNLOCKING FUNCTION The factory setting for the AUTOMATIC DOOR LOCKING/UNLOCkING FUNCTION is "ON". To change this feature's operation, follow the steps below: 1. Sit in the driver's seat with driver's door open. 2. Insert the key into the ignition switch, and turn it to 'ON" position (not "ACC") 5 times (ON > LOCK > ON > LOCK> ON > LOCK > ON> LOCK > ON) within a 10 second period. System Response: The STATUS MONITOR's LED turns on, and the PIEZO BUZZER sounds once. NOTE: You must perform the next steps within 30 seconds. 3. Select the customer's preferred operating mode. ABS/TCS - Zero Point Calibration Information Alignment: Technical Service Bulletins ABS/TCS - Zero Point Calibration Information T-SB-0020-08 March 25, 2008 Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment Service Category Brake Section Brake Control/Dynamic Control System Market USA Applicability Introduction The purpose of this TSB is to provide information on when and how to perform the zero point calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting the battery is a necessary step for performing the zero point calibration. Warranty Information Required Tools & Equipment ^ Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE). ^ The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the service procedures listed in this bulletin. Preliminary Information Perform this procedure if any of these repairs have been performed on the vehicle: ^ Wheel alignment has been adjusted. ^ Any chassis components have been removed/installed or replaced. Testing and Inspection Headlamp Dimmer Relay: Testing and Inspection INSPECT HEADLIGHT DIMMER RELAY CONTINUITY If continuity is not as specified, replace the relay. Page 4364 Wiring Diagram Step 1 Page 317 Knock Sensor: Description and Operation Knock Sensor Each knock sensor is fitted to the right bank and left bank of the cylinder block to detect engine knocking. This sensor contains a piezoelectric element which generates a voltage when it becomes deformed, which occurs when the cylinder block vibrates due to knocking. If engine knocking occurs, ignition timing is retarded to suppress it. Testing and Inspection Wiper Switch: Testing and Inspection INSPECT FRONT WIPER AND WASHER SWITCH CONTINUITY W/ Mist w/ MIST: Page 325 Applicable Vehicles Page 4811 D: Indicates related system. Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V). Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, 1H2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green O = Orange P = Pink R = Red SB = Sky Blue V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Page 3182 3. CONNECT PRESSURE FEED TUBE a. Torque the union bolt with a new gasket on each side of the tube. Torque: 47 Nm (475 kgf-cm, 34 ft. lbs.) HINT: Make sure the stopper of the tube is touching the PS pump body as shown, then torque the union bolt. b. Install the oil pressure switch to the pressure feed tube. Torque: 21 Nm (210 kgf-cm, 15 ft. lbs.) c. Connect the connector to the oil pressure switch. 4. CONNECT RETURN HOSE 5. INSTALL AIR CLEANER ASSEMBLY Tighten the 3 bolts. 6. BLEED POWER STEERING SYSTEM Page 1723 CHART 15 Page 3426 HINT: PreRunner is the model described below. RZN191L-TRPDKAB, RZN196L-CRPDKAB, VZN195L-CRPDKAB 1. REMOVE FRONT WHEEL Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.) 2. REMOVE SHOCK ABSORBER Page 4917 Quarter Window Glass: Service and Repair REMOVAL 1. REMOVE DOOR SCUFF PLATE Remove the 4 screws and plate. 2. REMOVE BACK PANEL UPPER GARNISH AND BACK PANEL TRIM a. Using a screwdriver, remove the back panel upper garnish. HINT: Tape the screwdriver tip before use. b. Remove the 3 bolts and back panel trim. Torque: 9.8 N.m (100 kgf.cm, 7 ft.lbf) 3. REMOVE BACK PANEL LOWER GARNISH Using a screwdriver, remove the back panel lower garnish. HINT: Tape the screwdriver tip before use. 4. REMOVE REAR SEAT CUSHIONS Remove the 4 bolts and rear seat cushions. Torque: 9.8 N.m (100 kgf.cm, 7 ft.lbf) 5. REMOVE FRONT AND REAR SEAT OUTER BELT ANCHORS Remove the 4 bolts, seat belt anchors and belt guide. Torque: 43 N.m (440 kgf.cm, 32 ft.lbf) 6. Remove Lock Handle Page 70 Engine Control Module: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Removal and Installation Blower Motor: Service and Repair Removal and Installation Blower Unit REMOVAL 1. REMOVE THESE PARTS: a. Glove compartment door b. Glove compartment door reinforcement c. Lower No.2 finish panel d. No.4 heater to register duct e. Front door scuff plate RH f. Cowl side trim RH g. Cooling unit Testing and Inspection Ignition Cable: Testing and Inspection ON-VEHICLE INSPECTION INSPECT HIGH-TENSION CORDS a. Remove the air cleaner hose. b. Disconnect the high-tension cords at the rubber boot. Do not pull on the high-tension cords. NOTE: Pulling on or bending the cords may damage the conductor inside. c. Using an ohmmeter, measure the high-tension cord resistance. Maximum resistance: 25 kohms per cord If the resistance is greater than maximum, check the terminals. If necessary, replace the high-tension cord. Page 2268 Overdrive Indicator Lamp: Testing and Inspection O/D Main Switch & O/D OFF Indicator Light Circuit CIRCUIT DESCRIPTION The O/D main switch is a momentary type switch. When pressing the O/D OFF main switch, the O/D OFF indicator light lights up and ECM prohibit shifting to O/D, and when pressing it again, the O/D OFF indicator light goes off and ECM allows shifting to O/D. Turning the IG switch OFF will reset the O/D OFF indicator light. Page 345 CHART 5 CHART 6 Page 1169 3. Start the engine and warm it up to normal operating temperatures before test-driving. 4. Perform a thorough test drive with several accelerations from a stop with "light throttle" application until proper transmission shifting is verified. Reset Procedure 2 1. Disconnect the negative battery cable for 5 minutes. 2. Reconnect battery cable. 3. Start the engine and warm it up to normal operating temperatures before test-driving. 4. Perform a thorough test drive with several accelerations from a stop with "light throttle" application until proper transmission shifting is verified. Page 2659 Step 2 Step 3 INSPECTION PROCEDURE Page 2575 Using a transmission jack, support the transmission. 10. REMOVE ENGINE REAR MOUNTING BRACKET Remove the 8 bolts and engine rear mounting bracket. Torque: Bolt A: 58 Nm (590 kgf-cm, 43 ft. lbs.) Bolt B: 18 Nm (185 kgf-cm, 13 ft. lbs.) 11. REMOVE ENGINE REAR MOUNTING Remove the 4 bolts and engine rear mounting. Torque: 65 Nm (660 kgf-cm, 48 ft. lbs.) 12. REMOVE TRANSMISSION a. Remove the 6 transmission mounting bolts from the engine. Torque: 72 Nm (730 kgf-cm, 53 ft. lbs.) b. Disconnect the wire harness from the transmission. c. Pull out the transmission up and toward the rear. d. Turn the transmission clockwise. e. Move the transmission backward again. f. Lower the front side of the transmission and remove it from the front side of the vehicle. INSTALLATION Page 2915 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 1779 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 446 7. REMOVE WATER BYPASS PIPE AND KNOCK SENSOR WIRE 8. REMOVE KNOCK SENSORS Using SST, remove the knock sensor. SST 09817-16011 9. INSPECT KNOCK SENSORS Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor. 10. REINSTALL KNOCK SENSORS Using SST, install the knock sensor. SST 09817-16011 Torque: 39 Nm (400 kg.cm, 29 ft.lb) 11. REINSTALL WATER BYPASS PIPE AND KNOCK SENSOR WIRE 12. REINSTALL INTAKE MANIFOLD ASSEMBLY 13. REINSTALL FUEL PRESSURE REGULATOR 14. REINSTALL INTAKE AIR CONNECTOR ASSEMBLY 15. REINSTALL NO.2 TIMING BELT COVER 16. REINSTALL AIR CLEANER HOSE 17. REFILL WITH ENGINE COOLANT Page 3142 VZN195L model If the steering axis inclination is not within the specified value, after the camber and caster have been correctly adjusted, recheck the steering knuckle and front wheel for bearing or looseness. 4. ADJUST CAMBER AND CASTER a. Loosen the front and/or rear adjusting cam nuts. b. Adjust the camber and caster by front and/or rear adjusting cams (See adjustment chart). HINT: Try to adjust the camber and caster to the center of the specified values. Page 4673 Splice Locations Page 3062 Description and Operation Brake Switch - TCC: Description and Operation Stop Light Switch Signal Engine This signal is used to detect when the brakes have been applied. The STP signal voltage is the same as the voltage supplied to the stop lights. The STP signal is used mainly to control the fuel cut-off engine speed (The fuel cut-off engine speed is reduced slightly when the vehicle is braking.). Automatic Transaxle The purpose of this circuit is to prevent the engine from stalling, while driving in lock-up condition, when brakes are suddenly applied. When the brake pedal is operated, this switch sends a signal to ECM. Then the ECM cancels operation of the lock-up clutch while braking is in progress. Page 4697 Step 2 Step 3 INSPECTION PROCEDURE Description and Operation Evaporative Vapor Pressure Sensor: Description and Operation Evaporative Emissions System The vapor pressure sensor and VSV for vapor pressure sensor are used to detect abnormalities in the evaporative emission control system. The ECM decides whether there is an abnormality in the evaporative emission control system based on the vapor pressure sensor signal. Testing and Inspection EFI Main Relay: Testing and Inspection 1. REMOVE EFI MAIN RELAY (Marking: EFI) 2. INSPECT EFI MAIN RELAY a. Inspect the relay continuity. 1. Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. 2. Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. b. Inspect the relay operation. 1. Apply battery positive voltage across terminals 1 and 2. 2. Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. 3. REINSTALL EFI MAIN RELAY Page 2250 Step 2 Step 3 INSPECTION PROCEDURE Description and Operation Transmission Mode Indicator - A/T: Description and Operation The ECM memory contains the shift programs for the NORMAL and POWER patterns, 2 position, L position and the lock-up patterns. Following the programs corresponding to the signals from the pattern select switch, the park/neutral position and other various sensors, the ECM switches the solenoid valves ON and OFF, and controls the transmission gear change and the lock-up clutch operation. Page 4466 Air Bag(s) Arming and Disarming: Service and Repair Release Method of Airbag Activation Prevention Mechanism Page 1640 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Page 4695 WIRING DIAGRAM Step 1 Page 3639 M: 6.0 mm (0.236 in.) Pitch: 1.0 mm (0.039 in.) NOTE: Tighten the bolts by hand until the bolts become difficult to turn. - Do not tighten the bolts too much. 2. Using a service-purpose wire harness tie down the steering wheel pad to the disc wheel. Wire harness: Stripped wire harness section 1.25 Sq.mm or more (0.0019 sq.in. or more) CAUTION: If a wire harness which is too thin or some other thing is used to tie down the steering wheel pad, it may be snapped by the shock when the airbag is deployed. This is highly dangerous. Always use a wire harness for vehicle use which is at least 1.25 Sq.mm (0.0019 Sq.in.). HINT: To calculate the square of the stripped wire harness section: Square = 3.14 x Sq.(Diameter) divided by 4 3. Using 3 wire harness, wind the wire harness at least 2 times each around the bolts installed on the left and right sides of the steering wheel pad. CAUTION: Tightly wind the wire harness around the bolts so that there is no slack. - If there is slackness In the wire harness, the steering wheel pad may come loose due to the shock when the airbag is deployed. This is highly dangerous. 4. Face the upper surface of the steering wheel pad upward. Separately tie the left and right sides of the steering wheel pad to the disc wheel Page 3452 Air Conditioning Switch: Service and Repair REMOVAL REMOVE A/C SWITCH a. Cover the switch with a cloth. b. Using pliers, pull out the switch. INSTALLATION Installation is in the reverse order of removal. Testing and Inspection Data Link Connector, A/T: Testing and Inspection Inspect the DLC 3 - 3RZ-FE: The vehicle's ECM uses the ISO 9141-2 communication protocol. The terminal arrangement of DLC 3 complies with SAE J1962 and matches the ISO 9141-2 format. - 5VZ-FE: The vehicle's ECM uses the V.P.W. (Variable Pulse Width) for communication to comply with SAE J1850. The terminal arrangement of DLC 3 complies with SAE J1962 and matches the V.P.W. format. HINT: If your display shows "UNABLE TO CONNECT TO VEHICLE" when you have connected the cable of OBD II scan tool or TOYOTA hand-held tester to DLC 3, turned the ignition switch ON and operated the scan tool, there is a problem on the vehicle side or tool side. If communication is normal when the tool is connected to another vehicle, inspect DLC 3 on the original vehicle. - If communication is still not possible when the tool is connected to another vehicle, the problem is probably in the tool itself, so consult the Service Department listed in the tool's instruction manual. Page 2916 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 1126 If necessary, replace the fluid coupling. c) Reinstall the fan to the fluid coupling with the 4 nuts. Torque: 7.4 Nm (75 kgf-cm, 65 inch lbs.) 3. INSPECT FAN PULLEY BRACKET Check the turning smoothness of the fan pulley. If necessary, replace the pulley bracket. 4. INSPECT TIMING BELT COMPONENTS Locations Page 2096 Page 3074 Splice Locations Page 1587 CHART 18 CHART 19 Specifications Piston: Specifications Piston Diameter (STD) Mark 1 ............................................................................................................ ........................................................................................ 93.356 - 93.366 mm Mark 2 ....................... .............................................................................................................................................................. ............... 93.367 - 93.376 mm Mark 3 ................................................................................................ .................................................................................................... 93.377 - 93.886 mm O/S 0.50 ........ .............................................................................................................................................................. ........................... 93.856 - 93.886 mm Standard Oil Clearance ....................................................................................................................... ....................................................... 0.134 - 0.154 mm Maximum Oil Clearance ................................. ....................................................................................................................................................... 0.174 mm Page 1375 COMPONENTS INSPECTION 1. DRAIN ENGINE COOLANT 2. REMOVE AIR CLEANER HOSE 3. REMOVE NO.2 TIMING BELT COVER 4. REMOVE INTAKE AIR CONNECTOR ASSEMBLY 5. REMOVE FUEL PRESSURE REGULATOR 6. REMOVE INTAKE MANIFOLD ASSEMBLY Specifications Water Pump: Specifications Water Pump W/ Bolts 20 Nm ABS/TCS - Zero Point Calibration Information Steering Angle Sensor: Technical Service Bulletins ABS/TCS - Zero Point Calibration Information T-SB-0020-08 March 25, 2008 Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment Service Category Brake Section Brake Control/Dynamic Control System Market USA Applicability Introduction The purpose of this TSB is to provide information on when and how to perform the zero point calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting the battery is a necessary step for performing the zero point calibration. Warranty Information Required Tools & Equipment ^ Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE). ^ The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the service procedures listed in this bulletin. Preliminary Information Perform this procedure if any of these repairs have been performed on the vehicle: ^ Wheel alignment has been adjusted. ^ Any chassis components have been removed/installed or replaced. Specifications Wheel Bearing: Specifications On models with serviceable wheel bearings, use a Lithium Multipurpose Grease. Page 584 2. Turn the ignition switch ON and push TOYOTA hand-held tester main switch ON. NOTE: Do not start the engine. 3. Select the ACTIVE TEST mode on the TOYOTA hand-held tester. 4. Please refer to the TOYOTA hand-held tester operator's manual for further details. 5. If you have no TOYOTA hand-held tester, connect the positive (+) and negative (-) leads from the battery to the fuel pump connector. 6. Pinch the fuel return hose. The pressure in the high pressure line will rise to approx. 400 kPa (4 kg/Sq.cm, 57 psi). In this state, check to see that there are no leaks from any part of the fuel system. NOTE: Always pinch the hose. Avoid bending as it may cause the hose to crack. 7. Turn the ignition switch OFF. 8. Disconnect the TOYOTA hand-held tester from the DLC3. Page 2710 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Disassembly and Assembly DISASSEMBLY 1. DISCONNECT CONNECTOR 2. REMOVE ECU a. Using a E5 torx wrench, remove the 4 screws. Torque: 1.8 Nm (18.4 kgf-cm, 16 inch lbs.) b. Remove the ECU from the actuator. NOTICE: Protect the actuator in order to prevent sealing surface from getting dirty and causing damage on the valve body. If the dirt and the like is stuck to the sealing surface, use plastic tools or soft objects to remove the dirt. Do not use chemical solvents. REASSEMBLY Reassembly is in the reverse order of disassembly. Page 3766 Front Seat Belt Extender Applications Page 798 1. INSTALL NEW BEARING a. Using SST and a press, install a new bearing to the steering knuckle. SST 09527-17011, 09950-60020 (09951-00910) b. Using snap ring pliers, install a snap ring. 2. INSTALL NEW OIL SEAL (OUTSIDE) a. Using SST and a plastic hammer, install a new oil seal (outside). SST 09223-15030, 09527-17011 b. Coat the oil seal lip with MP grease. 3. INSTALL AXLE HUB TO STEERING KNUCKLE a. Install the dust cover to the steering knuckle with the 4 bolts. Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.) b. Using SST and a press, install the axle hub to the steering knuckle. SST 09649-17010 4. INSTALL ABS SPEED SENSOR ROTOR/SPACER NOTICE: Do not scratch the serration of the speed sensor rotor. 5. w/ Freewheel hub: INSTALL NEW LOCK NUT a. Using SST, install and torque a new lock nut to the axle hub. SST 09318-12010 Torque: 274 Nm (2,800 kgf-cm, 203 ft. lbs.) Page 3844 Seat Belt Tensioner: Testing and Inspection Replacement Requirements REPLACE REQUIREMENTS In the following cases, replace the seat belt pretensioner. - If the seat belt pretensioner has been activated. - If the seat belt pretensioner has been found to be faulty in troubleshooting. - If the front seat outer belt has been found to be faulty during checking item functioning of SST. - If the front seat outer belt has been dropped. CAUTION: Be sure to follow the correct procedure, for removal and installation of the seat belt pretensioner. Testing and Inspection Power Mirror Switch: Testing and Inspection INSPECT MIRROR SWITCH CONTINUITY Left Side Left Side: Page 196 Steps 1 - 2 Page 4562 Seat Belt Reminder Buzzer: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Page 4946 W/ Intermittent w/ INTERMITTENT: If continuity is not as specified, replace the switch. INSPECT INTERMITTENT OPERATION a. Turn the wiper switch to INT position. b. Turn the intermittent time control switch to FAST position. c. Connect the positive (+) lead from the battery to terminal 16 and the negative (-) lead to terminal 2. d. Connect the positive (+) lead from the voltmeter to terminal 7 and the negative (-) lead to terminal 2, check that the meter needle indicates battery positive voltage. If operation is not as specified, replace the wiper and washer switch. Paint - Refinishing Information Paint: All Technical Service Bulletins Paint - Refinishing Information COLLISION REPAIR INFORMATION FOR THE COLLISION REPAIR PROFESSIONAL TITLE: TOPCOAT SAND & POLISH SECTION: REFINISH BULLETIN # 173 MODELS: ALL TOYOTA LEXUS AND SCION DATE: APRIL 2009 Customers have high expectations for automotive paint finish appearance and expect repairs to match factory color gloss and texture. Flawed refinish appearance is a cause of concern and will likely have a negative affect on customer satisfaction and retention. Toyota recognizes the reality of paint finish application in the shop environment. In addition to color matching and blending countermeasures to remove paint process intrusion (dirt nibs) are necessary to achieve an undetectable finish match. This is also common in manufacturing plants when process intrusion is encountered. Countermeasures are defined as; ultra-fine sanding to level nibs followed by polishing to a level of gloss and texture consistent with the original finish. Technicians undertaking these tasks should review applicable technical data sheets for product process and handling instructions as well as applicable safety information. Topcoat sand and polish is one of many paint finish repair techniques covered in Toyota T101 and Lexus L101 Paint Finish Repair training. Please visit for scheduling and registration information. Page 2251 Shift Indicator: Pinout Values and Diagnostic Parameters E 2 ELECTRONICALLY CONTROLLED TRANSMISSION SOLENOID 1, 2, 3-GROUND : Approx. 13 Ohm P 1 PARK/NEUTRAL POSITION SW 4-GROUND : Approx. 12 volts with ignition SW ON (Floor A/T), ACC (Column A/T) position O 4-A, S 4-B O/D MAIN SW A-1-A-3,B-5-B-10 : Open with O/D main SW at ON position Closed with O/D main SW at OFF position S 5-A,B STOP LIGHT SW A-1-A-2,B-1-B-2 : Closed with brake pedal depressed E 5-A, E 6-B, E 7-C, E 8-D ENGINE CONTROL MODULE S1-E1 : 9 - 14 volts S2,SL-E1 : 0 - 1.5 volts STP-E1 : 7.5 - 14 volts with brake pedal depressed : 0 - 1.5 volts with brake pedal released THW-E2 : 0.2 - 1.0 volts with coolant temp. 80 °C (176 °F) OIL-E2 : 4 - 5 volts with fluid temp. 20 °C (68 °F) VTA-E2 : 0.3 - 0.6 volts with throttle valve fully closed : 3.2 - 4.9 volts with throttle valve fully open VC-E2 : 4.5 - 5.5 volts OD1-E1 : 4.5 - 5.5 volts ODMS-E1 : 9 - 14 volts O/D main SW turned ON : 0 volts O/D main SW turned OFF SP1-E1 : Pulse generation with vehicle moving 2-E1 : 10 - 14 volts with shift lever at 2 position : 0-2 volts with shift lever at except 2 position L-E1 : 10 - 14 volts with shift lever at L position : 0 - 2 volts with shift lever at except L position OILW-E1 : 0.1 - 4.9 volts +B-E1 : 9 - 14 volts BATT-E1 : 9 - 14 volts Page 3811 Junction Box / No. 1 Page 4035 6. Mask-off wiper motor opening. 7. Attach Kent(TM) 12" extension tube (P/N 90175) to the nozzle on the can of Leak-Chek(TM) (P/N 50087). NOTE: Direct Leak-Chek(TM) spray material approximately 1 inch above seam. Spray force is very strong - make several test passes before actually spraying material into seam. 8. Spray Leak-Chek(TM) through the wiper motor opening. a. Spray material inside upper cowl, beginning in lower corner, and continuing toward the centerline of vehicle. b. Remove wand from the wiper motor opening and insert it into larger cowl openings on the right hand side. Continue spraying material along entire seam until seam is filled from R/F fender to L/F fender area. Spray Leak-Chek(TM) into seam a total of 3 times, allowing Leak-Chek(TM) to flash dry for 30-45 minutes between applications. (Drying time increases as outside temperature decreases.) 9. After final application of Leak-Chek(TM) has been allowed to dry for approximately one hour, flood area with water for 5-10 minutes. NOTE: Hold garden hose at top right front corner of windshield and point hose downward toward lower right hand corner of windshield as shown. 10. Check inside cab behind Heater/Air Conditioner box for evidence of water leakage during water leak check. 11. Carefully inspect "T" joint on right and left sides (close to heater motor box, and brake booster) for evidence of water leaks. 12. If no leaks are found, cowl area leak repair is complete. Reinstall wiper motor, cowl trim panel, wiper arms, and hood. Wiper Arm Torque: 20 N.m (205 kgf.cm, 15 ft.lbf) If water leaks are still present and are coming in from the cowl area, remove right front fender and proceed as follows: 13. Seal around entire perimeter of "L" bracket with Kent High Tech(TM) Clear Seam Sealer (see drawing for location of "L" bracket). 14. Using a flashlight, look through the 2" x 3" rectangular hole on side of vertical cowl panel and locate vertical seam that connects side of cowl to front cowl. Page 4175 Paint Codes & Color Names NOTE: Please contact your local paint representative for the actual paint mixing formulas or if you need help in color matching. Page 4728 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Diagram Information and Instructions Stop Light: Diagram Information and Instructions Key to Diagrams Key to Diagrams A: System Title. B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: (1) Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. Specifications Firing Order: Specifications Firing Order 1 - 2 - 3 - 4 - 5 - 6 Page 4326 Actuator Control Cable: Testing and Inspection FORD Made Step 1 INSPECTION PROCEDURE 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 3855 1. Install the retractor of front seat outer belt with the 2 bolts. Torque: Upper bolt: 4.9 N.m (50 kgf.cm, 43 in.lbf) Lower bolt: 43 N.m (440 kgf.cm, 32 ft.lbf) 2. Connect the pretensioner connector as shown in the illustration. b. Install the quarter trim. c. Install the coat hook with the screw. d. Install the front and rear seat outer belt floor anchors with the 2 bolts. Torque: 43 N.m (440 kgf.cm, 32 ft.lbf) e. Install the lock handle. 1. Install the lock handle with the 2 screws. 2. Install the cover. f. Install the front and rear seat outer belt shoulder anchors with the 2 bolts, then close the covers. Torque: 43 N.m (440 kgf.cm, 32 ft.lbf) g. Install the rear seat cushions with the 4 bolts. Torque: 9.8 N.m (100 kgf.cm, 7 ft.lbf) h. Install the back panel lower garnish. Page 4388 Audible Warning Device: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Paint - Chip Protection Tape Paint: All Technical Service Bulletins Paint - Chip Protection Tape Bulletin Number: BO001-00 Date: January 7, 2000 Title: REAR QUARTER PANEL PAINT CHIP PROTECTION Models: '95 - '00 Tacoma Introduction: A new anti-chip tape has been developed to help prevent repeat occurrences of paint chipping on the rear quarter panels of Tacoma compact pick-up trucks caused by the impact of road debris. Applicable Vehicles: All 1995 - 2000 model year Tacoma vehicles. Parts Information Repair Procedure: NOTE: This repair is to be used in conjunction with repainting of the truck bed due to excessive chipping of the rear quarter panel. NOTE: Apply anti-chipping tape only after the surface has been repainted, cured, and is not hotter than 38° C (100° F). Apply the anti-chipping tape directly to the painted surface of the rear quarter panel between the front edge of the rear quarter panels and the rear tires as shown. Warranty Information Removal and Installation Control Assembly: Service and Repair Removal and Installation Heater Control Assembly COMPONENTS REMOVAL 1. REMOVE THESE PARTS: a. Lower finish panel b. Glove compartment door c. No.2 Lower finish panel Page 1047 INSPECTION 1. INSPECT WATER PUMP a) Visually check the drain hole for coolant leakage. If leakage is found, replace the water pump. If engine coolant has leaked onto the timing belt, replace the timing belt. b) Turn the pulley, and check that the water pump bearing moves smoothly and quietly. If necessary, replace the water pump. 2. INSPECT FLUID COUPLING a) Remove the 4 nuts and fan from the fluid coupling. b) Check that the fluid coupling is not damaged and that no silicon oil leaks. Page 3111 Junction Box / No. 1 Details Page 66 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source How to Read Power Source Page 4770 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Antitheft - Automatic Door Lock Feature Programming Alarm Module: Technical Service Bulletins Antitheft - Automatic Door Lock Feature Programming BULLETIN NUMBER: AX005-00 DATE: April 14, 2000 TITLE: RS3OOO TVIP AUTOMATIC DOOR LOCK FEATURE PROGRAMMING MODELS: All Models Introduction As a convenience feature, the RS3OOO TVIP system is programmed to automatically lock all of the vehicle's doors (for vehicles equipped with power door locks) when the ignition key is turned to "ON" or "START", and unlock them when the key is turned back to "ACC" or "LOCK". The initial factory setting of this programmable feature is "ON". For some customers however, this feature is not desirable due to instances of passenger lockout when the driver enters the vehicle first and starts the ignition. For vehicles equipped with RS3OOO TVIP, this bulletin advises the dealers to communicate the following information to the customers at vehicle delivery: 1. Inform the customers of the RS3OOO system's automatic (ignition controlled) door lock/unlock feature. 2. Inquire about the customers' preference for it to be set "ON" or "OFF". 3. Reprogram the feature's setting according to the customer's preference. To change the feature's operation mode, follow the programming procedures. Verification of the Dealer-Installed Option (DIO) or Port-Installed Option (PIO) RS3OOO TVIP System can easily be performed by identifying the status monitor and remote transmitter. The remote transmitter has two buttons, Top and Bottom. The status monitor has a Toyota label, LED, and microphone. APPLICABLE VEHICLES All models equipped with DIO or PIO RS3000 TVIP Service and Repair Transmission Temperature Sensor/Switch: Service and Repair With SR5 ON-VEHICLE INSPECTION 1. DISCONNECT ATF TEMPERATURE SENSOR CONNECTOR 2. DISCONNECT OIL COOLER PIPE a. Remove the 3 bolts and clamps. b. Disconnect the oil cooler pipe. 3. REMOVE OIL COOLER ELBOW 4. REMOVE ATF TEMPERATURE SENSOR a. Remove the ATF temperature sensor. b. Remove the O-ring from the ATF temperature sensor. 5. INSTALL ATF TEMPERATURE SENSOR a. Coat a new O-ring with ATF and install it to the ATF temperature sensor. b. Install the ATF temperature sensor. Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.) 6. INSTALL OIL COOLER ELBOW 7. CONNECT OIL COOLER PIPE a. Connect the oil cooler pipe Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.) b. Install the 3 clamps and bolts. 8. CONNECT ATF TEMPERATURE SENSOR NOTICE: Be careful not to twist the wire harness. Speed Sensor, Front Wheel Speed Sensor: Service and Repair Speed Sensor, Front REMOVAL REMOVE SPEED SENSOR a. Disconnect the speed sensor connector. b. Remove the 2 (4WD, pre runner) or 4 (2WD) clamp bolts holding the sensor harness from the steering knuckle, upper arm and side rail. Torque: Upper arm: 8.0 Nm (82 kgf-cm, 71 inch lbs.) Side rail: 13 Nm (130 kgf-cm, 9 ft. lbs.) c. Remove the speed sensor installation bolt from the steering knuckle. Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.) NOTICE: At the time of installation, please refer to the following items. ^ There are no foreign objects on the sensor or the part of the knuckle to which the sensor is to be installed. ^ The sensor is installed flat against the knuckle when you tighten the bolt. When installing the resin clips, use new ones. INSTALLATION Installation is in the reverse order of removal. NOTICE: After installation, check the speed sensor signal. Specifications Valve Clearance: Specifications Valve Clearance (Cold) Intake ................................................................................................................................................... ................................. 0.13-0.23 mm (0.006-0.009 in) Exhaust ............................................................ ..................................................................................................................... 0.27-0.37 mm (0.011-0.014 in) Page 4012 If seam is not sealed properly, clean vertical and horizontal seam area with Acrysol(TM) cleaner. Use an air hose to dry all seams before applying sealer. NOTE: Hole is located behind fender. 15. Attach a 12 to 18 inch length of plastic tubing to tip of Kent High Tech(TM) Clear Seam Sealer. 16. Seal entire vertical joint with High Tech(TM) clear seam sealer. Allow sealer to dry according to instructions on tube. NOTE: Seams are inside boxed area and accessed through the square hole as shown. 17. Flood cowl area with water to confirm that there are no cowl seam leaks into cab. If water leaks are still present and there are no cowl area seam leaks, reinstall front fender and inspect for water entry along lower edge of interior door trim panel; then proceed as follows: 18. Remove door trim panel. 19. Flood R/F door glass area (spray water at door glass, belt-molding area). 20. Inspect sealer between plastic sheeting (moisture barrier) and metal door panel for voids/skips in sealer. If there are voids/skips between the plastic sheet and the door panel, it will need to be resealed. A. Using a heat gun, heat the butyl tape securing the plastic sheet to make removal easier. B. Use Kent Acrysol to clean the door panel and plastic sheet. NOTE: ^ Follow the directions provided by the cleaning agent. ^ To ensure proper sealing of the plastic sheeting, it is important that the door panel and plastic sheeting is extremely clean. C. Use 3M 8.0 mm butyl tape (P/N 08610) to reattach the plastic sheet to the door panel. Make sure there is a continuos solid bead sealing the plastic sheet to the door panel. 21. Inspect drain-back holes (small slits in metal door panel, near bottom of sealer) to determine if holes are covered by sealer material. If sealer covers drain-back holes (small slits in metal door panel) carefully pull up a portion of plastic sheet, clean out drain-back holes and Page 4301 If seam is not sealed properly, clean vertical and horizontal seam area with Acrysol(TM) cleaner. Use an air hose to dry all seams before applying sealer. NOTE: Hole is located behind fender. 15. Attach a 12 to 18 inch length of plastic tubing to tip of Kent High Tech(TM) Clear Seam Sealer. 16. Seal entire vertical joint with High Tech(TM) clear seam sealer. Allow sealer to dry according to instructions on tube. NOTE: Seams are inside boxed area and accessed through the square hole as shown. 17. Flood cowl area with water to confirm that there are no cowl seam leaks into cab. If water leaks are still present and there are no cowl area seam leaks, reinstall front fender and inspect for water entry along lower edge of interior door trim panel; then proceed as follows: 18. Remove door trim panel. 19. Flood R/F door glass area (spray water at door glass, belt-molding area). 20. Inspect sealer between plastic sheeting (moisture barrier) and metal door panel for voids/skips in sealer. If there are voids/skips between the plastic sheet and the door panel, it will need to be resealed. A. Using a heat gun, heat the butyl tape securing the plastic sheet to make removal easier. B. Use Kent Acrysol to clean the door panel and plastic sheet. NOTE: ^ Follow the directions provided by the cleaning agent. ^ To ensure proper sealing of the plastic sheeting, it is important that the door panel and plastic sheeting is extremely clean. C. Use 3M 8.0 mm butyl tape (P/N 08610) to reattach the plastic sheet to the door panel. Make sure there is a continuos solid bead sealing the plastic sheet to the door panel. 21. Inspect drain-back holes (small slits in metal door panel, near bottom of sealer) to determine if holes are covered by sealer material. If sealer covers drain-back holes (small slits in metal door panel) carefully pull up a portion of plastic sheet, clean out drain-back holes and Component Tests and General Diagnostics Engine Control Module: Component Tests and General Diagnostics CIRCUIT DESCRIPTION When the ignition switch is turned ON, battery positive voltage is applied to coil, closing the contacts of the EFI main relay (Marking: EFI) and supplying power to terminal +B of the ECM. WIRING DIAGRAM Page 4227 Page 2283 Overdrive Switch: Testing and Inspection O/D Cancel Signal Circuit CIRCUIT DESCRIPTION While driving uphill with cruise control activated, in order to minimize gear shifting and provide smooth cruising O/D may be prohibited temporarily under some conditions. The cruise control ECU sends O/D cut signals to the ECM as necessary and the ECM cancels O/D shifting until these signals are discontinued. WIRING DIAGRAM Page 4768 Splice Point J: Indicates a wiring Splice Point (Codes are "E"for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I 5 is indicated by the shaded section. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. N: Page No. How to Read Ground Points How to Read Ground Points Page 2626 Testing and Inspection Heater Control Valve: Testing and Inspection Water Valve 1. WARM UP ENGINE 2. DISCONNECT WATER VALVE CONTROL CABLE 3. INSPECT WATER VALVE OPERATION a. Check that warm air blown out the vent when the water valve lever is moved to "WARM" position. b. Check that cool air blown out when the water valve is moved to the "COOL" position. If operation is not as specified, replace the water valve. 4. CONNECT WATER VALVE CONTROL CABLE After connection, adjust the control cable. Page 4451 Clock: Testing and Inspection #1 Locations Page 1293 CHART 25 With Manual Steering Steering Gear: Service and Repair With Manual Steering Removal and Installation Part 1 Of 2 Page 3087 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Page 1848 u. Remove the other union bolt, 3 gaskets and fuel pipe from the delivery pipes. v. Reinstall the fuel pipe with 4 new gaskets and the 2 union bolts. Torque: 34.3 Nm (350 kg.cm, 25 ft.lb) w. Reconnect the negative (-) terminal cable to the battery. x. Check for fuel leaks. 3. INSPECT FUEL PUMP RESISTANCE Using an ohmmeter, measure the resistance between terminals 4 and 5. Resistance: 0.2 - 3.0 ohms at 20 °C (68 °F) If the resistance is not specified, replace the fuel pump and/or lead wire. 4. INSPECT FUEL PUMP RESISTANCE Connect the positive (+) lead from the battery to terminal 4 of the connector, and the negative (-) lead to terminal 5. Check that the fuel pump operates. NOTE: These tests must be done quickly (within 10 seconds) to prevent the coil from burning out. - Keep the fuel pump as far away from the battery as possible. - Always do switching at the battery side. If operation is not as specified, replace the fuel pump and/or lead wire. Page 2333 Recall 01E041000: Trailer Wire Harness Converter Defect Trailer Connector: Recalls Recall 01E041000: Trailer Wire Harness Converter Defect Equipment Description: Trailer towing wire harness converters which integrates the vehicle's tail lights, brake lights, and turn signal lights with those equipped on the trailer. Manufactured between May 1, 1999, and August 31, 2000, these converters were sold for installation on 1999-2000 Toyota Tundra and Tacoma vehicles. Affected part numbers are: PT207-34000, PT207-34002, PT207-04981, and PT214-04985. In the Tundra vehicles, the circuitry utilized in the converter was inadequate to properly manage vehicle and/or trailer-side voltage spikes. If the converter is exposed to a voltage spike, it may cause an electrical short or open circuit within the converter. Tacoma vehicles, due to deficient waterproofing and improper installation location of the converter, which is mounted in the lower portion of the tailgate cavity of the vehicle, an electrical short circuit will occur if water enters the converter housing. An electrical short or open circuit can cause a fault in the converter and a non-operational condition of the trailer lights. A vehicle crash can occur, possibly resulting in personal injury or death, if the vehicle is driven without operational trailer lights. Dealers will notify the customers and install a redesigned trailer towing wire harness converter free of charge. Owner notification is expect to begin August 2001. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Toyota at 1-800-331-4331. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Diagrams Page 327 Engine Bank Identification Specifications Engine Oil Drain Plug: Specifications Oil Drain Plug Torque .......................................................................................................................... .............................................................................................. 33 ft.lb Page 195 Clutch Switch: Testing and Inspection FORD Made CIRCUIT DESCRIPTION When the clutch pedal is depressed, the clutch switch sends a signal to the cruise control ECU. When the signal is input to the cruise control ECU during cruise control driving, the cruise control ECU cancels cruise control. Wiring Diagram Service Precautions Air Bag(s) Arming and Disarming: Service Precautions NOTE: TOYOTA trucks are equipped with SRS, which comprises a driver airbag and front passenger airbag. Failure to carry out service operations in the correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Further, if a mistake is made in servicing the SRS, it is possible that the SRS may fail to operate when required. Before performing servicing (including removal or installation of parts, inspection or replacement), be sure to read the following items carefully, then follow the correct procedures described in the repair manual. Malfunction symptoms of the SRS are difficult to confirm, so the DTCs become the most important source of information when troubleshooting. When troubleshooting the SRS, always inspect the DTCs before disconnecting the battery. Even in cases of a minor collision where the SRS does not deploy, the steering wheel pad, front passenger airbag assembly, airbag sensor assembly and front airbag sensor should be inspected. Never use SRS parts from another vehicle. When replacing parts, replace them with new parts. Never disassemble and repair the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor in order to reuse it. If the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor has been dropped, or if there are cracks, dents or other defects in the case, bracket or connector, replace them with new ones. Use a volt/ohmmeter with high impedance (10 K.Ohm/V minimum) for troubleshooting the system's electrical circuits. Information labels are attached to the periphery of the SRS components. Follow the instructions on the notes. After work on the SRS is completed, perform the SRS warning light check. If the vehicle is equipped with a mobile communication system, refer to the precaution in the Introduction system. CAUTION: Work must be started 90 seconds after the ignition switch is turned to the "LOCK" position and the negative (-) terminal cable is disconnected from the battery (The SRS is equipped with a back-up power source so that if work is started within 90 seconds from disconnecting the negative (-) terminal cable of the battery, the SRS may be deployed.). When the negative (-) terminal cable is disconnected from the battery, the memory of the clock and audio system will be canceled. So before starting work, make a record of the contents memorized in the audio memory system. When work is finished, reset the audio systems as they were before and adjust the clock. However, it is not possible to make a record of the memory contents. So when the work is finished, it will be necessary to explain this fact to the customer, and ask the customer to adjust the features and reset the memory. To avoid erasing the memory in each memory system, never use a back-up power supply from outside the vehicle. Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during repairs. Do not expose the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor directly to hot air or flames. Page 2593 Step 2 Step 3 INSPECTION PROCEDURE Page 4822 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 1846 Fuel Pressure: Testing and Inspection 1. CHECK FUEL PUMP OPERATION a. Connect a TOYOTA hand-held tester to the DLC3. b. Turn the ignition switch ON and push TOYOTA hand-held tester main switch ON. NOTE: Do not start the engine. c. Select the ACTIVE TEST mode on the TOYOTA hand-held tester. d. Please refer to the TOYOTA hand-held tester operator's manual for further details. e. If you have no TOYOTA hand-held tester, connect the positive (+) and negative (-) leads from the battery to the fuel pump connector. (See step 4) f. Check that there is pressure in the fuel inlet hose from the fuel filter. HINT: If there is fuel pressure, you will hear the sound of fuel flowing. If there is no pressure, check the M-fuse, fuses, EFI main relay,fuel pump, ECM and wiring connections. g. Turn the ignition switch OFF. h. Disconnect the TOYOTA hand-held tester from the DLC3. 2. CHECK FUEL PRESSURE a. Check the battery positive voltage is above 12 V. b. Disconnect the negative (-) terminal cable from the battery. c. Remove the 6 bolts, and disconnect the No.2 timing belt cover. d. Remove the union bolt holding the fuel pipe to the delivery pipe and gasket. Page 2312 Step 2 Step 3 INSPECTION PROCEDURE Page 4591 Page 4858 If continuity is not as specified, replace the switch. Page 2390 7. A340F: REMOVE OIL PIPE Pry up both pipe ends with a large screwdriver and remove the pipe. 8. DISCONNECT 3 CONNECTORS FROM EACH SOLENOID VALVES 9. REMOVE VALVE BODY a. A340E: Remove the 17 bolts. Bolt length: Bolt A: 23 mm (0.91 inch) Bolt B: 32 mm (1.26 inch) b. A340F: Remove the 16 bolts. Bolt length: Bolt A: 23 mm (0.91 inch) Bolt B: 32 mm (1.26 inch) Mud Guards - Production Change Splash Guard: Technical Service Bulletins Mud Guards - Production Change BODY BO019-00 July 28, 2000 Title: FRONT MUDGUARDS Models: '95 - '00 Tacoma 4x4 & PreRunner Introduction To help prevent damage to the exterior finish of Tacoma 4x4 and PreRunner vehicles, the front mudguards have been increased in width by 25 mm. Applicable Vehicles ^ 1995 - 2000 model year Tacoma 4x4 and PreRunner vehicles. Production Change Information Parts Information Repair Procedure Replace the previous mudguards with the countermeasure mudguards. Warranty Information Applicable Warranty*: This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Page 1503 Page 4758 Collision / Non-Collision Inspections Airbag Sensor Assembly: Testing and Inspection Collision / Non-Collision Inspections VEHICLE NOT INVOLVED IN COLLISION Check a diagnostic system. VEHICLE INVOLVED IN COLLISION WITH AIRBAG NOT DEPLOYED Check a diagnostic system. * VEHICLE INVOLVED IN COLLISION WITH AIRBAG DEPLOYED Replace the airbag sensor assembly. * * Refer to SRS Warning Light Check, and How to Display and Read Diagnostic Trouble Codes. See: Air Bag Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Displaying & Reading Trouble Codes System Diagnosis Air/Fuel Mixture: Testing and Inspection INSPECTION HINT: This check is used only to determine whether or not the idle CO/HC complies with regulations. 1. INITIAL CONDITIONS a) Engine at normal operating temperature b) Air cleaner installed c) All pipes and hoses of air induction system connected d) All accessories switched OFF e) All vacuum lines properly connected f) SFI system wiring connectors fully plugged g) Ignition timing checked correctly h) Transmission in neutral position i) Tachometer and CO/HC meter calibrated by hand 2. START ENGINE 3. RACE ENGINE AT 2,500 RPM FOR APPROX. 180 SECONDS 4. INSERT CO/HC METER TESTING PROBE AT LEAST 40 cm (1.3 ft) INTO TAILPIPE DURING IDLING 5. IMMEDIATELY CHECK CO/HC CONCENTRATION AT IDLE AND/OR 2,500 RPM Complete the measuring within 3 minutes. HINT: When doing the 2 mode (2,500 rpm and idle) test, follow the measurement order prescribed by the applicable local regulations Page 3756 B. Pinch the tongue plate stopper into the webbing using an adjustable wrench, and turn and push the adjustment screw by hand. HINT: Press the adjustment screw in order to position the male and female parts of the tongue plate stopper parallel to each other as shown in illustration. CAUTION: DO NOT use pliers. They may damage the webbing. C. When the adjustment screw for the adjustable wrench cannot be turned by hand, tighten the adjustment screw using a pair of adjustable joint pliers until the space between jaws of the adjustable wrench is 4.5 - 5.0 mm. (0.18 in. - 0.20 in. [See illustrations.]) Page 4318 Step 4 INSPECTION PROCEDURE Testing and Inspection Parking Brake Warning Switch: Testing and Inspection INSPECT PARKING BRAKE SWITCH CONTINUITY a. Check that continuity exists between terminals with the switch ON (switch pin released). b. Check that no continuity exists between terminals with the switch OFF (switch pin pushed in). If operation is not as specified, replace the switch. Page 1510 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Page 4581 Seat Belt Reminder Lamp: Fuse and Fusible Link Locations Relay Box / No. 2 Page 2427 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Page 2830 b. Position the valve body so that the valve piston lightly contacts the load sensing spring. c. Tighten the valve body mounting nuts. Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.) 6. BLEED BRAKE LINE 7. CHECK AND ADJUST LSP & BV FLUID PRESSURE Page 249 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Electrical Specifications Fuel Injector: Electrical Specifications Resistance Between Terminals 13.8 ohms Page 142 Right Side Right Side: If continuity is not as specified, replace the switch. Page 3065 Auxiliary Power Outlet: Fuse and Fusible Link Locations Relay Box / No. 2 Page 745 An airbag activation prevention mechanism is built into the connector for the squib circuit of the SRS. When release of the airbag activation prevention mechanism is directed in the troubleshooting procedure, as shown in the illustration of the connectors on the next pages, insert paper which has the same thickness as the male terminal between the terminal and the short spring. CAUTION: Never release the airbag activation prevention mechanism on the squib connector. NOTE: - Do not release the airbag activation prevention mechanism unless specifically directed by the troubleshooting procedure. - If the inserted paper is too thick the terminal and short spring may be damaged, so always use paper with the same thickness as the male terminal. Page 4437 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2015 d. Reconnect and install the high-tension cords as shown in the illustration. Page 2382 Valve Body: Locations Front Upper Valve Body Testing and Inspection Blower Motor Relay: Testing and Inspection INSPECT HEATER MAIN RELAY (Making: HTR) CONTINUITY If continuity is not as specified, replace the relay. Page 2769 E. Apply a small amount of the disc brake caliper grease (1-2 mm thick) to both sides of the pad support plates. NOTE: Do NOT apply grease to the friction surfaces of the brake pads or the disc rotor. F. If the pad support plate is fixed to the torque plate with adhesive tape, perform the operation according to the flow chart. G. Apply a small amount of the disc brake caliper grease (1-2 mm thick) to the caliper as indicated in the illustration. H. Install the brake pads with the anti-squeal shims. I. If equipped with anti-squeal spring: Install the anti-squeal springs. J. Press the piston in firmly and install the brake caliper. NOTE: ^ Clean excess grease. from brake pad and caliper. ^ Do NOT apply grease to the friction surfaces of the brake pads or the disc rotor. K. Install the wheel assembly. 2. Fixed Type Brake Caliper There are two types of brake pads: Testing and Inspection Tail Lamp Relay: Testing and Inspection INSPECT TAILLIGHT CONTROL RELAY CONTINUITY If continuity is not as specified, replace the relay. Page 813 Wheel Fastener: Service and Repair Rear REPLACEMENT 1. REMOVE REAR WHEEL AND BRAKE DRUM 2. REMOVE REAR HUB BOLT Using SST and a brass bar or an equivalent, remove the hub bolt. SST 09650-17011 3. INSTALL HUB BOLT a. Install a washer and nut to a new hub bolt as shown in the illustration. b. Using a brass bar or an equivalent to hold, install the hub bolt by torquing the nut. 4. INSTALL BRAKE DRUM AND REAR WHEEL Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.) Description and Operation Camshaft Position Sensor: Description and Operation The Camshaft Position Sensor Camshaft position sensor (G signal) consists of a magnet, iron core and pickup coil. The G signal plate has 1 tooth, on its outer circumference and is mounted on the RH camshaft timing pulley. When the camshafts rotate, the protrusion on the signal plate and the air gap on the pickup coil change, causing fluctuations in the magnetic field and generating an electromotive force in the pickup coil. The NE signal plate has 34 teeth and is mounted on the crankshaft timing pulley. The NE signal sensor generates 34 signals at every engine revolution. The ECM detects the standard crankshaft angle based on the G signal and the actual crankshaft angle and the engine speed by the NE signal. Page 1280 CHART 12 CHART 13 Page 629 b) Hold the tensioner with both hands and push the push rod strongly as shown to check that it doesn't move. If the push rod moves, replace the tensioner. NOTICE: Never hold the tensioner push rod facing downward. c) Measure the protrusion of the push rod from the housing end. Protrusion: 10.0 - 10.8 mm (0.394 - 0.425 inch) If the protrusion is not as specified, replace the tensioner. INSTALLATION 1. INSTALL CRANKSHAFT TIMING PULLEY a) Align the pulley set key with the key groove of the timing pulley and slide on the timing pulley. b) Slide on the timing pulley, facing the flange side inward. 2. INSTALL NO.1 IDLER PULLEY a) Using a 10 mm hexagon wrench, install the plate washer and idler pulley with bolt. Torque: 35 Nm (350 kgf-cm, 26 ft. lbs.) b) Check that the pulley bracket moves smoothly. 3. INSTALL NO.2 IDLER PULLEY a) Install the idler pulley with the bolt. Torque: 40 Nm (400 kgf-cm, 30 ft. lbs.) b) Check that the idler pulley moves smoothly. Page 2671 Step 3 Page 2926 Battery Replacement If a vehicle battery needs to be replaced for a warrantable condition, complete a Warranty Battery Label and affix it to the failed battery for proper warranty parts and claim processing. Include the Vehicle Identification Number ("IN) and warranty code on the Warranty Battery Label. Battery Maintenance Recommended Battery Maintenance: In addition to this new pre-delivery battery test, a monthly battery inspection is still required for stored vehicles. If your dealership is located in an area subject to extreme temperatures (hot or cold), periodic maintenance may need to be performed more frequently. To reduce parasitic battery drain on vehicles in storage for one week or more, the negative (-) battery cable should always be disconnected to reduce battery discharge. When the negative (-) battery cable is reconnected, please check and reset electrical components, such as the clock, radio, etc., and re-initialize all applicable systems/functions. Refer to the appropriate model and year service bulletins for specific details. For example: ^ TSB No. PD008-05, "Power System Initialization During PDS" (2005 model year) ^ TSB No. PDO14-06, "Power System Initialization During PDS" (2006 model year) Page 3434 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 1274 CHART 2 CHART 3 CHART 4 Specifications Idle Speed: Specifications Idle Speed 700 +/- 50 rpm Capacity Specifications Fluid - Differential: Capacity Specifications Differential Fluid Rear Short wheel base with locker ...................................................................................................... .................................................................................. 2.8 Qt Short wheel base without locker ............ .............................................................................................................................................................. ......... 2.7 Qt Extra long wheel base with locker .................................................................................. .............................................................................................. 3.1 Qt Extra long wheel base without locker ................................................................................................................................................... ........................ 2.6 Qt Page 3568 Air Conditioning Switch: Service and Repair REMOVAL REMOVE A/C SWITCH a. Cover the switch with a cloth. b. Using pliers, pull out the switch. INSTALLATION Installation is in the reverse order of removal. Page 2097 Page 3264 Steering Gear: Service and Repair With Power Steering Removal and Installation REMOVAL Part 1 Of 3 Page 2589 Step 4 Page 127 2. Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. 3. REINSTALL STARTER RELAY Page 348 CHART 10 Page 1454 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection COMPONENTS INSPECTION 1. DRAIN ENGINE COOLANT 2. DISCONNECT UPPER RADIATOR HOSE FROM WATER OUTLET 3. REMOVE NO.2 TIMING BELT COVER 4. REMOVE FUEL PIPE Remove the 2 union bolt, 4 gaskets and fuel pipe. Page 238 Key Reminder Switch: Ground Locations Page 1728 CHART 21 Page 2505 8. CHECK SPIDER BEARING a. Check that the spider bearing moves smoothly. b. Check the spider bearing axial play. Maximum bearing axial play: 0.05 mm (0.0020 inch) HINT: Install new spider bearings on the shaft side in the procedure described above. - When replacing the propeller shaft spider on pre runner and rear propeller shaft spider on 4WD vehicles, be sure that the grease fitting assembly hole is facing in the direction shown in the illustration on the next page. Page 2639 Page 64 D: Indicates related system. Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V). Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, 1H2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green O = Orange P = Pink R = Red SB = Sky Blue V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. System Diagnosis Air/Fuel Mixture: Testing and Inspection INSPECTION HINT: This check is used only to determine whether or not the idle CO/HC complies with regulations. 1. INITIAL CONDITIONS a) Engine at normal operating temperature b) Air cleaner installed c) All pipes and hoses of air induction system connected d) All accessories switched OFF e) All vacuum lines properly connected f) SFI system wiring connectors fully plugged g) Ignition timing checked correctly h) Transmission in neutral position i) Tachometer and CO/HC meter calibrated by hand 2. START ENGINE 3. RACE ENGINE AT 2,500 RPM FOR APPROX. 180 SECONDS 4. INSERT CO/HC METER TESTING PROBE AT LEAST 40 cm (1.3 ft) INTO TAILPIPE DURING IDLING 5. IMMEDIATELY CHECK CO/HC CONCENTRATION AT IDLE AND/OR 2,500 RPM Complete the measuring within 3 minutes. HINT: When doing the 2 mode (2,500 rpm and idle) test, follow the measurement order prescribed by the applicable local regulations Capacity Specifications Refrigerant: Capacity Specifications Charge Volume 600 +/- 50 g Page 320 7. REMOVE WATER BYPASS PIPE AND KNOCK SENSOR WIRE 8. REMOVE KNOCK SENSORS Using SST, remove the knock sensor. SST 09817-16011 9. INSPECT KNOCK SENSORS Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor. 10. REINSTALL KNOCK SENSORS Using SST, install the knock sensor. SST 09817-16011 Torque: 39 Nm (400 kg.cm, 29 ft.lb) 11. REINSTALL WATER BYPASS PIPE AND KNOCK SENSOR WIRE 12. REINSTALL INTAKE MANIFOLD ASSEMBLY 13. REINSTALL FUEL PRESSURE REGULATOR 14. REINSTALL INTAKE AIR CONNECTOR ASSEMBLY 15. REINSTALL NO.2 TIMING BELT COVER 16. REINSTALL AIR CLEANER HOSE 17. REFILL WITH ENGINE COOLANT Specifications Fluid Pan: Specifications Oil Pan X Transmission Case .............................................................................................................................................. 7.4 Nm (75 kg-cm, 65 inch lbs.) Page 3084 Page 432 Camshaft Position Sensor: Service and Repair COMPONENTS REPLACEMENT 1. REMOVE NO.2 TIMING BELT COVER 2. REMOVE CAMSHAFT POSITION SENSOR a. Disconnect the sensor connector. b. Remove the bolt and sensor. 3. REINSTALL NEW CAMSHAFT POSITION SENSOR a. Install a new sensor with the bolt. Torque: 7.8 Nm (80 kg.cm, 69 in.lb) b. Connect the sensor connector. Page 406 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 1679 Crankshaft Position Sensor: Service and Repair REPLACEMENT 1. REMOVE ENGINE UNDER COVER 2. REMOVE CRANKSHAFT POSITION SENSOR a. Disconnect the sensor connector. b. Remove the bolt and sensor. Torque: 7.8 Nm (80 kg.cm, 69 in.lb) 3. REINSTALL NEW CRANKSHAFT POSITION SENSOR a. Install the sensor with the bolt. b. Connect the sensor connector. 4. REINSTALL ENGINE UNDER COVER Testing and Inspection Power Door Lock Switch: Testing and Inspection INSPECT DRIVER'S DOOR LOCK CONTROL SWITCH CONTINUITY If continuity is not as specified, replace the switch. INSPECT PASSENGER'S DOOR LOCK CONTROL SWITCH CONTINUITY If continuity is not as specified, replace the switch. Component Inspection Idle Air Control Valve: Testing and Inspection Component Inspection INSPECT IAC VALVE OPERATION a. Connect the positive (+) lead from the battery to terminal +B and negative (-) lead to terminal RSC, and check that the valve is closed. b. Connect the positive (+) lead from the battery to terminal +B and negative (-) lead to terminal RSO, and check that the valve is open. If operation is not as specified, replace the IAC valve. Page 2218 Step 5 INSPECTION PROCEDURE Page 4579 Junction Box / No. 1 Page 1499 Splice Point J: Indicates a wiring Splice Point (Codes are "E"for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I 5 is indicated by the shaded section. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. N: Page No. How to Read Ground Points How to Read Ground Points Page 4605 Seat Belt Reminder Lamp: Pinout Values and Diagnostic Parameters B 6 BUCKLE SW 1-2 : Open with driver's seat belt in use D 15 DOOR COURTESY SW LH 1-GROUND : Closed with LH door open I 15-A SEAT BELT WARNING RELAY [INTEGRATION RELAY] 6-GROUND : Approx. 12 volts with ignition SW ON 12-GROUND : Always approx. 12 volts A-7-GROUND : Always continuity A-5-GROUND : Continuity with LH door open A-10-GROUND: Approx. 12 volts with ignition key in cylinder A-2-GROUND : 0 Volts for 4 - 8 seconds with ignition SW ON and 12 volts 4 - 8 seconds after ignition SW ON Page 1688 Knock Sensor: Description and Operation Knock Sensor Each knock sensor is fitted to the right bank and left bank of the cylinder block to detect engine knocking. This sensor contains a piezoelectric element which generates a voltage when it becomes deformed, which occurs when the cylinder block vibrates due to knocking. If engine knocking occurs, ignition timing is retarded to suppress it. Page 4806 Horn: Connector Locations Page 2858 Vacuum Brake Booster: Testing and Inspection ON-VEHICLE INSPECTION Fig. 2 Operational Test 1. OPERATING CHECK a. Depress the brake pedal several times with the engine off and check that there is no change in the pedal reserve distance. b. Depress the brake pedal and start the engine. If the pedal goes down slightly, operation is normal. 2. AIR TIGHTNESS CHECK a. Start the engine and stop it after 1 or 2 minutes. Depress the brake pedal several times slowly. If the pedal goes down farthest the 1st time, but gradually rises after the 2nd or 3rd time, the booster is air tight. b. Depress the brake pedal while the engine is running, and stop the engine with the pedal depressed. If there is no change in the pedal reserve travel after holding the pedal for 30 seconds, the booster is air tight. Service and Repair Transmission Temperature Sensor/Switch: Service and Repair With SR5 ON-VEHICLE INSPECTION 1. DISCONNECT ATF TEMPERATURE SENSOR CONNECTOR 2. DISCONNECT OIL COOLER PIPE a. Remove the 3 bolts and clamps. b. Disconnect the oil cooler pipe. 3. REMOVE OIL COOLER ELBOW 4. REMOVE ATF TEMPERATURE SENSOR a. Remove the ATF temperature sensor. b. Remove the O-ring from the ATF temperature sensor. 5. INSTALL ATF TEMPERATURE SENSOR a. Coat a new O-ring with ATF and install it to the ATF temperature sensor. b. Install the ATF temperature sensor. Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.) 6. INSTALL OIL COOLER ELBOW 7. CONNECT OIL COOLER PIPE a. Connect the oil cooler pipe Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.) b. Install the 3 clamps and bolts. 8. CONNECT ATF TEMPERATURE SENSOR NOTICE: Be careful not to twist the wire harness. Description and Operation Throttle Position Sensor: Description and Operation Throttle Position Sensor The throttle position sensor is mounted in the throttle body and detects the throttle valve opening angle. When the throttle valve is fully closed, a voltage of approximately 0.3 - 1 .0 V is applied to terminal VTA of the ECM. The voltage applied to terminals VTA of the ECM increases in proportion to the opening angle of the throttle valve and becomes approximately 2.7 - 5.2 V when the throttle valve is fully opened. The ECM ledges the vehicle driving conditions from these signals input from terminals VTA and uses them as one of the conditions to decide the air- fuel ratio correction, power increase correction and fuel-cut control etc. Description and Operation Mass Air Flow Meter: Description and Operation Mass Air Flow Meter The mass air flow meter uses a platinum hot wire. The hot wire air flow meter consists of a platinum hot wire, thermistor and a control circuit installed in a plastic housing. The hot wire air flow meter works on the principle that the hot wire and thermistor located in the intake air bypass of the housing detect any changes in the intake air temperature. The hot wire is maintained at the set temperature by controlling the current flow through the hot wire. This current flow is then measured as the output voltage of the mass air flow meter. The circuit is constructed so that the platinum hot wire and thermistor provide a bridge circuit, with the power transistor controlled so that the potential of A and B remains equal to maintain the set temperature. Page 308 Crankshaft Position Sensor: Service and Repair REPLACEMENT 1. REMOVE ENGINE UNDER COVER 2. REMOVE CRANKSHAFT POSITION SENSOR a. Disconnect the sensor connector. b. Remove the bolt and sensor. Torque: 7.8 Nm (80 kg.cm, 69 in.lb) 3. REINSTALL NEW CRANKSHAFT POSITION SENSOR a. Install the sensor with the bolt. b. Connect the sensor connector. 4. REINSTALL ENGINE UNDER COVER Page 4760 Junction Box / No. 1 Page 1187 Part 2 Of 2 (California Spec.) *1: Only for A/T *2: The ECM terminal voltage is fixed regardless of the output voltage from the sensor. Connectors (Except California Spec.) Page 1599 Page 1632 Page 1331 Testing and Inspection Starter Signal: Testing and Inspection CIRCUIT DESCRIPTION When the engine is cranked, the intake air flow is slow, so fuel vaporization is poor. A rich mixture is therefore necessary in order to achieve good startability. While the engine is being cranked, the battery positive voltage is applied to terminal STA of the ECM. The starter signal is mainly used to increase the fuel injection volume for the starting injection control and after starter injection control. WIRING DIAGRAM INSPECTION PROCEDURE HINT: This diagnostic chart is based on the premise that the engine is cranked normally. If the engine is not cranked, proceed to the Diagnosis By Symptom. Step 1 Page 193 Steps 1 - 3 Page 4667 Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Key to Diagrams Key to Diagrams A: System Title. B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: (1) Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. Page 480 Steps 1 - 2 Page 197 Steps 3 - 4 INSPECTION PROCEDURE Description and Operation Brake Fluid Solenoid Valve Relay: Description and Operation ABS Solenoid Relay This relay supplies power to each ABS solenoid. After the ignition switch is turned ON, if the initial check is OK, the relay goes on. Page 2043 4. REINSTALL NO.2 TIMING BELT COVER Page 2993 Auxiliary Power Outlet: Connector Locations Junction Box / No. 3 Page 2395 d. Apply FIPG to the oil pan. FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent e. Install the oil pan with the 19 bolts. Torque: 7.4 Nm (75 kgf-cm, 65 inch lbs.) 19. INSTALL DRAIN PLUG Torque: 20 Nm (205 kgf-cm, 15 ft. lbs.) 20. FILL AND CHECK ATF Page 1746 Oxygen Sensor: Locations Air-Fuel Ratio (A/F) Sensor Testing and Inspection Parking Brake Warning Switch: Testing and Inspection INSPECT PARKING BRAKE SWITCH CONTINUITY a. Check that continuity exists between terminals with the switch ON (switch pin released). b. Check that no continuity exists between terminals with the switch OFF (switch pin pushed in). If operation is not as specified, replace the switch. Page 2936 Page 2091 Shift Indicator: Fuse and Fusible Link Locations Relay Box / No. 2 Page 4507 Page 2173 Testing and Inspection Washer Fluid Level Switch: Testing and Inspection INSPECT WASHER LEVEL SWITCH a. Check that no continuity exists between terminals with the switch OFF (float up). b. Check that continuity exists between terminals with the switch ON (float down). If operation is not as specified, replace the switch. Component Locations Seat Belt Reminder Lamp: Component Locations Page 1637 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 2991 Page 3659 Impact Sensor: Service and Repair Removal and Installation COMPONENT REMOVAL NOTE: - If the wiring connector of the SRS is disconnected with the ignition switch at ON or ACC position, DTCs will be recorded. - Never use SRS parts from another vehicle. When replacing parts, replace then with new parts. - Never reuse the sensor involved in a collision when the SRS has deployed. - Never repair a sensor in order to reuse it. 1. REMOVE BATTERY a. Remove the bolt and battery clamp. b. Remove the battery and battery carrier. Page 2893 Repair Procedure 1. Disconnect the cable from the negative (-) battery terminal for MORE THAN two (2) seconds. 2. Reconnect the cable to the negative (-) battery terminal. 3. Perform the applicable zero point calibration of the yaw rate sensor and/or the steering angle sensor. HINT Refer to the applicable TSB or Repair Manual for the zero point calibration procedure. 4. Re-initialize all applicable systems available on the vehicle (power window sunroof power lift door etc.). Component Locations Auxiliary Power Outlet: Component Locations Page 797 3. w/ Freewheel hub: REMOVE LOCK NUT AND ABS SPEED SENSOR ROTOR/SPACER a. Using a chisel and hammer, loosen the staked part of the lock nut. NOTICE: Be careful not to damage the bushing. b. Using SST, remove the lock nut. SST 09318-12010 c. Remove the ABS speed sensor rotor/spacer. NOTICE: Take care not to scratch the serration of the speed sensor rotor. 4. REMOVE AXLE HUB FROM STEERING KNUCKLE a. Remove the 4 bolts and shift the dust cover towards the hub side (outside). b. Using SST, remove the axle hub from the steering knuckle. SST 09710-30021 (09710-03051), 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04031, 09957-04010, 09958-04011) c. Remove the dust cover from the steering knuckle. d. w/o Free wheel hub (4WD only): Remove the bearing spacer and ABS speed sensor rotor/ spacer. 5. REMOVE OIL SEAL (OUTSIDE) Using a screwdriver, remove the oil seal (outside) from the steering knuckle. 6. REMOVE BEARING FROM STEERING KNUCKLE a. Using snap ring pliers, remove the snap ring. b. Using SST and a press, remove the bearing from the steering knuckle. SST 09950-60020 (09951-00810), 09950-70010 (09951-07150) REASSEMBLY Page 1608 Oxygen Sensor: Locations Air-Fuel Ratio (A/F) Sensor Page 400 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. DENSO Made Clutch Switch: Testing and Inspection DENSO Made Clutch Switch Circuit CIRCUIT DESCRIPTION When the clutch pedal is depressed, the clutch switch sends a signal to the cruise control ECU. When the signal is input to the cruise control ECU during cruise control driving, the cruise control ECU cancels cruise control. Wiring Diagram Page 1356 Throttle Position Sensor: Service and Repair Refer to Fuel Delivery and Air Induction / Throttle Body / Service and Repair, for removal and installation of this component. Page 2534 Shift Indicator: Connector Locations Component Locations Seat Belt Reminder Lamp: Component Locations Description and Operation Brake Fluid Solenoid Valve Relay: Description and Operation ABS Solenoid Relay This relay supplies power to each ABS solenoid. After the ignition switch is turned ON, if the initial check is OK, the relay goes on. Page 4320 Steps 1 - 2 Page 4761 Junction Box / No. 3 Page 3028 Engine Room R/B # 2 Engine Room R/B # 2 Page 929 TOY 730 - 73mm Toyota Oil Filter Wrench M 0219 - 74mm Oil Filter Wrench Page 1689 Knock Sensor: Testing and Inspection Page 2771 Type "B" Brake Pad A. Remove the clip, pins and anti-rattle spring/pad retainer clip. B. Remove the brake pads with the anti-squeal shims. C. Clean any dust from the brake pads. D. Apply a small amount of the disc brake caliper grease (1-2 mm thick) to the areas indicated in the illustration. NOTE: Do NOT apply grease to the friction surfaces of the brake pads or the disc rotor. E. Install the brake pads with the anti-squeal shims. NOTE: Clean excess grease from the brake pads and caliper. F. Install the pad guide pin, clip and anti-squeal spring. G. Install the wheel assembly. Page 1122 Part 3 of 3 Page 1906 Fuel Pressure: Testing and Inspection 1. CHECK FUEL PUMP OPERATION a. Connect a TOYOTA hand-held tester to the DLC3. b. Turn the ignition switch ON and push TOYOTA hand-held tester main switch ON. NOTE: Do not start the engine. c. Select the ACTIVE TEST mode on the TOYOTA hand-held tester. d. Please refer to the TOYOTA hand-held tester operator's manual for further details. e. If you have no TOYOTA hand-held tester, connect the positive (+) and negative (-) leads from the battery to the fuel pump connector. (See step 4) f. Check that there is pressure in the fuel inlet hose from the fuel filter. HINT: If there is fuel pressure, you will hear the sound of fuel flowing. If there is no pressure, check the M-fuse, fuses, EFI main relay,fuel pump, ECM and wiring connections. g. Turn the ignition switch OFF. h. Disconnect the TOYOTA hand-held tester from the DLC3. 2. CHECK FUEL PRESSURE a. Check the battery positive voltage is above 12 V. b. Disconnect the negative (-) terminal cable from the battery. c. Remove the 6 bolts, and disconnect the No.2 timing belt cover. d. Remove the union bolt holding the fuel pipe to the delivery pipe and gasket. Page 2684 Transmission Speed Sensor: Description and Operation CIRCUIT DESCRIPTION The speed sensor for ABS detects the wheel speed and sends the appropriate signals to the ABS ECU. The ECU converts these signals into a pulse signal and outputs it to the combination meter. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. Page 796 HINT: PreRunner is the model described below. RZN191L-TRPDKAB, RZN196L-CRPDKAB, VZN195L-CRPDKAB 1. 4WD: REMOVE OIL SEAL (INSIDE) a. Clamp the axle hub in a soft jaw vise. HINT: Close vise until it holds hub bolts. Do not tighten further. b. Using a screwdriver, remove the oil seal (inside). 2. PreRunner: REMOVE GREASE CAP a. Clamp the axle hub in a soft jaw vise. HINT: Close vise until it holds hub bolts. Do not tighten further. b. Using a screwdriver, remove the grease cap. Page 3652 Impact Sensor: Description and Operation FRONT AIRBAG SENSOR The front airbag sensor is mounted inside each of the aprons. The sensor unit is a mechanical type. When the sensor detects deceleration force above a predetermined limit, contact is made in the sensor, sending a signal to the airbag sensor assembly. The sensor cannot be disassembled. Page 1745 Oxygen Sensor: Mechanical Specifications HEATED OXYGEN SENSOR Torque: ................................................................................................................................................ ................................. 20 N.m (200 kgf.cm, 14 ft.lbf) AIR-FUEL RATIO (A/F) SENSOR Torque: ................................................................................................................................................ ................................. 20 N.m (200 kgf.cm, 14 ft.lbf) Testing and Inspection Tail Lamp Relay: Testing and Inspection INSPECT TAILLIGHT CONTROL RELAY CONTINUITY If continuity is not as specified, replace the relay. Page 1273 CHART 1 Page 3861 Air Bag Deactivation Switch: Testing and Inspection 1. INSPECT PASSENGER AIRBAG MANUAL ON-OFF SWITCH CONTINUITY HINT: Release the airbag activation prevention mechanism of the passenger airbag manual on-off switch connector on the air- bag sensor assembly side. If continuity is not as specified, replace the switch. 2. INSPECT PASSENGER AIRBAG MANUAL ON-OFF INDICATOR OPERATION a. Check that continuity exists between 5 and 6. b. Connect the positive (+) lead from the battery to terminal 1 and negative (-) lead to terminal 2. c. Check that the indicator light lights up. If the operation is not as specified, replace the indicator. Page 2923 6. Select CHARGING from the Main Menu screen and press the SELECT soft key. 7. Select DIAGNOSTIC from the Charge Menu screen and press the SELECT soft key. 8. Select IN VEHICLE and press the NEXT soft key. 9. Select MODEL and press the NEXT soft key. NOTE: ^ "MODEL" or "STOCK # " MUST be used to receive a warranty code if the tester determines that the battery is bad. ^ "MODEL" and "STOCK # " are linked to custom algorithms and are the most accurate testing procedures. Page 2588 Step 3 Page 4434 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Page 3303 SST 09082-00700 CAUTION: When deploying the airbag, always use the specified SST: SRS Airbag Deployment Tool. 1. Connect the red clip of the SST to the battery positive (+) terminal and the black clip to the battery negative (-) terminal. HINT: Do not connect the yellow connector which will be connected with the supplemental restraint system. 2. Press the SST activation switch, and check that the LED of the SST activation switch lights up. CAUTION: If the LED lights up when the activation switch is not being pressed, SST malfunction is probable, so definitely do not use the SST. 3. Disconnect the SST from the battery. e. Install the SST. CAUTION: Place the disc wheel on the level ground 1. Connect the connectors of the 2 SST to the steering wheel pad connector. SST 09082-00700, 09082-00760 NOTE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. Also, secure some slack for the SST wire harness inside the disc wheel. Page 379 Oxygen Sensor: Description and Operation Air / Fuel Sensor Air / Fuel Sensor To obtain a high purification rate for the CO, HC and NOx components of the exhaust gas, a three-way catalytic converter is used, but for the most efficient use of the three-way catalytic converter, the air-fuel ratio must be precisely controlled so that it is always close to the stoichiometric air-fuel ratio. The A/F sensor has the characteristic that provides output voltage* approximately proportional to the existing air-fuel ratio. The A/F sensor output voltage* is used to provide feedback for the ECM to control the air- fuel ratio. By the A/F sensor output, the ECM can determine the deviation amount from the stoichiometric air-fuel ratio and control the proper injection time immediately. If the A/F sensor is malfunctioning, ECM is unable to perform accurate air-fuel ratio control. The A/F sensor is equipped with a heater which heats the zirconia element. The heater is controlled by the ECM. When the intake air volume is low (the temp. of the exhaust gas is low), current flows to the heater to heat the sensor for accurate oxygen concentration detection. * The voltage value changes at the inside of the ECM only. Page 3506 Evaporator Case: Testing and Inspection 1. CHECK EVAPORATOR FINS FOR BLOCKAGE If the fins are clogged, clean them with compressed air. 2. CHECK FITTING FOR CRACKS FOR SCRATCHES Repair as necessary. Page 4116 INSPECT DRIVER'S DOOR UNLOCK DETECTION SWITCH CONTINUITY If continuity is not as specified, replace the switch. INSPECT PASSENGER'S DOOR UNLOCK DETECTION SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 1572 Removal and Replacement Back Window Glass: Removal and Replacement REMOVAL REMOVE BACK WINDOW GLASS WITH WINDOW FRAME a. Using a screwdriver, loosen the weatherstrip from the body. NOTE: Be careful not to damage the body paint. HINT: Tape the screwdriver tip before use. b. Pry the lip of the weatherstrip outward from the interior part of the body flange. c. Pull the glass outwards, and remove it with the weatherstrip. INSTALLATION 1. INSTALL BACK WINDOW GLASS WITH WINDOW FRAME a. Install the working cord to the frame, as shown in the illustration. Page 251 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Specifications Crankshaft Main Bearing: Specifications Main Bearing Cap Bolts Torque .......................................................................................................... ............................................................................................................... 61 Nm Specifications Idle Speed: Specifications Idle Speed 700 +/- 50 rpm Page 2837 BRAKE MASTER CYLINDER W/ RELATED COMPONENTS Page 4972 6. Mask-off wiper motor opening. 7. Attach Kent(TM) 12" extension tube (P/N 90175) to the nozzle on the can of Leak-Chek(TM) (P/N 50087). NOTE: Direct Leak-Chek(TM) spray material approximately 1 inch above seam. Spray force is very strong - make several test passes before actually spraying material into seam. 8. Spray Leak-Chek(TM) through the wiper motor opening. a. Spray material inside upper cowl, beginning in lower corner, and continuing toward the centerline of vehicle. b. Remove wand from the wiper motor opening and insert it into larger cowl openings on the right hand side. Continue spraying material along entire seam until seam is filled from R/F fender to L/F fender area. Spray Leak-Chek(TM) into seam a total of 3 times, allowing Leak-Chek(TM) to flash dry for 30-45 minutes between applications. (Drying time increases as outside temperature decreases.) 9. After final application of Leak-Chek(TM) has been allowed to dry for approximately one hour, flood area with water for 5-10 minutes. NOTE: Hold garden hose at top right front corner of windshield and point hose downward toward lower right hand corner of windshield as shown. 10. Check inside cab behind Heater/Air Conditioner box for evidence of water leakage during water leak check. 11. Carefully inspect "T" joint on right and left sides (close to heater motor box, and brake booster) for evidence of water leaks. 12. If no leaks are found, cowl area leak repair is complete. Reinstall wiper motor, cowl trim panel, wiper arms, and hood. Wiper Arm Torque: 20 N.m (205 kgf.cm, 15 ft.lbf) If water leaks are still present and are coming in from the cowl area, remove right front fender and proceed as follows: 13. Seal around entire perimeter of "L" bracket with Kent High Tech(TM) Clear Seam Sealer (see drawing for location of "L" bracket). 14. Using a flashlight, look through the 2" x 3" rectangular hole on side of vertical cowl panel and locate vertical seam that connects side of cowl to front cowl. Locations Page 4805 Page 262 Key Reminder Switch: Pinout Values and Diagnostic Parameters B 6 BUCKLE SW 1-2 : Open with driver's seat belt in use D 15 DOOR COURTESY SW LH 1-GROUND : Closed with LH door open I 15-A SEAT BELT WARNING RELAY [INTEGRATION RELAY] 6-GROUND : Approx. 12 volts with ignition SW ON 12-GROUND : Always approx. 12 volts A 7-GROUND : Always continuity A 5-GROUND : Continuity with LH door open A 10-GROUND: Approx. 12 volts with ignition key in cylinder A 2-GROUND : 0 Volts for 4 - 8 seconds with ignition SW ON and 12 volts 4 - 8 seconds after ignition SW ON Page 1602 CHART 28 Page 1294 Page 2632 Shift Indicator: Ground Locations Page 2189 Fluid - A/T: Testing and Inspection a. Check the fluid level. HINT: Drive the vehicle so that the engine and transmission are at normal operating temperature. Fluid temp.: 70 - 80 °C (158 - 176 °F) - Only use the COOL range on the dipstick as a rough reference when the fluid is replaced or the engine does not run. 1. Park the vehicle on a level surface and set the parking brake. 2. With the engine idling and the brake pedal depressed, shift the shift lever into all positions from P to L position and return to P position. 3. Pull out the dipstick and wipe it clean. 4. Push it back fully into the pipe. 5. Pull it out and check that the fluid level is in the HOT range. If the level is not within the range, add new fluid. Fluid type: ATF ID-II or DEXRON(R)III (DEXRON(R)II) NOTE: Do not overfill. b. Check the fluid condition. If the fluid smells burnt or is black, replace it. c. Replace the ATF. 1. Remove the drain plug and drain the fluid. 2. Reinstall the drain plug securely. 3. With the engine OFF add new fluid through the oil filler pipe. Fluid type: ATF ID-II or DEXRON(R)III (DEXRON(R)II) Page 2338 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 1416 Spark Plug: Application and ID Recommended Spark Plugs ND K16TR11 NGK BKR5EKB-11 Specifications Compressor Clutch: Specifications Clearance 0.5 +/- 0.15 mm Page 3554 Refrigerant Pressure Sensor / Switch: Service and Repair REMOVAL 1. REMOVE EVAPORATOR 2. REMOVE PRESSURE SWITCH FROM LIQUID TUBE Disconnect the connector and remove the pressure switch. Torque: 10 Nm (100 kg.cm, 7 ft.lb) HINT: Lock the switch mounted on the tube with an open end wrench, being careful not to deform the tube and remove the switch. - At the time of installation, please refer to the following item. Lubricate a new O-ring with the compressor oil and install the switch. INSTALLATION Installation is in the reverse order of removal. Page 631 7. INSTALL TIMING BELT NOTICE: The engine should be cold. a) Remove any oil or water on the pulleys, and keep them clean. NOTICE: Only wipe the pulleys; do not use any cleansing agent. b) Face the front mark on the timing belt forward. c) Install the timing belt to the LH camshaft timing pulley. Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley. d) Install the timing belt to the No.2 idler pulley. e) Install the timing belt to the RH camshaft timing pulley. Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley. f) Install the timing belt to the water pump pulley. g) Install the timing belt to the crankshaft timing pulley. Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley. h) Install the timing belt to the No.1 idler pulley. 8. SET TIMING BELT TENSIONER a) Using a press, slowly press in the push rod using 981 - 9,807 N (100 - 1,000 kgf, 200 - 2,205 lbs.) of pressure. b) Align the holes of the push rod and housing, pass a 1.27 mm hexagon wrench through the holes to keep the setting position of the push rod. c) Release the press. d) Install the dust boot to the tensioner. Page 2917 Battery: Technical Service Bulletins Electrical - Battery Maintenance and Testing PRODUCT GENERAL INFORMATION PG001-06 Title: BATTERY MAINTENANCE FOR IN-STOCK VEHICLES & PRE-DELIVERY Models: All Models & Model Years January 26, 2006 TSB REVISION NOTICE: ^ November 28, 2006: "Required SSTs" have been updated (SST P/N 00002-MCGR8 has been added). "Recommended Equipment" has been removed (superseded by SST P/N 00002-MCGR8). Screen prints and text have been updated in the "Battery Inspection Procedure". "Battery Service Procedure" has been renamed "Battery Inspection Results". Two sections have been added for SST P/N 00002-MCGR8: "Battery Charging Procedure" and "Battery Charging Results". PLEASE READ ENTIRE TSB. Previous versions of this TSB should be discarded. TSB UPDATE NOTICE: The information contained in this TSB supersedes TSB No. PG017-02. TSB No. PGO17-02 is now obsolete and should be discarded. Introduction A battery in a stored vehicle is subject to conditions that can reduce its performance and life. These conditions include storage period, temperature, parasitic drain, and battery load. Because of these factors, battery inspection and maintenance are required in order to ensure proper operation and optimal battery life. As a matter of policy, Toyota does not provide battery warranty coverage for discharged and/or failed batteries due to lack of maintenance. It is the dealer's responsibility to maintain the specified State of Charge (SOC) of the vehicle's battery while in stock and assure proper State of Charge (SOC) at delivery. To eliminate customer service concerns due to an undercharged battery during the first few weeks of ownership, all dealers should check battery State of Charge (SOC) and recharge, if necessary, within 48 hours of delivery to customers. Applicable Vehicles ^ All models and model years. Warranty Information Locations Fuse: Locations Relay Box / No. 2 Page 665 Specified amount: 600 ± 50 g (21.16 ± 1.76 oz.) 5. INSPECT FOR LEAKAGE OF REFRIGERANT Using a gas leak detector, check for leakage of refrigerant. 6. INSPECT AIR CONDITIONING OPERATION Page 975 9. INSTALL TIMING BELT TENSIONER a) Temporarily install the tensioner with the 2 bolts. b) Alternately tighten the 2 bolts. Torque: 27 Nm (280 kgf-cm, 20 ft. lbs.) c) Remove the 1.27 mm hexagon wrench from the tensioner. 10. CHECK VALVE TIMING a) Turn the crankshaft, and align the timing marks of the crankshaft timing pulley and oil pump body. NOTICE: Always turn the crankshaft clockwise. b) Check that the timing marks of the RH and LH timing pulleys with the timing marks of the No.3 timing belt cover as shown in the illustration. If the marks do not align, remove the timing belt and reinstall it. c) Remove the crankshaft pulley bolt. 11. INSTALL TIMING BELT GUIDE Install the guide, facing the cup side outward. Page 2042 Camshaft Position Sensor: Service and Repair COMPONENTS REPLACEMENT 1. REMOVE NO.2 TIMING BELT COVER 2. REMOVE CAMSHAFT POSITION SENSOR a. Disconnect the sensor connector. b. Remove the bolt and sensor. 3. REINSTALL NEW CAMSHAFT POSITION SENSOR a. Install a new sensor with the bolt. Torque: 7.8 Nm (80 kg.cm, 69 in.lb) b. Connect the sensor connector. Page 3432 1. INSTALL NEW BEARING a. Using SST and a press, install a new bearing to the steering knuckle. SST 09527-17011, 09950-60020 (09951-00910) b. Using snap ring pliers, install a snap ring. 2. INSTALL NEW OIL SEAL (OUTSIDE) a. Using SST and a plastic hammer, install a new oil seal (outside). SST 09223-15030, 09527-17011 b. Coat the oil seal lip with MP grease. 3. INSTALL AXLE HUB TO STEERING KNUCKLE a. Install the dust cover to the steering knuckle with the 4 bolts. Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.) b. Using SST and a press, install the axle hub to the steering knuckle. SST 09649-17010 4. INSTALL ABS SPEED SENSOR ROTOR/SPACER NOTICE: Do not scratch the serration of the speed sensor rotor. 5. w/ Freewheel hub: INSTALL NEW LOCK NUT a. Using SST, install and torque a new lock nut to the axle hub. SST 09318-12010 Torque: 274 Nm (2,800 kgf-cm, 203 ft. lbs.) Adjustments Hood: Adjustments HOOD ADJUSTMENT HINT: Since the centering bolt is used as the hood hinge set bolt, the hood cannot be adjusted with it on. Substitute the bolt with the washer for the centering bolt. 1. ADJUST HOOD IN FORWARD/ REARWARD AND LEFT/ RIGHT DIRECTIONS Adjust the hood by loosening the hood side hinge bolts. Torque: A: 13 N.m (130 kgf.cm, 10 ft.lbf) B: 18 N.m (180 kgf.cm, 13 ft.lbf) 2. ADJUST FRONT EDGE OF HOOD IN VERTICAL DIRECTION Adjust the hood by turning the cushions. Page 507 Step 4 Page 4186 Paint: By Symptom Technical Service Bulletin # BO001-00 Date: 000107 Paint - Chip Protection Tape Bulletin Number: BO001-00 Date: January 7, 2000 Title: REAR QUARTER PANEL PAINT CHIP PROTECTION Models: '95 - '00 Tacoma Introduction: A new anti-chip tape has been developed to help prevent repeat occurrences of paint chipping on the rear quarter panels of Tacoma compact pick-up trucks caused by the impact of road debris. Applicable Vehicles: All 1995 - 2000 model year Tacoma vehicles. Parts Information Repair Procedure: NOTE: This repair is to be used in conjunction with repainting of the truck bed due to excessive chipping of the rear quarter panel. NOTE: Apply anti-chipping tape only after the surface has been repainted, cured, and is not hotter than 38° C (100° F). Apply the anti-chipping tape directly to the painted surface of the rear quarter panel between the front edge of the rear quarter panels and the rear tires as shown. Warranty Information Technical Service Bulletin # BO001-00 Date: 000107 Paint - Chip Protection Tape Bulletin Number: BO001-00 Date: Page 3140 Alignment: Service and Repair NOTICE: For Zero Point Calibration information, please refer to: TSB T-SB-0020-8 (3/25/08). NOTE: RZN161L: 4WD Regular Cab, Short Wheelbase with 3RZ-FE engine RZN171L: 4WD Extra Cab, Extra Long Wheelbase with 3RZ-FE engine RZN191L: 2WD PreRunner Regular Cab, Short Wheelbase with 3RZ-FE engine RZN196L: 2WD PreRunner Extra Cab, Extra Long Wheelbase with 3RZ-FE engine VZN170L: 4WD Extra Cab, Extra Long Wheelbase with 5VZ-FE engine VZN195L: 2WD PreRunner Extra Cab, Extra Long Wheelbase with 5VZ-FE engine INSPECTION HINT: PreRunner is the model described below. RZN191L-TRPDKAB, RZN196L-CRPDKAB, VZN195L-CRPDKAB 1. MEASURE VEHICLE HEIGHT Vehicle Height: Measuring points: A: Ground clearance of spindle center. B: Ground clearance of front adjusting cam bolt center. C: Ground clearance of leaf spring front hanger pin bolt center. D: Ground clearance of rear axle shaft center. NOTICE: Before inspecting the wheel alignment, adjust the vehicle height to the specified value. If the vehicle height is not the specified value, try to adjust it by pushing down on or lifting the body. Page 1263 A/F and 02 Sensor Identification Page 3261 b. Install the pinion assembly into the rack housing. HINT: ^ Ensure that the pinion end is securely located in the bearing of the rack housing. ^ Do not engage the pinion teeth with the rack teeth. 4. INSTALL PINION BEARING ADJUSTING SCREW a. Apply sealant to 2 or 3 threads of the screw. Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent b. Using SST, install the screw. SST 09922-10010 Torque: 17 Nm (174 kgf-cm, 13 ft. lbs.) NOTICE: Use SST 09922-10010 in the direction shown in the illustration. HINT: Use a torque wrench with a fulcrum length of 300 mm (11.81 inch). 5. INSTALL PINION BEARING ADJUSTING SCREW LOCK NUT a. Apply sealant to 2 or 3 threads of the nut. Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent b. Using SST to stop the pinion bearing adjusting screw, and using SST, torque the nut. SST 09922-10010 Torque: 88 Nm (894 kgf-cm, 65 ft. lbs.) NOTICE: Use SST 09922-10010 in the direction shown in the illustration. HINT: Use a torque wrench with a fulcrum length of 425 mm (16.73 inch). 6. INSTALL DUST COVER 7. INSTALL RACK GUIDE SEAT, RACK GUIDE, RACK GUIDE SPRING AND RACK GUIDE SPRING CAP a. Install the seat to the guide. b. Apply sealant to 2 or 3 threads of the cap. Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent c. Temporarily install the cap. 8. ADJUST TOTAL PRELOAD Page 1917 Fuel Return Line: Service Precautions FUEL TANK AND LINE PRECAUTION - Always use new gaskets when replacing the fuel tank or component parts. - Apply the proper torque to all parts tightened. Page 3318 e. Draw a new line on the masking tape of the steering wheel as shown in the illustration. f. Measure the distance between the 2 lines on the masking tape of the steering wheel. g. Convert the measured distance to steering angle. Measured distance 1 mm (0.04 inch) = Steering angle approximately 1°. HINT: Make a note of the steering angle. 2. ADJUST STEERING ANGLE a. Draw a line on the RH and LH tie rod and rack ends where it can easily be seen. b. Using a paper gauge, measure the distance from RH and LH tie rod ends to the rack end screws. HINT: ^ Measure the RH side and LH side. ^ Make a note of the measured values. c. Remove the RH and LH boot clips from the rack boots. d. Loosen the RH and LH lock nuts. e. Turn the RH and LH rack end by the same amount (but in different directions) according to the steering angle. 1 turn 360° of rack end (1.5 mm ( 1.5mm ( 0.059 in.) horizontal movement ) = 12° of steering angle f. Tighten the RH and LH lock nuts. Torque: 55 Nm (560 kgf-cm, 41 ft. lbs.) NOTICE: Make sure that the difference in length between RH and LH tie rod ends and rack end screws are within 1.5 mm (0.059 inch). g. Install the RH and LH boot clips. Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Key to Diagrams Key to Diagrams A: System Title. B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: (1) Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. Page 59 Refer to Reset Procedure 2 for the vehicles with Electronically Controlled Automatic Transmissions: Reset Procedure 1 1. Connect the Toyota Diagnostic Tester to the vehicle. 2. Reset the ECM (PCM). Refer to the procedures below. Page 2674 Overdrive Switch: Testing and Inspection O/D Cancel Signal Circuit CIRCUIT DESCRIPTION While driving uphill with cruise control activated, in order to minimize gear shifting and provide smooth cruising O/D may be prohibited temporarily under some conditions. The cruise control ECU sends O/D cut signals to the ECM as necessary and the ECM cancels O/D shifting until these signals are discontinued. WIRING DIAGRAM Page 1770 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source How to Read Power Source Page 3316 Steering Wheel: Service and Repair Replacement Requirements REPLACEMENT In the following cases, replace the steering wheel pad, steering wheel or spiral cable. CAUTION: For removal and installation of the steering wheel pad, and be sure to follow the correct procedure. Page 4141 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 1335 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Page 4237 Paint: Application and ID Removal and Installation Starter Motor: Service and Repair Removal and Installation Page 2927 Battery: Specifications Parasitic Draw: Information not supplied by the manufacturer. Page 4694 Transmission Mode Indicator - A/T: Testing and Inspection CIRCUIT DESCRIPTION The ECM memory contains the shift programs for the NORMAL and POWER patterns, 2 position, L position and the lock-up patterns. Following the programs corresponding to the signals from the pattern select switch, the park/neutral position and other various sensors, the ECM switches the solenoid valves ON and OFF, and controls the transmission gear change and the lock-up clutch operation. Page 1259 Oxygen Sensor: Technical Service Bulletins Engine Controls - Bank 1/Bank 2 O2 Sensor identification ENGINE EG034-07 Title: ENGINE BANK 1 AND BANK 2 A/F AND O2 IDENTIFICATION Models: '93 - '08 Applicable Models June 28, 2007 The information contained in this TSB supercedes TSB No. EG037-04. TSB No. EG037-04 is now obsolete and should be discarded. Introduction This service bulletin provides information on the proper identification of engine bank 1 and engine bank 2 for correct A/F sensor and oxygen sensor replacement. This bulletin contains information that identifies engine bank 1 and engine bank 2 on the following engines: 1AZ-FE, 2AZ-FE, 2AZ-FE (PZEV), 1GR-FE, 2GR-FE, 2GR-FSE, 2JZ-GE, 1MZ-FE, 3MZ-FE, 1UR-FSE, 3UR-FE, 2UZ-FE, 3UZ-FE, 5VZ-FE, and 1ZZ-FE. ^ Bank 1 (B1) refers to the bank that includes cylinder No. 1. ^ Bank 2 (B2) refers to the bank opposite bank 1. ^ Sensor 1 (S1) refers to the sensor that is located before the catalytic converters. ^ Sensor 2 (S2) refers to the sensor that is located after the catalytic converters. Warranty Information Testing and Inspection Instrument Panel Relay: Testing and Inspection INSPECT BULB CHECK RELAY OPERATION a. Connect the positive (+) lead from the battery to terminal C through a 1.4 W test bulb and the negative (-) lead to terminal B, check that the test bulb does not light up. b. Connect the positive (+) lead from the battery to terminal A and check that the test bulb lights up. If operation is not as specified, replace the relay. Component Tests and General Diagnostics Seat Belt Reminder Lamp: Component Tests and General Diagnostics INSPECT SEAT BELT WARNING LIGHT a. Remove the integration relay from the No.1 J/B. b. Ground terminal 9 on the junction block side connector. c. Turn the ignition switch ON and check that the warning light lights up. If the warning light does not light up, inspect the bulb or wire harness. Page 2101 Junction Box / No. 3 Page 2356 Transmission Mode Indicator - A/T: Testing and Inspection CIRCUIT DESCRIPTION The ECM memory contains the shift programs for the NORMAL and POWER patterns, 2 position, L position and the lock-up patterns. Following the programs corresponding to the signals from the pattern select switch, the park/neutral position and other various sensors, the ECM switches the solenoid valves ON and OFF, and controls the transmission gear change and the lock-up clutch operation. Page 2909 2. Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. 3. REINSTALL STARTER RELAY Page 2223 Page 4438 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Page 2129 WIRING DIAGRAM Component Locations Shift Indicator: Component Locations Page 291 Mass Air Flow Meter: Testing and Inspection INSPECTION 1. INSPECT MAF METER RESISTANCE Using an ohmmeter, measure the resistance between terminals THA and E2. If the resistance is not as specified, replace the MAF meter. Temperature Resistance at -20 °C (-4 °F) 13.6 - 18.4 Kohms at -20 °C (68 °F) 2.2 - 2.7 Kohms at -60 °C (140 °F) 0.5 - 0.7 Kohms 2. INSPECT MAF METER OPERATION a. Connect the MAF meter connector. b. Using a voltmeter, connect the positive (+) tester probe to terminal VG, and negative (-) tester probe to terminal E2G. c. Turn the ignition switch ON. d. Blow air into the MAF meter, and check that the voltage fluctuates. If operation is not as specified, replace the MAF meter. e. Turn the ignition switch OFF. f. Disconnect the MAF meter connector. Page 4043 Required Materials Warranty Information Applicable Warranty*: This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Repair Procedure 1. Remove Wiper Arms, Plastic Cowl Cover and Wiper Motor (store wiper links up against bottom of windshield). NOTE: Mark wiper arm linkage attached to wiper motor and wiper motor splined shaft prior to removing the 12 mm retaining nut. 2. Spray Acrysol(TM) under entire lip of 1/2" pinch weld and wipe dry with a clean paper towel. FOLLOW DIRECTIONS ON SIDE OF CAN CAREFULLY. Dry open seam with compressed air prior to applying sealer. NOTE: Do not use a red shop towel to wipe surfaces because shop towels are contaminated with silicone. 3. Apply a small bead of Kent High Tech(TM) Clear Seam Sealer to underside front edge of the pinch weld from fender to fender as shown. Page 2269 WIRING DIAGRAM Page 3026 Engine Compartment Instrument Panel Locations Page 3337 Ball Joint: Testing and Inspection INSPECTION HINT: PreRunner is the model described below. RZN191L-TRPDKAB, RZN196L-CRPDKAB, VZN195L-CRPDKAB INSPECT LOWER BALL JOINT EXCESSIVE PLAY ON-VEHICLE a. Remove the front wheel and install the hub nuts to the disc. b. Using a dial indicator, check the lower ball joint for excessive play when you push the hub nuts up and down with a force of 294 N (30 kgf, 66 lbs). Maximum: 0.5 mm (0.020 inch) Paint - Refinishing Bumper Cover Paint: All Technical Service Bulletins Paint - Refinishing Bumper Cover PAINT PA003-02 REVISED June 4, 2002 Title REFINISHING REPLACEMENT BUMPER COVERS Models All '83 - '05 Models TSB REVISION NOTICE: ^ February 14, 2005: Applicable Vehicles now includes 2004 - 2005 model years. Previous versions of this TSB should be discarded. Introduction In cases where a bumper cover is being replaced a special preparation process is necessary to assure the refinish is customer acceptable. This bulletin provides the recommended refinishing procedure for new bumper covers. Applicable Vehicles ^ All 1983 - 2005 model year Toyota vehicles. Required Tools & Material Note:Please visit www.3m.comlautomotive to find the nearest store that sells 3M automotive products. Warranty Information Refinishing Procedure 1. Mix a solution of mild soap (car wash soap with no wax additives) and clean water. Note: Carefully follow mixing instructions on the soap container. Too much soap or too much water may cause surface contamination or rinsing difficulty. Description and Operation Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Sensor A thermistor that is built into the engine coolant temperature sensor changes the resistance value according to the engine coolant temperature. The lower the engine coolant temperature sensor, the greater the thermistor resistance value, and the higher the engine coolant temperature sensor temperature, the lower the thermistor resistance value. The engine coolant temperature sensor is connected to the ECM. The 5 V power source voltage in the ECM is applied to the engine coolant temperature sensor from the terminal THA via a resistor R. That is, the resistor R and the engine coolant temperature sensor are connected in series. When the resistance value of the engine coolant temperature sensor changes in accordance with changes in the engine coolant temperature, the potential at terminal THA also changes. Based on this signal, the ECM increases the fuel injection volume to improve driveability during cold engine operation. Page 2572 Front Suspension Spring ( Coil / Leaf ): Service and Repair Front For information regarding the Service and Repair of this component and the system that it is a part of, please refer to Control Arm; Service and Repair; Front Lower. Page 1733 CHART 24 Page 137 LH RH INSPECT DOOR KEY LOCK AND UNLOCK SWITCH CONTINUITY If continuity is not as specified, replace the switch. If continuity is not as specified, replace the switch. Description and Operation Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor The crankshaft position sensor, which detects the engine speed and crankshaft angle signal (NE signal), has been installed on the oil pump body. The NE signal plate has 34 teeth. The NE signal sensor generates 34 signals at every engine revolution. The ECM detects the standard crankshaft angle based on the G signal, and the actual crankshaft angle and the engine speed by the NE signal. Locations Page 4045 NOTE: Hold garden hose at top right front corner of windshield and point hose downward toward lower right hand corner of windshield as shown. 10. Check inside cab behind Heater/Air Conditioner box for evidence of water leakage during water leak check. 11. Carefully inspect "T" joint on right and left sides (close to heater motor box, and brake booster) for evidence of water leaks. 12. If no leaks are found, cowl area leak repair is complete. Reinstall wiper motor, cowl trim panel, wiper arms, and hood. Wiper Arm Torque: 20 N.m (205 kgf.cm, 15 ft.lbf) If water leaks are still present and are coming in from the cowl area, remove right front fender and proceed as follows: 13. Seal around entire perimeter of "L" bracket with Kent High Tech(TM) Clear Seam Sealer (see drawing for location of "L" bracket). 14. Using a flashlight, look through the 2" x 3" rectangular hole on side of vertical cowl panel and locate vertical seam that connects side of cowl to front cowl. If seam is not sealed properly, clean vertical and horizontal seam area with Acrysol(TM) cleaner. Use an air hose to dry all seams before applying sealer. NOTE: Hole is located behind fender. 15. Attach a 12 to 18 inch length of plastic tubing to tip of Kent High Tech(TM) Clear Seam Sealer. 16. Seal entire vertical joint with High Tech(TM) clear seam sealer. Allow sealer to dry according to instructions on tube. NOTE: Seams are inside boxed area and accessed through the square hole as shown. 17. Flood cowl area with water to confirm that there are no cowl seam leaks into cab. If water leaks are still present and there are no cowl area seam leaks, reinstall front fender and inspect for water entry along lower edge of interior door trim panel; then proceed as follows: 18. Remove door trim panel. Page 2336 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Testing and Inspection Brake Pedal Assy: Testing and Inspection ON-VEHICLE INSPECTION 1. CHECK PEDAL HEIGHT Pedal height from asphalt seat: 154.6 - 164.6 mm (6.087 - 6.480 inch) 2. IF NECESSARY, ADJUST PEDAL HEIGHT a. Disconnect the connector from the stop light switch. b. Loosen the stop light switch lock nut and remove the stop light switch. c. Loosen the push rod lock nut. d. Adjust the pedal height by turning the pedal push rod. e. Tighten the push rod lock nut. Torque: 25 Nm (260 kgf-cm, 19 ft. lbs.) f. Install the stop light switch. g. Push the brake pedal in 5 - 15 mm (0.20 - 0.59 inch), turn the stop light switch to lock the nut in the position where the stop light goes off. h. Push the brake pedal in 5 - 15 mm (0.20 - 0.59 inch), check that stop light lights up. i. After adjusting the pedal height, check the pedal freeplay. 3. CHECK PEDAL FREEPLAY a. Stop the engine and depress the brake pedal several times until there is no more vacuum left in the booster. b. Push in the pedal by hand until the second resistance begins to be felt. Measure the distance. Pedal freeplay: 3 - 6 mm (0.12 - 0.24 inch) HINT: The freeplay to the 1st resistance is due to the play between the clevis and pin. This is magnified up to 1 - 3 mm (0.04 - 0.12 inch) at Page 2309 Step 5 INSPECTION PROCEDURE Page 4803 Service and Repair Seals and Gaskets: Service and Repair REPLACEMENT HINT: PreRunner is the model described below. RZN191L-TRPDKAB, RZN196L-CRPDKAB, VZN195L-CRPDKAB 1. DRAIN DIFFERENTIAL OIL 2. DISCONNECT REAR PROPELLER SHAFT 3. REMOVE COMPANION FLANGE Antitheft - Automatic Door Lock Feature Programming Alarm Module: Technical Service Bulletins Antitheft - Automatic Door Lock Feature Programming BULLETIN NUMBER: AX005-00 DATE: April 14, 2000 TITLE: RS3OOO TVIP AUTOMATIC DOOR LOCK FEATURE PROGRAMMING MODELS: All Models Introduction As a convenience feature, the RS3OOO TVIP system is programmed to automatically lock all of the vehicle's doors (for vehicles equipped with power door locks) when the ignition key is turned to "ON" or "START", and unlock them when the key is turned back to "ACC" or "LOCK". The initial factory setting of this programmable feature is "ON". For some customers however, this feature is not desirable due to instances of passenger lockout when the driver enters the vehicle first and starts the ignition. For vehicles equipped with RS3OOO TVIP, this bulletin advises the dealers to communicate the following information to the customers at vehicle delivery: 1. Inform the customers of the RS3OOO system's automatic (ignition controlled) door lock/unlock feature. 2. Inquire about the customers' preference for it to be set "ON" or "OFF". 3. Reprogram the feature's setting according to the customer's preference. To change the feature's operation mode, follow the programming procedures. Verification of the Dealer-Installed Option (DIO) or Port-Installed Option (PIO) RS3OOO TVIP System can easily be performed by identifying the status monitor and remote transmitter. The remote transmitter has two buttons, Top and Bottom. The status monitor has a Toyota label, LED, and microphone. APPLICABLE VEHICLES All models equipped with DIO or PIO RS3000 TVIP Supercharger - Squeak/Rattle Noises From Idler Pulley Idler Pulley: All Technical Service Bulletins Supercharger - Squeak/Rattle Noises From Idler Pulley REF.: 3.4L V6 SUPERCHARGER NO.: SC001-00 DATE: AUGUST 1, 2000 MODEL: 4Runner, Tacoma, T100, and Tundra with 3.4L V6. SUPERCHARGER DRIVE-BELT IDLER PULLEY Due to a possible out-of-tolerance condition on the idler pulley shaft, some pulleys may have bearings that spin on the inner shaft and may cause a squeaking or rattling noise. The supercharger may be perfectly fine and the source of the noise may simply be the idler pulley PART NUMBER INFORMATION PRODUCTION EFFECTIVE: Supercharger Assemblies with Serial Numbers from: 10481 to: 10990 CHECK PROCEDURE: This condition can be verified by removing the supercharger drive belt and checking the movement of the pulley on the shaft The pulley should not slide fore and aft on the shaft. INSTALLATION PROCEDURE: Loosen the drive belt. Remove the idler plate assembly. Retain all the hardware. Remove the idler pulley sub-assembly from the idler plate assembly. Replace it with the supplied new idler pulley sub-assembly. Replace the idler plate assembly and all of the hardware. The tightening torques are shown in the table. Reinstall and tension the drive belt to 120-ft lbs. for a new belt or 80 ft lbs. for a used belt (any belt used for more than 10 minutes). WARRANTY INFORMATION:* * The idler pulley assembly is warrantable only for 12 months from the point-of-first-sale. If the supercharger assembly was dealer installed, then TRD matches the balance of the new vehicle powertrain warranty. Page 3384 Suspension Strut / Shock Absorber: Service and Repair Rear Shock Absorber REMOVAL HINT: PreRunner is the model described below. RZN191L-TRPDKAB, RZN196L-CRPDKAB, VZN195L-CRPDKAB 1. SUPPORT BODY WITH SAFETY STANDS a. Jack up and support the body an safety stands. b. Lower the axle housing until the leaf spring tension is free, and keep it at this position. 2. REMOVE REAR SHOCK ABSORBER a. Remove the 2 rear shock absorber set bolts. Torque: 2WD: 26 Nm (260 kgf-cm, 19 ft. lbs.) 4WD and PreRunner: 71 Nm (730 kgf-cm, 53 ft. lbs.) Brakes - Pad Clicking Noise Brake Pad: All Technical Service Bulletins Brakes - Pad Clicking Noise BRAKES BR004-00 October 20, 2000 Title: BRAKE PAD CLICKING NOISE Models: '90- '00 All Models Introduction A clicking type noise may be noticed when first applying the brakes after changing vehicle travel direction (Drive/Forward to Reverse, Reverse to Drive/Forward). This is a normal noise caused by the required brake pad-to-caliper clearances. When the direction of travel is changed, the brake pads may "shift" towards the new direction of travel. When the brake pad contacts the caliper, a clicking noise may be heard. To minimize this clicking noise, a disc brake caliper grease has been made available for use during brake service/maintenance operations. Under normal usage conditions this grease should be effective for a period of 6 months to 1 year. Applicable Vehicles ^ 1990 - 2000 model year Toyota vehicles, all models. Parts Information Warranty Information Application Procedure There are two types of brake calipers: floating and fixed. Check the type of brake caliper installed on the vehicle by removing the wheel assembly. 1. Floating Type Brake Caliper A. Lift up or remove the brake caliper and suspend it securely. HINT: Do not disconnect the flexible hose from the brake caliper. B. If equipped with anti-squeal spring: Remove the anti-squeal springs. C. Remove the brake pads with anti-squeal shims. D. Remove the pad support plates from the torque plate. Clean any dust from the pad support plates, torque plates and brake pads. Page 402 Page 2558 Step 2 Step 3 INSPECTION PROCEDURE Page 3643 Clockspring Assembly / Spiral Cable: Service and Repair Airbag Assembly Connectors DISCONNECTION a. Place a finger on the slider. b. Slide the slider to release lock. c. Disconnect the connector. CONNECTION a. Align a lock part of male connector and a slider of female connector in the same direction as shown in the illustration, fit in them without rubbing. b. Make sure to insert until they are locked. After fitting in pull them slightly to check that they are locked. (When locked, make sure that the outer returns to its original position and sound at the time of fitting in can be heard.) HINT: As the slider slides, do not touch it. - Be careful not to deform the release board. If the release board is deformed, replace it with a new one. Page 3228 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Page 4333 Cruise Control Switch: Testing and Inspection Main Switch Circuit (Cruise Control Switch) DENSO Made CIRCUIT DESCRIPTION When the cruise control main switch is turned off, the cruise control does not operate. Wiring Diagram Page 3808 Specifications Valve Clearance: Specifications Valve Clearance (Cold) Intake ................................................................................................................................................... ................................. 0.13-0.23 mm (0.006-0.009 in) Exhaust ............................................................ ..................................................................................................................... 0.27-0.37 mm (0.011-0.014 in) Page 3823 Page 3829 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 555 6. ADJUST TOE-IN AND WHEEL ANGLE HINT: First, check or adjust the lengths of the rack ends, then adjust the toe-in. Rack end length difference: 1.5 mm (0.059 inch) or less a. Remove the 2 clips. b. Loosen the tie rod end lock nuts. c. Turn the right and left rack ends by an equal amount to adjust the toe-in. HINT: Try to adjust the toe-in to the center of the specified value. d. Make sure that the lengths of the right and left rack ends are the same. Rack end length difference: 1.5 mm (0.059 inch) or less e. Tighten the tie rod end lock nuts. Torque: 55 Nm (560 kgf-cm, 41 ft. lbs.) f. Place the boots on the seats and install the clips. HINT: Make sure that the boots are not twisted. g. Inspect the wheel angle. Turn the steering wheel fully and measure the turning angle. Wheel Turning Angle: If the right and left wheel turning angles differ from the specified value, readjust the toe-win and wheel angle within the specified value. At this time, the right and left error lengths of the rack end may be less than 1.5 mm (0.059 inch). Removal and Installation Hydraulic Control Assembly - Antilock Brakes: Service and Repair Removal and Installation REMOVAL 1. REMOVE BRAKE LINE COVER Page 1876 c. When connecting the flare nut on the high pressure pipe union, observe these procedures: 1. Apply a light coat of engine oil to the flare and tighten the flare nut by hand. 2. Using SST, tighten the flare nut to the specified torque. SST 09631-22020 Torque: 28 Nm (285 kg.cm, 21 ft.lb) HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). d. Observe these precautions when removing and installing the injectors. 1. Never reuse the O-ring. 2. When placing a new O-ring on the injector, take care not to damage it in any way. 3. Coat a new O-ring with spindle oil or gasoline before installing-never use engine, gear or brake oil. e. Install the injector to the delivery pipe and intake manifold, as shown in the illustration. f. Check that there are no fuel leaks after doing maintenance anywhere on the fuel system. 1. Connect a TOYOTA hand-held tester to the DLC3. Page 1399 2. Turn the ignition switch ON and push TOYOTA hand-held tester main switch ON. NOTE: Do not start the engine. 3. Select the ACTIVE TEST mode on the TOYOTA hand-held tester. 4. Please refer to the TOYOTA hand-held tester operator's manual for further details. 5. If you have no TOYOTA hand-held tester, connect the positive (+) and negative (-) leads from the battery to the fuel pump connector. 6. Pinch the fuel return hose. The pressure in the high pressure line will rise to approx. 400 kPa (4 kg/Sq.cm, 57 psi). In this state, check to see that there are no leaks from any part of the fuel system. NOTE: Always pinch the hose. Avoid bending as it may cause the hose to crack. 7. Turn the ignition switch OFF. 8. Disconnect the TOYOTA hand-held tester from the DLC3. Description and Operation Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor The crankshaft position sensor, which detects the engine speed and crankshaft angle signal (NE signal), has been installed on the oil pump body. The NE signal plate has 34 teeth. The NE signal sensor generates 34 signals at every engine revolution. The ECM detects the standard crankshaft angle based on the G signal, and the actual crankshaft angle and the engine speed by the NE signal. Connector Locations Key Reminder Switch: Connector Locations Page 1170 Page 1570 A. The Diagnostic Tester displays 17" as a value of the Time $81" (see illustration). B. Find the Conversion Factor value of Time $81" in the O2S Failure Threshold chart. 0.3906 is specified for Time $81 in this chart. C. Multiply "17" in step "A" by 0.3906 (Conversion Factor) in step "B." 17 x 0.3906 = 6.6% D. If the answer is within the Standard Value of TEST LIMIT, the Time $81" can be confirmed to be normal. NOTE: ^ "LOW SW V" indicates the O2S voltage when the O2S status changes from rich to lean. ^ "HIGH SW V" indicates the O2S voltage when the O2S status changes from lean to rich. ^ If the O2S voltage is lower than "LOW SW V," the O2S status is lean. ^ If the O2S voltage is higher than "HIGH SW V," the O2S status is rich. NOTE: Before the O2S Monitor completes or after the ignition switch is turned OFF, the Diagnostic Tester displays the viewable upper limit or a lower limit of the test value (example: 0 V, 1.275 V, Os [seconds], 10.2s, 0 and 255). Page 242 D: Indicates related system. Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V). Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, 1H2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green O = Orange P = Pink R = Red SB = Sky Blue V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Page 1262 Engine Bank Identification Page 2939 a. Check the positive (+) rectifier. 1. Using an ohmmeter, connect one tester probe to the positive (+) terminal and the other to each rectifier terminal. 2. Reverse the polarity of the tester probes and repeat step (a). 3. Check that one shows continuity and the other shows no continuity. If continuity is not as specified, replace the rectifier holder. b. Check the negative (-) rectifier. 1. Using an ohmmeter, connect one tester probe to each negative (-) terminal and the other to each rectifier terminal. 2. Reverse the polarity of the tester probes and repeat step (a). 3. Check that one shows continuity and the other shows no continuity. If continuity is not as specified, replace the rectifier holder. 5. INSPECT BEARING Check the bearing is not rough or worn. If necessary, replace the bearing. Page 4361 f. Read the blinking pattern of the CRUISE MAIN indicator light. g. After performing the check, turn the main switch OFF. HINT: When 2 or more signals are input to the ECU, the lowest numbered code will be displayed first. Page 3329 a. Lift up the vehicle. b. Place the lever under the tire, and inspect the tree play while lifting the tire using a wooden stick, etc., as a fulcrum. 3. Inspect the Suspension Arm Ball Joint Free Play A. Lift up the vehicle B. Inspect the free play while moving the control arm by hand. (Reference) Free Play Inspection Method (Gauge Installation) ^ Position the dial gauge between the arm (upper or lower) and the knuckle, and measure free play. (This illustration shows how to measure free play for vehicles with double wishbone type suspension with coil spring.) 4. Inspect Ball Joint Dust Cover Check for cracks and grease leaks on the dust cover (boots). Turning Torque Inspection Inspect Ball Joint Turning Torque Move the stud back and forth 5 times, and then turn the stud continuously at 3-5 seconds per turn, and measure the turning torque at the 5th turn. HINT: Refer to the table for standard values for the turning torque. Page 4004 reinstall plastic sheet against metal door panel. Confirm that there are no voids between sealer and plastic sheet and between sealer and metal door panel. 22. Flood all areas with water to confirm that there are no leaks into cab area. 23. If no leaks are present, reinstall door trim panel. Removal and Installation Power Steering Pump: Service and Repair Removal and Installation Part 1 Of 2 Page 3873 2. REMOVE FRONT AIRBAG SENSOR RH a. Disconnect the front airbag sensor connector. NOTE: Disconnect the connector with the front airbag sensor installed. b. Remove the 2 nuts and front airbag sensor RH. 3. REMOVE FRONT AIRBAG SENSOR LH a. Disconnect the front airbag sensor connector. NOTE: Disconnect the connector with the front airbag sensor installed. b. Remove the 2 bolts and front airbag sensor LH. INSTALLATION 1. INSTALL FRONT AIRBAG SENSOR LH AND RH a. Install the front airbag sensor with the 2 bolts and 2 nuts with the arrows on the sensors facing toward the front of the vehicle. Torque: 20 Nm (205 kg.cm, 15 ft.lb) NOTE: Connection of the connector is done after the sensor has been installed. - Make sure the sensor is installed with the specified torque. Body - Plastic Bumper Refinishing Rear Bumper Cover / Fascia: Technical Service Bulletins Body - Plastic Bumper Refinishing TITLE: PLASTIC BUMPER REFINISHING SECTION: REFINISH BULLETIN # 170 MODELS: ALL TOYOTA LEXUS and SCION DATE: OCTOBER 2008 When it is necessary to replace a damaged plastic bumper, proper consideration should be given to preparation and refinishing to ensure high quality, long-term durability, and customer satisfaction. While it is important to follow paint manufacturer recommendations for application of refinish materials, this bulletin provides Toyota recommended procedures for cleaning and preparation of original equipment (OE) raw plastic bumpers. Background: Toyota bumper covers are manufactured using several types of plastic however, cleaning and preparation procedures outlined here are applicable to all Toyota, Lexus, and Scion raw plastic OE bumpers. Soap-base mold release agent replaced the wax-base type beginning in 1995 to reduce volatile organic compound (VOC) emissions produced by the use of cleaning solvents. This topic is covered in Collision Repair Information Bulletin (CRIB) #69. Thorough cleaning with recommended soap and water removes soap-base mold release agent. Cleaning and Preparation: ^ Wash new part thoroughly inside and out with a hot water and ph neutral wax-free carwash soap solution. Rinse well and dry with clean towels. Cleaning and Preparation, Continued^ Clean exterior surface and all edges thoroughly with paint manufacturer recommended plastic parts cleaner or water-base wax and grease remover, or a 1-1 mixture of isopropyl alcohol and deionized water. ^ Scuff exterior surface and all edges with a medium to fine scuff pad (as recommended by paint manufacturer), with sanding paste and clean water. Repeat wash sequence, rinse well and dry with clean towels. ^ Examine the bumper closely, especially hard to reach areas. Re-scuff any areas that do not appear to have been scuffed sufficiently. Repeat wash- rinse-dry sequence. ^ Make final surface inspection and clean with paint manufacturer recommended cleaner or a 1-1 mixture of isopropyl alcohol and deionized water. ^ Apply anti-static measures. ^ Apply adhesion promoter per paint manufacturer7s recommendations. ^ Apply primer and topcoats per paint manufacturer7s recommendations. Note: Toyota recommends the use of adhesion promoter and elastifier for all OE raw plastic bumpers to ensure adhesion, flexibility, and long-term durability of topcoats; and the use of refinish materials that meet or exceed the Toyota new vehicle limited paint finish warranty. Toyota, Lexus and Scion bumpers are primarily made from TSOP (Toyota Super Olefin Polymer). This type of plastic requires the use of adhesion Page 1476 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Page 2334 Shift Interlock: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Page 567 Fuel Pressure: Specifications Volume Specification Information not supplied by the manufacturer. Page 360 CHART 23 Page 3372 2. Install a new rivet into the holes of the spring leaf and clip. Then rivet with a press. d. Install spring center bolt. 1. Align the leaf holes and secure the leaves with a vise. 2. Install the spring center bolt. Torque: 44 Nm (450 kgf-cm, 33 ft. lbs.) e. Bend the spring clip. 1. Using a hammer, bend the spring clip into the position. 3. 2WD (Except PreRunner): REPLACE SPRING BUMPER a. Remove the 2 bolts and spring bumper. b. Install the 2 bolts and spring bumper. Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.) INSTALLATION Installation is in the reverse order of removal. Page 3285 16. INSTALL 2 TURN PRESSURE TUBES a. Install a new union seat to the rack housing. b. Install a new union seat to the control valve housing. c. Using SST, install the tube. SST 09633-00020 Torque: 20 Nm (203 kgf-cm, 15 ft. lbs.) HINT: ^ Use a torque wrench with a fulcrum length of 300 mm (11.81 inch). ^ This torque value is effective in case that SST is parallel to a torque wrench. Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Key to Diagrams Key to Diagrams A: System Title. B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: (1) Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. Testing and Inspection Wiper Switch: Testing and Inspection INSPECT FRONT WIPER AND WASHER SWITCH CONTINUITY W/ Mist w/ MIST: Page 2447 a. Coat a new oil seal lip with MP grease. b. 2RZ-FE:-Using SST and a hammer, install the oil seal. SST 09554-30011 Oil seal drive in depth: 1.5 mm (0.059 inch) c. 3RZ-FE, 5VZ-FE w/o Diff. lock: Using SST and a plastic hammer, install the oil seal until its surface is flush with the differential carrier end. SST 09316-12010, 09649-17010 Oil seal drive in depth: 0.5 mm (0.020 inch) HINT: Connect SST with vinyl tape. d. 3RZ-FE, 5VZ-FE w/ Diff. lock: Using SST and a hammer, install the oil seal. SST 09214-76011 Oil seal drive in depth: 1.0 mm (0.039 inch) 13. INSTALL COMPANION FLANGE a. Place the companion flange on the drive pinion. b. Coat the threads of a new nut with hypoid gear oil. c. Using SST to hold the flange, torque the nut. SST 09330-00021 Torque: 2RZ-FE: 108 Nm (1,100 kgf-cm, 80 ft. lbs.) 3RZ-FE, 5VZ-FE w/o Diff. lock: 147 Nm (1,500 kgf-cm, 109 ft. lbs.) 3RZ-FE, 5VZ-FE w/ Diff. lock: 196 Nm (2,000 kgf-cm, 145 ft. lbs.) Testing and Inspection Seat Belt Buckle Switch: Testing and Inspection INSPECT BUCKLE SWITCH CONTINUITY a. Check that continuity exists between terminals on the switch side connector with the switch ON (belt unfastened). b. Check that no continuity exists between terminals on the switch side connector with the switch OFF (belt fastened). If operation is not as specified, replace the seat belt inner. Page 613 HINT: Apply SST (B) at a slight angle on the side marked with "9" or "7", at the position shown in the illustration. - When SST (B) is inserted too deeply, it will get pinched by the shim. To prevent it from being stuck, insert it gently from the intake side, at a slight angle. 4) Using a small screwdriver and magnetic finger, remove the adjusting shim. b) Determine the replacement adjusting shim size by following the Formula or Charts: 1) Using a micrometer, measure the thickness of the removed shim. 2) Calculate the thickness of a new shim so the valve clearance comes within the specified value. T Thickness of used shim A Measured valve clearance N Thickness of new shim Intake: N = T + (A - 0.18 mm (0.007 inch)) Exhaust: N = T + (A - 0.32 mm (0.013 inch)) Page 2996 Description and Operation Camshaft Position Sensor: Description and Operation The Camshaft Position Sensor Camshaft position sensor (G signal) consists of a magnet, iron core and pickup coil. The G signal plate has 1 tooth, on its outer circumference and is mounted on the RH camshaft timing pulley. When the camshafts rotate, the protrusion on the signal plate and the air gap on the pickup coil change, causing fluctuations in the magnetic field and generating an electromotive force in the pickup coil. The NE signal plate has 34 teeth and is mounted on the crankshaft timing pulley. The NE signal sensor generates 34 signals at every engine revolution. The ECM detects the standard crankshaft angle based on the G signal and the actual crankshaft angle and the engine speed by the NE signal. Page 4060 1. Temporarily install the new parts and measure each part in accordance with the body dimension diagram. 2. Temporarily install the front fender and hood, and check the fit. Page 2735 HINT: The brake pedal should not be depressed twice and/or returned while setting to the specified pressure. Read the value of rear brake pressure 2 seconds after adjusting the specified fluid pressure. If the brake pressure is incorrect, adjust the fluid pressure. 4. IF NECESSARY, ADJUST FLUID PRESSURE a. Adjust the length of the No. 2 shackle. Low pressure - Lengthen A High pressure - Shorten A Initial Set: Adjustment Range: HINT: One turn of the nut changes the fluid pressure as shown in the following table. Rear Brake Pressure: b. If the pressure cannot be adjusted by the No. 2 shackle, raise or lower the valve body. Low pressure - Lower body High pressure - Raise body c. Torque the nuts. Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.) d. Adjust the length of the No. 1 shackle again. If it cannot be adjusted, inspect the valve housing. Page 1857 Idle Speed: Testing and Inspection INSPECTION 1. INITIAL CONDITIONS a) Engine at normal operating temperature b) Air cleaner installed c) All pipes and hoses of air induction system connected d) All accessories switched OFF e) All vacuum lines properly connected f) SFI system wiring connectors fully plugged g) Ignition timing checked correctly h) Transmission in neutral position i) A/C switch is OFF 2. CONNECT TOYOTA HANDHELD TESTER OR OBDII SCAN TOOL 3. INSPECT IDLE SPEED a) Race the engine speed at 1,000 rpm for approx. 5 seconds. b) Check the idle speed. Idle speed: 700 ± 50 rpm If the idle speed is not as specified, check the IAC valve and air intake system. 4. DISCONNECT TOYOTA HANDHELD TESTER OR OBDII SCAN TOOL Page 326 Page 2634 Shift Indicator: Locations Component Locations Page 4576 Page 3473 Compressor Clutch: Testing and Inspection 1. SET ON MANIFOLD GAUGE SET 2. START ENGINE 3. INSPECT COMPRESSOR FOR METALLIC SOUND Check if there is an abnormal metallic sound from the compressor when the A/C switch is on. If abnormal metallic sound is heard, replace the compressor assembly. 4. INSPECT REFRIGERANT PRESSURE See "ON-VEHICLE INSPECTION" of AIR CONDITIONING SYSTEM. 5. STOP ENGINE 6. INSPECT VISUALLY FOR LEAKAGE OF REFRIGERANT FROM SAFETY SEAL Using a gas leak detector, check for leakage of refrigerant. If there is any leakage, replace the compressor assembly. 7. SET OFF MANIFOLD GAUGE SET 8. MAKE THESE VISUAL CHECK: a. Leakage of grease from the clutch bearing. b. Signs of oil on the pressure plate Repair or replace, as necessary. 9. INSPECT MAGNETIC CLUTCH BEARING FOR NOISE a. Start engine. b. Check for abnormal noise from near the compressor when the A/C switch is OFF. If abnormal noise is being emitted, replace the magnetic clutch. 10. INSPECT MAGNETIC CLUTCH OPERATION a. Disconnect the connector. b. Connect the positive (+) lead from the battery to terminal on the magnetic clutch connector and the negative (-) lead to the body ground. c. Check that the magnetic clutch is energized. If operation is not as specified, replace the magnetic clutch. Locations Page 4641 a. Connect the positive (+) lead from the battery to terminal 12. b. Connect the negative (-) lead from the battery to terminals 5,7 and 10. c. Check the chime sounds. d. Disconnect the negative (-) lead from the battery to terminal 10. e. Check that the chime stops sounding. f. Connect the negative (-) lead from the battery to terminal 10. g. Connect the positive (+) lead from the battery to terminal 6. h. Check that the chime stops sounding. If operation is not as specified, replace the relay. 4. INSPECT INTEGRATION RELAY CIRCUIT a. Remove the relay from the junction block No.1 and inspect the connectors on the junction block side. Page 2394 b. Install the oil strainer case with the 5 bolts. Torque: 10 Nm (100 kgf-cm, 7 ft. lbs.) c. Install a new gasket to the oil strainer case. d. Install the oil strainer with the 11 bolts. Torque: 6.9 Nm (70 kgf-cm, 61 inch lbs.) 18. INSTALL OIL PAN a. A340E: Install the 4 magnets in the indications of the oil pan. b. A340F: Install the 6 magnets in the indications of the oil pan. c. Remove any packing material and be careful not to drop oil on the contacting surfaces of the transmission case and oil pan. DENSO Made Cruise Control Indicator Lamp: Testing and Inspection DENSO Made CIRCUIT DESCRIPTION When the cruise control main switch is turned ON, CRUISE MAIN indicator light lights up. Wiring Diagram Page 2496 1. 3-joint type: SEPARATE PROPELLER SHAFT AND INTERMEDIATE SHAFT a. Place matchmarks on the flanges. b. Remove the 4 nuts, bolts and washers. c. Separate the propeller shaft and intermediate shaft. 2. 3-joint type: REMOVE FLANGE FROM INTERMEDIATE SHAFT a. Using a chisel and hammer, loosen the staked part of the nut. b. Using SST to hold the flange, remove the nut and spacer. SST 09330-00021 c. Place matchmarks on the flange and shaft. d. Using SST, remove the flange from the intermediate shaft. SST 09950-30011 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020) e. Remove the spacer. 3. 3-joint type: REMOVE CENTER SUPPORT BEARING FROM INTERMEDIATE SHAFT 4. REMOVE SLEEVE YOKE FROM PROPELLER SHAFT a. Place matchmarks on the sleeve yoke and shaft. b. Pull out the sleeve yoke from the shaft. c. Remove the dust cover from the shaft. INSPECTION NOTICE: Be careful not to grip the propeller shaft tube too tightly in a vise as this will cause deformation. Component Tests and General Diagnostics Engine Control Module: Component Tests and General Diagnostics CIRCUIT DESCRIPTION When the ignition switch is turned ON, battery positive voltage is applied to coil, closing the contacts of the EFI main relay (Marking: EFI) and supplying power to terminal +B of the ECM. WIRING DIAGRAM Page 2241 Junction Box / No. 3 Fuse and Fusible Link Locations Replacement Requirements Airbag Sensor Assembly: Service and Repair Replacement Requirements REPLACEMENT REQUIREMENTS In the following cases, replace the airbag sensor assembly. - If the SRS has been deployed in a collision. - If the airbag sensor assembly has been found to be faulty in troubleshooting. - If the airbag sensor assembly has been dropped. CAUTION: For removal and installation of the airbag sensor assembly. Be sure to follow the correct procedure. Page 2729 Repair Procedure 1. Disconnect the cable from the negative (-) battery terminal for MORE THAN two (2) seconds. 2. Reconnect the cable to the negative (-) battery terminal. 3. Perform the applicable zero point calibration of the yaw rate sensor and/or the steering angle sensor. HINT Refer to the applicable TSB or Repair Manual for the zero point calibration procedure. 4. Re-initialize all applicable systems available on the vehicle (power window sunroof power lift door etc.). Specifications Connecting Rod Bearing: Specifications Bearing Clearance STD ..................................................................................................................................................... .................. 0.024 - 0.053 mm (0.0009 - 0.021 in) O/S 0.25 .............................................................................................................................................................. 0.023 - 0.069 mm (0.0009 - 0.0027 in) Maximum ............................................................................... ......................................................................................................... 0.08 mm (0.0031 in) Bearing Center Wall Thickness Mark 1 .................................................................................................................................................. ............... 1.484 - 1.488 mm (0.0584 - 0.0586 in) Mark 2 .................................................................... ............................................................................................. 1.488 - 1.492 mm (0.0586 - 0.0587 in) Mark 3 .................................................................................................................................................. ............... 1.492 - 1.496 mm (0.0587 - 0.0589 in) Page 3352 3. DISCONNECT UPPER BALL JOINT a. Remove the coffer pin and loosen the nut. Torque: 105 Nm (1,100 kgf-cm, 80 ft. lbs.) HINT: At the time of installation, if the hole for the cotter pin are not aligned, tighten the nut further up to 60°. b. Using SST, disconnect the upper ball joint. SST 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04031, 09958-04011) c. Support the steering knuckle securely. d. Remove the nut. 4. REMOVE UPPER SUSPENSION ARM Remove the nut, bolt, 2 washers and upper suspension arm. Torque: 115 Nm (1,200 kgf-cm, 87 ft. lbs.) HINT: At the time of installation, after stabilizing the suspension, torque the nut. INSTALLATION Installation is in the reverse order of removal. HINT: After installation, check the front wheel alignment. DENSO Made Brake Switch (Cruise Control): Testing and Inspection DENSO Made CIRCUIT DESCRIPTION When the brake pedal is on depressed, battery positive voltage normally applies through the STOP fuse and stop light switch to terminal STP-of the ECU, and the ECU turns the cruise control off. A fail-safe function is provided so that cancel functions normally, even if there is a malfunction in the stop light signal circuit. If the harness connected to terminal STP-has an open circuit, terminal STP-will have battery positive voltage and the cruise control will be turned off. Also, when the brake is on, the magnetic clutch is cut mechanically by the stop light switch, turning the cruise control oft. (See operation of the magnetic clutch) Wiring Diagram Page 3016 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Page 4657 Junction Box / No. 3 Page 2330 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source How to Read Power Source Page 4003 If seam is not sealed properly, clean vertical and horizontal seam area with Acrysol(TM) cleaner. Use an air hose to dry all seams before applying sealer. NOTE: Hole is located behind fender. 15. Attach a 12 to 18 inch length of plastic tubing to tip of Kent High Tech(TM) Clear Seam Sealer. 16. Seal entire vertical joint with High Tech(TM) clear seam sealer. Allow sealer to dry according to instructions on tube. NOTE: Seams are inside boxed area and accessed through the square hole as shown. 17. Flood cowl area with water to confirm that there are no cowl seam leaks into cab. If water leaks are still present and there are no cowl area seam leaks, reinstall front fender and inspect for water entry along lower edge of interior door trim panel; then proceed as follows: 18. Remove door trim panel. 19. Flood R/F door glass area (spray water at door glass, belt-molding area). 20. Inspect sealer between plastic sheeting (moisture barrier) and metal door panel for voids/skips in sealer. If there are voids/skips between the plastic sheet and the door panel, it will need to be resealed. A. Using a heat gun, heat the butyl tape securing the plastic sheet to make removal easier. B. Use Kent Acrysol to clean the door panel and plastic sheet. NOTE: ^ Follow the directions provided by the cleaning agent. ^ To ensure proper sealing of the plastic sheeting, it is important that the door panel and plastic sheeting is extremely clean. C. Use 3M 8.0 mm butyl tape (P/N 08610) to reattach the plastic sheet to the door panel. Make sure there is a continuos solid bead sealing the plastic sheet to the door panel. 21. Inspect drain-back holes (small slits in metal door panel, near bottom of sealer) to determine if holes are covered by sealer material. If sealer covers drain-back holes (small slits in metal door panel) carefully pull up a portion of plastic sheet, clean out drain-back holes and Page 1938 Idle Air Control Valve: Service and Repair COMPONENTS REMOVAL 1. REMOVE THROTTLE BODY Lower Control Arm: Service and Repair Lower REMOVAL HINT: PreRunner is the model described below. RZN191L-TRPDKAB, RZN196L-CRPDKAB, VZN195L-CRPDKAB 1. REMOVE FRONT WHEEL Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.) 2. REMOVE STEERING GEAR ASSEMBLY 3. DISCONNECT STABILIZER BAR LINK Remove the nut and disconnect the stabilizer bar link from the lower suspension arm. Torque: 69 Nm (700 kgf-cm, 51 ft. lbs.) Page 117 Airbag Sensor Assembly: Service and Repair Removal and Installation COMPONENTS REMOVAL NOTE: Do not open the cover or the case of the ECU and various electrical devices unless absolutely necessary. If the IC terminals are touched, the IC may be destroyed by static electricity. 1. REMOVE FRONT CONSOLE BOX 2. REMOVE LOWER CENTER COVER Replacement Requirements Clockspring Assembly / Spiral Cable: Service and Repair Replacement Requirements REPLACEMENT REQUIREMENTS In the following cases, replace the steering wheel pad, steering wheel or spiral cable CAUTION: Be sure to follow the correct procedure for removal and installation of the steering wheel pad. Page 3923 WARRANTY INFORMATION PROGRAMMING PROCEDURE AUTOMATIC (IGNITION-CONTROLLED) DOOR LOCKING/UNLOCKING FUNCTION The factory setting for the AUTOMATIC DOOR LOCKING/UNLOCkING FUNCTION is "ON". To change this feature's operation, follow the steps below: 1. Sit in the driver's seat with driver's door open. 2. Insert the key into the ignition switch, and turn it to 'ON" position (not "ACC") 5 times (ON > LOCK > ON > LOCK> ON > LOCK > ON> LOCK > ON) within a 10 second period. System Response: The STATUS MONITOR's LED turns on, and the PIEZO BUZZER sounds once. NOTE: You must perform the next steps within 30 seconds. 3. Select the customer's preferred operating mode. Page 1774 Vehicle Speed Sensor: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Page 1498 D: Indicates related system. Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V). Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, 1H2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green O = Orange P = Pink R = Red SB = Sky Blue V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Page 3271 Part 3 Of 3 DISASSEMBLY NOTICE: When using a vise, do not overtighten it. Page 4376 Locations Page 1960 Mass Air Flow Meter: Testing and Inspection INSPECTION 1. INSPECT MAF METER RESISTANCE Using an ohmmeter, measure the resistance between terminals THA and E2. If the resistance is not as specified, replace the MAF meter. Temperature Resistance at -20 °C (-4 °F) 13.6 - 18.4 Kohms at -20 °C (68 °F) 2.2 - 2.7 Kohms at -60 °C (140 °F) 0.5 - 0.7 Kohms 2. INSPECT MAF METER OPERATION a. Connect the MAF meter connector. b. Using a voltmeter, connect the positive (+) tester probe to terminal VG, and negative (-) tester probe to terminal E2G. c. Turn the ignition switch ON. d. Blow air into the MAF meter, and check that the voltage fluctuates. If operation is not as specified, replace the MAF meter. e. Turn the ignition switch OFF. f. Disconnect the MAF meter connector. Page 111 Airbag Sensor Assembly: Description and Operation AIRBAG SENSOR ASSEMBLY The airbag sensor assembly is mounted on the floor inside the center cluster. The airbag sensor assembly consists of a airbag sensor, safing sensor, diagnosis circuit, ignition control and drive circuit, etc. It receives signals from the airbag sensor assembly and judges whether the SRS must be activated or not and diagnosis system malfunctions. Page 2832 2. DISCONNECT SPRING FROM VALVE Using pliers, remove the clip, and remove the spring from the valve. 3. REMOVE SHACKLES NO.1 AND NO.2 a. Remove the nut and bolt, and remove the load sensing spring and 2 plate washers. b. Loosen the 2 nuts, and remove the shackle No. 1 from the shackle No. 2. 4. DISASSEMBLE LOAD SENSING SPRING a. Remove the 4 bushings, 2 collars and 2 rubber plats. b. Remove the load sensing valve boot and load sensing spring boot. INSPECTION INSPECT VALVE PISTON PIN AND LOAD SENSING CONTACT SURFACE FOR WEAR Wear limit: 0.7 mm (0.028 inch) REASSEMBLY Specifications Axle Nut: Specifications Front Wheel Hub Lock Nut 235 Nm (174 ft.lb) Page 4521 If circuit is as specified, try replacing the relay with a new one. If circuit is not as specified, inspect the circuits connected to other parts. Page 653 2. Turn the ignition switch ON and push TOYOTA hand-held tester main switch ON. NOTE: Do not start the engine. 3. Select the ACTIVE TEST mode on the TOYOTA hand-held tester. 4. Please refer to the TOYOTA hand-held tester operator's manual for further details. 5. If you have no TOYOTA hand-held tester, connect the positive (+) and negative (-) leads from the battery to the fuel pump connector. 6. Pinch the fuel return hose. The pressure in the high pressure line will rise to approx. 400 kPa (4 kg/Sq.cm, 57 psi). In this state, check to see that there are no leaks from any part of the fuel system. NOTE: Always pinch the hose. Avoid bending as it may cause the hose to crack. 7. Turn the ignition switch OFF. 8. Disconnect the TOYOTA hand-held tester from the DLC3. Page 2061 Spark Plug: Specifications Torque Specification Spark Plug x Cylinder Head ................................................................................................................ ......................................................................... 18 Nm Page 4310 Brake Switch (Cruise Control): Testing and Inspection FORD Made CIRCUIT DESCRIPTION When the brake is on, battery positive voltage normally applies through the STOP fuse and stop light switch to terminal STP-of the ECU, and the ECU turns the cruise control off. A fail-safe function is provided so that cancel functions normally, even if there is a malfunction in the stop light signal circuit. If the harness connected to terminal STP-has an open circuit, terminal STP-will have battery positive voltage and the cruise control will be turned off. Also, when the brake is on, the magnetic clutch is cut mechanically by the stop light switch, turning the cruise control off. Wiring Diagram Page 2829 2. REMOVE LSP & BV ASSEMBLY a. Using SST, disconnect the brake lines from the valve body. SST 09023-00100 b. Remove the clip from the flexible hose bracket. c. 2WD: Remove the 3 valve bracket mounting bolts and spacer, and remove the LSP & BV assembly. d. 4WD and Pre runner: Remove the 3 valve bracket mounting bolts, spacer and flexible hose bracket mounting bolt, and remove the LSP & BV assembly and flexible hose bracket. INSTALLATION 1. INSTALL LSP & BV ASSEMBLY TO FRAME a. 2WD: Install the 3 valve bracket mounting bolts and spacer with the LSP & BV assembly. b. 4WD and Pre runner: Install the 3 valve bracket mounting bolts, spacer and flexible hose bracket mounting bolt with the LSP & BV assembly and flexible hose bracket. Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.) 2. CONNECT BRAKE LINE Using SST, connect the brake lines. Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.) SST 09023-00100 3. CONNECT SHACKLE NO. 2 TO SHACKLE BRACKET a. Install the shackle No. 2 to the shackle No. 1 with the 2 nuts. b. Set dimension A. Initial Set: c. Tighten the lock nut. Torque: 24 Nm (250 kgf-cm, 18 ft. lbs.) d. Install the shackle No. 2 with the 2 cushions and collar to the shackle bracket. e. Install the nut to fix the cushion retainer. Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.) 4. SET REAR AXLE LOAD 5. SET VALVE BODY a. When pulling down the load sensing spring, confirm that the valve piston moves down smoothly. Page 2715 Repair Procedure 1. Disconnect the cable from the negative (-) battery terminal for MORE THAN two (2) seconds. 2. Reconnect the cable to the negative (-) battery terminal. 3. Perform the applicable zero point calibration of the yaw rate sensor and/or the steering angle sensor. HINT Refer to the applicable TSB or Repair Manual for the zero point calibration procedure. 4. Re-initialize all applicable systems available on the vehicle (power window sunroof power lift door etc.). Page 297 Camshaft Position Sensor: Service and Repair COMPONENTS REPLACEMENT 1. REMOVE NO.2 TIMING BELT COVER 2. REMOVE CAMSHAFT POSITION SENSOR a. Disconnect the sensor connector. b. Remove the bolt and sensor. 3. REINSTALL NEW CAMSHAFT POSITION SENSOR a. Install a new sensor with the bolt. Torque: 7.8 Nm (80 kg.cm, 69 in.lb) b. Connect the sensor connector. Page 2245 Harness Locations Page 3749 Seat Belt: Specifications Seat Belt Page 3227 Key Reminder Switch: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Page 3533 Hose/Line HVAC: Service and Repair LOCATION REPLACEMENT 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM 2. REPLACE FAULTY TUBE OR HOSE NOTE: Cap the open fittings immediately to keep moisture or dirt out of the system. 3. TIGHTEN JOINT OF BOLT OR NUT AT SPECIFIED TOQUE NOTE: Connections should not be torqued tighter than the specified torque. 4. EVACUATE AIR IN REFRIGERATION SYSTEM AND CHARGE SYSTEM WITH REFRIGERANT Diagram Information and Instructions Key Reminder Switch: Diagram Information and Instructions Key to Diagrams Key to Diagrams A: System Title. B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: (1) Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. Electrode Gap Specification Spark Plug: Specifications Electrode Gap Specification Electrode Gap Correct Gap ......................................................................................................................................... ........................................................................ 1.1 mm Page 3290 Service Information Page 4068 Page 4633 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 3020 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Page 1333 Vehicle Speed Sensor: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Page 633 12. INSTALL NO.1 TIMING BELT COVER AND STARTER WIRE BRACKET a) Check that the timing belt cover gaskets have cracks or peeling, etc. If the gasket does have cracks or peeling, etc., replace it using these steps. Using a screwdriver and gasket scraper, remove all the old gasket material. - Thoroughly clean all components to remove all the loose material. - Remove the backing paper from a new gasket and install the gasket evenly to the part of the belt cover shaded back in the illustration. b) Install the timing belt cover with the 4 bolts. Torque: 9 Nm (90 kgf-cm, 80 inch lbs.) c) Install the starter wire bracket with the 2 bolts. 13. INSTALL CRANKSHAFT PULLEY a) Align the pulley set key with the key groove of the pulley, and slide the pulley. b) Using SST, install a new bolt. SST 09213-54015 (90119-08216), 09330-00021 Torque: 300 Nm (3,000 kgf-cm, 217 ft. lbs.) 14. INSTALL FAN BRACKET a) Install the fan bracket with the bolt and nut. b) Install the PS pump adjusting strut with the nut. Page 2132 Step 4 Page 3208 Air Bag(s) Arming and Disarming: Service and Repair Release Method of Airbag Activation Prevention Mechanism Locations Page 561 6. ADJUST TOE-IN AND WHEEL ANGLE HINT: First, check or adjust the lengths of the rack ends, then adjust the toe-in. Rack end length difference: 1.5 mm (0.059 inch) or less a. Remove the 2 clips. b. Loosen the tie rod end lock nuts. c. Turn the right and left rack ends by an equal amount to adjust the toe-in. HINT: Try to adjust the toe-in to the center of the specified value. d. Make sure that the lengths of the right and left rack ends are the same. Rack end length difference: 1.5 mm (0.059 inch) or less e. Tighten the tie rod end lock nuts. Torque: 55 Nm (560 kgf-cm, 41 ft. lbs.) f. Place the boots on the seats and install the clips. HINT: Make sure that the boots are not twisted. g. Inspect the wheel angle. Turn the steering wheel fully and measure the turning angle. Wheel Turning Angle: If the right and left wheel turning angles differ from the specified value, readjust the toe-win and wheel angle within the specified value. At this time, the right and left error lengths of the rack end may be less than 1.5 mm (0.059 inch). Page 4947 INSPECT REAR WIPER AND WASHER SWITCH CONTINUITY If continuity is not as specified, replace the switch. INSPECT WASHER LINKED OPERATION a. Connect the positive (+) lead from the battery to terminal 16 and the negative (-) lead to terminal 2. b. Connect the positive (+) lead from the voltmeter to terminal 7 and the negative (-) lead to terminal 2. c. Push in the washer switch, and check that the voltage changes as shown in the table. If operation is not as specified, replace the wiper and washer switch. Page 792 HINT: PreRunner is the model described below. RZN191L-TRPDKAB, RZN196L-CRPDKAB, VZN195L-CRPDKAB 1. REMOVE FRONT WHEEL Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.) 2. REMOVE SHOCK ABSORBER Page 2011 Crankshaft Position Sensor: Service and Repair REPLACEMENT 1. REMOVE ENGINE UNDER COVER 2. REMOVE CRANKSHAFT POSITION SENSOR a. Disconnect the sensor connector. b. Remove the bolt and sensor. Torque: 7.8 Nm (80 kg.cm, 69 in.lb) 3. REINSTALL NEW CRANKSHAFT POSITION SENSOR a. Install the sensor with the bolt. b. Connect the sensor connector. 4. REINSTALL ENGINE UNDER COVER Page 891 Drive Belt: Testing and Inspection A/C System 1. INSPECT DRIVE BELT'S INSTALLATION CONDITION Check that the drive belt fits properly in the ribbed grooves. 2. INSPECT DRIVE BELT TENSION Using a belt tension gauge, check the drive belt tension. Drive belt tension: New belt 160 ± 25 lb Used belt 100 ± 20 lb HINT: "New belt" refers to a belt which has been used less than 5 minutes on a running engine. - "Used belt" refers to a belt which has been used on a running engine for 5 minutes or more. - After installing the drive belt, check that it fits properly in the ribbed grooves. Page 4042 A. Using a heat gun, heat the butyl tape securing the plastic sheet to make removal easier. B. Use Kent Acrysol to clean the door panel and plastic sheet. NOTE: ^ Follow the directions provided by the cleaning agent. ^ To ensure proper sealing of the plastic sheeting, it is important that the door panel and plastic sheeting is extremely clean. C. Use 3M 8.0 mm butyl tape (P/N 08610) to reattach the plastic sheet to the door panel. Make sure there is a continuos solid bead sealing the plastic sheet to the door panel. 21. Inspect drain-back holes (small slits in metal door panel, near bottom of sealer) to determine if holes are covered by sealer material. If sealer covers drain-back holes (small slits in metal door panel) carefully pull up a portion of plastic sheet, clean out drain-back holes and reinstall plastic sheet against metal door panel. Confirm that there are no voids between sealer and plastic sheet and between sealer and metal door panel. 22. Flood all areas with water to confirm that there are no leaks into cab area. 23. If no leaks are present, reinstall door trim panel. Technical Service Bulletin # BO026R-00 Date: 050112 Body - Water Leaks to The Interior BODY BO026-00 Title: WATER LEAK FIELD-FIX REPAIR INSTRUCTIONS Models: '97 - '04 Tacoma October 27, 2000 TSB Revision Notice: ^ January 12, 2005: Applicable Vehicles has been updated to include 2004 model year. ^ August 25, 2003: VIN and Applicable Model Information has changed, and repair procedure has been expanded and clarified. ^ October 27, 2000: This TSB updates B0016-98 dated June 12, 1998. B016-98 is now obsolete and should be discarded. Previous versions of this TSB should be discarded. Introduction Use the following field-fix procedures if water is present on the floor carpeting and it can be confirmed that the water is leaking into the cab from either the upper cowl or side cowl seam, or moisture barrier behind the door trim panel. Applicable Vehicles 1997 - 2004 model year Tacoma vehicles. Testing and Inspection Control Module HVAC: Testing and Inspection Air Conditioning Amplifier INSPECT AMPLIFIER CIRCUIT a. Remove the glove compartment door. b. Disconnect the amplifier connector and inspect the connector on wire harness side, as shown in the chart. Test conditions: - Turn ignition switch to ON - Blower speed switch HI If the circuit is not as specified, inspect the circuits connected to other parts. c. Connect the connector to amplifier and inspect wire harness side connector from the back side, as shown in the chart. Test conditions - Running engine at idle speed - Blower speed switch at "HI" position - A/C switch ON - Temperature control lever at "COOL" position - Set on manifold gauge set Testing and Inspection Headlamp Dimmer Switch: Testing and Inspection INSPECT LIGHT CONTROL SWITCH CONTINUITY If continuity is not as specified, replace the switch. INSPECT HEADLIGHT DIMMER SWITCH CONTINUITY Testing and Inspection Windshield Washer Switch: Testing and Inspection INSPECT FRONT WIPER AND WASHER SWITCH CONTINUITY W/ Mist w/ MIST: Page 407 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Testing and Inspection Power Window Switch: Testing and Inspection INSPECT POWER WINDOW MASTER SWITCH CONTINUITY Driver's Switch (Window Unlock) Driver's Switch (Window Unlock) Driver's Switch (Window Lock) Driver's Switch (Window lock) Page 4124 Right Side Right Side: If continuity is not as specified, replace the switch. Page 1897 Fuel Pressure Regulator: Service and Repair Page 1986 Throttle Body: Testing and Inspection Component Inspection INSPECTION 1. CLEAN THROTTLE BODY a. Using a soft brush and carburetor cleaner, clean the cast parts. b. Using compressed air, clean all the passages and apertures. NOTE: To prevent deterioration, do not clean the throttle position sensor and IAC valve. 2. INSPECT THROTTLE VALVE a. Apply vacuum to the throttle opener. b. Check that there is no clearance between the throttle stop screw and throttle lever when the throttle valve is fully closed. Throttle valve fully closed angle: 10° 3. INSPECT THROTTLE POSITION SENSOR a. Apply vacuum to the throttle opener. b. Insert a feeler gauge between the throttle stop screw and stop lever. c. Using an ohmmeter, measure the resistance between each terminal. Diagram Information and Instructions Key Reminder Switch: Diagram Information and Instructions Key to Diagrams Key to Diagrams A: System Title. B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: (1) Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. Page 3002 Page 3501 If circuit is as specified, try replacing the amplifier with a new one. If the circuit is not as specified, inspect the circuits connected to other parts. Service Precautions Air Bag(s) Arming and Disarming: Service Precautions NOTE: TOYOTA trucks are equipped with SRS, which comprises a driver airbag and front passenger airbag. Failure to carry out service operations in the correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Further, if a mistake is made in servicing the SRS, it is possible that the SRS may fail to operate when required. Before performing servicing (including removal or installation of parts, inspection or replacement), be sure to read the following items carefully, then follow the correct procedures described in the repair manual. Malfunction symptoms of the SRS are difficult to confirm, so the DTCs become the most important source of information when troubleshooting. When troubleshooting the SRS, always inspect the DTCs before disconnecting the battery. Even in cases of a minor collision where the SRS does not deploy, the steering wheel pad, front passenger airbag assembly, airbag sensor assembly and front airbag sensor should be inspected. Never use SRS parts from another vehicle. When replacing parts, replace them with new parts. Never disassemble and repair the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor in order to reuse it. If the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor has been dropped, or if there are cracks, dents or other defects in the case, bracket or connector, replace them with new ones. Use a volt/ohmmeter with high impedance (10 K.Ohm/V minimum) for troubleshooting the system's electrical circuits. Information labels are attached to the periphery of the SRS components. Follow the instructions on the notes. After work on the SRS is completed, perform the SRS warning light check. If the vehicle is equipped with a mobile communication system, refer to the precaution in the Introduction system. CAUTION: Work must be started 90 seconds after the ignition switch is turned to the "LOCK" position and the negative (-) terminal cable is disconnected from the battery (The SRS is equipped with a back-up power source so that if work is started within 90 seconds from disconnecting the negative (-) terminal cable of the battery, the SRS may be deployed.). When the negative (-) terminal cable is disconnected from the battery, the memory of the clock and audio system will be canceled. So before starting work, make a record of the contents memorized in the audio memory system. When work is finished, reset the audio systems as they were before and adjust the clock. However, it is not possible to make a record of the memory contents. So when the work is finished, it will be necessary to explain this fact to the customer, and ask the customer to adjust the features and reset the memory. To avoid erasing the memory in each memory system, never use a back-up power supply from outside the vehicle. Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during repairs. Do not expose the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor directly to hot air or flames. Page 4630 Key Reminder Switch: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Testing and Inspection Blower Motor Resistor: Testing and Inspection INSPECT BLOWER RESISTOR RESISTANCE If resistance is not as specified, replace the blower resistor. Page 2194 Capacity: A340E: 1.6 liters (1.7 US qts, 1.4 Imp. qts) A340F: 2.0 liters (2.1 US qts, 1.8 Imp. qts) 4. Start the engine and shift the shift lever into all positions from P to L position and then shift into P position. 5. With the engine idling, check the fluid level. Add fluid up to the COOL level on the dipstick. 6. Check the fluid level at the normal operating temperature, 70 - 80 °C (158 - 176 °F), and add as necessary. NOTE: Do not overfill. d. Check the fluid leaks. Check for leaks in the transmission. If there are leaks, it is necessary to repair or replacements, FIPGs, oil seals, plugs or other parts. e. Inspect and adjust the throttle cable. 1. Check that the throttle valve is fully closed. 2. Check that the inner cable is not slack. 3. Measure the distance between the outer cable end and stopper on the cable. Standard distance: 0 - 1 mm (0 - 0.04 in.) If the distance is not standard, adjust the cable by the adjusting nuts. f. Column shift: Inspect and adjust the shift lever position. When shifting the shift lever from the N position to other positions, check that the lever can be shifted smoothly and accurately to each position and that the position indicator correctly indicates the position. If the indicator is not aligned with the correct position, carry out the following adjustment procedures. Page 4069 Perform the procedure shown if there is any lamp malfunction. Specifications Headliner: Specifications Roof Headlining (Regular Cab) Air/Fuel Ratio Sensor Oxygen Sensor: Testing and Inspection Air/Fuel Ratio Sensor Air-Fuel Ratio (A/F) Sensor COMPONENTS INSPECTION 1. INSPECT HEATER RESISTANCE OF A/F SENSOR a. Disconnect the sensor connector. b. Using an ohmmeter, measure the resistance between terminals +B and HT. Resistance: at 20 °C (68 °F) 0.8 - 1.4 ohms at 800 °C (1,472 °F) 1.8 - 3.2 ohms If the resistance is not as specified, replace the sensor. Torque: 20 Nm (200 kg.cm, 14 ft.lb) c. Connect the sensor connector. 2. INSPECT OPERATION OF A/F SENSOR Page 244 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source How to Read Power Source Page 3847 a. Check functioning of SST. CAUTION: When activating the seat belt pretensioner, always use the specified SST: SRS Airbag Deployment Tool. SST 09082-00700, 09082-00740 1. Connect the SST to the battery. Connect the red clip of the SST to the battery positive (+) terminal and the black clip to the battery negative (-) terminal. HINT: Do not connect the yellow connector which will be connected with the seat belt pretensioner. 2. Check functioning of SST. Press the SST activation switch, and check the LED of the SST activation switch lights up. CAUTION: If the LED lights up when the activation switch is not being pressed, SST malfunction is probable, so definitely do not use the SST. b. Regular cab: Disconnect the pretensioner connector. 1. Remove the front seat outer belt floor anchor. 2. Remove the front seat outer belt shoulder anchor. 3. Remove the retractor cover. 4. Remove the retractor of front seat outer belt. Page 1222 Mass Air Flow Meter: Service and Repair REMOVAL 1. REMOVE AIR CLEANER CASE a. Disconnect the air cleaner hose. b. Disconnect the MAF meter connector. c. Remove the 3 bolts and air cleaner case. 2. REMOVE MAF METER a. Remove the 2 screws and MAF meter. b. Remove the O-ring from the MAF meter. INSTALLATION 1. INSTALL MAF METER a. Install the O-ring to the MAF meter. b. Install the MAF meter with the 2 screws. 2. INSTALL AIR CLEANER CASE a. Install the air cleaner case with the 3 bolts. b. Connect the MAF meter connector. c. Connect the air cleaner hose. Page 2457 5. DISCONNECT BRAKE LINE AND PARKING BRAKE CABLE a. Using SST, disconnect the brake line from the wheel cylinder. SST 09751-36011 Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.) b. 2WD: Remove the 2 bolts and disconnect the parking brake cable. Torque: 9.3 Nm (95 kgf-cm, 82 inch lbs.) 6. REMOVE REAR AXLE SHAFT ASSEMBLY a. Remove the 4 backing plate mounting nuts. Torque: 68 Nm (700 kgf-cm, 50 ft. lbs.) b. Pull out the rear axle shaft assembly from the rear axle housing. NOTICE: Be careful not to damage the oil seal. 7. REMOVE O-RING FROM REAR AXLE HOUSING INSPECTION 1. w/ ABS: REMOVE BEARING RETAINER (DIFFERENTIAL SIDE) AND ABS SPEED SENSOR ROTOR a. Attach 4 nuts to the serration bolts and remove the serration bolts from the backing plate using a hammer. NOTICE: Do not reuse the nuts previously removed from the vehicle. b. Grind the retainer and sensor rotor surfaces using a grinder, then chisel them out with a chisel. c. Attach washers and nuts to the serration bolts, then torque the nuts to install the serration bolts to the backing plate. d. Remove the 4 nuts and washers from the serration bolts. 2. REMOVE SNAP RING FROM AXLE SHAFT Using a snap ring expander, remove the snap ring. 3. REMOVE REAR AXLE SHAFT FROM BACKING PLATE Page 2842 4. REMOVE PISTON STOPPER BOLT Using a screwdriver, push the pistons in all the way and remove the piston stopper bolt and gasket. HINT: Tape the screwdriver tip before use. Torque: w/o ABS: 8.0 Nm (80 kgf-cm, 69 inch lbs.) w/ ABS: 10 Nm (100 kgf-cm, 7 ft. lbs.) 5. REMOVE 2 PISTONS AND SPRINGS a. Push in the piston with a screwdriver and remove the snap ring with snap ring pliers. HINT: Tape the screwdriver tip before use. b. Remove the No. 1 piston and spring by hand, pulling straight out, not at an angle. NOTICE: ^ If pulled out and installed at an angle, there is a possibly that the cylinder bore could be damaged. ^ At the time of disassembly, be careful not to damage the rubber lips on the pistons. c. Place a rag and 2 wooden blocks on the work table, and lightly tap the cylinder flange against the block edges until the No. 2 piston and spring drops out of the cylinder. HINT: Make sure the distance (A) from the rag to the top of the blocks is at least 100 mm (3.94 inch). INSPECTION HINT: Clean the disassembled parts with compressed air. 1. INSPECT CYLINDER BORE FOR RUST OR SCORING 2. INSPECT CYLINDER FOR WEAR OR DAMAGE If necessary, clean or replace the cylinder. Page 1597 Page 1384 CAUTION: Put a shop towel under the delivery pipe. Slowly loosen the union bolt. e. Install SST (pressure gauge) to the delivery pipe with the 2 gaskets and SST (union and union bolt). SST 09268-45012 Torque: 34.3 Nm (350 kg.cm, 25 ft.lb) f. Wipe off any splattered gasoline. g. Connect a TOYOTA hand-held tester to the DLC3. (See step 1) h. Reconnect the negative (-) terminal cable to the battery. i. Turn the ignition switch ON. j. Measure the fuel pressure. Fuel pressure: 265-304 kPa (2.7-3.1 kg/Sq.cm,38 - 44 psi) If pressure is high, replace the fuel pressure regulator. If pressure is low, check the fuel hoses, fuel hose connections, fuel pump, fuel filter and fuel pressure regulator. k. Disconnect the TOYOTA hand-held tester from the DLC3. l. Reinstall the No.2 timing belt cover with the 6 bolts. Torque: 9 Nm (90 kg.cm, 80 in.lb) m. Start the engine. n. Disconnect the vacuum sensing hose from the fuel pressure regulator, and plug the hose end. o. Measure the fuel pressure at idle. Fuel pressure: 265 - 304 kPa (2.7 - 3.1 kg/Sq.cm, 38 - 44 psi) p. Reconnect the vacuum sensing hose to the fuel pressure regulator. q. Measure the fuel pressure at idle. Fuel pressure: 226 - 265 kPa (2.3 - 2.7 kg/Sq.cm, 33 - 38 psi) If pressure is not as specified, check the vacuum sensing hose and fuel pressure regulator and fuel pressure regulator. r. Stop the engine. s. Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped. Fuel pressure: 147 kPa (1.5 kg/Sq.cm, 21 psi) or more If pressure is not as specified, check the fuel pump, pressure regulator and/or injectors. t. After checking fuel pressure, disconnect the negative (-) terminal cable from the battery and carefully remove the SST to prevent gasoline from splashing. SST 09268-45012 Page 2573 Manual Transmission/Transaxle: Service and Repair REMOVAL 1. REMOVE TRANSMISSION SHIFT LEVER a. Remove the front and rear console boxes and the rear console box cover. b. Remove the 4 screws and shift lever boot retainer. Electrical Specifications Oxygen Sensor: Electrical Specifications Air/Fuel Ratio Sensor Resistance: at 20°C (68°F): 0.8 - 1.4 ohms at 800°C (1,472°F): 1.8 - 3.2 ohms Heated Oxygen Sensor Resistance Between Terminals +B and HT: at 20°C (68°F) 11 - 16 Ohms at 800°C (1,472°F) 23 - 32 Ohms Page 3745 Warranty Information APPLICABLE WARRANTY ^ This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to correction of a problem based upon a customer's specific complaint. Parts Information Repair Procedure 1. Shift the tongue plate to the upper portion of the tongue plate stopper and temporarily hold it with a clip or tape. 2. Remove any pieces of the original tongue plate stopper in the webbing with a pair of diagonal pliers. NOTE Be careful not to damage the webbing, since this may compromise the safety of this seatbelt. CAUTION Damaged or weakened seat belts may break in an accident and injure the occupant. The seat belt assembly MUST be replaced if: ^ The webbing is cut, frayed, worn, or damaged. ^ It has been used during a severe impact (inspect the label to ensure no impact damage has occurred) Page 1852 c. When connecting the flare nut on the high pressure pipe union, observe these procedures: 1. Apply a light coat of engine oil to the flare and tighten the flare nut by hand. 2. Using SST, tighten the flare nut to the specified torque. SST 09631-22020 Torque: 28 Nm (285 kg.cm, 21 ft.lb) HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). d. Observe these precautions when removing and installing the injectors. 1. Never reuse the O-ring. 2. When placing a new O-ring on the injector, take care not to damage it in any way. 3. Coat a new O-ring with spindle oil or gasoline before installing-never use engine, gear or brake oil. e. Install the injector to the delivery pipe and intake manifold, as shown in the illustration. f. Check that there are no fuel leaks after doing maintenance anywhere on the fuel system. 1. Connect a TOYOTA hand-held tester to the DLC3. Page 2976 2. REMOVE STARTER HOUSING, CLUTCH ASSEMBLY AND GEAR a. Remove the 2 screws. Torque: 5.9 Nm (60 kg.cm, 52 in.lb) for 1.4 kW 9.3 Nm (95 kg.cm, 82 in.lb) for 1.8 kW b. Remove the starter housing, return spring, the clutch assembly, idler gear and bearing from the magnetic switch assembly. 3. REMOVE STEEL BALL Using a magnetic finger, remove the steel ball from the clutch shaft hole. 4. REMOVE BRUSH HOLDER a. Remove the 2 screws end frame from the field frame. Page 3393 FRONT AXLE HUB REPLACEMENT AND OVERHAUL W/ RELATED COMPONENTS Page 1176 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Page 620 Timing Belt: Diagrams TIMING BELT REPLACEMENT W/ RELATED COMPONENTS Part 1 Of 2 Part 1 of 2 Page 246 Locations Page 4680 Shift Indicator: Pinout Values and Diagnostic Parameters E 2 ELECTRONICALLY CONTROLLED TRANSMISSION SOLENOID 1, 2, 3-GROUND : Approx. 13 Ohm P 1 PARK/NEUTRAL POSITION SW 4-GROUND : Approx. 12 volts with ignition SW ON (Floor A/T), ACC (Column A/T) position O 4-A, S 4-B O/D MAIN SW A-1-A-3,B-5-B-10 : Open with O/D main SW at ON position Closed with O/D main SW at OFF position S 5-A,B STOP LIGHT SW A-1-A-2,B-1-B-2 : Closed with brake pedal depressed E 5-A, E 6-B, E 7-C, E 8-D ENGINE CONTROL MODULE S1-E1 : 9 - 14 volts S2,SL-E1 : 0 - 1.5 volts STP-E1 : 7.5 - 14 volts with brake pedal depressed : 0 - 1.5 volts with brake pedal released THW-E2 : 0.2 - 1.0 volts with coolant temp. 80 °C (176 °F) OIL-E2 : 4 - 5 volts with fluid temp. 20 °C (68 °F) VTA-E2 : 0.3 - 0.6 volts with throttle valve fully closed : 3.2 - 4.9 volts with throttle valve fully open VC-E2 : 4.5 - 5.5 volts OD1-E1 : 4.5 - 5.5 volts ODMS-E1 : 9 - 14 volts O/D main SW turned ON : 0 volts O/D main SW turned OFF SP1-E1 : Pulse generation with vehicle moving 2-E1 : 10 - 14 volts with shift lever at 2 position : 0-2 volts with shift lever at except 2 position L-E1 : 10 - 14 volts with shift lever at L position : 0 - 2 volts with shift lever at except L position OILW-E1 : 0.1 - 4.9 volts +B-E1 : 9 - 14 volts BATT-E1 : 9 - 14 volts Testing and Inspection EFI Main Relay: Testing and Inspection 1. REMOVE EFI MAIN RELAY (Marking: EFI) 2. INSPECT EFI MAIN RELAY a. Inspect the relay continuity. 1. Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. 2. Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. b. Inspect the relay operation. 1. Apply battery positive voltage across terminals 1 and 2. 2. Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. 3. REINSTALL EFI MAIN RELAY Page 3575 Refrigerant Pressure Sensor / Switch: Service and Repair REMOVAL 1. REMOVE EVAPORATOR 2. REMOVE PRESSURE SWITCH FROM LIQUID TUBE Disconnect the connector and remove the pressure switch. Torque: 10 Nm (100 kg.cm, 7 ft.lb) HINT: Lock the switch mounted on the tube with an open end wrench, being careful not to deform the tube and remove the switch. - At the time of installation, please refer to the following item. Lubricate a new O-ring with the compressor oil and install the switch. INSTALLATION Installation is in the reverse order of removal. Page 76 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Page 312 Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor The intake air temperature sensor is built into the air cleaner cap and senses the intake air temperature. A thermistor built in the sensor changes the resistance value according to the intake air temperature. The lower the intake air temperature, the greater the thermistor resistance value, and the higher the intake air temperature, the lower the thermistor resistance value. The intake air temperature sensor is connected to the ECM. The 5 V power source voltage in the ECM is applied to the intake air temperature sensor from the terminal THA via a resistor R. That is, the resistor R and the intake air temp. sensor are connected in series. When the resistance value of the intake air temp. sensor changes in accordance with changes in the intake air temperature, the potential at terminal THA also changes. Based on this signal, the ECM increases the fuel injection volume to improve driveability during cold engine operation. Page 1524 Part 2 Of 2 (Except California Spec.) *1: A/T *2: M/T Page 3834 Seat Belt Reminder Lamp: Description and Operation General Description SRS Warning Light The SRS warning light is located on the combination meter. It goes on to alert the driver of trouble in the system when a malfunction is detected in the airbag sensor assembly self-diagnosis. In normal operating conditions when the ignition switch is turned to the ACC or ON position, the light goes on for about 6 seconds and then goes OFF. Page 2672 Step 4 Page 4311 Steps 1 - 2 Page 3181 1. REMOVE AIR CLEANER ASSEMBLY Loosen the 3 bolts. 2. DISCONNECT RETURN HOSE NOTICE: Take care not to spill fluid on the drive belt. 3. DISCONNECT PRESSURE FEED TUBE a. Disconnect the connector from the oil pressure switch. b. Remove the oil pressure switch from the pressure feed tube. c. Remove the union bolt and 2 gaskets, and disconnect the tube from the PS vane pump assembly. 4. REMOVE DRIVE BELT a. Loosen the bolt A and nut B. b. Loosen the bolt C. 5. REMOVE PS VANE PUMP ASSEMBLY Remove the bolt A and nut B. INSTALLATION 1. INSTALL PS VANE PUMP ASSEMBLY Temporarily tighten the bolt A and nut B. 2. INSTALL DRIVE BELT a. Tightening the bolt C, adjust drive belt tension. b. Torque the bolt A and nut B. Torque: 43 Nm (440 kgf-cm, 32 ft. lbs.) Page 1000 Idle Speed: Testing and Inspection INSPECTION 1. INITIAL CONDITIONS a) Engine at normal operating temperature b) Air cleaner installed c) All pipes and hoses of air induction system connected d) All accessories switched OFF e) All vacuum lines properly connected f) SFI system wiring connectors fully plugged g) Ignition timing checked correctly h) Transmission in neutral position i) A/C switch is OFF 2. CONNECT TOYOTA HANDHELD TESTER OR OBDII SCAN TOOL 3. INSPECT IDLE SPEED a) Race the engine speed at 1,000 rpm for approx. 5 seconds. b) Check the idle speed. Idle speed: 700 ± 50 rpm If the idle speed is not as specified, check the IAC valve and air intake system. 4. DISCONNECT TOYOTA HANDHELD TESTER OR OBDII SCAN TOOL Page 4941 W/ Intermittent w/ INTERMITTENT: If continuity is not as specified, replace the switch. INSPECT INTERMITTENT OPERATION a. Turn the wiper switch to INT position. b. Turn the intermittent time control switch to FAST position. c. Connect the positive (+) lead from the battery to terminal 16 and the negative (-) lead to terminal 2. d. Connect the positive (+) lead from the voltmeter to terminal 7 and the negative (-) lead to terminal 2, check that the meter needle indicates battery positive voltage. If operation is not as specified, replace the wiper and washer switch. Page 4496 Junction Box / No. 1 Drivetrain - Drive/Axle Shaft Replacement Precautions Drive/Propeller Shaft: Technical Service Bulletins Drivetrain - Drive/Axle Shaft Replacement Precautions TRANSMISSION & CLUTCH TC003-07 Title: DRIVESHAFT ASSEMBLY REPLACEMENT Models: '90 - '07 Toyota Introduction The purpose of this bulletin is to provide information regarding anti-corrosion grease that is present on replacement driveshaft assemblies. It is important to remove this grease prior to installing the hub nut to prevent overtightening. This also applies when reusing an old driveshaft that may have come into contact with oil or foreign matter. Applicable Vehicles ^ 1990 - 2007 model year Toyota vehicles. Required Tools & Material Repair Procedure Clean the threaded area of the driveshaft with Toyota Brake Cleaner (or equivalent) to remove the anti-corrosion grease, oil, or foreign matter before installing the driveshaft into the vehicle. NOTE: A new axle hub nut may be required when installing the driveshaft. Check the Repair Manual procedure for more information. Warranty Information Component Tests and General Diagnostics Shift Indicator: Component Tests and General Diagnostics A/T.P. (Automatic Transmission Parking) Indicator Circuit CIRCUIT DESCRIPTION The propeller shaft and wheels are free even when the transmission shift lever is set to P as long as the transfer shift lever is in Neutral position. The A/T.P. indicator light lights up to warn the drive that the propeller shaft and wheels are not locked. If the A/T.P. indicator light goes on, the transfer shift lever should be shifted out of N position WIRING DIAGRAM Step 1 Page 4928 d. Remove the glass. NOTE: Leave as much of the adhesive on the body as possible when cutting off the glass. INSTALLATION 1. CLEAN AND SHAPE CONTACT SURFACE OF BODY a. Using a knife, cut away any rough areas on the body. HINT: Leave as much of the adhesive on the body as possible. b. Clean the cutting surface of the adhesive with a piece of shop rag saturated in a cleaner. HINT: Even if all the adhesive has been removed, clean the body. 2. CLEAN REMOVED GLASS a. Remove the damaged dam. b. Using a scraper, remove the adhesive sticking to the glass. c. Clean the glass with a cleaner. NOTE: Be careful not to damage the glass. - Do not touch the glass after cleaning it. 3. INSTALL NEW DAM Install a new dam with the double - stick tape as shown in the illustration. NOTE: Do not touch the glass face after cleaning it. Page 4961 W/ Intermittent w/ INTERMITTENT: If continuity is not as specified, replace the switch. INSPECT INTERMITTENT OPERATION a. Turn the wiper switch to INT position. b. Turn the intermittent time control switch to FAST position. c. Connect the positive (+) lead from the battery to terminal 16 and the negative (-) lead to terminal 2. d. Connect the positive (+) lead from the voltmeter to terminal 7 and the negative (-) lead to terminal 2, check that the meter needle indicates battery positive voltage. If operation is not as specified, replace the wiper and washer switch. Page 3342 HINT: PreRunner is the model described below. RZN191L-TRPDKAB, RZN196L-CRPDKAB, VZN195L-CRPDKAB REMOVE STEERING KNUCKLE WITH AXLE HUB INSPECTION INSPECT UPPER BALL JOINT FOR ROTATION CONDITION Page 1250 7. REMOVE WATER BYPASS PIPE AND KNOCK SENSOR WIRE 8. REMOVE KNOCK SENSORS Using SST, remove the knock sensor. SST 09817-16011 9. INSPECT KNOCK SENSORS Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor. 10. REINSTALL KNOCK SENSORS Using SST, install the knock sensor. SST 09817-16011 Torque: 39 Nm (400 kg.cm, 29 ft.lb) 11. REINSTALL WATER BYPASS PIPE AND KNOCK SENSOR WIRE 12. REINSTALL INTAKE MANIFOLD ASSEMBLY 13. REINSTALL FUEL PRESSURE REGULATOR 14. REINSTALL INTAKE AIR CONNECTOR ASSEMBLY 15. REINSTALL NO.2 TIMING BELT COVER 16. REINSTALL AIR CLEANER HOSE 17. REFILL WITH ENGINE COOLANT Page 2825 4. IF NECESSARY, ADJUST FLUID PRESSURE a. Adjust the length of the No. 2 shackle. Low pressure - Lengthen A High pressure - Shorten A Initial Set: Adjustment Range: HINT: One turn of the nut changes the fluid pressure as shown in the following table. Rear Brake Pressure: b. If the pressure cannot be adjusted by the No. 2 shackle, raise or lower the valve body. Low pressure - Lower body High pressure - Raise body c. Torque the nuts. Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.) d. Adjust the length of the No. 1 shackle again. If it cannot be adjusted, inspect the valve housing. 5. IF NECESSARY, CHECK VALVE BODY a. Assemble the valve body in the uppermost position. Page 4543 Step 4 Component Tests and General Diagnostics Key Reminder Switch: Component Tests and General Diagnostics Ignition Switch and Key Unlock Warning Switch INSPECTION 1. INSPECT IGNITION SWITCH CONTINUITY If continuity is not as specified, replace the switch. 2. INSPECT KEY UNLOCK WARNING SWITCH CONTINUITY If continuity is not as specified, replace the switch. 3. Key Unlock Warning System: INSPECT INTEGRATION RELAY OPERATION Page 4813 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source How to Read Power Source Page 3527 HINT: It is not necessary to drain out all the coolant. 3. DISCONNECT WATER HOSES FROM HEATER RADIATOR PIPES a. Using pliers, grip the claw of the hose clip and slide the clip along the hose b. Disconnect the water hoses from the heater radiator pipes. HINT: At the time of installation, please refer to the following items. Push the water hose onto the heater radiator pipe as far as the second ridge on the pipe. - Install the hose clip in the position, as shown in the illustration. 4. REMOVE INSTRUMENT PANEL AND REINFORCEMENT 5. REMOVE DEFROSTER NOZZLE AND HEATER TO REGISTER DUCT 6. REMOVE HEATER UNIT Remove the 2 bolts, nut and heater unit. INSTALLATION Installation is in the reverse order of removal. Page 2546 Page 4674 Harness Locations Component Tests and General Diagnostics Shift Indicator: Component Tests and General Diagnostics A/T.P. (Automatic Transmission Parking) Indicator Circuit CIRCUIT DESCRIPTION The propeller shaft and wheels are free even when the transmission shift lever is set to P as long as the transfer shift lever is in Neutral position. The A/T.P. indicator light lights up to warn the drive that the propeller shaft and wheels are not locked. If the A/T.P. indicator light goes on, the transfer shift lever should be shifted out of N position WIRING DIAGRAM Step 1 Page 2188 Fluid - A/T: Fluid Type Specifications Transmission Fluid .............................................................................................................................. ................................................. ATF Dexron II or III Page 1492 Refer to Reset Procedure 1 for the vehicles with Electronically Controlled Automatic Transmissions: Paint - Refinishing Information Paint: All Technical Service Bulletins Paint - Refinishing Information COLLISION REPAIR INFORMATION FOR THE COLLISION REPAIR PROFESSIONAL TITLE: TOPCOAT SAND & POLISH SECTION: REFINISH BULLETIN # 173 MODELS: ALL TOYOTA LEXUS AND SCION DATE: APRIL 2009 Customers have high expectations for automotive paint finish appearance and expect repairs to match factory color gloss and texture. Flawed refinish appearance is a cause of concern and will likely have a negative affect on customer satisfaction and retention. Toyota recognizes the reality of paint finish application in the shop environment. In addition to color matching and blending countermeasures to remove paint process intrusion (dirt nibs) are necessary to achieve an undetectable finish match. This is also common in manufacturing plants when process intrusion is encountered. Countermeasures are defined as; ultra-fine sanding to level nibs followed by polishing to a level of gloss and texture consistent with the original finish. Technicians undertaking these tasks should review applicable technical data sheets for product process and handling instructions as well as applicable safety information. Topcoat sand and polish is one of many paint finish repair techniques covered in Toyota T101 and Lexus L101 Paint Finish Repair training. Please visit for scheduling and registration information. Page 4319 Clutch Switch: Testing and Inspection FORD Made CIRCUIT DESCRIPTION When the clutch pedal is depressed, the clutch switch sends a signal to the cruise control ECU. When the signal is input to the cruise control ECU during cruise control driving, the cruise control ECU cancels cruise control. Wiring Diagram Page 2285 Step 2 Step 3 INSPECTION PROCEDURE Testing and Inspection VSV For Evaporative Emission: Testing and Inspection VSV FOR EVAPORATIVE EMISSION (EVAP) 1. REMOVE VSV a. Disconnect the connector and 2 EVAP hoses. b. Remove the screw and VSV. 2. INSPECT VSV a. Inspect the VSV for open circuit. Using an ohmmeter, check that there is continuity between the terminals. Resistance: 30-34 ohms at 20 °C (68 °F) If there is no continuity, replace the VSV. b. Inspect the VSV for ground. Using an ohmmeter, check that there is no continuity between each terminal and the body. If there is continuity, replace the VSV. Testing and Inspection Turn Signal Flasher: Testing and Inspection INSPECT TURN SIGNAL FLASHER OPERATION a. Connect the positive (+) lead from the battery to terminal 2 and the negative (-) lead to terminal 3. b. Connect the 2 turn signal light bulbs parallel to each other to terminals 1 and 3, check that the bulbs flash. HINT: The turn signal lights should flash 60 or 120 times per minute. If one of the front or rear turn signal lights has an open circuit, the number of flashers will be more than 140 per minute. If operation is not as specified, replace the flasher. Electrode Gap Specification Spark Plug: Specifications Electrode Gap Specification Electrode Gap Correct Gap ......................................................................................................................................... ........................................................................ 1.1 mm Testing and Inspection Headlamp Dimmer Relay: Testing and Inspection INSPECT HEADLIGHT DIMMER RELAY CONTINUITY If continuity is not as specified, replace the relay. Page 2214 WIRING DIAGRAM Description and Operation Throttle Position Sensor: Description and Operation Throttle Position Sensor The throttle position sensor is mounted in the throttle body and detects the throttle valve opening angle. When the throttle valve is fully closed, a voltage of approximately 0.3 - 1 .0 V is applied to terminal VTA of the ECM. The voltage applied to terminals VTA of the ECM increases in proportion to the opening angle of the throttle valve and becomes approximately 2.7 - 5.2 V when the throttle valve is fully opened. The ECM ledges the vehicle driving conditions from these signals input from terminals VTA and uses them as one of the conditions to decide the air- fuel ratio correction, power increase correction and fuel-cut control etc. Steering Wheel Nut - Torque Standardization Steering Wheel: Technical Service Bulletins Steering Wheel Nut - Torque Standardization STEERING ST001-01 February 16, 2001 Title: STEERING WHEEL NUT SERVICE SPECIFICATION Models: All Applicable Models Introduction To make the steering wheel installation procedure similar for all models. the steering wheel nut tightening torque has been standardized. Warranty Information Page 2232 Diagrams Page 401 Page 1736 CHART 26 Description and Operation Throttle Position Sensor: Description and Operation Throttle Position Sensor The throttle position sensor is mounted in the throttle body and detects the throttle valve opening angle. When the throttle valve is fully closed, a voltage of approximately 0.3 - 1 .0 V is applied to terminal VTA of the ECM. The voltage applied to terminals VTA of the ECM increases in proportion to the opening angle of the throttle valve and becomes approximately 2.7 - 5.2 V when the throttle valve is fully opened. The ECM ledges the vehicle driving conditions from these signals input from terminals VTA and uses them as one of the conditions to decide the air- fuel ratio correction, power increase correction and fuel-cut control etc. Page 1195 Step 7 Step 8 INSPECTION PROCEDURE Page 2965 a. Connect the battery and ammeter to the starter as shown. b. Check that the starter rotates smoothly and steadily with the pinion gear moving out. Check that the ammeter reads the specified current. Specified Current Specified current: INSPECTION 1. INSPECT ARMATURE COIL a. Check the commutator for open circuit. Using an ohmmeter, check that there is continuity between the segments of the commutator. If there is no continuity between any segment, replace the armature. b. Check the commutator for ground. Using an ohmmeter, check that there is no continuity between the commutator and armature coil core. If there is continuity, replace the armature. 2. INSPECT COMMUTATOR a. Check the commutator for the dirty and burnt surfaces. If the surface is dirty or burnt, correct it with sandpaper (No.400) or on a lathe. Page 118 3. REMOVE AIRBAG SENSOR ASSEMBLY a. Disconnect the connector. NOTE: Remove the connector with the sensor assembly installed. b. Using a torx wrench remove the 3 screws and airbag sensor assembly. Torx wrench: T40 (Part No.09042-00020 or locally manufactured tool) INSTALLATION NOTE: - Never use SRS parts from another vehicle. When replacing parts, replace with new parts. - Never reuse the airbag sensor assembly involved in a collision when the airbag has deployed. - Never repair a sensor in order to reuse it. 1. INSTALL AIRBAG SENSOR ASSEMBLY a. Using a torx wrench, install the airbag sensor assembly with the 3 screws. Torx wrench: T40 (Part No.09042-00020 or locally manufactured tool) Torque: 20 Nm (205 kg.cm, 15 ft.lb) b. Connect the connector. NOTE: Installation of the connector is done after the sensor assembly has been installed. - Make sure the sensor assembly is installed to the specified torque. - If the sensor assembly has been dropped, or there are cracks, dents or other defects in the case, bracket or connector, replace the sensor assembly with a new one. - When installing the airbag sensor assembly, take care that the SRS wiring does not interfere with other parts and is not pinched between other parts. - After installation, shake the sensor assembly to check that there is no looseness. 2. INSTALL REMOVED PARTS Page 2107 Page 658 TOY 730 - 73mm Toyota Oil Filter Wrench M 0219 - 74mm Oil Filter Wrench ABS/TCS - Zero Point Calibration Information Steering Angle Sensor: Technical Service Bulletins ABS/TCS - Zero Point Calibration Information T-SB-0020-08 March 25, 2008 Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment Service Category Brake Section Brake Control/Dynamic Control System Market USA Applicability Introduction The purpose of this TSB is to provide information on when and how to perform the zero point calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting the battery is a necessary step for performing the zero point calibration. Warranty Information Required Tools & Equipment ^ Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE). ^ The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the service procedures listed in this bulletin. Preliminary Information Perform this procedure if any of these repairs have been performed on the vehicle: ^ Wheel alignment has been adjusted. ^ Any chassis components have been removed/installed or replaced. Specifications Crankshaft Gear/Sprocket: Specifications Crankshaft Pulley Torque .................................................................................................................... ...................................................................... 300 Nm Page 4675 Page 3168 Power Steering Fluid: Fluid Type Specifications Lubricant Lubricant Type Automatic Transmission Fluid Dexron II or Dexron III Page 1581 CHART 10 Testing and Inspection Washer Fluid Level Switch: Testing and Inspection INSPECT WASHER LEVEL SWITCH a. Check that no continuity exists between terminals with the switch OFF (float up). b. Check that continuity exists between terminals with the switch ON (float down). If operation is not as specified, replace the switch. Page 1181 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Page 3009 Splice Point J: Indicates a wiring Splice Point (Codes are "E"for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I 5 is indicated by the shaded section. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. N: Page No. How to Read Ground Points How to Read Ground Points Body - Plastic Bumper Refinishing Front Bumper Cover / Fascia: Technical Service Bulletins Body - Plastic Bumper Refinishing TITLE: PLASTIC BUMPER REFINISHING SECTION: REFINISH BULLETIN # 170 MODELS: ALL TOYOTA LEXUS and SCION DATE: OCTOBER 2008 When it is necessary to replace a damaged plastic bumper, proper consideration should be given to preparation and refinishing to ensure high quality, long-term durability, and customer satisfaction. While it is important to follow paint manufacturer recommendations for application of refinish materials, this bulletin provides Toyota recommended procedures for cleaning and preparation of original equipment (OE) raw plastic bumpers. Background: Toyota bumper covers are manufactured using several types of plastic however, cleaning and preparation procedures outlined here are applicable to all Toyota, Lexus, and Scion raw plastic OE bumpers. Soap-base mold release agent replaced the wax-base type beginning in 1995 to reduce volatile organic compound (VOC) emissions produced by the use of cleaning solvents. This topic is covered in Collision Repair Information Bulletin (CRIB) #69. Thorough cleaning with recommended soap and water removes soap-base mold release agent. Cleaning and Preparation: ^ Wash new part thoroughly inside and out with a hot water and ph neutral wax-free carwash soap solution. Rinse well and dry with clean towels. Cleaning and Preparation, Continued^ Clean exterior surface and all edges thoroughly with paint manufacturer recommended plastic parts cleaner or water-base wax and grease remover, or a 1-1 mixture of isopropyl alcohol and deionized water. ^ Scuff exterior surface and all edges with a medium to fine scuff pad (as recommended by paint manufacturer), with sanding paste and clean water. Repeat wash sequence, rinse well and dry with clean towels. ^ Examine the bumper closely, especially hard to reach areas. Re-scuff any areas that do not appear to have been scuffed sufficiently. Repeat wash- rinse-dry sequence. ^ Make final surface inspection and clean with paint manufacturer recommended cleaner or a 1-1 mixture of isopropyl alcohol and deionized water. ^ Apply anti-static measures. ^ Apply adhesion promoter per paint manufacturer7s recommendations. ^ Apply primer and topcoats per paint manufacturer7s recommendations. Note: Toyota recommends the use of adhesion promoter and elastifier for all OE raw plastic bumpers to ensure adhesion, flexibility, and long-term durability of topcoats; and the use of refinish materials that meet or exceed the Toyota new vehicle limited paint finish warranty. Toyota, Lexus and Scion bumpers are primarily made from TSOP (Toyota Super Olefin Polymer). This type of plastic requires the use of adhesion Page 4002 6. Mask-off wiper motor opening. 7. Attach Kent(TM) 12" extension tube (P/N 90175) to the nozzle on the can of Leak-Chek(TM) (P/N 50087). NOTE: Direct Leak-Chek(TM) spray material approximately 1 inch above seam. Spray force is very strong - make several test passes before actually spraying material into seam. 8. Spray Leak-Chek(TM) through the wiper motor opening. a. Spray material inside upper cowl, beginning in lower corner, and continuing toward the centerline of vehicle. b. Remove wand from the wiper motor opening and insert it into larger cowl openings on the right hand side. Continue spraying material along entire seam until seam is filled from R/F fender to L/F fender area. Spray Leak-Chek(TM) into seam a total of 3 times, allowing Leak-Chek(TM) to flash dry for 30-45 minutes between applications. (Drying time increases as outside temperature decreases.) 9. After final application of Leak-Chek(TM) has been allowed to dry for approximately one hour, flood area with water for 5-10 minutes. NOTE: Hold garden hose at top right front corner of windshield and point hose downward toward lower right hand corner of windshield as shown. 10. Check inside cab behind Heater/Air Conditioner box for evidence of water leakage during water leak check. 11. Carefully inspect "T" joint on right and left sides (close to heater motor box, and brake booster) for evidence of water leaks. 12. If no leaks are found, cowl area leak repair is complete. Reinstall wiper motor, cowl trim panel, wiper arms, and hood. Wiper Arm Torque: 20 N.m (205 kgf.cm, 15 ft.lbf) If water leaks are still present and are coming in from the cowl area, remove right front fender and proceed as follows: 13. Seal around entire perimeter of "L" bracket with Kent High Tech(TM) Clear Seam Sealer (see drawing for location of "L" bracket). 14. Using a flashlight, look through the 2" x 3" rectangular hole on side of vertical cowl panel and locate vertical seam that connects side of cowl to front cowl. Page 4901 Passenger's Switch (Window Unlock) Passenger's Switch (Window Unlock) Passenger's Switch (Window Lock) Passenger's Switch (Window lock) If continuity is not as specified, replace the switch. INSPECT POWER WINDOW SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 2019 Ignition Coil: Testing and Inspection INSPECT IGNITION COIL a. Remove the air cleaner hose. b. Disconnect the high-tension cords and ignition coil connectors from the ignition coils. c. Inspect the primary coil resistance. Using an ohmmeter, measure the resistance between the positive (+) and negative (-) terminals. Primary coil resistance: cold 0.67 - 1.05 ohms Hot 0.85 - 1.23 ohms If the resistance is not as specified, replace the ignition coil. d. Remove the ignition coils. e. Inspect the secondary coil resistance. Using an ohmmeter, measure the resistance between the positive (+) and high-tension terminals. Secondary coil resistance: cold 9.3 - 16.0 ohms Hot 11.7 - 18.8 ohms If the resistance is not as specified, replace the ignition coil. f. Reinstall the ignition coils. g. Reconnect the ignition coil connectors and the high-tension cords. h. Reinstall the air cleaner hose. Page 4187 January 7, 2000 Title: REAR QUARTER PANEL PAINT CHIP PROTECTION Models: '95 - '00 Tacoma Introduction: A new anti-chip tape has been developed to help prevent repeat occurrences of paint chipping on the rear quarter panels of Tacoma compact pick-up trucks caused by the impact of road debris. Applicable Vehicles: All 1995 - 2000 model year Tacoma vehicles. Parts Information Repair Procedure: NOTE: This repair is to be used in conjunction with repainting of the truck bed due to excessive chipping of the rear quarter panel. NOTE: Apply anti-chipping tape only after the surface has been repainted, cured, and is not hotter than 38° C (100° F). Apply the anti-chipping tape directly to the painted surface of the rear quarter panel between the front edge of the rear quarter panels and the rear tires as shown. Warranty Information Page 4436 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 1709 Page 3268 4. CONNECT INTERMEDIATE NO. 2 SHAFT 5. CONNECT RH AND LH TIE ROD ENDS 6. POSITION FRONT WHEEL FACING STRAIGHT AHEAD HINT: Do it with the front of the vehicle jacked up. 7. CENTER SPIRAL CABLE 8. INSTALL STEERING WHEEL a. Align the matchmarks; on the wheel and steering column main shaft. b. Temporarily tighten the wheel set nut. c. Connect the connector. 9. BLEED POWER STEERING SYSTEM 10. CHECK STEERING WHEEL CENTER POINT 11. TORQUE STEERING WHEEL SET NUT Torque: 35 Nm (360 kgf-cm, 26 ft. lbs.) 12. INSTALL STEERING WHEEL PAD 13. CHECK FRONT WHEEL ALIGNMENT 14. INSTALL ENGINE UNDER COVER Tighten the 4 bolts. Disassembly and Reassembly Page 2111 Step 2 Step 3 INSPECTION PROCEDURE Page 3015 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Page 833 8. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts. 9. Install and uniformly tighten the 10 bearing cap bolts, in several passes. Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.) b. Install the exhaust camshaft of the RH cylinder head. 1. Apply new engine oil to the thrust portion and journal of the camshaft. 2. Align the timing marks (2 dot marks) of the camshaft drive and driven gears. 3. Place the exhaust camshaft on the cylinder head. 4. Install the 4 bearing caps in their proper locations. 5. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts. 6. Install and uniformly tighten the 8 bearing cap bolts, in several passes. Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.) 7. Remove the service bolt. c. Install the intake camshaft of the LH cylinder head. 1. Apply new engine oil to the thrust portion and journal of the camshaft. Page 2554 Electrical - SRS And HV Wiring Repairs Battery System, Hybrid Drive: Technical Service Bulletins Electrical - SRS And HV Wiring Repairs TITLE: SRS & HV WIRING REPAIRS SECTION: ELECTRICAL BULLETIN # 156 MODELS: ALL TOYOTA LEXUS and SCION MODELS DATE: AUGUST 2007 There are no approved repairs to Supplemental Restraint System (SRS) or High Voltage (HV) wiring or connectors. SRS system wiring and connectors are color coded yellow and HV wiring is orange however vehicle-specific wiring diagrams are the best source for identifying wiring in these circuits. Wiring diagrams are available through the Technical Information System (TIS) www.techinfo.toyota.com. If SRS or HV wiring or connectors are suspected of damage they should be inspected thoroughly. Damaged wiring and/or connectors require replacement of the affected harness. Follow all precautions and procedures outlined in model-specific repair manuals for replacing SRS wiring or components. Only Certified Hybrid Service Technicians are qualified to replace HV system wiring and components. Page 184 Steps 1 - 2 Page 3732 D. Verify the male pin of the tongue plate stopper has deformed evenly in the hole of the female part and is firmly held to the belt webbing. Page 616 c) Install a new adjusting shim. 1) Place a new adjusting shim on the valve lifter, with imprinted numbers facing down. 2) Using SST (A), press down the valve lifter and remove SST (B). SST 09248-55040 (09248-05410, 09248-05420) d) Recheck the valve clearance. 6. REINSTALL CYLINDER HEAD COVERS 7. REINSTALL INTAKE AIR CONNECTOR Page 3777 Technical Service Bulletin # BO002-00 Date: 000121 Introduction Bulletin Number: BO002-00 Date: January21, 2000 Title: SEAT BELT EXTENDER Models: '98 - '00 Model Year INTRODUCTION: Toyota customers who find it necessary to increase the length of their seat belts may obtain Seat Belt Extenders at no cost through their local Toyota dealer. ^ The extender is available in 6 inch, 9 inch, 12 inch, 15 inch and 18 inch lengths. ^ The extender is available only in black. ^ Owners are informed of the Seat Belt Extender availability through the Toyota Owner's Manual included in each vehicle. The customer (individual requiring the extender) must visit a Toyota dealership to have the required measurements made and to complete the Seat Belt Extender worksheet. The worksheet will allow the proper fitting and selection of a Seat Belt Extender for the customer. The dealership personnel should then determine the applicable part number and place a Critical Order through the TDN Parts Network. The dealership service department should complete the affixed Seat Belt Extender Customer Information Label and review the "Owner Instruction Sheet" with the customer. The dealership should give a copy of the completed Worksheet to the customer and keep the original in the customer's file. To assure utmost owner satisfaction, it is recommended that a dealership designate one person to coordinate all activities related to the Seat Belt Extender issue. From past sales history, it is recommended that dealerships do not stock Seat Belt Extenders due to low demand and the need for customer fitting. This bulletin contains the following information: Procedure and Sample Label Application Charts Part Number Information Owner Instructions Seat Belt Extender Worksheet Affected Vehicles: All Toyota models, 1998 through 2000 model years. Warranty Information Removal and Installation Generator: Service and Repair Removal and Installation COMPONENTS REMOVAL 1. REMOVE GENERATOR DRIVE BELT a. Loosen the adjusting lock nut and pivot bolt. b. Loosen the adjusting bolt, and remove the drive belt. 2. REMOVE GENERATOR a. Disconnect the generator connector. b. Remove the nut, and disconnect the generator wire. c. Remove the pivot bolt and adjusting lock nut. d. Remove the generator. Torque: 51 Nm (520 kg.cm, 38 ft.lb) for pivot bolt 18.5 Nm (189 kg.cm, 25 ft.lb) for adjusting lock nut INSTALLATION Installation is in the reverse order of removal. Page 1727 Page 4903 e. Check that the current increases to approximately 14.5 A or more when the window stops going down. HINT: The circuit breaker opens for some 4 - 40 seconds after the window stops going down, so that the check must be done before the circuit breaker operates. If operation is as specified, replace the master switch. Page 4104 Difficulties during Remote Keyless Entry Transmitter Programming can arise due to confusion between Toyota Factory Wireless systems and Toyota Port/Dealer installed systems. This bulletin will assist in identifying the system/correct remote transmitters for each vehicle, and provide the location of the most accurate programming procedure for each system. Applicable Vehicles ^ All applicable Toyota vehicles. Warranty Information System Identification Page 527 Passenger's Switch (Window Unlock) Passenger's Switch (Window Unlock) Passenger's Switch (Window Lock) Passenger's Switch (Window lock) If continuity is not as specified, replace the switch. INSPECT POWER WINDOW SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 2196 Check that the engine can be started with the shift lever only in the N or P position, but not in other positions. If it is not as stated above, carry out the following adjustment procedure. 1. Loosen the park/neutral position switch bolt and set the shift lever to the N position. 2. Align the groove and neutral basic line. 1. Hold the switch in position and tighten the bolt. Torque: 13 Nm (130 kg.cm, 10 ft.lb) For continuity inspection of the park/neutral position switch. i. Check the idle speed. Connect OBD II scan tool or TOYOTA hand-held tester to the DLC 3 and inspect the idle speed. idle speed (in N position and air conditioner OFF): 3RZ-FE: 700 ± 50 rpm 5VZ-FE: 700 ± 50 rpm ABS/TCS - Zero Point Calibration Information Steering Angle Sensor: Technical Service Bulletins ABS/TCS - Zero Point Calibration Information T-SB-0020-08 March 25, 2008 Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment Service Category Brake Section Brake Control/Dynamic Control System Market USA Applicability Introduction The purpose of this TSB is to provide information on when and how to perform the zero point calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting the battery is a necessary step for performing the zero point calibration. Warranty Information Required Tools & Equipment ^ Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE). ^ The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the service procedures listed in this bulletin. Preliminary Information Perform this procedure if any of these repairs have been performed on the vehicle: ^ Wheel alignment has been adjusted. ^ Any chassis components have been removed/installed or replaced. Page 4582 Seat Belt Reminder Lamp: Ground Locations Page 3248 Part 2 Of 3 Page 1494 3. Start the engine and warm it up to normal operating temperatures before test-driving. 4. Perform a thorough test drive with several accelerations from a stop with "light throttle" application until proper transmission shifting is verified. Reset Procedure 2 1. Disconnect the negative battery cable for 5 minutes. 2. Reconnect battery cable. 3. Start the engine and warm it up to normal operating temperatures before test-driving. 4. Perform a thorough test drive with several accelerations from a stop with "light throttle" application until proper transmission shifting is verified. Page 3169 Power Steering Fluid: Testing and Inspection INSPECTION 1. CHECK FLUID LEVEL a. Keep the vehicle level. b. With the engine stopped, check the fluid level in the oil reservoir. If necessary, add fluid. Fluid: ATF DEXRON II or III HINT: Check that the fluid level is within the HOT LEVEL range on the reservoir cap dipstick. If the fluid is cold, check that it is within the COLD LEVEL range. c. Start the engine and run it at idle. d. Turn the steering wheel from lock to lock several times to boost fluid temperature. Fluid temperature: 80°C (176°F) e. Check for foaming or emulsification. If there is foaming or emulsification, bleed power steering system. f. With the engine idling, measure the fluid level in the oil reservoir. g. Stop the engine. h. Wait a few minutes and remeasure the fluid level in the oil reservoir. Maximum fluid level rise: 5 mm (0.20 inch) If a problem is found, bleed power steering system. i. Check the fluid level. 2. CHECK STEERING FLUID PRESSURE a. 5VZ-FE Engine: Loosen the 3 bolts and air cleaner assembly. b. Disconnect the pressure feed tube from the PS vane pump. Page 1289 Page 3594 REPLACE REQUIREMENTS In the following cases, replace the seat belt pretensioner. - If the seat belt pretensioner has been activated. - If the seat belt pretensioner has been found to be faulty in troubleshooting. - If the front seat outer belt has been found to be faulty during checking item functioning of SST. - If the front seat outer belt has been dropped. CAUTION: Be sure to follow the correct procedure, for removal and installation of the seat belt pretensioner. Page 2740 the pedal. If correct, check the stop light switch clearance. If the clearance is OK, then troubleshoot the brake system. Stop light switch clearance: 0.5 - 2.4 mm (0.020 - 0.094 inch) 4. CHECK PEDAL RESERVE DISTANCE Release the parking brake. With the engine running, depress the pedal and measure the pedal reserve distance, as shown. Pedal reserve distance, 'a', at 490 N (50 kgf, 110.2 lbs): More than 72 mm (2.83 inch) If incorrect, troubleshoot the brake system. Page 4711 Stop Light: Fuse and Fusible Link Locations Junction Box / No. 3 Page 1662 Mass Air Flow Meter: Testing and Inspection INSPECTION 1. INSPECT MAF METER RESISTANCE Using an ohmmeter, measure the resistance between terminals THA and E2. If the resistance is not as specified, replace the MAF meter. Temperature Resistance at -20 °C (-4 °F) 13.6 - 18.4 Kohms at -20 °C (68 °F) 2.2 - 2.7 Kohms at -60 °C (140 °F) 0.5 - 0.7 Kohms 2. INSPECT MAF METER OPERATION a. Connect the MAF meter connector. b. Using a voltmeter, connect the positive (+) tester probe to terminal VG, and negative (-) tester probe to terminal E2G. c. Turn the ignition switch ON. d. Blow air into the MAF meter, and check that the voltage fluctuates. If operation is not as specified, replace the MAF meter. e. Turn the ignition switch OFF. f. Disconnect the MAF meter connector. Testing and Inspection Speedometer Head: Testing and Inspection INSPECT SPEEDOMETER ON-VEHICLE Using a speedometer tester, inspect the speedometer for allowable indication error and check the operation of the odometer. HINT: Tire wear and tire over or under inflation will increase the indication error. If error is excessive, replace the speedometer. Diagrams Page 3107 Engine Compartment Instrument Panel Locations Specifications Idle Speed: Specifications Idle Speed 700 +/- 50 rpm A/T, M/T - Alignment Pin Service Precaution Manual Transmission/Transaxle: Technical Service Bulletins A/T, M/T - Alignment Pin Service Precaution T-SB-0053-08 May 8, 2008 Alignment Pin Installation during Transmission/Transaxle Assembly Installation Service Category Drivetrain Section Automatic Transmission/Transaxle Market USA Applicability Introduction The purpose of this TSB is to provide information regarding the installation of alignment pins during transmission/transaxle assembly installation. Missing alignment pins may result in incorrect alignment and failure of the transmission/transaxle assembly. Use the information below when installing a transmission/transaxle assembly. Parts Information Warranty Information Repair Procedure 1. Inspect the rear side of the engine block assembly for 2 alignment pins. ^ If there are less than 2 alignment pins present one may have been removed with the transmission/transaxle assembly. Check the removed assembly for the missing alignment pins. Go to step 2. Page 751 Engine Compartment Instrument Panel Locations Testing and Inspection Igniter: Testing and Inspection ON-VEHICLE INSPECTION NOTE: "Cold" and "Hot" in these sentences express the temperature of the coils themselves. "Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F). INSPECT IGNITOR AND SPARK TEST Check that the spark occurs. 1. Disconnect high-tension cords from spark plug. 2. Remove the spark plug. 3. Install the spark plug to each high-tension cord. 4. Ground the spark plug. 5. Check if spark occurs while engine is being cranked. NOTE: To prevent excess fuel being injected from the injectors during this test, do not crank the engine for more 5 - 10 seconds at a time. If the spark does not occur, do the test as per the flow chart. 6. Using a 16 mm plug wrench, install the spark plugs. Torque: 18 N.m (195 kgf.cm, 15 ft.lbf) 7. Reinstall the ignition coil with ignitor. Page 3276 NOTICE: Make sure to install the oil seal facing the correct direction. d. Coat a new bearing with molybdenum disulfide lithium base grease. e. Using SST, press in the bearing. SST 09950-60010 (09951-00330), 09950-70010 (09951-07150) 3. IF NECESSARY, REPLACE OIL SEAL a. Using SST, press out the oil seal from the bearing guide nut. SST 09950-60010 (09951-00320), 09950-70010 (09951-07100) b. Coat a new oil seal lip with power steering fluid. c. Using SST, press in the oil seal. SST 09950-60010 (09951-00280, 09951-00360, 09952-06010), 09950-70010 (09951-07100) NOTICE: Make sure to install the oil seal facing the correct direction. 4. INSPECT BEARING a. Check the needle roller bearing of the rack housing for pitmarks or damage. If faulty, replace the rack housing. b. Coat the inside of the bearing with molybdenum disulfide lithium base grease. Page 2106 Harness Locations Page 1500 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source How to Read Power Source Page 3005 Page 3185 1. MEASURE PS VANE PUMP ROTATING TORQUE a. Check that the pump rotates smoothly without abnormal noise. b. Using a torque wrench, check the pump rotating torque. Rotating torque: 0.27 Nm (2.8 kgf-cm, 2.4 inch lbs.) or less 2. REMOVE VANE PUMP PULLEY Using SST to stop the pulley rotating, remove the pulley set nut. SST 09960-10010 (09962-01000, 09963-01000) 3. REMOVE OIL RESERVOIR a. Remove the 3 bolts and oil reservoir. b. Remove the O-ring from the oil reservoir. 4. REMOVE PRESSURE PORT UNION, FLOW CONTROL VALVE AND SPRING Remove the O-ring from the union. 5. REMOVE BRACKET Remove the 2 bolts. 6. REMOVE REAR HOUSING a. Remove the 2 bolts. b. Remove the 2 O-rings from the housing. 7. REMOVE WAVE WASHER 8. REMOVE SIDE PLATE 9. REMOVE GASKET 10. REMOVE CAM RING, VANE PLATES AND VANE PUMP ROTOR a. Remove the 10 plates. NOTICE: Take care not to drop the plate. b. Using a screwdriver, remove the snap ring from the vane pump shaft. 11. REMOVE VANE PUMP SHAFT 12. REMOVE STRAIGHT PINS Remove the 2 pins from the front housing. INSPECTION NOTICE: When using a vise, do not overtighten it. Page 623 Part 2 Of 2 REMOVAL 1. REMOVE ENGINE UNDER COVER 2. DRAIN ENGINE COOLANT 3. DISCONNECT UPPER RADIATOR HOSE Testing and Inspection Air Conditioning Switch: Testing and Inspection INSPECTION 1. INSPECT A/C INDICATOR OPERATION a. Connect the positive (+) lead from the battery to terminal 6 and the negative (-) lead to terminal 4. b. Push the A/C button in and then check that the indicator lights up. If operation is not as specified, replace the switch. 2. INSPECT DIMMING OPERATION a. Connect positive (+) lead from the battery to terminal 6 and negative (-) lead to terminal 4 and 1. b. Connect the positive (+) lead from the battery to terminal 3 and then check that the indicator dims. If operation is not as specified, replace the switch. 3. INSPECT A/C SWITCH CONTINUITY If operation is not as specified, replace the switch or test the bulb. Page 2564 WIRING DIAGRAM Step 1 Page 253 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 3583 - Use gloves and safety glasses when handling a steering wheel pad with the deployed airbag. - Always wash your hands with water after completing the operation. - Do not apply water; etc. to a steering wheel pad with the deployed airbag. 1. AIRBAG DEPLOYMENT WHEN SCRAPPING VEHICLE HINT: Have a battery ready as the power source to deploy the airbag. (a) Check the functioning of the SST. CAUTION: When deploying the airbag, always use the specified SST: SRS Airbag Deployment Tool. SST 09082-00700 (1) Connect the SST to the battery. Connect the red clip of the SST to the battery positive (+) terminal and the black clip to the battery negative (-) terminal. HINT: Do not connect the yellow connector which will be connected with the supplemental restraint system. Page 875 c) Install a new adjusting shim. 1) Place a new adjusting shim on the valve lifter, with imprinted numbers facing down. 2) Using SST (A), press down the valve lifter and remove SST (B). SST 09248-55040 (09248-05410, 09248-05420) d) Recheck the valve clearance. 6. REINSTALL CYLINDER HEAD COVERS 7. REINSTALL INTAKE AIR CONNECTOR Page 4589 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Page 2458 a. Position SST on the backing plate with the 4 nuts. SST 09521-25011 b. Using a press, remove the rear axle shaft and bearing retainer from the backing plate. c. Remove the SST. 4. INSPECT AXLE SHAFT Using a dial indicator, measure the runout of the shaft and flange. Maximum shaft runout: 2.0 mm (0.079 inch) Maximum flange runout: 0.1 mm (0.004 inch) If the rear axle shaft or flange are damaged or worn, or if runout is greater than the maximum, replace the rear axle shaft. 5. REMOVE OUTER OIL SEAL Using SST, remove the oil seal. SST 09308-00010 6. REPLACE REAR AXLE BEARING Page 2721 Wheel Speed Sensor: Description and Operation Speed Sensor The speed sensor detects wheel speed and sends the appropriate signals to the ECU. These signals are used to control the ABS system. Each of the front and rear rotors has 48 serrations. When the rotors rotate, a magnetic field emitted by a permanent magnet in the speed sensor generates an AC voltage. Since the frequency of this AC voltage changes in direct proportion to the speed of the rotor, the frequency is used by the ECU to detect the speed of each wheel. Page 528 Using an ammeter: INSPECT ONE TOUCH POWER WINDOW SYSTEM a. Disconnect the connector of the master switch. b. Connect the positive (+) lead from the ammeter to terminal 4 on the wire harness side connector and the negative (-) lead to negative terminal of the battery. c. Connect the positive (+) lead from the battery to terminal 9 on the wire harness side connector. d. As the window goes down, check that the current increases to approximately 7.0 A. e. Check that the current increases to approximately 14.5 A or more when the window stops going down. HINT: The circuit breaker opens for some 4 - 40 seconds after the window stops going down, so that the check must be done before the circuit breaker operates. If the operation is as specified, replace the master switch. Using an ammeter with a current - measuring probe: INSPECT ONE TOUCH POWER WINDOW SYSTEM a. Remove the master switch with the connector connected. b. Attach a current-measuring probe to terminal 3 of the wire harness. c. Turn the ignition switch ON and set the power window switch in the down position. d. As the window goes down, check that the current increases to approximately 7.0 A. Page 3874 - If the sensor has been dropped, or there are cracks, dents or other defects in the case, brackets or connector, replace the removed sensor with new one. - The front sensor is equipped with an electrical connection check mechanism. Be sure to lock this mechanism securely when connecting the connector. If the connector is not securely locked, a malfunction code will be detected by the diagnostic system. b. Connect the front airbag sensor connectors. 2. INSTALL BATTERY a. Install the battery carrier and battery. b. Install the battery clamp with the bolt. Page 4539 Overdrive Indicator Lamp: Testing and Inspection O/D Main Switch & O/D OFF Indicator Light Circuit CIRCUIT DESCRIPTION The O/D main switch is a momentary type switch. When pressing the O/D OFF main switch, the O/D OFF indicator light lights up and ECM prohibit shifting to O/D, and when pressing it again, the O/D OFF indicator light goes off and ECM allows shifting to O/D. Turning the IG switch OFF will reset the O/D OFF indicator light. Page 3100 Engine Room Fuse Details Interior J/B # 1 Page 303 5. REMOVE ECT SENSOR a. Disconnect the ECT sensor connector. b. Using a 19 mm dean socket wrench, remove the ECT sensor and gasket. 6. INSPECT ECT SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: Refer to the graph If the resistance is not as specified, replace the ECT sensor. 7. REINSTALL ECT SENSOR a. Install a new gasket to the ECT sensor. b. Using a 19 mm deep socket, install the ECT sensor. Torque: 20 Nm (200 kg.cm, 14 ft.lb) c. Connect the ECT sensor connector. 8. REINSTALL FUEL PIPE Install the fuel pipe with 4 new gaskets and the 2 union bolts. Torque: 34.3 Nm (350 kg. cm, 25 ft.lb) 9. REINSTALL NO.2 TIMING BELT COVER 10. RECONNECT UPPER RADIATOR HOSE TO WATER OUTLET 11. REFILL WITH ENGINE COOLANT Page 3254 Part 1 Of 2 Page 250 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Locations Knock Sensor: Locations ABS/TCS - Zero Point Calibration Information Yaw Rate Sensor: Technical Service Bulletins ABS/TCS - Zero Point Calibration Information T-SB-0020-08 March 25, 2008 Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment Service Category Brake Section Brake Control/Dynamic Control System Market USA Applicability Introduction The purpose of this TSB is to provide information on when and how to perform the zero point calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting the battery is a necessary step for performing the zero point calibration. Warranty Information Required Tools & Equipment ^ Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE). ^ The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the service procedures listed in this bulletin. Preliminary Information Perform this procedure if any of these repairs have been performed on the vehicle: ^ Wheel alignment has been adjusted. ^ Any chassis components have been removed/installed or replaced. Page 352 CHART 15 Description and Operation Mass Air Flow Meter: Description and Operation Mass Air Flow Meter The mass air flow meter uses a platinum hot wire. The hot wire air flow meter consists of a platinum hot wire, thermistor and a control circuit installed in a plastic housing. The hot wire air flow meter works on the principle that the hot wire and thermistor located in the intake air bypass of the housing detect any changes in the intake air temperature. The hot wire is maintained at the set temperature by controlling the current flow through the hot wire. This current flow is then measured as the output voltage of the mass air flow meter. The circuit is constructed so that the platinum hot wire and thermistor provide a bridge circuit, with the power transistor controlled so that the potential of A and B remains equal to maintain the set temperature. Engine/Transmission Controls - Resetting ECM Memory Engine Control Module: Technical Service Bulletins Engine/Transmission Controls - Resetting ECM Memory TRANSMISSION & CLUTCH TC002-03 REVISED Title: ECM RESET MEMORY FUNCTION Models: '00 - '05 All Models June 10, 2003 TSB REVISION NOTICE: ^ December 20, 2004: Applicable Vehicles section has been updated - 2004 and 2005 model years added, models and model years updated for various models; and Reset Procedure 2 has been revised. ^ January 16, 2004: Tundra vehicles were added to the Applicable Vehicles chart. ^ December 17, 2003: T-100 vehicles were removed from the Applicable Vehicles chart. Previous versions of this TSB should be discarded. Introduction Whenever an automatic transmission is replaced, overhauled or individual components are replaced, use this procedure to clear Engine Control Module (ECM, SAE term: Powertrain Control Module, PCM) "Learned Values" to minimize subsequent performance concerns. CAUTION: Failure to follow the procedure below may lengthen the time to readjust the ECM "Learned Values," potentially resulting in performance concerns. Required SSTs Warranty Information Applicable Vehicles Locations Relay Box: Locations Relay Box / No. 2 Page 1052 a) Remove the 4 nuts and fan from the fluid coupling. b) Check that the fluid coupling is not damaged and that no silicon oil leaks. If necessary, replace the fluid coupling. c) Reinstall the fan to the fluid coupling with the 4 nuts. Torque: 7.4 Nm (75 kgf-cm, 65 inch lbs.) 3. INSPECT FAN PULLEY BRACKET Check the turning smoothness of the fan pulley. If necessary, replace the pulley bracket. 4. INSPECT TIMING BELT COMPONENTS INSTALLATION 1. INSTALL WATER PUMP a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the water pump and cylinder block. ^ Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove. ^ Thoroughly clean all components to remove all the loose material. ^ Using a non-residue solvent, clean both sealing surfaces. b) Apply seal packing to the water pump groove as shown in the illustration. Seal packing: Part No. 08826-00100 or equivalent ^ Install a nozzle that has been cut to a 2 - 3 mm (0.08 - 0.12 inch) opening. ^ Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied. ^ Immediately remove nozzle from the tube and reinstall cap. c) Install the water pump with the 7 bolts. Page 1820 c. Inspect the VSV operation. 1. Check that air does not flow from ports E to F. 2. Apply battery positive voltage across the terminals. 3. Check that air flows from ports E to F. If operation is not as specified, replace the VSV. 3. REINSTALL VSV Description and Operation Camshaft Position Sensor: Description and Operation The Camshaft Position Sensor Camshaft position sensor (G signal) consists of a magnet, iron core and pickup coil. The G signal plate has 1 tooth, on its outer circumference and is mounted on the RH camshaft timing pulley. When the camshafts rotate, the protrusion on the signal plate and the air gap on the pickup coil change, causing fluctuations in the magnetic field and generating an electromotive force in the pickup coil. The NE signal plate has 34 teeth and is mounted on the crankshaft timing pulley. The NE signal sensor generates 34 signals at every engine revolution. The ECM detects the standard crankshaft angle based on the G signal and the actual crankshaft angle and the engine speed by the NE signal. Page 509 Overdrive Switch: Testing and Inspection O/D Cancel Signal Circuit CIRCUIT DESCRIPTION While driving uphill with cruise control activated, in order to minimize gear shifting and provide smooth cruising O/D may be prohibited temporarily under some conditions. The cruise control ECU sends O/D cut signals to the ECM as necessary and the ECM cancels O/D shifting until these signals are discontinued. WIRING DIAGRAM Page 1750 Oxygen Sensor: Description and Operation Air / Fuel Sensor Air / Fuel Sensor To obtain a high purification rate for the CO, HC and NOx components of the exhaust gas, a three-way catalytic converter is used, but for the most efficient use of the three-way catalytic converter, the air-fuel ratio must be precisely controlled so that it is always close to the stoichiometric air-fuel ratio. The A/F sensor has the characteristic that provides output voltage* approximately proportional to the existing air-fuel ratio. The A/F sensor output voltage* is used to provide feedback for the ECM to control the air- fuel ratio. By the A/F sensor output, the ECM can determine the deviation amount from the stoichiometric air-fuel ratio and control the proper injection time immediately. If the A/F sensor is malfunctioning, ECM is unable to perform accurate air-fuel ratio control. The A/F sensor is equipped with a heater which heats the zirconia element. The heater is controlled by the ECM. When the intake air volume is low (the temp. of the exhaust gas is low), current flows to the heater to heat the sensor for accurate oxygen concentration detection. * The voltage value changes at the inside of the ECM only. Component Locations Audible Warning Device: Component Locations Page 3309 HINT: Have a battery ready as the power source to deploy the airbag. a. Remove the steering wheel pad. CAUTION: When storing the steering wheel pad, keep the upper surface of the pad facing upward. b. Using a service-purpose wire harness, tie down the steering wheel pad to the disc wheel. Wire harness: Stripped wire harness section 1.25 Sq.mm or more (0.0019 Sq.in.. or more) CAUTION: If a wire harness which is too thin or some other thing is used to tie down the steering wheel pad, it may be snapped by the shock when the airbag is deployed. This is highly dangerous. Always use a wire harness for vehicle use which is at least 1.25 Sq.mm (0.0019 Sq.in). HINT: To calculate the square of the stripped wire harness section: Square = 3.14 x (Diameter)2 divided by 4 1. Install the 2 bolts with washers in the 2 bolt holes in the steering wheel pad. Bolt: L: 35.0 mm (1.387 in.) M: 6.0 mm (0.236 in.) Pitch: 1.0 mm (0.039 in.) NOTE: Tighten the bolts by hand until the bolts become difficult to turn. - Do not tighten the bolts too much. Page 720 j. With the engine idling and valve fully opened, turn the steering wheel to full lock. Minimum fluid pressure: 8,336 kPa (85 kgf/cm2, 1209 psi) NOTICE: ^ Do not maintain lock position for more than 10 seconds. ^ Do not let the fluid temperature become too high. k. Disconnect the SST l. Connect the pressure feed tube. m. 5VZ-FE Engine: Install the air cleaner and 3 bolts. n. Bleed the power steering system. Page 3628 Clockspring Assembly / Spiral Cable: Description and Operation Spiral Cable (in Combination Switch) A spiral cable is used as an electrical joint from the vehicle body side to the steering wheel. Page 1715 CHART 2 CHART 3 CHART 4 Page 2963 Locations Page 2637 Page 2270 Step 1 Step 2 Page 3843 - Check for cuts minute cracks in wire harness or marked discoloration on the front seat outer belt. CAUTION: For removal and installation of the front seat outer belt, Be sure to follow the correct procedure. 2. PRETENSIONER IS ACTIVATED a. Perform a diagnostic system check. b. Perform a visual check which includes the following items with the front seat outer belt removed from the vehicle. - Check for deformation of the quarter panel. - Check for damage on the connector and wire harness. Page 1179 Engine Control Module: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Page 2357 WIRING DIAGRAM Step 1 Page 2956 Step 4 INSPECTION PROCEDURE Page 1590 CHART 21 Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Key to Diagrams Key to Diagrams A: System Title. B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: (1) Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. Locations Vehicle Lifting: Locations Page 409 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Testing and Inspection Daytime Running Lamp Resistor: Testing and Inspection INSPECT DAYTIME RESISTOR RESISTANCE CONTINUITY If continuity is not as specified, replace the resistor. Page 4570 Seat Belt Reminder Buzzer: Description and Operation Current always flows to TERMINAL 12 of the integration relay through the DOME fuse. 1. SEAT BELT WARNING SYSTEM When the ignition SW is turned ON, current flows from the GAUGE fuse to TERMINAL 6 of the integration relay. At the same time, current flows to TERMINAL A 2 of the relay from the GAUGE fuse through the seat belt warning light. This current activates the integration relay and, for approx. 4-8 seconds, the current flowing through the warning light flows from TERMINAL A 2 of the relay to TERMINAL A 7 to GROUND, causing the warning light to light up. At the same time as the warning light lights up, a buckle SW ON signal is input to TERMINAL A 3 of the integration relay, the current flowing from TERMINAL 12 of the integration relay flows to TERMINAL A 7 to GROUND and the seat belt warning buzzer sounds for approx. 4 - 8 seconds. However, if the seat belt is put ON (Buckle SW OFF) during this period (while the buzzer is sounding), a signal input to TERMINAL A 3 of the integration relay stops and the current flowing from TERMINAL 12 of the integration relay to TERMINAL A 7 to GROUND is cut, causing the buzzer to stop. 2. KEY REMINDER SYSTEM With the ignition key inserted in the key cylinder (Unlock warning SW ON), the ignition SW still oft and front LH door open (Door courtesy SW ON), a signal is input to TERMINAL A 10, A 5 of the integration relay, the integration relay operates and current flows from TERMINAL 6 of the relay to TERMINAL A 7 to GROUND and the key reminder buzzer sounds. Page 3381 HINT: PreRunner is the model described below. RZN191L-TRPDKAB, RZNI96L-CRPDKAB, VZN195L-CRPDKAB REMOVE SUSPENSION SUPPORT AND COIL SPRING a. Using SST, compress the coil spring until there is a clearance on both ends. Testing and Inspection Oil Pressure Sender: Testing and Inspection INSPECT LOW OIL PRESSURE SWITCH a. Disconnect the connector from the switch. b. Check that continuity exists between terminal and ground with the engine stopped. c. Check that no continuity exists between terminal and ground with the engine running. HINT: Oil pressure should be over 49 kPa (0.5 kg/sq.cm, 7.1 psi). If operation is not as specified, replace the switch. Page 2020 Ignition Coil: Service and Repair COMPONENTS REPLACEMENT 1. REMOVE AIR CLEANER HOSE 2. DISCONNECT HIGH-TENSION CORDS FROM IGNITION COILS 3. REMOVE IGNITION COILS a. Disconnect the connector from the ignition coil. b. Remove the bolt and ignition coil from the LH cylinder head. Page 3351 Control Arm: Service and Repair Upper REMOVAL HINT: PreRunner is the model described below. RZN191L-TRPDKAB, RZN196L-CRPDKAB, VZN195L-CRPDKAB 1. REMOVE SHOCK ABSORBER WITH COIL SPRING 2. w/ ABS: DISCONNECT ABS SPEED SENSOR WIRE HARNESS CLAMP Remove the 2 bolts and ABS speed sensor wire harness clamps from the steering knuckle and upper suspension arm. Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.) Replacement Requirements Airbag Sensor Assembly: Service and Repair Replacement Requirements REPLACEMENT REQUIREMENTS In the following cases, replace the airbag sensor assembly. - If the SRS has been deployed in a collision. - If the airbag sensor assembly has been found to be faulty in troubleshooting. - If the airbag sensor assembly has been dropped. CAUTION: For removal and installation of the airbag sensor assembly. Be sure to follow the correct procedure. Page 4774 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Page 2902 Clutch Switch: Testing and Inspection FORD Made Clutch Switch Circuit CIRCUIT DESCRIPTION When the clutch pedal is depressed, the clutch switch sends a signal to the cruise control ECU. When the signal is input to the cruise control ECU during cruise control driving, the cruise control ECU cancels cruise control. Wiring Diagram Page 4771 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 2235 Page 1249 COMPONENTS INSPECTION 1. DRAIN ENGINE COOLANT 2. REMOVE AIR CLEANER HOSE 3. REMOVE NO.2 TIMING BELT COVER 4. REMOVE INTAKE AIR CONNECTOR ASSEMBLY 5. REMOVE FUEL PRESSURE REGULATOR 6. REMOVE INTAKE MANIFOLD ASSEMBLY Page 2310 Overdrive Switch: Testing and Inspection O/D Cancel Signal Circuit CIRCUIT DESCRIPTION While driving uphill with cruise control activated, in order to minimize gear shifting and provide smooth cruising O/D may be prohibited temporarily under some conditions. The cruise control ECU sends O/D cut signals to the ECM as necessary and the ECM cancels O/D shifting until these signals are discontinued. WIRING DIAGRAM Page 663 Hose/Line HVAC: Testing and Inspection 1. INSPECTION HOSE AND TUBE CONNECTIONS FOR LOOSENESS 2. INSPECT HOSES AND TUBES FOR LEAKAGE Using a gas leak detector, check for leakage of refrigerant. Page 2540 Page 2434 Page 1593 CHART 23 Page 1330 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Page 3797 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 3485 5. REMOVE CONDENSER a. Remove the liquid tube clamping bolt. b. Remove the 2 condenser mounting bolts and pull out the condenser. HINT: At the time of installation, please refer to the following item. If condenser is replaced, add compressor oil to the condenser. ADD 40 - 50 cc (1.4 - 1.7 fl.oz.) Compressor oil: ND-OIL 8 or equivalent INSTALLATION Installation is in the reverse order of removal. Page 1085 b) Remove the 1 screw, 11 clips and radiator grille. 4. DISCONNECT UPPER RADIATOR HOSE 5. DISCONNECT RADIATOR RESERVOIR HOSE 6. DISCONNECT LOWER RADIATOR HOSE 7. REMOVE RADIATOR NO.2 FAN SHROUD 8. A/T: DISCONNECT OIL COOLER HOSES 9. REMOVE RADIATOR Remove the 4 bolts and the radiator. Torque: 12 Nm (120 kgf-cm, 8.7 ft. lbs.) HINT: Insert the tabs of the radiator support through the radiator service holes. DISASSEMBLY 1. REMOVE NO.1 FAN SHROUD Remove the 4 bolts and No.1 fan shroud. 2. REMOVE RADIATOR SUPPORTS Using a torx wrench, remove the 4 torx screws and the 2 radiator supports. Torx wrench: T30 (Part No. 09042-00010 or locally manufactured tool) HINT: Lift up the floor carpet and loosen the screw. REASSEMBLY Reassembly is in the reverse order of disassembly. Testing and Inspection EFI Main Relay: Testing and Inspection 1. REMOVE EFI MAIN RELAY (Marking: EFI) 2. INSPECT EFI MAIN RELAY a. Inspect the relay continuity. 1. Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. 2. Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. b. Inspect the relay operation. 1. Apply battery positive voltage across terminals 1 and 2. 2. Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. 3. REINSTALL EFI MAIN RELAY Page 2879 Repair Procedure 1. Disconnect the cable from the negative (-) battery terminal for MORE THAN two (2) seconds. 2. Reconnect the cable to the negative (-) battery terminal. 3. Perform the applicable zero point calibration of the yaw rate sensor and/or the steering angle sensor. HINT Refer to the applicable TSB or Repair Manual for the zero point calibration procedure. 4. Re-initialize all applicable systems available on the vehicle (power window sunroof power lift door etc.). Page 4457 Steps 1 - 2 INSPECTION PROCEDURE Wheels/Tires - Spare Tire Carrier Operation Information Spare Tire Carrier: Technical Service Bulletins Wheels/Tires - Spare Tire Carrier Operation Information PRODUCT GENERAL INFORMATION PG005-03 REVISED Title: SPARE TIRE CARRIER OPERATION Models: '91 - '08 Land Cruiser, '96 - '08 4Runner & Tacoma, '98 - '08 Sienna, '00 - '08 Tundra, '01 '08 Sequoia August 19, 2003 TSB REVISION NOTICE: ^ October 4, 2007: 2007 - 2008 model years have been added to Applicable Vehicles. ^ September 27, 2005: 2005 - 2006 model years have been added to Applicable Vehicles. The previous TSB should be discarded. Introduction The spare tire carrier may become damaged if an impact wrench or any other type of power tool is used to raise or lower the spare tire. The Owner's Manual, as well as a label near the drive nut, warns against the usage of an impact wrench or other power tools. Applicable Vehicles ^ 1991 - 2008 model year Land Cruiser vehicles. ^ 1996 - 2008 model year 4Runner and Tacoma vehicles. ^ 1998 - 2008 model year Sienna vehicles. ^ 2000 - 2008 model year Tundra vehicles. ^ 2001 - 2008 model year Sequoia vehicles. Operation Procedure Refer to the vehicle's Owner's Manual for vehicle specific instructions. 1. Locate the drive nut for the spare tire carrier. Refer to the vehicle's Owner's Manual for specific location. 2. Using the hub nut box wrench from the vehicle's tire tools kit, lower the spare tire to the ground. 3. Remove the tire from the carrier. 4. Installation of the spare tire is the reverse of removal. Warranty Information Page 744 Air Bag(s) Arming and Disarming: Service and Repair Release Method of Airbag Activation Prevention Mechanism Paint - Codes & Code Label Locations Paint: All Technical Service Bulletins Paint - Codes & Code Label Locations Bulletin Number: PA001-00 Group: PAINT Date: January 28, 2000 Title: 2000 MODEL YEAR PAINT CODES Models: All '00 Models Introduction: Attached for your reference is a list of all 2000 model year OEM paint codes. NOTE: The body color code is on the vehicle Certification Regulation Label, located on the left front door "B" Pillar or door rear lower surface. Applicable Vehicles: All 2000 Models. Warranty Information Page 3396 HINT: PreRunner is the model described below. RZN191L-TRPDKAB, RZN196L-CRPDKAB, VZN195L-CRPDKAB 1. REMOVE FRONT WHEEL Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.) 2. REMOVE SHOCK ABSORBER A/T - Fluid Requirements Fluid - CVT: Technical Service Bulletins A/T - Fluid Requirements TRANSMISSION & CLUTCH TC001-02 May 24, 2002 Title: AUTOMATIC TRANSMISSION FLUID REQUIREMENTS Models: All '00 - '02 Models & '03 Corolla & Matrix Introduction Please refer to the table for correct application of Dexron(R) III (Dexron(R) II) and Toyota Type T-IV Automatic Transmission Fluids or equivalent. Parts Information Warranty Information Page 235 Junction Box / No. 1 Service and Repair Wheel Cylinder: Service and Repair For information regarding the service and repair of this component and the system that it is a part of, please refer to Drum Brake System; Service and Repair. Testing and Inspection Antenna Motor: Testing and Inspection Auto Antenna Models: INSPECT ANTENNA MOTOR a. Connect the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal 2. b. Check that the motor turns (The Antenna moves upward). NOTE: These tests must be done quickly (within 3-5 seconds) to prevent the coil from burning out. c. Then, reverse the polarity, check that the motor turns the opposite way (The Antenna moves downward). NOTE: These tests must be done quickly (within 3-5 seconds) to prevent the coil from burning out. Page 2479 3. w/ Freewheel hub: REMOVE LOCK NUT AND ABS SPEED SENSOR ROTOR/SPACER a. Using a chisel and hammer, loosen the staked part of the lock nut. NOTICE: Be careful not to damage the bushing. b. Using SST, remove the lock nut. SST 09318-12010 c. Remove the ABS speed sensor rotor/spacer. NOTICE: Take care not to scratch the serration of the speed sensor rotor. 4. REMOVE AXLE HUB FROM STEERING KNUCKLE a. Remove the 4 bolts and shift the dust cover towards the hub side (outside). b. Using SST, remove the axle hub from the steering knuckle. SST 09710-30021 (09710-03051), 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04031, 09957-04010, 09958-04011) c. Remove the dust cover from the steering knuckle. d. w/o Free wheel hub (4WD only): Remove the bearing spacer and ABS speed sensor rotor/ spacer. 5. REMOVE OIL SEAL (OUTSIDE) Using a screwdriver, remove the oil seal (outside) from the steering knuckle. 6. REMOVE BEARING FROM STEERING KNUCKLE a. Using snap ring pliers, remove the snap ring. b. Using SST and a press, remove the bearing from the steering knuckle. SST 09950-60020 (09951-00810), 09950-70010 (09951-07150) REASSEMBLY Page 2550 Relay Box / No. 2 Ground Locations Page 2388 Valve Body: Service and Repair ON-VEHICLE REPAIR CAUTION: When working with FIPG material, you must observe the followings. Using a razor blade and a gasket scraper, remove all old FIPG material from the gasket surfaces. - Thoroughly clean all components to remove all loose material. - Clean both sealing surfaces with a non-residue sol vent. - Apply FIPG in an approximately 1 mm (0.04 inch) wide bead along the sealing surface. - Parts must be assembled within 10 minutes of application. Otherwise, the FIPG material must be removed and reapplied. 1. REMOVE DRAIN PLUG AND DRAIN ATF 2. REMOVE OIL PAN NOTICE: Some fluid will remain in the oil pan. a. Remove the 19 bolts. b. Install the blade of SST between the transmission case and oil pan, cut off applied sealer, and remove the oil pan. SST 09032-00100 NOTICE: When removing the oil pan, be careful not to damage the oil pan flange. 3. EXAMINE PARTICLES IN PAN Remove the magnets and use them to collect steel particles. Carefully look at 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) ........................................................................................................................ ................................................ bushing wear Description and Operation Air Bag Deactivation Switch: Description and Operation PASSENGER AIRBAG MANUAL ON-OFF SWITCH Passenger airbag manual on-off switch is mounted on the center cluster finish panel. By turning the passenger airbag manual on-off switch to OFF with the ignition key, the passenger airbag system can be disabled. Also, in order to notify the passenger that the passenger airbag is disabled, OFF indicator inside the switch will light up. Page 1418 f. Adjust the electrode gap. Carefully bend the outer electrode to obtain the correct electrode gap. Correct electrode gap: 1.1 mm (0.043 in.) g. Using a 16 mm plug wrench, reinstall the spark plugs. Torque: 18 Nm (180 kg.cm, 13 ft.lb) h. Reinstall the 3 ignition coils. i. Reconnect the 3 high-tension cords. Testing and Inspection Parking Brake Warning Switch: Testing and Inspection INSPECT PARKING BRAKE SWITCH CONTINUITY a. Check that continuity exists between terminals with the switch ON (switch pin released). b. Check that no continuity exists between terminals with the switch OFF (switch pin pushed in). If operation is not as specified, replace the switch. Page 3189 NOTICE: When using a vise, do not overtighten it. 1. COAT WITH POWER STEERING FLUID 2. INSTALL STRAIGHT PINS Using a plastic hammer, tap in 2 new pins to the front housing. NOTICE: Be careful not to damage the pins. 3. INSTALL VANE PUMP SHAFT 4. INSTALL CAM RING Install the ring with the inscribed mark facing outward. HINT: Align the holes of the cam ring with the straight pins. 5. INSTALL VANE PUMP ROTOR a. Install the rotor with the inscribed mark facing outward. b. Install a new snap ring to the vane pump shaft. 6. INSTALL VANE PLATES Install the 10 plates with the round end facing outward. 7. INSTALL GASKET Install a new gasket on the front housing. Page 2903 Steps 1 - 2 Page 1669 4. REINSTALL NO.2 TIMING BELT COVER Page 1284 CHART 18 CHART 19 Component Tests and General Diagnostics Key Reminder Switch: Component Tests and General Diagnostics Ignition Switch and Key Unlock Warning Switch INSPECTION 1. INSPECT IGNITION SWITCH CONTINUITY If continuity is not as specified, replace the switch. 2. INSPECT KEY UNLOCK WARNING SWITCH CONTINUITY If continuity is not as specified, replace the switch. 3. Key Unlock Warning System: INSPECT INTEGRATION RELAY OPERATION Page 4910 b. Apply soapy water to the contact surface of the body and the weatherstrip lip. c. Hold the glass in position on the body. d. install the glass by pulling the cord from the room side, while pushing weatherstrip from the outside with your open hand. e. To mark the glass fit in place, tap from the outside with your open hand. 2. INSPECT FOR LEAKS AND REPAIR a. Conduct a leak test after the hardening time has elapsed. b. Seal any leak with sealant. Part No. 08833-00030 or equivalent Page 718 Power Steering Fluid: Testing and Inspection INSPECTION 1. CHECK FLUID LEVEL a. Keep the vehicle level. b. With the engine stopped, check the fluid level in the oil reservoir. If necessary, add fluid. Fluid: ATF DEXRON II or III HINT: Check that the fluid level is within the HOT LEVEL range on the reservoir cap dipstick. If the fluid is cold, check that it is within the COLD LEVEL range. c. Start the engine and run it at idle. d. Turn the steering wheel from lock to lock several times to boost fluid temperature. Fluid temperature: 80°C (176°F) e. Check for foaming or emulsification. If there is foaming or emulsification, bleed power steering system. f. With the engine idling, measure the fluid level in the oil reservoir. g. Stop the engine. h. Wait a few minutes and remeasure the fluid level in the oil reservoir. Maximum fluid level rise: 5 mm (0.20 inch) If a problem is found, bleed power steering system. i. Check the fluid level. 2. CHECK STEERING FLUID PRESSURE a. 5VZ-FE Engine: Loosen the 3 bolts and air cleaner assembly. b. Disconnect the pressure feed tube from the PS vane pump. Page 3913 The table contains all of the necessary information to correctly identify the type of system installed, and where to go to get programming procedures for each vehicle. NOTE: Should a vehicle having both VIP and Factory systems available (as identified in the following table) be brought in without any remotes (or one non-working remote), use the following tips to help determine which type of wireless system (O.E. or PIO/PIO) the vehicle has. ^ Look at the Trim Level of the vehicle. Higher-grade vehicles will tend to have O.E. systems, while entry-grade vehicles will tend to have VIP For example, the 2001 Camry XLE has Factory RKE, but the LE and CE grades have VIP. ^ Look for a "Status Monitor" with a glass breakage sensor and an LED externally installed into the dashboard or on the center console. Most VIP systems will have this. ^ Locate the ECU (refer to the applicable vehicle VIP Manual installation instructions for location). Once located, refer to the part label. ^ Attempt to perform the factory wireless programming procedure to get a response from the vehicle. Select the "confirmation mode" and see if any "Lock/Unlock" response is received, if so, the vehicle has a factory system. Page 1735 Page 4317 Steps 1 - 3 Page 1806 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 3274 d. Remove the O-ring from the rack housing. 11. REMOVE CONTROL VALVE ASSEMBLY a. Using SST, loosen the bearing guide nut. SST 09631-20060 b. Wind vinyl tape to the control valve shaft. c. Using a plastic hammer, tap out the valve assembly with the nut from the control valve housing. NOTICE: Be careful not to damage the oil seal lip. d. Remove the nut from the valve assembly. NOTICE: Be careful not to damage the oil seal lip. e. Remove the O-ring from the nut. 12. REMOVE CYLINDER END STOPPER a. Using SST, remove the stopper. SST 09922-10010 NOTICE: Use SST 09922-10010 in the direction shown in the illustration. b. Remove the O-ring from the stopper. 13. REMOVE STEERING RACK AND OIL SEAL Testing and Inspection Parking Brake Warning Switch: Testing and Inspection INSPECT PARKING BRAKE SWITCH CONTINUITY a. Check that continuity exists between terminals with the switch ON (switch pin released). b. Check that no continuity exists between terminals with the switch OFF (switch pin pushed in). If operation is not as specified, replace the switch. Page 2549 Junction Box / No. 3 Fuse and Fusible Link Locations Check Steering Wheel Free Play and Effort Steering Wheel: Testing and Inspection Check Steering Wheel Free Play and Effort INSPECTION 1. CHECK STEERING WHEEL FREEPLAY With the vehicle stopped and tires facing straight ahead, rock the steering wheel gently back and forth with light finger pressure. Freeplay should not exceed the maximum. Maximum freeplay: 30 mm (1.18 inch) 2. CHECK STEERING EFFORT a. Center the steering wheel. b. Remove the steering wheel pad. c. Start the engine and run it at idle. d. Measure the steering effort in both directions. Reference: 4.9 Nm (50 kgf-cm, 43 inch lbs.) HINT: Be sure to consider the tire type, pressure and contact surface before making your diagnosis. e. Torque the steering wheel set nut. Torque: 35 Nm (360 kgf-cm, 26 ft. lbs.) f. Install the steering wheel pad. Testing and Inspection EFI Main Relay: Testing and Inspection 1. REMOVE EFI MAIN RELAY (Marking: EFI) 2. INSPECT EFI MAIN RELAY a. Inspect the relay continuity. 1. Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. 2. Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. b. Inspect the relay operation. 1. Apply battery positive voltage across terminals 1 and 2. 2. Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. 3. REINSTALL EFI MAIN RELAY Page 1550 7. REMOVE WATER BYPASS PIPE AND KNOCK SENSOR WIRE 8. REMOVE KNOCK SENSORS Using SST, remove the knock sensor. SST 09817-16011 9. INSPECT KNOCK SENSORS Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor. 10. REINSTALL KNOCK SENSORS Using SST, install the knock sensor. SST 09817-16011 Torque: 39 Nm (400 kg.cm, 29 ft.lb) 11. REINSTALL WATER BYPASS PIPE AND KNOCK SENSOR WIRE 12. REINSTALL INTAKE MANIFOLD ASSEMBLY 13. REINSTALL FUEL PRESSURE REGULATOR 14. REINSTALL INTAKE AIR CONNECTOR ASSEMBLY 15. REINSTALL NO.2 TIMING BELT COVER 16. REINSTALL AIR CLEANER HOSE 17. REFILL WITH ENGINE COOLANT Page 4514 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Specifications Axle Nut: Specifications Front Wheel Hub Lock Nut 235 Nm (174 ft.lb) Page 4818 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Page 1815 Catalytic Converter: Testing and Inspection 1. INSPECT EXHAUST PIPE ASSEMBLY a. Check the connections for looseness or damage. b. Check the clamps for weakness, cracks or damage. 2. INSPECT TWC Check for dents or damage. If any part of the protector is damaged or dented to the extent that it contacts the TWC, repair or replace it. 3. INSPECT TWC HEAT INSULATOR a. Check the heat insulator for damage. b. Check for adequate clearance between the TWC and heat insulator. Page 3258 7. REMOVE RACK GUIDE SPRING CAP, RACK GUIDE SPRING, RACK GUIDE AND RACK GUIDE SEAT a. Using SST, remove the cap. SST 09631-10021 b. Remove the seat from the guide. 8. REMOVE DUST COVER 9. REMOVE PINION BEARING ADJUSTING SCREW LOCK NUT Using SST, remove the nut. SST 09922-10010 NOTICE: Use SST 09922-10010 in the direction shown in the illustration. 10. REMOVE PINION BEARING ADJUSTING SCREW Using SST, remove the screw. SST 09922-10010 NOTICE: Use SST 09922-10010 in the direction shown in the illustration. 11. REMOVE STEERING PINION ASSEMBLY a. Fully pull the steering rack from the pinion housing side of the rack housing and align the cutout portion of the rack with the pinion assembly. b. Remove the pinion assembly from the rack housing. 12. REMOVE STEERING RACK Remove the rack from the rack housing without revolving it. Page 3362 Stabilizer Bar: Service and Repair REMOVAL HINT: PreRunner is the model described below. RZN191L-TRPDKAB, RZN196L-CRPDKAB VZN195L-CRPDKAB 1. REMOVE FRONT WHEELS Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.) 2. DISCONNECT STABILIZER BAR LINKS a. Remove the nut and disconnect the stabilizer bar link from the lower suspension arm. Torque: 69 Nm (700 kgf-cm, 51 ft. lbs.) HINT: If the ball joint stud turns together with the nut, use a hexagon wrench to hold the stud. b. Employ the same manner described above to the other side. Page 2213 Overdrive Indicator Lamp: Testing and Inspection O/D Main Switch & O/D OFF Indicator Light Circuit CIRCUIT DESCRIPTION The O/D main switch is a momentary type switch. When pressing the O/D OFF main switch, the O/D OFF indicator light lights up and ECM prohibit shifting to O/D, and when pressing it again, the O/D OFF indicator light goes off and ECM allows shifting to O/D. Turning the IG switch OFF will reset the O/D OFF indicator light. Heated Oxygen Sensor Oxygen Sensor: Description and Operation Heated Oxygen Sensor Heated Oxygen Sensor The ECM observes the waveform of the heated oxygen sensor located behind the catalyst to determine whether the catalyst performance has deteriorated. If the catalyst is functioning normally, the waveform of the heated oxygen sensor located behind the catalyst switches back and forth between rich and lean much more slowly. When the waveform of the heated oxygen sensor located behind the catalyst alternates flutteringly between rich and lean, it indicates that catalyst performance has deteriorated. Page 3748 D. Verify the male pin of the tongue plate stopper has deformed evenly in the hole of the female part and is firmly held to the belt webbing. Page 1643 Part 1 Of 2 (Except California Spec.) Diagram Information and Instructions Dome Lamp: Diagram Information and Instructions Key to Diagrams Key to Diagrams A: System Title. B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: (1) Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. Page 627 22. REMOVE LH CAMSHAFT TIMING PULLEY a) Using SST, loosen the pulley bolt. SST 09960-10010 (09962-01000, 09963-01000) b) Remove the bolt, knock pin and timing pulley. 23. REMOVE NO.2 IDLER PULLEY Remove the bolt and idler pulley. 24. REMOVE NO.1 IDLER PULLEY Using a 10 mm hexagon wrench, remove the pivot bolt, idler pulley and plate washer. 25. REMOVE CRANKSHAFT TIMING PULLEY Remove the timing pulley. HINT: If the pulley cannot be removed by hand, use SST and a service bolt to remove the timing pulley. SST 09950-50011 (09951-05010, 09952-05010, 09953-05020, 09954-05010) INSPECTION 1. INSPECT TIMING BELT NOTICE: Do not bend, twist or turn the timing belt inside out. - Do not allow the timing belt to come into contact with oil, water or steam. - Do not utilize timing belt tension when installing or removing the mount bolt of the camshaft timing pulley. Page 2424 Page 3269 Part 1 Of 3 Page 3029 Engine Room Fuse Details Interior J/B # 1 Page 1501 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Page 2332 Page 971 If there are any defects, as shown in the illustrations, check these points: 1) Premature parting Check for proper installation. Check the timing cover gasket for damage and proper installation. 2) If the belt teeth are cracked or damaged, check to see if either camshaft is locked. 3) If there is noticeable wear or cracks on the belt face, check to see if there are nicks on the side of the idler pulley lock and water pump. 4) If there is wear or damage on only one side of the belt, check the belt guide and the alignment of each pulley. 5) If there is noticeable wear on the belt teeth, check the timing cover for damage, correct gasket installation, and for foreign material on the pulley teeth. If necessary, replace the timing belt. 2. INSPECT IDLER PULLEYS a) Visually check the seal portion of the idler pulley for oil leakage. If leakage is found, replace the idler pulley. b) Check that the idler pulley turns smoothly. If necessary, replace the idler pulley. 3. INSPECT TIMING BELT TENSIONER a) Visually check the seal portion of the tensioner for oil leakage. HINT: If there is only the faintest trace of oil on the seal on the push rod side, the tensioner is all right. If leakage is found, replace the tensioner. Testing and Inspection EFI Main Relay: Testing and Inspection 1. REMOVE EFI MAIN RELAY (Marking: EFI) 2. INSPECT EFI MAIN RELAY a. Inspect the relay continuity. 1. Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. 2. Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. b. Inspect the relay operation. 1. Apply battery positive voltage across terminals 1 and 2. 2. Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. 3. REINSTALL EFI MAIN RELAY Component Locations Cigarette Lighter: Component Locations Page 646 Assenmacher Specialty Tools 1-800-525-2943 Page 2523 Step 1 Step 2 Testing and Inspection Backup Lamp Relay: Testing and Inspection INSPECT BACK-UP LIGHT RELAY CONTINUITY If continuity is not as specified, replace the relay. Page 4378 Junction Box / No. 1 Junction Box / No. 3 Page 2633 Page 1739 Page 2537 Junction Box / No. 3 Page 1265 2. Start the engine. 3. Perform the drive pattern to run and complete the Oxygen Sensor (O2S) Monitor. HINT: The 02S Monitor is completed when the following conditions are met: ^ Two (2) minutes or more passed after the engine start. ^ The Engine Coolant Temperature (ECT) is 167°F (75°C) or more. ^ Cumulative running time at 30 mph (48 km/h) or more exceeds 6 minutes. ^ Vehicle is in closed loop. ^ The fuel-cut is operated for 8 seconds or more (for Rear O2S Monitor). A. Allow the engine to idle for two minutes. B. Warm up the engine until the Engine Coolant Temperature (ECT) reaches 167°F (75°C). C. Drive the vehicle over 30 mph (48 km/h) for more than 40 seconds. D. Stop the vehicle and allow the engine to idle for more than 20 seconds. E. Repeat steps C and D at least 8 times in one driving cycle. (Do not cycle the ignition key.) In addition, perform the following steps for the Rear O2S Readiness Monitor: A. Select second gear. B. Allow the vehicle to run at 30 mph (48 km/h) or more. C. Keep the accelerator pedal "off-idle" for more than 10 seconds. D. Immediately after step C, release the accelerator pedal for at least 10 seconds without depressing the brake pedal (to execute the fuel-cut). E. Decelerate the vehicle until the vehicle speed reaches less than 6mph (10km/h). F. Repeat steps B - E at least twice in one driving cycle. Accessing O2S Test Results 1. On the Diagnostic Tester* screen, select the following menus: ^ DIAGNOSTICS ^ CARB OBD II Page 356 Page 1877 2. Turn the ignition switch ON and push TOYOTA hand-held tester main switch ON. NOTE: Do not start the engine. 3. Select the ACTIVE TEST mode on the TOYOTA hand-held tester. 4. Please refer to the TOYOTA hand-held tester operator's manual for further details. 5. If you have no TOYOTA hand-held tester, connect the positive (+) and negative (-) leads from the battery to the fuel pump connector. 6. Pinch the fuel return hose. The pressure in the high pressure line will rise to approx. 400 kPa (4 kg/Sq.cm, 57 psi). In this state, check to see that there are no leaks from any part of the fuel system. NOTE: Always pinch the hose. Avoid bending as it may cause the hose to crack. 7. Turn the ignition switch OFF. 8. Disconnect the TOYOTA hand-held tester from the DLC3. Page 3637 4. Move the SST at least 10 m (33 ft) away from the front of the vehicle. 5. Close all the doors and windows of the vehicle. NOTE: Take care not to damage the SST wire harness. 6. Connect the SST red clip to the battery positive (+) terminal and the black clip to the negative (-) terminal. c. Deploy the airbag. 1. Check that no one is inside the vehicle or within 10 m (33 ft) area around the vehicle. 2. Press the SST activation switch and deploy the airbag. CAUTION: The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment. - Use gloves and safety glasses when handling a steering wheel pad with the deployed airbag. - Always wash your hands with water after completing the operation. - Do not apply water, etc. to a steering wheel pad with the deployed airbag. - When scrapping a vehicle, deploy the airbag and scrap the vehicle with the steering wheel pad still installed. - When moving a vehicle for scrapping which has a steering wheel pad with deployed airbag, use gloves and safety glasses. HINT: The airbag deploys simultaneously as the LED of the SST activation switch lights up. Dispose of the steering wheel pad (with airbag). CAUTION: - The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment. - he deployed airbag, use gloves and safety glasses. - Use gloves and safety glasses when handling a steering wheel pad with deployed airbag. - Always wash your hands with water after completing the operation. - Do not apply water, etc. to a steering wheel pad with deployed airbag. 1. Remove the steering wheel pad from the steering wheel. 2. Place the steering wheel pad in a vinyl bag, tie the end tightly and dispose of it in the same way as other general parts disposal. Deployment When Disposing of Steering Wheel Pad Page 4727 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 72 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Page 3447 Wheel Fastener: Service and Repair Rear REPLACEMENT 1. REMOVE REAR WHEEL AND BRAKE DRUM 2. REMOVE REAR HUB BOLT Using SST and a brass bar or an equivalent, remove the hub bolt. SST 09650-17011 3. INSTALL HUB BOLT a. Install a washer and nut to a new hub bolt as shown in the illustration. b. Using a brass bar or an equivalent to hold, install the hub bolt by torquing the nut. 4. INSTALL BRAKE DRUM AND REAR WHEEL Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.) Page 2119 Step 2 Step 3 INSPECTION PROCEDURE Page 1630 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source How to Read Power Source Service Precautions Air Bag(s) Arming and Disarming: Service Precautions NOTE: TOYOTA trucks are equipped with SRS, which comprises a driver airbag and front passenger airbag. Failure to carry out service operations in the correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Further, if a mistake is made in servicing the SRS, it is possible that the SRS may fail to operate when required. Before performing servicing (including removal or installation of parts, inspection or replacement), be sure to read the following items carefully, then follow the correct procedures described in the repair manual. Malfunction symptoms of the SRS are difficult to confirm, so the DTCs become the most important source of information when troubleshooting. When troubleshooting the SRS, always inspect the DTCs before disconnecting the battery. Even in cases of a minor collision where the SRS does not deploy, the steering wheel pad, front passenger airbag assembly, airbag sensor assembly and front airbag sensor should be inspected. Never use SRS parts from another vehicle. When replacing parts, replace them with new parts. Never disassemble and repair the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor in order to reuse it. If the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor has been dropped, or if there are cracks, dents or other defects in the case, bracket or connector, replace them with new ones. Use a volt/ohmmeter with high impedance (10 K.Ohm/V minimum) for troubleshooting the system's electrical circuits. Information labels are attached to the periphery of the SRS components. Follow the instructions on the notes. After work on the SRS is completed, perform the SRS warning light check. If the vehicle is equipped with a mobile communication system, refer to the precaution in the Introduction system. CAUTION: Work must be started 90 seconds after the ignition switch is turned to the "LOCK" position and the negative (-) terminal cable is disconnected from the battery (The SRS is equipped with a back-up power source so that if work is started within 90 seconds from disconnecting the negative (-) terminal cable of the battery, the SRS may be deployed.). When the negative (-) terminal cable is disconnected from the battery, the memory of the clock and audio system will be canceled. So before starting work, make a record of the contents memorized in the audio memory system. When work is finished, reset the audio systems as they were before and adjust the clock. However, it is not possible to make a record of the memory contents. So when the work is finished, it will be necessary to explain this fact to the customer, and ask the customer to adjust the features and reset the memory. To avoid erasing the memory in each memory system, never use a back-up power supply from outside the vehicle. Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during repairs. Do not expose the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor directly to hot air or flames. Page 1368 Crankshaft Position Sensor: Service and Repair REPLACEMENT 1. REMOVE ENGINE UNDER COVER 2. REMOVE CRANKSHAFT POSITION SENSOR a. Disconnect the sensor connector. b. Remove the bolt and sensor. Torque: 7.8 Nm (80 kg.cm, 69 in.lb) 3. REINSTALL NEW CRANKSHAFT POSITION SENSOR a. Install the sensor with the bolt. b. Connect the sensor connector. 4. REINSTALL ENGINE UNDER COVER Page 1534 2. REMOVE IAC VALVE Remove the 4 screws, IAC valve and gasket. HINT: At the time of installation, please refer to the following items. Place a new gasket on the throttle body. INSTALLATION Installation is in the reverse order of removal. Page 4413 Junction Box / No. 3 Page 3081 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source How to Read Power Source Testing and Inspection Evaporator Temperature Sensor / Switch: Testing and Inspection Thermistor 1. REMOVE GLOVE COMPARTMENT DOOR 2. INSPECT THERMISTOR RESISTANCE a. Disconnect the connector b. Measure resistance between terminals 2 and 5. Standard resistance: 1,500 Ohms at 25 °C (77 °F) If resistance is not as specified, proceed next inspection. INSPECT THERMISTOR RESISTANCE a. Place the thermistor in cold water, and while changing the temperature of the water, measure resistance at the connector and at the same time, measure temperature of the water with a thermometer. b. Compare the 2 readings on the chart. If resistance value is not as specified, replace the thermistor. Testing and Inspection Receiver Dryer: Testing and Inspection INSPECT FITTINGS FOR LEAKAGE Using a gas leak detector, check for leakage. If there is leakage, check the tightening toque at the joints. ABS/TCS - Zero Point Calibration Information Steering Angle Sensor: Technical Service Bulletins ABS/TCS - Zero Point Calibration Information T-SB-0020-08 March 25, 2008 Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment Service Category Brake Section Brake Control/Dynamic Control System Market USA Applicability Introduction The purpose of this TSB is to provide information on when and how to perform the zero point calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting the battery is a necessary step for performing the zero point calibration. Warranty Information Required Tools & Equipment ^ Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE). ^ The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the service procedures listed in this bulletin. Preliminary Information Perform this procedure if any of these repairs have been performed on the vehicle: ^ Wheel alignment has been adjusted. ^ Any chassis components have been removed/installed or replaced. Antitheft - Automatic Door Lock Feature Programming Alarm Module: Technical Service Bulletins Antitheft - Automatic Door Lock Feature Programming BULLETIN NUMBER: AX005-00 DATE: April 14, 2000 TITLE: RS3OOO TVIP AUTOMATIC DOOR LOCK FEATURE PROGRAMMING MODELS: All Models Introduction As a convenience feature, the RS3OOO TVIP system is programmed to automatically lock all of the vehicle's doors (for vehicles equipped with power door locks) when the ignition key is turned to "ON" or "START", and unlock them when the key is turned back to "ACC" or "LOCK". The initial factory setting of this programmable feature is "ON". For some customers however, this feature is not desirable due to instances of passenger lockout when the driver enters the vehicle first and starts the ignition. For vehicles equipped with RS3OOO TVIP, this bulletin advises the dealers to communicate the following information to the customers at vehicle delivery: 1. Inform the customers of the RS3OOO system's automatic (ignition controlled) door lock/unlock feature. 2. Inquire about the customers' preference for it to be set "ON" or "OFF". 3. Reprogram the feature's setting according to the customer's preference. To change the feature's operation mode, follow the programming procedures. Verification of the Dealer-Installed Option (DIO) or Port-Installed Option (PIO) RS3OOO TVIP System can easily be performed by identifying the status monitor and remote transmitter. The remote transmitter has two buttons, Top and Bottom. The status monitor has a Toyota label, LED, and microphone. APPLICABLE VEHICLES All models equipped with DIO or PIO RS3000 TVIP Page 4721 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Page 4671 Relay Box / No. 2 Ground Locations Page 4422 Splice Locations Page 3940 Perform the procedure shown if there is any lamp malfunction. Description and Operation Evaporative Vapor Pressure Sensor: Description and Operation Evaporative Emissions System The vapor pressure sensor and VSV for vapor pressure sensor are used to detect abnormalities in the evaporative emission control system. The ECM decides whether there is an abnormality in the evaporative emission control system based on the vapor pressure sensor signal. Page 2229 Junction Box / No. 3 Page 4365 Steps 2 - 3 INSPECTION PROCEDURE Page 4999 If seam is not sealed properly, clean vertical and horizontal seam area with Acrysol(TM) cleaner. Use an air hose to dry all seams before applying sealer. NOTE: Hole is located behind fender. 15. Attach a 12 to 18 inch length of plastic tubing to tip of Kent High Tech(TM) Clear Seam Sealer. 16. Seal entire vertical joint with High Tech(TM) clear seam sealer. Allow sealer to dry according to instructions on tube. NOTE: Seams are inside boxed area and accessed through the square hole as shown. 17. Flood cowl area with water to confirm that there are no cowl seam leaks into cab. If water leaks are still present and there are no cowl area seam leaks, reinstall front fender and inspect for water entry along lower edge of interior door trim panel; then proceed as follows: 18. Remove door trim panel. 19. Flood R/F door glass area (spray water at door glass, belt-molding area). 20. Inspect sealer between plastic sheeting (moisture barrier) and metal door panel for voids/skips in sealer. If there are voids/skips between the plastic sheet and the door panel, it will need to be resealed. A. Using a heat gun, heat the butyl tape securing the plastic sheet to make removal easier. B. Use Kent Acrysol to clean the door panel and plastic sheet. NOTE: ^ Follow the directions provided by the cleaning agent. ^ To ensure proper sealing of the plastic sheeting, it is important that the door panel and plastic sheeting is extremely clean. C. Use 3M 8.0 mm butyl tape (P/N 08610) to reattach the plastic sheet to the door panel. Make sure there is a continuos solid bead sealing the plastic sheet to the door panel. 21. Inspect drain-back holes (small slits in metal door panel, near bottom of sealer) to determine if holes are covered by sealer material. If sealer covers drain-back holes (small slits in metal door panel) carefully pull up a portion of plastic sheet, clean out drain-back holes and Page 4559 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Page 1104 5. REMOVE ECT SENSOR a. Disconnect the ECT sensor connector. b. Using a 19 mm dean socket wrench, remove the ECT sensor and gasket. 6. INSPECT ECT SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: Refer to the graph If the resistance is not as specified, replace the ECT sensor. 7. REINSTALL ECT SENSOR a. Install a new gasket to the ECT sensor. b. Using a 19 mm deep socket, install the ECT sensor. Torque: 20 Nm (200 kg.cm, 14 ft.lb) c. Connect the ECT sensor connector. 8. REINSTALL FUEL PIPE Install the fuel pipe with 4 new gaskets and the 2 union bolts. Torque: 34.3 Nm (350 kg. cm, 25 ft.lb) 9. REINSTALL NO.2 TIMING BELT COVER 10. RECONNECT UPPER RADIATOR HOSE TO WATER OUTLET 11. REFILL WITH ENGINE COOLANT Page 438 Crankshaft Position Sensor: Service and Repair REPLACEMENT 1. REMOVE ENGINE UNDER COVER 2. REMOVE CRANKSHAFT POSITION SENSOR a. Disconnect the sensor connector. b. Remove the bolt and sensor. Torque: 7.8 Nm (80 kg.cm, 69 in.lb) 3. REINSTALL NEW CRANKSHAFT POSITION SENSOR a. Install the sensor with the bolt. b. Connect the sensor connector. 4. REINSTALL ENGINE UNDER COVER Page 3082 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Page 3739 NOTE: Affix the fluorocarbon resin tape on the shoulder belt anchor to the other side following the same procedure. NOTE: If the seat belt requires cleaning to remove dirt, only use a neutral detergent or lukewarm water to clean. Use the seat belt after it is completely dried, to confirm proper operation. Page 4416 Cigarette Lighter: Ground Locations Page 2624 Page 3335 Ball Joint: Diagrams Upper Page 2636 Locations Page 2234 Page 4096 Page 3292 Steering Wheel: Service Precautions SRS AIRBAG PRECAUTION TOYOTA vehicles are equipped with an SRS (Supplemental Restraint System) such as the driver airbag, front passenger airbag, side airbag, curtain airbag (if equipped), and seat belt pretensioner. Failure to carry out service operation in the correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the precautionary notices in RESTRAINT SYSTEMS.See: Restraint Systems Page 1025 f. Adjust the electrode gap. Carefully bend the outer electrode to obtain the correct electrode gap. Correct electrode gap: 1.1 mm (0.043 in.) g. Using a 16 mm plug wrench, reinstall the spark plugs. Torque: 18 Nm (180 kg.cm, 13 ft.lb) h. Reinstall the 3 ignition coils. i. Reconnect the 3 high-tension cords. Page 1698 Engine Bank Identification Page 2471 FRONT AXLE HUB REPLACEMENT AND OVERHAUL W/ RELATED COMPONENTS Page 4775 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Page 3813 Seat Belt Reminder Lamp: Fuse and Fusible Link Locations Relay Box / No. 2 Page 2105 Splice Locations Page 1050 Page 3484 Condenser HVAC: Service and Repair REMOVAL 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM HINT: At the time of installation, please refer to the following item. Evacuate air from refrigeration system. Charge system with refrigerant and inspect for leakage of refrigerant. Specified amount: 600 ± 50 g (21.16 ± 1.76 oz.) 2. REMOVE THESE PARTS: a. Radiator grille b. Horns c. Hood lock set bolts d. Center brace 3. REMOVE 2 LIQUID TUBES a. Remove the 2 bolts and disconnect the liquid tubes from receiver Torque: 6.0 Nm (60 kg.cm, 52 in.lb) NOTE: Cap the open fittings immediately to keep moisture or dirt out of the system. HINT: At the time of installation, please refer to the following item. Lubricate 2 new O-rings with compressor oil and install the tubes. b. Loosen the 2 nuts and remove the 2 liquid tubes. Torque: 14 Nm (140 kg.cm, 10 ft.lb) NOTE: Cap the open fittings immediately to keep moisture or dirt out of the system. HINT: At the time of installation, please refer to the following item. Lubricate 2 new O-rings with compressor oil and install the tubes. 4. DISCONNECT DISCHARGE HOSE FROM CONDENSER a. Remove the piping clamp set bolt. b. Remove the bolt and disconnect the hose. Torque: 10 Nm (100 kg.cm, 7 ft.lb) NOTE: Cap the open fitting immediately to keep moisture or dirt out of the system. HINT: At the time of installation, please refer to the following item. Lubricate a new O-rings with compressor oil and install the tubes. Page 664 Hose/Line HVAC: Service and Repair LOCATION REPLACEMENT 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM 2. REPLACE FAULTY TUBE OR HOSE NOTE: Cap the open fittings immediately to keep moisture or dirt out of the system. 3. TIGHTEN JOINT OF BOLT OR NUT AT SPECIFIED TOQUE NOTE: Connections should not be torqued tighter than the specified torque. 4. EVACUATE AIR IN REFRIGERATION SYSTEM AND CHARGE SYSTEM WITH REFRIGERANT Page 1522 Part 2 Of 2 (California Spec.) *1: Only for A/T *2: The ECM terminal voltage is fixed regardless of the output voltage from the sensor. Connectors (Except California Spec.) Page 1185 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Locations Page 364 Page 965 Timing Belt: Service and Repair Part 1 Of 2 Page 4213 2. Scrub the bumper covers with the soap and water solution, making sure all difficult-to-reach areas are thoroughly cleaned. 3. Rinse the entire bumper cover with clean deionized water, making sure all difficult-to-reach areas are thoroughly rinsed. 4. Dry the surface with a clean towel before water dries on the surface. Clean, dry compressed air from an oil-less compressor may be substituted for drying with a towel. 5. Degrease the surface with a wax, grease, and silicone remover. Note: Lacquer thinner or brake cleaner will NOT remove silicone. You MUST use a wax, grease, and silicone remover. Carefully follow application instructions on the container label. Fish eyes or other paint irregularities may result from not following instructions. 6. Apply a generous amount of sanding paste with a gray 3M ScotchBrite pad. Only a gray pad should be used during the sanding process. Sand the entire bumper cover surface. Be sure all difficult-to-reach areas are thoroughly sanded. 7. Clean the entire bumper cover with car wash soap and water. Be sure all difficult-to-reach areas are thoroughly cleaned. 8. Rinse the entire bumper with clean deionized water. Be sure all difficult-to-reach areas are thoroughly rinsed. 9. Degrease the surface with an anti-static plastic parts cleaner and a white body shop towel or paper towel. Note: Never use a red shop towel to wipe the surface (contains silicone). 10. Assure the bumper is firmly held in place to a steady fixture. 11. Apply a plastic parts adhesion promoter to the surface, according to the manufacturer's recommendations. 12. Apply plastic parts primer to the surface, according to the paint manufacturer's recommendations. 13. Since bumpers are made of flexible plastic urethane material, use a two-part urethane finish paint system with plasticizer (flex agent) for all bumper and cladding repairs. Apply the appropriate top coat to the surface, according to the paint manufacturer's recommendations. 14. If heat is applied to cure the paint, assure the surface temperature does not exceed 80°C (176°F.) For additional information concerning the refinish process for plastic bumpers/cladding, please contact your respective refinish paint manufacturer's local representative. Testing and Inspection Stop Light Switch: Testing and Inspection Stop Light System INSPECTION 1. w/o Cruise Control: INSPECT STOP LIGHT SWITCH CONTINUITY If continuity is not as specified, replace the switch. 2. W/ Cruise Control: INSPECT STOP LIGHT SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 1177 Removal and Installation Hydraulic Control Assembly - Antilock Brakes: Service and Repair Removal and Installation REMOVAL 1. REMOVE BRAKE LINE COVER Locations Description and Operation Throttle Position Sensor: Description and Operation Throttle Position Sensor The throttle position sensor is mounted in the throttle body and detects the throttle valve opening angle. When the throttle valve is fully closed, a voltage of approximately 0.3 - 1 .0 V is applied to terminal VTA of the ECM. The voltage applied to terminals VTA of the ECM increases in proportion to the opening angle of the throttle valve and becomes approximately 2.7 - 5.2 V when the throttle valve is fully opened. The ECM ledges the vehicle driving conditions from these signals input from terminals VTA and uses them as one of the conditions to decide the air- fuel ratio correction, power increase correction and fuel-cut control etc. Page 1300 CHART 29 Air/Fuel Ratio Sensor Oxygen Sensor: Testing and Inspection Air/Fuel Ratio Sensor Air-Fuel Ratio (A/F) Sensor COMPONENTS INSPECTION 1. INSPECT HEATER RESISTANCE OF A/F SENSOR a. Disconnect the sensor connector. b. Using an ohmmeter, measure the resistance between terminals +B and HT. Resistance: at 20 °C (68 °F) 0.8 - 1.4 ohms at 800 °C (1,472 °F) 1.8 - 3.2 ohms If the resistance is not as specified, replace the sensor. Torque: 20 Nm (200 kg.cm, 14 ft.lb) c. Connect the sensor connector. 2. INSPECT OPERATION OF A/F SENSOR Testing and Inspection Windshield Washer Spray Nozzle: Testing and Inspection INSPECTION INSPECT WASHER NOZZLE While operating the washer, check that the point where the washer fluid hits the windshield and the surge area are within the range indicated by the hatched line. A: Approx. 150 mm (5.90 in.) B: Approx. 50 mm (1.97 in.) C: Approx. 120 mm (4.72 in.) D: Approx. 65 mm (2.55 in.) E: Approx. 105 mm (4.13 in.) F: Approx. 162 mm (6.37 in.) G: Approx. 156 mm (6.14 in.) H: Approx. 287.7 mm (11.32 in.) I: Approx. 211.4 mm (8.32 in.) J: Approx. 238.6 mm (9.39 in.) K: Approx. 189 mm (7.44 in.) L: Approx. 102.5 mm (4.03 in.) M: Approx. 0 - 50 mm (0 1.97 in.) 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 2947 c. Tighten the 5 screws until there is a clearance of at least 1 mm (0.04 in.) between the brush holder cover and connector. 6. INSTALL REAR END COVER a. Install the end cover with the 3 nuts. Torque: 4.5 Nm (45 kg.cm, 39 in.lb) b. Install the terminal insulator with the nut. Torque: 4.1 Nm (42 kg.cm, 36 in.lb) 7. CHECK THAT ROTOR ROTATES SMOOTHLY REPLACEMENT 1. REPLACE BRUSHES a. Unsolder and remove the brush and spring. b. Run the wire of a new brush through the spring and the hole in the brush holder, and insert the spring and brush into the brush holder. Procedures Seat Belt Tensioner: Procedures Replacement Requirements REPLACE REQUIREMENTS In the following cases, replace the seat belt pretensioner. - If the seat belt pretensioner has been activated. - If the seat belt pretensioner has been found to be faulty in troubleshooting. - If the front seat outer belt has been found to be faulty during checking item functioning of SST. - If the front seat outer belt has been dropped. CAUTION: Be sure to follow the correct procedure, for removal and installation of the seat belt pretensioner. Deployment and Disposal DISPOSAL HINT: When scrapping vehicles equipped with a supplemental restraint system or disposing of a front seat outer belt (with seat belt pretensioner) always first activate the seat belt pretensioner in accordance with the procedure described below. If any abnormality occurs in the seat belt pretensioner operation, contact the SERVICE DEPT. of TOYOTA MOTOR SALES, U.S.A.,INC. When disposing of a front seat outer belt (with seat belt pretensioner) activated in a collision, follow the same procedure given in step 1-(d) in "DISPOSAL". CAUTION: - Never dispose of front seat outer belt which has an inactivated pretensioner. - The seat belt pretensioner produces a sizeable exploding sound when it activates, so perform the operation out-of-door and where it will not create a nuisance to nearby residents. - When activating the seat belt pretensioner, always use the specified SST. (SRS Airbag Deployment Tool) Perform the operation in a place away from electrical noise. SST 09082-00700,09082-00740 - When activating a front seat outer belt (with seat belt pretensioner), perform the operation at least 10 m (33 ft) away from the front seat outer belt. - Use gloves and safety glasses when handling a front seat outer belt with activated pretensioner. - Always wash your hands with water after completing the operation. - Do not apply water, etc. to a front seat outer belt with activated pretensioner. 1. SEAT BELT PRETENSIONER ACTIVATION WHEN SCRAPPING VEHICLE HINT: Have a battery ready as the power source to activate the seat belt pretensioner. Page 1237 Crankshaft Position Sensor: Testing and Inspection INSPECT CRANKSHAFT POSITION SENSOR a. Remove the sensor connector. b. Using an ohmmeter, measure the resistance between the terminals. Resistance: Cold 1,630 - 2,740 ohms Hot 2,065 - 3,225 ohms c. Reinstall the sensor. Page 3223 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source How to Read Power Source 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 3172 Power Steering Fluid: Service and Repair For information regarding the Service and Repair of this component and the system that it is a part of, please refer to Power Steering Bleeding. Page 2526 Step 5 INSPECTION PROCEDURE Page 893 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 1226 Camshaft Position Sensor: Testing and Inspection INSPECT CAMSHAFT POSITION SENSOR a. Disconnect the sensor connector. b. Using an ohmmeter, measure the resistance between the terminals. Resistance: cold 835 - 1,400 ohms Hot 1,060 - 1,645 ohms If the resistance is not as specified, replace the sensor. c. Reconnect the camshaft position sensor connector. Page 964 Part 2 Of 2 Part 2 of 2 Page 5009 reinstall plastic sheet against metal door panel. Confirm that there are no voids between sealer and plastic sheet and between sealer and metal door panel. 22. Flood all areas with water to confirm that there are no leaks into cab area. 23. If no leaks are present, reinstall door trim panel. Page 1429 Page 1271 Page 2246 Page 404 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Page 4384 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source How to Read Power Source Page 630 4. INSTALL LH CAMSHAFT TIMING PULLEY a) Face the flange side of the timing pulley outward. b) Align the knock pin on the camshaft with the knock pin groove of the timing pulley, and slide on the timing pulley. c) Using SST, install the pulley bolt. SST 09960-10010 (09962-01000, 09963-01000) Torque: 110 Nm (1,100 kgf-cm, 81 ft. lbs.) 5. INSTALL RH CAMSHAFT TIMING PULLEY a) Face the flange side of the timing pulley outward. b) Align the knock pin on the camshaft with the knock pin groove of the timing pulley, and slide on the timing pulley. c) Using SST, install the pulley bolt. SST 09960-10010 (09962-01000, 09963-01000) Torque: 110 Nm (1,100 kgf-cm, 81 ft. lbs.) 6. SET NO.1 CYLINDER TO TDC/COMPRESSION a) Temporarily install the crankshaft pulley bolt to the crankshaft. b) Turn the crankshaft, and align the timing marks of the crankshaft timing pulley and oil pump body. c) Using SST, turn the camshaft pulley, align the timing marks of the timing pulley and No.3 timing belt cover. SST 09960-10010 (09962-01000, 09963-01000) Page 3771 Warranty Information Procedure and Sample Label 1. Owner requests a Seat Belt Extender from dealer. 2. Dealer verifies the need for a Seat Belt Extender and obtains a current copy of this TSB and copies the Worksheet. 3. Dealer measures the customer and completes the Worksheet. Dealer determines the correct part number and places a Critical Order for the part through the IDN Parts Network. 4. Dealer receives Seat Belt Extender and calls the customer in to check fit of the part. 5. If the Seat Belt Extender fit is good, dealership personnel completes the Customer Information Label on the part, explains usage of the part, and gives the customer a copy of the completed Worksheet. 6. Dealer places copy of the completed Worksheet in the customer's records. Application Charts Sample Seat Belt Extender Customer Information Label Page 1520 Step 7 Step 8 INSPECTION PROCEDURE Page 3801 Page 1829 c. Inspect the VSV operation. 1. Check that air flows from ports E to G. 2. Apply battery positive voltage across the terminals. 3. Check that air flows from ports E to F. If operation is not as specified, replace the VSV. 3. REINSTALL VSV ABS/TCS - Zero Point Calibration Information Steering Angle Sensor: Technical Service Bulletins ABS/TCS - Zero Point Calibration Information T-SB-0020-08 March 25, 2008 Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment Service Category Brake Section Brake Control/Dynamic Control System Market USA Applicability Introduction The purpose of this TSB is to provide information on when and how to perform the zero point calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting the battery is a necessary step for performing the zero point calibration. Warranty Information Required Tools & Equipment ^ Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE). ^ The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the service procedures listed in this bulletin. Preliminary Information Perform this procedure if any of these repairs have been performed on the vehicle: ^ Wheel alignment has been adjusted. ^ Any chassis components have been removed/installed or replaced. Page 1710 Page 603 f. Adjust the electrode gap. Carefully bend the outer electrode to obtain the correct electrode gap. Correct electrode gap: 1.1 mm (0.043 in.) g. Using a 16 mm plug wrench, reinstall the spark plugs. Torque: 18 Nm (180 kg.cm, 13 ft.lb) h. Reinstall the 3 ignition coils. i. Reconnect the 3 high-tension cords. Page 4415 Cigarette Lighter: Fuse and Fusible Link Locations Relay Box / No. 2 Page 2806 NOTICE: Apply lithium soap base glycol grease to the parts indicated by the arrows. Page 1317 Throttle Position Sensor: Service and Repair Refer to Fuel Delivery and Air Induction / Throttle Body / Service and Repair, for removal and installation of this component. Page 1769 Splice Point J: Indicates a wiring Splice Point (Codes are "E"for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I 5 is indicated by the shaded section. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. N: Page No. How to Read Ground Points How to Read Ground Points Page 1194 Step 3 Step 4 Step 5 Step 6 Page 1427 b) Turn the crankshaft 2/3 of a revolution (240°), and check only the valves indicated in the illustration. Measure the valve clearance. (See step (a)) c) Turn the crankshaft a further 2/3 of a revolution (240°), and check only the valves indicated in the illustration. Measure the valve clearance. (See step (a)) 5. ADJUST VALVE CLEARANCE a) Remove the adjusting shim. 1) Turn the camshaft so that the cam lobe for the valve to be adjusted faces up. 2) Turn the valve lifter with a screwdriver so that the notches are perpendicular to the camshaft. 3) Using SST (A), press down the valve lifter and place SST (B) between the camshaft and valve lifter. Remove SST (A). SST 09248-55040 (09248-05410, 09248-05420) Page 3341 Ball Joint: Service and Repair Upper REMOVAL Page 2918 Required SSTs Battery Inspection Procedure All vehicles are to be inspected according to the procedures listed below using the Digital Battery System Analyzer (P/N 00002-V8150-KIT) no more than 48 hours prior to customer vehicle delivery. In hybrid vehicles, the Digital Battery System Analyzer (SST P/N 00002-V81 50-KIT) is to be used ONLY on the AUXILIARY (12 volt) battery. 1. Connect test clamps to the battery. (If the analyzer does NOT power up automatically, press the POWER button.) 2. Select the correct USER ID (if applicable) and press the NEXT soft key. 3. Enter USER PIN (if applicable) and press the NEXT soft key. NOTE: For details on defining USER ID or PIN, refer to the NVS-8150 Instruction Manual. Page 1255 Applicable Vehicles Page 1346 Evaporative Vapor Pressure Sensor: Testing and Inspection Vapor Pressure Sensor 1. INSPECT POWER SOURCE VOLTAGE OF VAPOR PRESSURE SENSOR a. Disconnect the vapor pressure sensor connector. b. Turn the ignition switch ON. c. Using a voltmeter, measure the voltage between connector terminals VC and E2 of the wiring harness side. Voltage: 4.5 - 5.5 V d. Turn the ignition switch OFF. e. Reconnect the vapor pressure sensor connector. 2. INSPECT POWER OUTPUT OF VAPOR PRESSURE SENSOR a. Turn the ignition switch ON. b. Disconnect the vacuum hose from the vapor pressure sensor. c. Connect a voltmeter to terminals PTNK and E2 of the ECM, and measure the output voltage under ambient atmospheric pressure. 1. Apply vacuum (2.0 kpa, 15 mmHg, 0.59 in.Hg) to the vapor pressure sensor. Voltage: 1.3 - 2.1 V 2. Release the vacuum from the vapor pressure sensor. Voltage: 3.0 - 3.6 V 3. Apply pressure (1.5 kPa, 15 gf/Sq.cm, 0.22 psi) to the vapor pressure sensor. Voltage: 4.2 - 4.8 V d. Reconnect the vacuum hose to the vapor pressure sensor. Page 2077 Step 3 Locations Intake Air Temperature Sensor: Locations The Intake Air Temperature (IAT) Sensor is installed in the Mass Air Flow (MAF) Meter. Testing and Inspection Windshield Washer Switch: Testing and Inspection INSPECT FRONT WIPER AND WASHER SWITCH CONTINUITY W/ Mist w/ MIST: Page 1481 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Service Precautions Air Bag(s) Arming and Disarming: Service Precautions NOTE: TOYOTA trucks are equipped with SRS, which comprises a driver airbag and front passenger airbag. Failure to carry out service operations in the correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Further, if a mistake is made in servicing the SRS, it is possible that the SRS may fail to operate when required. Before performing servicing (including removal or installation of parts, inspection or replacement), be sure to read the following items carefully, then follow the correct procedures described in the repair manual. Malfunction symptoms of the SRS are difficult to confirm, so the DTCs become the most important source of information when troubleshooting. When troubleshooting the SRS, always inspect the DTCs before disconnecting the battery. Even in cases of a minor collision where the SRS does not deploy, the steering wheel pad, front passenger airbag assembly, airbag sensor assembly and front airbag sensor should be inspected. Never use SRS parts from another vehicle. When replacing parts, replace them with new parts. Never disassemble and repair the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor in order to reuse it. If the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor has been dropped, or if there are cracks, dents or other defects in the case, bracket or connector, replace them with new ones. Use a volt/ohmmeter with high impedance (10 K.Ohm/V minimum) for troubleshooting the system's electrical circuits. Information labels are attached to the periphery of the SRS components. Follow the instructions on the notes. After work on the SRS is completed, perform the SRS warning light check. If the vehicle is equipped with a mobile communication system, refer to the precaution in the Introduction system. CAUTION: Work must be started 90 seconds after the ignition switch is turned to the "LOCK" position and the negative (-) terminal cable is disconnected from the battery (The SRS is equipped with a back-up power source so that if work is started within 90 seconds from disconnecting the negative (-) terminal cable of the battery, the SRS may be deployed.). When the negative (-) terminal cable is disconnected from the battery, the memory of the clock and audio system will be canceled. So before starting work, make a record of the contents memorized in the audio memory system. When work is finished, reset the audio systems as they were before and adjust the clock. However, it is not possible to make a record of the memory contents. So when the work is finished, it will be necessary to explain this fact to the customer, and ask the customer to adjust the features and reset the memory. To avoid erasing the memory in each memory system, never use a back-up power supply from outside the vehicle. Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during repairs. Do not expose the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor directly to hot air or flames. Page 4927 Windshield: Service and Repair REMOVAL 1. REMOVE INNER REAR VIEW MIRROR 2. REMOVE SUN VISORS AND HOLDERS 3. REMOVE ASSIST GRIPS 4. REMOVE QUARTER TRIM 5. REMOVE FRONT PILLAR GARNISHES 6. REMOVE COWL LOUVER 7. REMOVE WIPER ARMS 8. REMOVE WINDSHIELD OUTSIDE UPPER MOULDING a. Using a knife, cut off the moulding, as shown in the illustration. NOTE: Do not damage the body with the knife. b. Remove the remaining moulding. 9. REMOVE WINDSHIELD GLASS a. Push piano wire through between the body and glass from the interior. b. Tie both wire ends to a wooden block or similar object. HINT: Apply protective tape to the outer surface to keep the surface from being scratched. NOTE: When separating the glass, take care not to damage the paint and interior and exterior ornaments. To prevent scratching the safety pad when removing the windshield, place a plastic sheet between the piano wire and safety pad. c. Cut the adhesive by pulling the piano wire around it. Page 1908 u. Remove the other union bolt, 3 gaskets and fuel pipe from the delivery pipes. v. Reinstall the fuel pipe with 4 new gaskets and the 2 union bolts. Torque: 34.3 Nm (350 kg.cm, 25 ft.lb) w. Reconnect the negative (-) terminal cable to the battery. x. Check for fuel leaks. 3. INSPECT FUEL PUMP RESISTANCE Using an ohmmeter, measure the resistance between terminals 4 and 5. Resistance: 0.2 - 3.0 ohms at 20 °C (68 °F) If the resistance is not specified, replace the fuel pump and/or lead wire. 4. INSPECT FUEL PUMP RESISTANCE Connect the positive (+) lead from the battery to terminal 4 of the connector, and the negative (-) lead to terminal 5. Check that the fuel pump operates. NOTE: These tests must be done quickly (within 10 seconds) to prevent the coil from burning out. - Keep the fuel pump as far away from the battery as possible. - Always do switching at the battery side. If operation is not as specified, replace the fuel pump and/or lead wire. Testing and Inspection Stop Light Switch: Testing and Inspection Stop Light System INSPECTION 1. w/o Cruise Control: INSPECT STOP LIGHT SWITCH CONTINUITY If continuity is not as specified, replace the switch. 2. W/ Cruise Control: INSPECT STOP LIGHT SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 1221 Mass Air Flow Meter: Testing and Inspection INSPECTION 1. INSPECT MAF METER RESISTANCE Using an ohmmeter, measure the resistance between terminals THA and E2. If the resistance is not as specified, replace the MAF meter. Temperature Resistance at -20 °C (-4 °F) 13.6 - 18.4 Kohms at -20 °C (68 °F) 2.2 - 2.7 Kohms at -60 °C (140 °F) 0.5 - 0.7 Kohms 2. INSPECT MAF METER OPERATION a. Connect the MAF meter connector. b. Using a voltmeter, connect the positive (+) tester probe to terminal VG, and negative (-) tester probe to terminal E2G. c. Turn the ignition switch ON. d. Blow air into the MAF meter, and check that the voltage fluctuates. If operation is not as specified, replace the MAF meter. e. Turn the ignition switch OFF. f. Disconnect the MAF meter connector. Page 2749 3. REMOVE CALIPER Remove the 2 mounting bolts and caliper. Torque: 123 Nm (1,250 kgf-cm, 90 ft. lbs.) 4. REMOVE CLIP, 2 PINS AND ANTI-RATTLE SPRING 5. REMOVE 2 PADS WITH 4 ANTI-SQUEAL SHIMS INSTALLATION Installation is in the reverse order of removal. HINT: After installation, fill the brake reservoir with brake fluid, bleed brake system and check for leaks. See: Brake Bleeding Page 695 Capacity: A340E: 1.6 liters (1.7 US qts, 1.4 Imp. qts) A340F: 2.0 liters (2.1 US qts, 1.8 Imp. qts) 4. Start the engine and shift the shift lever into all positions from P to L position and then shift into P position. 5. With the engine idling, check the fluid level. Add fluid up to the COOL level on the dipstick. 6. Check the fluid level at the normal operating temperature, 70 - 80 °C (158 - 176 °F), and add as necessary. NOTE: Do not overfill. d. Check the fluid leaks. Check for leaks in the transmission. If there are leaks, it is necessary to repair or replacements, FIPGs, oil seals, plugs or other parts. e. Inspect and adjust the throttle cable. 1. Check that the throttle valve is fully closed. 2. Check that the inner cable is not slack. 3. Measure the distance between the outer cable end and stopper on the cable. Standard distance: 0 - 1 mm (0 - 0.04 in.) If the distance is not standard, adjust the cable by the adjusting nuts. f. Column shift: Inspect and adjust the shift lever position. When shifting the shift lever from the N position to other positions, check that the lever can be shifted smoothly and accurately to each position and that the position indicator correctly indicates the position. If the indicator is not aligned with the correct position, carry out the following adjustment procedures. Diagrams Page 3066 Auxiliary Power Outlet: Ground Locations Testing and Inspection Igniter: Testing and Inspection ON-VEHICLE INSPECTION NOTE: "Cold" and "Hot" in these sentences express the temperature of the coils themselves. "Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F). INSPECT IGNITOR AND SPARK TEST Check that the spark occurs. 1. Disconnect high-tension cords from spark plug. 2. Remove the spark plug. 3. Install the spark plug to each high-tension cord. 4. Ground the spark plug. 5. Check if spark occurs while engine is being cranked. NOTE: To prevent excess fuel being injected from the injectors during this test, do not crank the engine for more 5 - 10 seconds at a time. If the spark does not occur, do the test as per the flow chart. 6. Using a 16 mm plug wrench, install the spark plugs. Torque: 18 N.m (195 kgf.cm, 15 ft.lbf) 7. Reinstall the ignition coil with ignitor. Locations Fuse: Locations Relay Box / No. 2 Page 2841 Brake Master Cylinder: Service and Repair Disassembly and Assembly DISASSEMBLY 1. REMOVE RESERVOIR a. Remove the set screw and pull out the reservoir. Torque: w/o ABS: 1.5 Nm (15 kgf-cm, 13 inch lbs.) w/ ABS: 1.7 Nm (18 kgf-cm, 16 inch lbs.) b. Remove the cap and strainer from the reservoir. 2. REMOVE 2 GROMMETS 3. PLACE CYLINDER IN VISE Page 178 5. REMOVE ECT SENSOR a. Disconnect the ECT sensor connector. b. Using a 19 mm dean socket wrench, remove the ECT sensor and gasket. 6. INSPECT ECT SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: Refer to the graph If the resistance is not as specified, replace the ECT sensor. 7. REINSTALL ECT SENSOR a. Install a new gasket to the ECT sensor. b. Using a 19 mm deep socket, install the ECT sensor. Torque: 20 Nm (200 kg.cm, 14 ft.lb) c. Connect the ECT sensor connector. 8. REINSTALL FUEL PIPE Install the fuel pipe with 4 new gaskets and the 2 union bolts. Torque: 34.3 Nm (350 kg. cm, 25 ft.lb) 9. REINSTALL NO.2 TIMING BELT COVER 10. RECONNECT UPPER RADIATOR HOSE TO WATER OUTLET 11. REFILL WITH ENGINE COOLANT Testing and Inspection Brake Warning Indicator: Testing and Inspection INSPECT BRAKE WARNING LIGHT a. Disconnect the connectors from the level warning switch and parking brake switch. b. Connect terminals on the wire harness side connector of the level warning switch connector. c. Turn the ignition switch ON and check that the warning light lights up. If the warning light does not light up, test the bulb. Locations Transmission Speed Sensor: Locations CIRCUIT DESCRIPTION The speed sensor for ABS detects the wheel speed and sends the appropriate signals to the ABS ECU. The ECU converts these signals into a pulse signal and outputs it to the combination meter. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. Page 426 Throttle Position Sensor: Service and Repair Refer to Fuel Delivery and Air Induction / Throttle Body / Service and Repair, for removal and installation of this component. Page 3170 c. Connect SST, as shown below. SST 09640-10010 (09641-01010, 09641-01030, 09641-01060) NOTICE: Check, that the valve of the SST is in the open position. d. Bleed the power steering system. e. Start the engine and run it at idle. f. Turn the steering wheel from lock to lock several times to boost fluid temperature. Fluid temperature: 80°C (176°F) g. With the engine idling, close the valve of the SST and observe the reading on the SST. Minimum fluid pressure: 8,336 kPa (85 kgf/cm2, 1,209 psi) NOTICE: Do not keep the valve closed for more than 10 seconds. Do not let the fluid temperature become too high. h. With the engine idling, open the valve fully. i. Measure the fluid pressure at engine speeds of 1,000 rpm and 3,000 rpm. Difference fluid pressure: 490 kPa (5 kgf/cm2, 71 psi) or less NOTICE: Do not turn the steering wheel. Page 2958 Steps 1 - 2 Page 1985 c. Disconnect the vacuum hose from the throttle opener, and plug the hose end. d. Check the throttle opener setting speed. Throttle opener setting speed: 900 - 1,950 rpm If the throttle opener setting is not as specified, replace the throttle body. e. Stop the engine. f. Reconnect the vacuum hose to the throttle opener. g. Start the engine and check that the idle speed returns to the correct speed. Page 2752 NOTICE: Apply lithium soap base glycol grease to the parts indicated by the arrows. Page 515 Transmission Position Switch/Sensor: Service and Repair ON-VEHICLE REPAIR 1. DISCONNECT 2 OIL COOLER PIPES 2. DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 3. REMOVE PARK/NEUTRAL POSITION SWITCH a. Pry off the lock washer and remove the nut. b. Remove the bolt and pull out the park/neutral position switch. 4. INSTALL AND ADJUST PARK/NEUTRAL POSITION SWITCH Torque: Nut: 6.9 Nm (70 kgf-cm, 61 inch lbs.) Bolt: 13 Nm (130 kgf-cm, 9 ft. lbs.) 5. CONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 6. CONNECT 2 OIL COOLER PIPES Body - Water Leaks to The Interior Front Door Panel: All Technical Service Bulletins Body - Water Leaks to The Interior BODY BO026-00 Title: WATER LEAK FIELD-FIX REPAIR INSTRUCTIONS Models: '97 - '04 Tacoma October 27, 2000 TSB Revision Notice: ^ January 12, 2005: Applicable Vehicles has been updated to include 2004 model year. ^ August 25, 2003: VIN and Applicable Model Information has changed, and repair procedure has been expanded and clarified. ^ October 27, 2000: This TSB updates B0016-98 dated June 12, 1998. B016-98 is now obsolete and should be discarded. Previous versions of this TSB should be discarded. Introduction Use the following field-fix procedures if water is present on the floor carpeting and it can be confirmed that the water is leaking into the cab from either the upper cowl or side cowl seam, or moisture barrier behind the door trim panel. Applicable Vehicles 1997 - 2004 model year Tacoma vehicles. Required Materials Warranty Information Page 3550 Refrigerant Oil: Fluid Type Specifications Type ND-OIL 8 Page 2030 Knock Sensor: Testing and Inspection Page 2559 Shift Indicator: Pinout Values and Diagnostic Parameters E 2 ELECTRONICALLY CONTROLLED TRANSMISSION SOLENOID 1, 2, 3-GROUND : Approx. 13 Ohm P 1 PARK/NEUTRAL POSITION SW 4-GROUND : Approx. 12 volts with ignition SW ON (Floor A/T), ACC (Column A/T) position O 4-A, S 4-B O/D MAIN SW A-1-A-3,B-5-B-10 : Open with O/D main SW at ON position Closed with O/D main SW at OFF position S 5-A,B STOP LIGHT SW A-1-A-2,B-1-B-2 : Closed with brake pedal depressed E 5-A, E 6-B, E 7-C, E 8-D ENGINE CONTROL MODULE S1-E1 : 9 - 14 volts S2,SL-E1 : 0 - 1.5 volts STP-E1 : 7.5 - 14 volts with brake pedal depressed : 0 - 1.5 volts with brake pedal released THW-E2 : 0.2 - 1.0 volts with coolant temp. 80 °C (176 °F) OIL-E2 : 4 - 5 volts with fluid temp. 20 °C (68 °F) VTA-E2 : 0.3 - 0.6 volts with throttle valve fully closed : 3.2 - 4.9 volts with throttle valve fully open VC-E2 : 4.5 - 5.5 volts OD1-E1 : 4.5 - 5.5 volts ODMS-E1 : 9 - 14 volts O/D main SW turned ON : 0 volts O/D main SW turned OFF SP1-E1 : Pulse generation with vehicle moving 2-E1 : 10 - 14 volts with shift lever at 2 position : 0-2 volts with shift lever at except 2 position L-E1 : 10 - 14 volts with shift lever at L position : 0 - 2 volts with shift lever at except L position OILW-E1 : 0.1 - 4.9 volts +B-E1 : 9 - 14 volts BATT-E1 : 9 - 14 volts Page 3723 NOTE: Affix the fluorocarbon resin tape on the shoulder belt anchor to the other side following the same procedure. NOTE: If the seat belt requires cleaning to remove dirt, only use a neutral detergent or lukewarm water to clean. Use the seat belt after it is completely dried, to confirm proper operation. Electrical - SRS And HV Wiring Repairs Air Bag Harness: Technical Service Bulletins Electrical - SRS And HV Wiring Repairs TITLE: SRS & HV WIRING REPAIRS SECTION: ELECTRICAL BULLETIN # 156 MODELS: ALL TOYOTA LEXUS and SCION MODELS DATE: AUGUST 2007 There are no approved repairs to Supplemental Restraint System (SRS) or High Voltage (HV) wiring or connectors. SRS system wiring and connectors are color coded yellow and HV wiring is orange however vehicle-specific wiring diagrams are the best source for identifying wiring in these circuits. Wiring diagrams are available through the Technical Information System (TIS) www.techinfo.toyota.com. If SRS or HV wiring or connectors are suspected of damage they should be inspected thoroughly. Damaged wiring and/or connectors require replacement of the affected harness. Follow all precautions and procedures outlined in model-specific repair manuals for replacing SRS wiring or components. Only Certified Hybrid Service Technicians are qualified to replace HV system wiring and components. Component Locations Page 1925 a. Check the fuel lines for cracks or leakage, and all connections for deformation. b. Check the fuel tank vapor vent system hoses and connections for looseness, sharp bends or damage. c. Check the fuel tank for deformation, cracks, fuel leakage or tank band looseness. d. Check the filler neck for damage or fuel leakage. e. Hose and pipe connections are as shown in the illustration. If a problem is found, repair or replace the parts as necessary. Page 3176 Part 2 Of 2 POWER STEERING VANE PUMP REPLACEMENT AND OVERHAUL W/ RELATED COMPONENTS Description and Operation Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Sensor A thermistor that is built into the engine coolant temperature sensor changes the resistance value according to the engine coolant temperature. The lower the engine coolant temperature sensor, the greater the thermistor resistance value, and the higher the engine coolant temperature sensor temperature, the lower the thermistor resistance value. The engine coolant temperature sensor is connected to the ECM. The 5 V power source voltage in the ECM is applied to the engine coolant temperature sensor from the terminal THA via a resistor R. That is, the resistor R and the engine coolant temperature sensor are connected in series. When the resistance value of the engine coolant temperature sensor changes in accordance with changes in the engine coolant temperature, the potential at terminal THA also changes. Based on this signal, the ECM increases the fuel injection volume to improve driveability during cold engine operation. Page 3459 2. REMOVE BLOWER UNIT a. Disconnect the connector from the blower motor. b. Disconnect the air inlet damper control cable from the blower motor. HINT: At the time of installation, please refer to the following item. For installing the control cable, refer to "INSTALLATION" of "HEATER CONTROL ASSEMBLY". c. Remove the nut, bolt and blower unit. INSTALLATION Installation is in the reverse order of removal. Blower Motor REMOVAL 1. REMOVE GLOVE COMPARTMENT DOOR 2. REMOVE BLOWER MOTOR a. Disconnect the connector. b. Remove the 3 screws and motor. INSTALLATION Installation is in the reverse order of removal. Bleeding the Brake System Brake Bleeding: Service and Repair Bleeding the Brake System BRAKE FLUID BLEEDING HINT: If any work is done on the brake system or if air is suspected in the brake lines, bleed the air from the system. NOTICE: Do not let brake fluid remain on a painted surface. Wash it off immediately. 1. FILL BRAKE RESERVOIR WITH BRAKE FLUID Check the fluid level in the reservoir after bleeding each wheel. Add fluid, if necessary. Fluid: SAE J1703 or FMVSS No. 116 DOT 3 2. BLEED MASTER CYLINDER HINT: If the master cylinder has been disassembled or if the reservoir becomes empty, bleed the air from the master cylinder. a. Disconnect the brake lines from the master cylinder. b. Slowly depress the brake pedal and hold it. c. Block off the outlet plug with your finger, and release the brake pedal. d. Repeat (b) and (c) 3 or 4 times. Testing and Inspection Positive Crankcase Ventilation Valve: Testing and Inspection 1. INSPECT PCV VALVE a. Remove the PCV valve. 1. Disconnect the PCV hose from the PCV valve. 2. Remove the PCV valve. b. Install a clean hose to the PCV valve. c. Inspect the PCV valve operation. 1. Blow air into the cylinder head cover side, and check that air passes through easily. CAUTION: Do not suck air through the valve. Petroleum substances inside the valve are harmful. 2. Blow air into the air intake chamber side, and check that air passes through with difficulty. d. Remove the clean hose from the PCV valve. e. Reinstall the PCV valve. Page 329 Oxygen Sensor: Technical Service Bulletins Engine Controls - Bank 1/Bank 2 O2 Sensor identification ENGINE EG034-07 Title: ENGINE BANK 1 AND BANK 2 A/F AND O2 IDENTIFICATION Models: '93 - '08 Applicable Models June 28, 2007 The information contained in this TSB supercedes TSB No. EG037-04. TSB No. EG037-04 is now obsolete and should be discarded. Introduction This service bulletin provides information on the proper identification of engine bank 1 and engine bank 2 for correct A/F sensor and oxygen sensor replacement. This bulletin contains information that identifies engine bank 1 and engine bank 2 on the following engines: 1AZ-FE, 2AZ-FE, 2AZ-FE (PZEV), 1GR-FE, 2GR-FE, 2GR-FSE, 2JZ-GE, 1MZ-FE, 3MZ-FE, 1UR-FSE, 3UR-FE, 2UZ-FE, 3UZ-FE, 5VZ-FE, and 1ZZ-FE. ^ Bank 1 (B1) refers to the bank that includes cylinder No. 1. ^ Bank 2 (B2) refers to the bank opposite bank 1. ^ Sensor 1 (S1) refers to the sensor that is located before the catalytic converters. ^ Sensor 2 (S2) refers to the sensor that is located after the catalytic converters. Warranty Information Page 3755 Seat Belt: Service and Repair NOTE: The content of this article/image reflects the changes identified in TSB BO017-07. Introduction A new service part for the seat belt tongue plate stopper has been introduced. Installation procedures are provided to supplement the Repair Procedures. Installation Procedure 1. Preparation A. Shift the tongue plate to the upper portion of the tongue plate stopper, and temporarily hold it with a clip or tape. B. Remove any pieces of the original tongue plate stopper in the webbing, with a pair of pliers. CAUTION: Damaged or weakened seat belts may break in an accident and injure the occupant. The seat belt assembly MUST be replaced if: - The webbing is cut, frayed, worn, or damaged. - It has been used in a severe impact. Inspect the entire length of webbing for damage and replace the assembly if needed. Be careful NOT to damage the webbing during repair. 2. Install the NEW tongue plate stopper A. Install a NEW tongue plate stopper in the hole of the webbing. NOTE: Be sure to install the stopper in the correct direction as shown in the illustration. Page 4712 Stop Light: Ground Locations Page 1024 Spark Plug: Testing and Inspection INSPECT SPARK PLUGS a. Disconnect the 3 high-tension cords. b. Remove the 3 ignition coils. c. Using a 16 mm plug wrench, remove the 6 spark plugs. d. Clean the spark plugs. If the electrode has traces of wet carbon, allow it to dry and then clean with a spark plug cleaner. Air pressure: Below 588 kPa (6 kg/Sq.cm, 85 psi) Duration: 20 seconds or less HINT: If there are traces of oil, remove it with gasoline before using the spark plug cleaner. e. Visually check the spark plug for thread damage and insulator damage. If abnormal, replace the spark plug. Recommended spark plug: DENSO made K16TR11 NGK made BKR5EKB-11 Page 1800 Page 73 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 4027 If seam is not sealed properly, clean vertical and horizontal seam area with Acrysol(TM) cleaner. Use an air hose to dry all seams before applying sealer. NOTE: Hole is located behind fender. 15. Attach a 12 to 18 inch length of plastic tubing to tip of Kent High Tech(TM) Clear Seam Sealer. 16. Seal entire vertical joint with High Tech(TM) clear seam sealer. Allow sealer to dry according to instructions on tube. NOTE: Seams are inside boxed area and accessed through the square hole as shown. 17. Flood cowl area with water to confirm that there are no cowl seam leaks into cab. If water leaks are still present and there are no cowl area seam leaks, reinstall front fender and inspect for water entry along lower edge of interior door trim panel; then proceed as follows: 18. Remove door trim panel. 19. Flood R/F door glass area (spray water at door glass, belt-molding area). 20. Inspect sealer between plastic sheeting (moisture barrier) and metal door panel for voids/skips in sealer. If there are voids/skips between the plastic sheet and the door panel, it will need to be resealed. A. Using a heat gun, heat the butyl tape securing the plastic sheet to make removal easier. B. Use Kent Acrysol to clean the door panel and plastic sheet. NOTE: ^ Follow the directions provided by the cleaning agent. ^ To ensure proper sealing of the plastic sheeting, it is important that the door panel and plastic sheeting is extremely clean. C. Use 3M 8.0 mm butyl tape (P/N 08610) to reattach the plastic sheet to the door panel. Make sure there is a continuos solid bead sealing the plastic sheet to the door panel. 21. Inspect drain-back holes (small slits in metal door panel, near bottom of sealer) to determine if holes are covered by sealer material. If sealer covers drain-back holes (small slits in metal door panel) carefully pull up a portion of plastic sheet, clean out drain-back holes and Page 358 CHART 22 Description and Operation Camshaft Position Sensor: Description and Operation The Camshaft Position Sensor Camshaft position sensor (G signal) consists of a magnet, iron core and pickup coil. The G signal plate has 1 tooth, on its outer circumference and is mounted on the RH camshaft timing pulley. When the camshafts rotate, the protrusion on the signal plate and the air gap on the pickup coil change, causing fluctuations in the magnetic field and generating an electromotive force in the pickup coil. The NE signal plate has 34 teeth and is mounted on the crankshaft timing pulley. The NE signal sensor generates 34 signals at every engine revolution. The ECM detects the standard crankshaft angle based on the G signal and the actual crankshaft angle and the engine speed by the NE signal. Page 1649 Step 3 Step 4 Step 5 Step 6 Locations Page 3912 Page 4628 Page 1374 Knock Sensor: Testing and Inspection Body - Water Leaks to The Interior Cowl: All Technical Service Bulletins Body - Water Leaks to The Interior BODY BO026-00 Title: WATER LEAK FIELD-FIX REPAIR INSTRUCTIONS Models: '97 - '04 Tacoma October 27, 2000 TSB Revision Notice: ^ January 12, 2005: Applicable Vehicles has been updated to include 2004 model year. ^ August 25, 2003: VIN and Applicable Model Information has changed, and repair procedure has been expanded and clarified. ^ October 27, 2000: This TSB updates B0016-98 dated June 12, 1998. B016-98 is now obsolete and should be discarded. Previous versions of this TSB should be discarded. Introduction Use the following field-fix procedures if water is present on the floor carpeting and it can be confirmed that the water is leaking into the cab from either the upper cowl or side cowl seam, or moisture barrier behind the door trim panel. Applicable Vehicles 1997 - 2004 model year Tacoma vehicles. Required Materials Warranty Information Page 3307 SST. b. Install the SST. CAUTION: Check that there is no looseness in the steering wheel and steering wheel pad. 1. Remove the steering column lower cover. Remove the 3 screws and steering column lower cover as shown in the illustration. 2. Disconnect the airbag connector of the spiral cable. 3. Connect the SST connector to the airbag connector of the spiral cable. SST 09082-00700 4. Move the SST at least 10 m (33 ft) away from the front of the vehicle. 5. Close all the doors and windows of the vehicle. NOTE: Take care not to damage the SST wire harness. 6. Connect the SST red clip to the battery positive (+) terminal and the black clip to the negative (-) terminal. Page 1361 Camshaft Position Sensor: Testing and Inspection INSPECT CAMSHAFT POSITION SENSOR a. Disconnect the sensor connector. b. Using an ohmmeter, measure the resistance between the terminals. Resistance: cold 835 - 1,400 ohms Hot 1,060 - 1,645 ohms If the resistance is not as specified, replace the sensor. c. Reconnect the camshaft position sensor connector. Page 4379 Audible Warning Device: Fuse and Fusible Link Locations Relay Box / No. 2 Page 4823 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Page 3310 2. Using 3 wire harness, wind the wire harness at least 2 times each around the bolts installed on the left and right sides of the steering wheel pad. CAUTION: Tightly wind the wire harness around the bolts so that there is no slack. - If there is slack in the wire harness, the steering wheel pad may come loose due to the shock when the airbag Is deployed. This is highly dangerous. 3. Face the upper surface of the steering wheel pad upward. Separately tie the left and right sides of the steering wheel pad to the disc wheel through the hub nut holes. Position the steering wheel pad connector so that it hangs downward through a hub hole in the disc wheel. CAUTION: Make sure that the wire harness is tight. It is very dangerous when looseness in the wire harness results in the steering wheel pad coming free through the shock from the airbag deploying. - Always tie down the steering wheel pad with the pad side facing upward. It is very dangerous if the steering wheel pad is tied down with the metal surface facing upward as the wire harness will be cut by the shock from the airbag deploying and the steering wheel pad will be thrown into the air. NOTE: The disc wheel will be marked by airbag deployment, so when disposing of the airbag use a redundant disc wheel. c. Check functioning of the SST. SST 09082-0700 System Outline Seat Belt Reminder Lamp: Description and Operation System Outline Current always flows to TERMINAL 12 of the integration relay through the DOME fuse. 1. SEAT BELT WARNING SYSTEM When the ignition SW is turned ON, current flows from the GAUGE fuse to TERMINAL 6 of the integration relay. At the same time, current flows to TERMINAL A 2 of the relay from the GAUGE fuse through the seat belt warning light. This current activates the integration relay and, for approx. 4-8 seconds, the current flowing through the warning light flows from TERMINAL A 2 of the relay to TERMINAL A 7 to GROUND, causing the warning light to light up. At the same time as the warning light lights up, a buckle SW ON signal is input to TERMINAL A 3 of the integration relay, the current flowing from TERMINAL 12 of the integration relay flows to TERMINAL A 7 to GROUND and the seat belt warning buzzer sounds for approx. 4 - 8 seconds. However, if the seat belt is put ON (Buckle SW OFF) during this period (while the buzzer is sounding), a signal input to TERMINAL A 3 of the integration relay stops and the current flowing from TERMINAL 12 of the integration relay to TERMINAL A 7 to GROUND is cut, causing the buzzer to stop. 2. KEY REMINDER SYSTEM With the ignition key inserted in the key cylinder (Unlock warning SW ON), the ignition SW still oft and front LH door open (Door courtesy SW ON), a signal is input to TERMINAL A 10, A 5 of the integration relay, the integration relay operates and current flows from TERMINAL 6 of the relay to TERMINAL A 7 to GROUND and the key reminder buzzer sounds. Page 3041 Engine Compartment Instrument Panel Locations Page 4505 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source How to Read Power Source Page 3423 FRONT AXLE HUB REPLACEMENT AND OVERHAUL W/ RELATED COMPONENTS Page 3398 c. Support the brake caliper securely. 7. DISCONNECT LOWER BALL JOINT Remove the 4 bolts and disconnect the lower ball joint. Torque: 80 Nm (820 kgf-cm, 59 ft. lbs.) 8. REMOVE STEERING KNUCKLE a. Remove the cotter pin and loosen the nut. Torque: 105 Nm (1,100 kgf-cm, 80 ft. lbs.) HINT: At the time of installation, if the holes for the cotter pin are not aligned, tighten the nut further up to 60°. b. Using SST, disconnect the steering knuckle. SST 09950-40011 (09951-04010, 09952-04010, 09553-04020, 09554-04010, 09955-04031, 09958-04011) c. Remove the nut and steering knuckle. NOTICE: 4WD: Be careful not to damage the oil seal and drive shaft boot. HINT: 4WD: When it is difficult to disconnect the drive shaft, tap the tip of the drive shaft with a plastic hammer. INSTALLATION Installation is in the reverse order of removal. HINT: After installation, bleed the brake system , check the front wheel alignment and ABS speed sensor signal. Page 2031 COMPONENTS INSPECTION 1. DRAIN ENGINE COOLANT 2. REMOVE AIR CLEANER HOSE 3. REMOVE NO.2 TIMING BELT COVER 4. REMOVE INTAKE AIR CONNECTOR ASSEMBLY 5. REMOVE FUEL PRESSURE REGULATOR 6. REMOVE INTAKE MANIFOLD ASSEMBLY Page 511 Step 2 Step 3 INSPECTION PROCEDURE Diagrams Page 1560 Engine Bank Identification Page 4731 Stop Light: Electrical Diagrams Service Hints S 5-A, B STOP LIGHT SW A-2-A-1,B-2-B-1 : Closed with brake pedal depressed Page 1667 Camshaft Position Sensor: Testing and Inspection INSPECT CAMSHAFT POSITION SENSOR a. Disconnect the sensor connector. b. Using an ohmmeter, measure the resistance between the terminals. Resistance: cold 835 - 1,400 ohms Hot 1,060 - 1,645 ohms If the resistance is not as specified, replace the sensor. c. Reconnect the camshaft position sensor connector. Page 1006 2. Turn the ignition switch ON and push TOYOTA hand-held tester main switch ON. NOTE: Do not start the engine. 3. Select the ACTIVE TEST mode on the TOYOTA hand-held tester. 4. Please refer to the TOYOTA hand-held tester operator's manual for further details. 5. If you have no TOYOTA hand-held tester, connect the positive (+) and negative (-) leads from the battery to the fuel pump connector. 6. Pinch the fuel return hose. The pressure in the high pressure line will rise to approx. 400 kPa (4 kg/Sq.cm, 57 psi). In this state, check to see that there are no leaks from any part of the fuel system. NOTE: Always pinch the hose. Avoid bending as it may cause the hose to crack. 7. Turn the ignition switch OFF. 8. Disconnect the TOYOTA hand-held tester from the DLC3. Page 3071 Junction Box / No. 3 Fuse and Fusible Link Locations Bleeding the Brake System Brake Bleeding: Service and Repair Bleeding the Brake System BRAKE FLUID BLEEDING HINT: If any work is done on the brake system or if air is suspected in the brake lines, bleed the air from the system. NOTICE: Do not let brake fluid remain on a painted surface. Wash it off immediately. 1. FILL BRAKE RESERVOIR WITH BRAKE FLUID Check the fluid level in the reservoir after bleeding each wheel. Add fluid, if necessary. Fluid: SAE J1703 or FMVSS No. 116 DOT 3 2. BLEED MASTER CYLINDER HINT: If the master cylinder has been disassembled or if the reservoir becomes empty, bleed the air from the master cylinder. a. Disconnect the brake lines from the master cylinder. b. Slowly depress the brake pedal and hold it. c. Block off the outlet plug with your finger, and release the brake pedal. d. Repeat (b) and (c) 3 or 4 times. Page 2423 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Testing and Inspection Temperature Gauge: Testing and Inspection INSPECT ENGINE COOLANT TEMPERATURE RECEIVER GAUGE OPERATION a. Disconnect the connector from the sender gauge. b. Turn the ignition switch ON and check that the receiver gauge needle indicates COOL. c. Ground terminal on the wire harness side connector through a 3.4 W test bulb. d. Turn the ignition switch ON, and check that the bulb lights up and the receiver gauge needle moves to the hot side. If operation is as specified, replace the sender gauge. Then, recheck the system. If operation is not as specified, measure the receiver gauge resistance. INSPECT ENGINE COOLANT TEMPERATURE RECEIVER GAUGE RESISTANCE Measure the resistance between terminals. Page 2797 HINT: The brake pedal should not be depressed twice and/or returned while setting to the specified pressure. Read the value of rear brake pressure 2 seconds after adjusting the specified fluid pressure. If the brake pressure is incorrect, adjust the fluid pressure. 4. IF NECESSARY, ADJUST FLUID PRESSURE a. Adjust the length of the No. 2 shackle. Low pressure - Lengthen A High pressure - Shorten A Initial Set: Adjustment Range: HINT: One turn of the nut changes the fluid pressure as shown in the following table. Rear Brake Pressure: b. If the pressure cannot be adjusted by the No. 2 shackle, raise or lower the valve body. Low pressure - Lower body High pressure - Raise body c. Torque the nuts. Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.) d. Adjust the length of the No. 1 shackle again. If it cannot be adjusted, inspect the valve housing. Page 4568 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Page 4067 Wire Harness Fuse Location Troubleshooting Procedure On-Vehicle Inspection Drive Belt: Testing and Inspection On-Vehicle Inspection INSPECTION INSPECT DRIVE BELT a. Visually check the belt for excessive wear, frayed cords etc. If any defect has been found, replace the drive belt. HINT: Cracks on the rib side of a belt are considered acceptable. If the belt has chunks missing from the ribs, it should be replaced. b. Using a belt tension gauge, measure the belt tension. Belt tension gauge: DENSO BTG-20 (95506-00020) Borroughs No. BT-33-73F Drive belt tension: New belt: 135-180 lbs. Used belt: 85-120 lbs. If the belt tension is not as specified, adjust it. HINT: "New belt" refers to a belt which has been used less than 5 minutes on a running engine. - "Used belt" refers to a belt which has been used on a running engine for 5 minutes or more. - After installing a belt, check that it fits properly in the ribbed grooves. - Check with your hand to confirm that the belt has not slipped out of the groove on the bottom of the pulley. - After installing a new belt, run the engine for about 5 minutes and recheck the belt tension. Page 4723 Page 3418 * For vehicle capacity weight. ** For reduced loads (1 to 4 passengers). *** For trailer towing. Page 86 Step 7 Step 8 INSPECTION PROCEDURE Electrical Specifications Oxygen Sensor: Electrical Specifications Air/Fuel Ratio Sensor Resistance: at 20°C (68°F): 0.8 - 1.4 ohms at 800°C (1,472°F): 1.8 - 3.2 ohms Heated Oxygen Sensor Resistance Between Terminals +B and HT: at 20°C (68°F) 11 - 16 Ohms at 800°C (1,472°F) 23 - 32 Ohms Testing and Inspection Condenser HVAC: Testing and Inspection 1. INSPECT CONDENSER FINS FOR BLOCKAGE OR DAMAGE - If the fins are clogged, wash them with water and dry with compressed air NOTE: Be careful not to damage the fins. - If the fins are bent, straighten them with a screwdriver or pliers. 2. INSPECT CONDENSER AND FITTINGS FOR LEAKAGE Using a gas leak detector, check for leakage of refrigerant. If there is leakage, check the tightening torque at the joints. Testing and Inspection Power Window Switch: Testing and Inspection INSPECT POWER WINDOW MASTER SWITCH CONTINUITY Driver's Switch (Window Unlock) Driver's Switch (Window Unlock) Driver's Switch (Window Lock) Driver's Switch (Window lock) Page 1839 Evaporative Vapor Pressure Sensor: Testing and Inspection Vapor Pressure Sensor 1. INSPECT POWER SOURCE VOLTAGE OF VAPOR PRESSURE SENSOR a. Disconnect the vapor pressure sensor connector. b. Turn the ignition switch ON. c. Using a voltmeter, measure the voltage between connector terminals VC and E2 of the wiring harness side. Voltage: 4.5 - 5.5 V d. Turn the ignition switch OFF. e. Reconnect the vapor pressure sensor connector. 2. INSPECT POWER OUTPUT OF VAPOR PRESSURE SENSOR a. Turn the ignition switch ON. b. Disconnect the vacuum hose from the vapor pressure sensor. c. Connect a voltmeter to terminals PTNK and E2 of the ECM, and measure the output voltage under ambient atmospheric pressure. 1. Apply vacuum (2.0 kpa, 15 mmHg, 0.59 in.Hg) to the vapor pressure sensor. Voltage: 1.3 - 2.1 V 2. Release the vacuum from the vapor pressure sensor. Voltage: 3.0 - 3.6 V 3. Apply pressure (1.5 kPa, 15 gf/Sq.cm, 0.22 psi) to the vapor pressure sensor. Voltage: 4.2 - 4.8 V d. Reconnect the vacuum hose to the vapor pressure sensor. Page 2170 Page 3278 c. Expand a new teflon ring with your fingers. NOTICE: Be careful not to overexpand the ring. d. Coat the ring with power steering fluid. e. Install the ring to the rack, and settle it down with your fingers. 9. IF NECESSARY, REPLACE TEFLON RINGS a. Using a screwdriver, remove the 4 rings from the control valve assembly. NOTICE: Be careful not to damage the grooves for the ring. b. Expand 4 new rings with your fingers. NOTICE: Be careful not to overexpand the ring. c. Coat the rings with power steering fluid. d. Install the rings to the control valve assembly, and settle them down with your fingers. e. Carefully slide the tapered end of SST over the rings until the ring fits to the steering rack. SST 09631-20081 NOTICE: Be careful not to damage the rings. 10. IF NECESSARY, REPLACE UNION SEATS Page 3284 b. Using a spanner to hold the steering rack steady, and using SST, torque the rack end. SST 09922-10010 Torque: 76 Nm (770 kgf-cm, 56 ft. lbs.) NOTICE: Use SST 09922-10010 in the direction shown in the illustration. HINT: Use a torque wrench with a fulcrum length of 345 mm (13.58 inch). c. Using a brass bar and hammer, stake the washer. NOTICE: Avoid any impact to the rack. 14. INSTALL RH AND LH RACK BOOTS, CLAMPS AND CLIPS a. Ensure that the tube hole is not clogged with grease. HINT: If the tube hole is clogged, the pressure inside the boot will change after it is assembled and the steering wheel is turned. b. Install the boot. NOTICE: Be careful not to damage or twist the boot. c. Tighten a new clamp, as shown in the illustration. 15. INSTALL RH AND LH TIE ROD ENDS AND LOCK NUTS a. Screw the lock nut and tie rod end onto the rack end until the matchmarks are aligned. b. After adjusting toe-in, torque the nut. Torque: 55 Nm (560 kgf-cm, 41 ft. lbs.) Page 4722 Page 1905 Fuel Pressure: Specifications Volume Specification Information not supplied by the manufacturer. Page 339 Page 4050 3. ADJUST HOOD LOCK Adjust the lock by loosening the bolts. Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf) Page 920 Engine Oil: Service and Repair REPLACEMENT CAUTION: Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants, which may cause skin cancer. - Care should be taken, therefore, when changing engine, oil to minimize the frequency and length of time your skin is exposed to used engine oil. Protective clothing and gloves that cannot be penetrated by oil should be worn. The skin should be thoroughly washed with soap and water, or use water-less hand cleaner, to remove any used engine oil. Do not use gasoline, thinners, or solvents. - In order to preserve the environment, used oil and used oil filters must be disposed of only at designated disposal sites. 1. DRAIN ENGINE OIL a) Remove the oil filler cap. b) Remove the oil dipstick. c) Remove the oil drain plug and drain the oil into a container. 2. REPLACE OIL FILTER a) Using SST, remove the oil filter (located on left side of the cylinder block). SST 09228-07501 b) Clean the filter contact surface on the filter mounting. c) Apply clean engine oil to the gasket of a new oil filter. d) Tighten the filter by hand until the gasket contacts the seat of the filter mounting. Then using SST, give it an additional 3/4 turn to seat the filter. SST 09228-07501 3. REFILL WITH ENGINE OIL a) Clean and install the oil drain plug with a new gasket. b) Fill the engine with new oil. Oil capacity: c) Reinstall the oil filler cap. 4. START ENGINE AND CHECK FOR LEAKS 5. RECHECK ENGINE LEVEL Page 3089 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 3187 If it is more than the maximum, replace the plate and/or rotor with one having the same mark stamped on the cam ring. Inscribed mark: 1, 2, 3, 4 or None HINT: There are 5 vane plate lengths with the following rotor and cam ring marks: 3. INSPECT FLOW CONTROL VALVE a. Coat the valve with power steering fluid and check that it falls smoothly into the valve hole by its own weight. b. Check the flow control valve for leakage. Close one of the holes and apply compressed air 392-490 kPa (4-5 kgf/cm2, 57-71 psi) into the opposite side, and confirm that air does not come out from the end holes. Page 2459 a. Using SST and a press, remove the bearing. SST 09223-56010, 09950-60010 (09951-00560) b. Using SST and a press, install a new bearing. SST 09515-30010, 09950-60020 (09951-00890) 7. INSTALL NEW OUTER OIL SEAL Using SST and a hammer, install a new oil seal. SST 09950-60010 (09951-00610), 09950-70010 (09951-07150) 8. REPLACE BEARING CASE a. Remove the oil seal (outer side) and bearing. b. Install 4 nuts to the serration bolts. c. Using a hammer, remove the serration bolts and bearing case. d. Position the backing plate on a new bearing case and using 2 socket wrenches, install the serration bolts. e. Install a new bearing and oil seal (outer side). Page 3803 Seat Belt Reminder Buzzer: Testing and Inspection INSPECT INTEGRATION RELAY SEAT BELT WARNING SYSTEM OPERATION a. Connect the positive (+) lead from the battery to terminal 12 and negative (-) lead from the battery to terminal 7. b. Connect the terminal 2 to terminal 5 through the 3.4 W test bulb. c. Connect the negative (-) lead from the battery to terminal 3. d. Check that the bulb lights and the chime sounds for 4 - 8 seconds. e. Return to step (a) and operate the chime again. f. Check that the buzzer does not sound when disconnecting terminal 3 from the negative (-) lead. g. Check that the chime stops sounding. HINT: Check the chime within a period of 4 to 8 seconds. If operation is not as specified, replace the relay. Testing and Inspection Washer Fluid Level Switch: Testing and Inspection INSPECT WASHER LEVEL SWITCH a. Check that no continuity exists between terminals with the switch OFF (float up). b. Check that continuity exists between terminals with the switch ON (float down). If operation is not as specified, replace the switch. Page 1268 Specifications Planetary Gears: Specifications Front Planetary Gear Maximum Inside Diameter .............................................................................................................................................................. 24.08 mm (0.9480 inch) Planetary Pinion Thrust Clearance Standard .............................................................................................................................................. .................. 0.20 - 0.60 mm (0.0079 - 0.0236 inch) Maximum ............................................................. ............................................................................................................................ 1.0 mm (0.0394 inch) Planetary Sun Gear Sun Gear Bushing Inside Diameter, Maximum ............................................................................................................................... 27.08 mm (1.0661 inch) Rear Planetary Gear Planetary Pinion Gear Thrust Clearance Standard .............................................................................................................................................. .................. 0.20 - 0.60 mm (0.0079 - 0.0236 inch) Maximum ............................................................. .......................................................................................................................... 1.00 mm (0.0394 inch) Page 3196 Repair Procedure 1. Disconnect the cable from the negative (-) battery terminal for MORE THAN two (2) seconds. 2. Reconnect the cable to the negative (-) battery terminal. 3. Perform the applicable zero point calibration of the yaw rate sensor and/or the steering angle sensor. HINT Refer to the applicable TSB or Repair Manual for the zero point calibration procedure. 4. Re-initialize all applicable systems available on the vehicle (power window sunroof power lift door etc.). Page 1622 Refer to Reset Procedure 1 for the vehicles with Electronically Controlled Automatic Transmissions: Page 870 Valve Clearance: Testing and Inspection INSPECTION HINT: Inspect and adjust the valve clearance when the engine is cold. 1. REMOVE INTAKE AIR CONNECTOR 2. REMOVE CYLINDER HEAD COVERS 3. SET NO.1 CYLINDER TO TDC/COMPRESSION a) Turn the crankshaft pulley, and align its groove with timing mark "0" of the No.1 timing belt cover. b) Check that the timing marks (1 dot) of the camshaft drive and driven gears are in straight line on the cylinder heads surface as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) and align the marks. 4. INSPECT VALVE CLEARANCE a) Check only the valves indicated in the illustration. 1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft. 2) Record out of specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim. Valve clearance (Cold): Input Signal Check Cruise Control Switch: Testing and Inspection Input Signal Check DENSO Made HINT: 1. For check No.1 - No.2: Turn the ignition switch ON. 2. For check No.3: - Turn ignition switch ON. - Shift to D position. 3. For check No.4: - Jack up the vehicle. - Start the engine. - Shift to D position. a. Press the control switch to SET/COAST or RES/ACC position and hold it down or hold it up "1". b. Push the main switch ON "2". c. Check that the CRUISE MAIN indicator light blinks twice or 3 times repeatedly after 3 seconds. d. Turn the SET/COAST or RES/ACC switch OFF. e. Operate each switch as listed in the table. Page 4300 6. Mask-off wiper motor opening. 7. Attach Kent(TM) 12" extension tube (P/N 90175) to the nozzle on the can of Leak-Chek(TM) (P/N 50087). NOTE: Direct Leak-Chek(TM) spray material approximately 1 inch above seam. Spray force is very strong - make several test passes before actually spraying material into seam. 8. Spray Leak-Chek(TM) through the wiper motor opening. a. Spray material inside upper cowl, beginning in lower corner, and continuing toward the centerline of vehicle. b. Remove wand from the wiper motor opening and insert it into larger cowl openings on the right hand side. Continue spraying material along entire seam until seam is filled from R/F fender to L/F fender area. Spray Leak-Chek(TM) into seam a total of 3 times, allowing Leak-Chek(TM) to flash dry for 30-45 minutes between applications. (Drying time increases as outside temperature decreases.) 9. After final application of Leak-Chek(TM) has been allowed to dry for approximately one hour, flood area with water for 5-10 minutes. NOTE: Hold garden hose at top right front corner of windshield and point hose downward toward lower right hand corner of windshield as shown. 10. Check inside cab behind Heater/Air Conditioner box for evidence of water leakage during water leak check. 11. Carefully inspect "T" joint on right and left sides (close to heater motor box, and brake booster) for evidence of water leaks. 12. If no leaks are found, cowl area leak repair is complete. Reinstall wiper motor, cowl trim panel, wiper arms, and hood. Wiper Arm Torque: 20 N.m (205 kgf.cm, 15 ft.lbf) If water leaks are still present and are coming in from the cowl area, remove right front fender and proceed as follows: 13. Seal around entire perimeter of "L" bracket with Kent High Tech(TM) Clear Seam Sealer (see drawing for location of "L" bracket). 14. Using a flashlight, look through the 2" x 3" rectangular hole on side of vertical cowl panel and locate vertical seam that connects side of cowl to front cowl. Page 2629 Junction Box / No. 3 Page 1644 Part 2 Of 2 (Except California Spec.) *1: A/T *2: M/T Page 601 Spark Plug: Application and ID Recommended Spark Plugs ND K16TR11 NGK BKR5EKB-11 Page 2638 Connector Locations Page 2547 Junction Box / No. 1 Page 2555 Shift Indicator: Description and Operation Previous automatic transmissions have selected each gear shift using mechanically controlled throttle hydraulic pressure, governor hydraulic pressure and lock-up hydraulic pressure. The electronically controlled transmission, however, electrically controls the governor pressure and lock-up sensor through the solenoid valve. Control of the solenoid valve by the engine control module based on the input signals from each sensor makes smooth driving possible by shift selection for each gear which is most appropriate to the driving conditions at that time. 1. GEAR SHIFT OPERATION During driving, the engine control module selects the shift for each gear which is most appropriate to the driving conditions, based on input signals from the engine coolant temp. sensor to TERMINAL THW of the engine control module and also the input signals to TERMINAL SP2+ of the engine control module from the vehicle speed sensor devoted to the electronically controlled transmission. Current is then output to the electronically controlled transmission solenoid. When shifting to 1st speed, current flows from TERMINAL S1 of the engine control module to TERMINAL 1 of the electronically controlled transmission solenoid to GROUND, and continuity to the No.1 solenoid causes the shift. For 2nd speed, current flows from TERMINAL S1 of the engine control module to TERMINAL 1 of the electronically controlled transmission solenoid to GROUND, and from TERMINAL S2 of the engine control module to TERMINAL 2 of the electronically controlled transmission solenoid to GROUND. And continuity to solenoid No.1 and No.2 causes the shift. For 3rd speed, there is no continuity to No.1 solenoid, only to No.2 causing the shift. Shifting into 4th speed (Overdrive) takes place when there is no continuity to either No.1 or No.2 solenoid. 2. LOCK-UP OPERATION When the engine control module judges from each signal that lock-up operation conditions have been met, current flows from TERMINAL SL of the engine control module to TERMINAL 3 of the electronically controlled transmission solenoid to GROUND, causing continuity to the lock-up solenoid and causing lock-up operation. 3. STOP LIGHT SW CIRCUIT If the brake pedal is depressed (Stop light SW ON) when driving in lock-up condition, a signal is input to TERMINAL STP of the engine control module, the engine control module operates and continuity to the lock-up solenoid is cut. 4. OVERDRIVE CIRCUIT * O/D main SW ON When the O/D main SW is turned ON (SW point is open), a signal is input to TERMINAL ODMS of the engine control module and engine control module operation causes gear shift when the conditions for overdrive are met. * O/D main SW OFF When the O/D main SW is turned OFF (SW point is closed), a signal is input into TERMINAL ODMS of the engine control module, and turns on the O/D OFF indicator light. This activates the ECU, and the transmission system is controlled not to shift to overdrive. 5. A/T OIL TEMP. WARNING When the A/T oil temp. sensor affixed to the transmission case detects that the fluid temp. is 150 °C (302 °F) or more, the engine control module operates and the current flowing through the GAUGE fuse flows to the A/T oil temp. warning light to TERMINAL OILW of the engine control module to GROUND, so that the warning light lights up, informing that the oil temp. is high. When the oil temp. drops to 120 °C (248 °F) or less, the engine control module stops operating and the warning light goes out. Page 2840 4. REMOVE MASTER CYLINDER a. Remove the 4 nuts, 3-way and check valve bracket. Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.) b. Pull out the master cylinder and gasket. INSTALLATION HINT: ^ Before installation, adjust the length of the brake booster push rod. ^ After installation, fill the brake reservoir with brake fluid, bleed brake system and check for leaks. See: Brake Bleeding ^ Check and adjust the brake pedal. See: Brake Pedal Assy/Testing and Inspection Locations Page 4103 ^ February 28, 2003: In Wireless Transmitter Identification section Figures 5, 9, 10,1 2, and 13 as shown are updated to include 2003 model year; Figure 11 updated to include 1999 and 2003 model year. ^ January 17, 2003: 2003 model year added to Solara in the Application Chart. ^ The information contained in this TSB supercedes TSB EL010-01, dated October 26, 2001. The previous TSB, EL010-01, should be discarded. Introduction Page 4084 Roof Headlining (Extra Cab) Page 3422 Wheel Bearing: Diagrams Removal and Installation Brake Caliper: Service and Repair Removal and Installation REMOVAL 1. REMOVE FRONT WHEEL Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.) 2. DISCONNECT FLEXIBLE HOSE Remove the union bolt and 2 gaskets from the caliper, then disconnect the flexible hose from the caliper. Torque: 30 Nm (310 kgf-cm, 22 ft. lbs.) HINT: At the time of installation, install the flexible hose lock securely in the lock hole in the caliper. Locations Page 368 Body - Paintless Dent Repair Information Paint: All Technical Service Bulletins Body - Paintless Dent Repair Information TITLE: PAINTLESS DENT REPAIR SECTION: EXTERIOR BULLETIN # 146 MODELS: TOYOTA, SCION AND LEXUS DATE: SEPTEMBER 2006 Toyota has developed the following guidelines for the use of "Paintless Dent Repair (PDR) procedures on all Toyota, Scion and Lexus vehicles. PDR is used to reduce the cost of repairing minor dents and to avoid color match and refinish issues that may arise. Be sure to choose your PDR service provider carefully and always review their professional qualifications to ensure they are up to date on the latest PDR techniques and procedures. Repair Precautions ^ Always refer to the specific vehicle schematic (available from your PDR provider) for locations where PDR is possible. ^ Pay close attention to the locations of accessories and subassemblies that may utilize wire harnesses or drain hoses, etc. ^ PDR is often complicated by panel contour, placement of reinforcements, and location of electrical and mechanical components. ^ PDR Technicians should be aware of and take the necessary precautions to prevent damage to electrical and mechanical components while performing PDR repairs. General Repair Guidelines ^ The PDR process should only be considered when the exterior paint surface is not broken or cracked. A 30X power hand held microscope (available from most body shop jobbers) should be used to determine if the paint surface shows evidence of cracking. ^ Pushing and prying on the back side of body panels can disrupt the factory rust and corrosion protective coatings. PDR technicians must take steps to prevent corrosion coating damage or restore it with approved equivalent materials. PDR service companies performing PDR repairs should be knowledgeable and capable of restoring corrosion protective coatings damaged during PDR repairs. PLEASE ROUTE THIS BULLETIN TO YOUR COLLISION REPAIR CENTER MANAGER AND COLLISION REPAIR TECHNICIANS ^ Prying, pushing, or pulling on body panels may cause stretching beyond the flexible limits of the paint coatings causing delamination (paint coating separation) or micro-cracking. These conditions may not be immediately detectable (use a 30X magnifying hand-held microscope to inspect for cracks). Important: The PDR process uses special tools to access otherwise inaccessible areas. Drilling of holes, prying away or cutting reinforcements or welded structural components to gain access to perform a PDR is strictly prohibited and, if done, may void the manufacturer's corrosion protection warranty. ^ Using blocks or wedges between window moldings and door glass (for tool access) is also prohibited. This process can damage window moldings and reduce the factory designed-in pressure of the inner belt molding on the base of the door glass. ^ Window guard protectors must be used to protect window glass during PDR operations. Specific Repair Guidelines ^ Panels with multiple dents, including hail damage, may be considered for PDR as long as the original panel integrity (strength) is maintained. If a panel exhibits any evidence of loss of strength due to the number of dents, the panel should not be considered for PDR. If after performing a PDR repair the panel exhibits evidence of loss of strength, the panel must be repaired using conventional body shop processes. ^ Round/oval dents may be removed if they are 2 inches or more away from panel edges or body lines and are no larger than the diameter of a soft ball. ^ Creases that are up to 4 long may be considered for removal. Note: Sharp creases cannot be removed using PDR. ^ Dents or protrusions, of up to 6mm, from the reverse side, on hoods, trunks, fenders, and quarter panels may be considered, but extreme caution must Removal and Installation Wheel Bearing: Service and Repair Removal and Installation REMOVAL Page 3938 Wire Harness Fuse Location Troubleshooting Procedure Page 2351 Torque Converter: Testing and Inspection INSPECTION 1. INSPECT ONE-WAY CLUTCH a. Install SST in the inner race of one-way clutch. SST 09350-30020 (09351-32010) b. Install SST so that it fits in the notch of the converter hub and outer race of the one-way clutch. SST 09350-30020 (09351-32010, 09351-32020) c. With the torque converter clutch standing on its side, check that the clutch locks when turned counterclockwise, and rotates freely and smoothly clockwise. If necessary, clean the converter clutch and retest the clutch. Replace the converter clutch if the clutch still fails the test. 2. MEASURE DRIVE PLATE RUNOUT AND INSPECT RING GEAR Set up a dial indicator, measure drive plate runout. Maximum runout: 0.20 mm (0.0079 inch) If runout is not within the specification, replace the drive plate. If installing a new drive plate, note the orientation of spacers and tight the bolts. Torque: 3RZ-FE: 74 Nm (750 kgf-cm, 54 ft. lbs.) 5VZ-FE: 83 Nm (850 kgf-cm, 61 ft. lbs.) Page 2563 Transmission Mode Indicator - A/T: Testing and Inspection CIRCUIT DESCRIPTION The ECM memory contains the shift programs for the NORMAL and POWER patterns, 2 position, L position and the lock-up patterns. Following the programs corresponding to the signals from the pattern select switch, the park/neutral position and other various sensors, the ECM switches the solenoid valves ON and OFF, and controls the transmission gear change and the lock-up clutch operation. Specifications Timing Belt Tensioner: Specifications Timing Belt Tensioner Torque ................................................................................................................................................. ........................................................................ 27 Nm Page 3123 Engine Compartment Instrument Panel Locations Component Locations Horn: Component Locations Page 2492 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 Testing and Inspection Tail Lamp Relay: Testing and Inspection INSPECT TAILLIGHT CONTROL RELAY CONTINUITY If continuity is not as specified, replace the relay. Page 2519 Step 1 Page 68 Testing and Inspection Power Window Relay: Testing and Inspection INSPECT POWER MAIN RELAY CONTINUITY If continuity is not as specified, replace the relay. Page 2670 Step 1 Step 2 Page 3400 HINT: PreRunner is the model described below. RZN191L-TRPDKAB, RZN196L-CRPDKAB, VZN195L-CRPDKAB 1. 4WD: REMOVE OIL SEAL (INSIDE) a. Clamp the axle hub in a soft jaw vise. HINT: Close vise until it holds hub bolts. Do not tighten further. b. Using a screwdriver, remove the oil seal (inside). 2. PreRunner: REMOVE GREASE CAP a. Clamp the axle hub in a soft jaw vise. HINT: Close vise until it holds hub bolts. Do not tighten further. b. Using a screwdriver, remove the grease cap. Page 2673 Step 5 INSPECTION PROCEDURE Page 2408 Steps 1 - 2 Page 1721 CHART 12 CHART 13 Page 1890 Fuel Injector: Service and Repair REMOVAL 1. REMOVE AIR CLEANER HOSE 2. REMOVE INTAKE AIR CONNECTOR ASSEMBLY 3. REMOVE FUEL PRESSURE REGULATOR 4. DISCONNECT FUEL INLET PIPE CAUTION: Catch leaking fuel in a container. 5. REMOVE FUEL PIPE 6. DISCONNECT INJECTOR CONNECTORS 7. REMOVE DELIVERY PIPES AND INJECTORS NOTE: Be careful not to drop the Injectors when removing the delivery pipes. - Pay attention to put any hung load on the injector to and from the side direction. a. Remove the 4 bolts and delivery pipes together with the 6 injectors b. Remove the 4 spacers from the intake manifold. c. Pull out the 6 injectors from the delivery pipes. d. Remove the 2 O-ring and insulator from each injector. INSTALLATION 1. INSTALL INJECTORS AND DELIVERY PIPES a. Install a new insulator to each injector. b. Apply a light coat of spindle oil or gasoline to 2 new O-rings and install them to each injector. c. While turning the injector clockwise and counterclockwise, push it to the delivery pipes. Install the 6 injectors. Page 350 CHART 12 CHART 13 Page 2511 Flex Plate: Specifications Drive Plate Bolts 83 Nm (61 ft.lb) Sequence Page 1768 D: Indicates related system. Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V). Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, 1H2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green O = Orange P = Pink R = Red SB = Sky Blue V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Page 770 Junction Box / No. 1 Details Page 3601 Air Bag(s) Arming and Disarming: Service and Repair Release Method of Airbag Activation Prevention Mechanism Page 1127 Water Pump: Service and Repair Page 2104 Page 366 Airbag(s) Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Airbag(s) Arming and Disarming CAUTION: * Work must be started 90 seconds after the ignition switch is turned to the "LOCK" position and the negative (-) terminal cable is disconnected from the battery. (The SRS is equipped with a back-up power source so that if work is started within 90 seconds of disconnecting the negative (-) terminal cable of the battery, the SRS may be deployed.) * When the negative (-) terminal cable is disconnected from the battery, the memory of the clock and audio system will be canceled. So before starting work, make a record of the contents memorized in the audio memory system. When work is finished, reset the audio systems as before and adjust the clock. To avoid erasing the memory of each memory system, never use a backup power supply from outside the vehicle. * Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during repairs. * Do not expose the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor directly to hot air or flames. AIR BAG SYSTEM DISARMING The Air Bag/Supplemental Restraint System (SRS) incorporates a backup energy source that maintains sufficient deployment voltage for up to 90 seconds after the ignition is turned Off and the battery has been disconnected. Before disconnecting battery, note radio station settings, since all vehicle memory will be lost. Never use a backup power source from outside the vehicle. 1. Turn ignition to Lock, then disconnect battery ground cable. 2. Wait at least 90 seconds after disconnection before beginning service or diagnostic procedures. AIR BAG SYSTEM ARMING 1. Ensure ignition is in Lock position. 2. Connect battery ground cable. 3. Wait at least 10 seconds before turning ignition from Lock position. 4. Turn ignition to ACC or On position and ensure SRS lamp lights, then goes off after approximately six seconds. If lamp remains lit, an SRS condition is indicated. Refer to Restraint Systems, Air Bag Systems, Testing And Inspection. See: Restraint Systems/Air Bag Systems/Testing and Inspection Diagram Information and Instructions Audible Warning Device: Diagram Information and Instructions Key to Diagrams Key to Diagrams A: System Title. B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: (1) Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. ABS/TCS - Zero Point Calibration Information Steering Angle Sensor: Technical Service Bulletins ABS/TCS - Zero Point Calibration Information T-SB-0020-08 March 25, 2008 Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment Service Category Brake Section Brake Control/Dynamic Control System Market USA Applicability Introduction The purpose of this TSB is to provide information on when and how to perform the zero point calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting the battery is a necessary step for performing the zero point calibration. Warranty Information Required Tools & Equipment ^ Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE). ^ The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the service procedures listed in this bulletin. Preliminary Information Perform this procedure if any of these repairs have been performed on the vehicle: ^ Wheel alignment has been adjusted. ^ Any chassis components have been removed/installed or replaced. Page 1037 3) Select a new shim with a thickness as close as possible to the calculated values. HINT: Shims are available in 17 sizes in increments of 0.050 mm (0.0020 inch), from 2.500 mm (0.0984 inch) to 3.300 mm (0.1299 inch). Page 259 a. Connect the positive (+) lead from the battery to terminal 12. b. Connect the negative (-) lead from the battery to terminals 5,7 and 10. c. Check the chime sounds. d. Disconnect the negative (-) lead from the battery to terminal 10. e. Check that the chime stops sounding. f. Connect the negative (-) lead from the battery to terminal 10. g. Connect the positive (+) lead from the battery to terminal 6. h. Check that the chime stops sounding. If operation is not as specified, replace the relay. 4. INSPECT INTEGRATION RELAY CIRCUIT a. Remove the relay from the junction block No.1 and inspect the connectors on the junction block side. Page 2539 Shift Indicator: Ground Locations Service Precautions Air Bag(s) Arming and Disarming: Service Precautions NOTE: TOYOTA trucks are equipped with SRS, which comprises a driver airbag and front passenger airbag. Failure to carry out service operations in the correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Further, if a mistake is made in servicing the SRS, it is possible that the SRS may fail to operate when required. Before performing servicing (including removal or installation of parts, inspection or replacement), be sure to read the following items carefully, then follow the correct procedures described in the repair manual. Malfunction symptoms of the SRS are difficult to confirm, so the DTCs become the most important source of information when troubleshooting. When troubleshooting the SRS, always inspect the DTCs before disconnecting the battery. Even in cases of a minor collision where the SRS does not deploy, the steering wheel pad, front passenger airbag assembly, airbag sensor assembly and front airbag sensor should be inspected. Never use SRS parts from another vehicle. When replacing parts, replace them with new parts. Never disassemble and repair the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor in order to reuse it. If the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor has been dropped, or if there are cracks, dents or other defects in the case, bracket or connector, replace them with new ones. Use a volt/ohmmeter with high impedance (10 K.Ohm/V minimum) for troubleshooting the system's electrical circuits. Information labels are attached to the periphery of the SRS components. Follow the instructions on the notes. After work on the SRS is completed, perform the SRS warning light check. If the vehicle is equipped with a mobile communication system, refer to the precaution in the Introduction system. CAUTION: Work must be started 90 seconds after the ignition switch is turned to the "LOCK" position and the negative (-) terminal cable is disconnected from the battery (The SRS is equipped with a back-up power source so that if work is started within 90 seconds from disconnecting the negative (-) terminal cable of the battery, the SRS may be deployed.). When the negative (-) terminal cable is disconnected from the battery, the memory of the clock and audio system will be canceled. So before starting work, make a record of the contents memorized in the audio memory system. When work is finished, reset the audio systems as they were before and adjust the clock. However, it is not possible to make a record of the memory contents. So when the work is finished, it will be necessary to explain this fact to the customer, and ask the customer to adjust the features and reset the memory. To avoid erasing the memory in each memory system, never use a back-up power supply from outside the vehicle. Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during repairs. Do not expose the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor directly to hot air or flames. ABS/TCS - Zero Point Calibration Information Steering Angle Sensor: Technical Service Bulletins ABS/TCS - Zero Point Calibration Information T-SB-0020-08 March 25, 2008 Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment Service Category Brake Section Brake Control/Dynamic Control System Market USA Applicability Introduction The purpose of this TSB is to provide information on when and how to perform the zero point calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting the battery is a necessary step for performing the zero point calibration. Warranty Information Required Tools & Equipment ^ Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE). ^ The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the service procedures listed in this bulletin. Preliminary Information Perform this procedure if any of these repairs have been performed on the vehicle: ^ Wheel alignment has been adjusted. ^ Any chassis components have been removed/installed or replaced. Page 4544 Step 5 INSPECTION PROCEDURE Page 4335 Wiring Diagram Step 1 Air/Fuel Ratio Sensor Oxygen Sensor: Testing and Inspection Air/Fuel Ratio Sensor Air-Fuel Ratio (A/F) Sensor COMPONENTS INSPECTION 1. INSPECT HEATER RESISTANCE OF A/F SENSOR a. Disconnect the sensor connector. b. Using an ohmmeter, measure the resistance between terminals +B and HT. Resistance: at 20 °C (68 °F) 0.8 - 1.4 ohms at 800 °C (1,472 °F) 1.8 - 3.2 ohms If the resistance is not as specified, replace the sensor. Torque: 20 Nm (200 kg.cm, 14 ft.lb) c. Connect the sensor connector. 2. INSPECT OPERATION OF A/F SENSOR Page 357 CHART 21 Page 3645 a. Spiral Cable b. Upper And Lower Column Covers c. Steering Wheel d. Steering Wheel Pad Page 65 Splice Point J: Indicates a wiring Splice Point (Codes are "E"for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I 5 is indicated by the shaded section. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. N: Page No. How to Read Ground Points How to Read Ground Points Page 488 Repair Procedure 1. Disconnect the cable from the negative (-) battery terminal for MORE THAN two (2) seconds. 2. Reconnect the cable to the negative (-) battery terminal. 3. Perform the applicable zero point calibration of the yaw rate sensor and/or the steering angle sensor. HINT Refer to the applicable TSB or Repair Manual for the zero point calibration procedure. 4. Re-initialize all applicable systems available on the vehicle (power window sunroof power lift door etc.). Page 4713 Stop Light: Splice Locations Specifications Compression Check: Specifications Compression Pressure ........................................................................................................................ ..................................................... 1,200 kPa or More Minimum Pressure .......................................... ....................................................................................................................................................... 1,000 kPa Difference Between Each Cylinder ..................................................................................... .......................................................................... 100 kPa or Less Page 3624 Air Bag Deactivation Switch: Testing and Inspection 1. INSPECT PASSENGER AIRBAG MANUAL ON-OFF SWITCH CONTINUITY HINT: Release the airbag activation prevention mechanism of the passenger airbag manual on-off switch connector on the air- bag sensor assembly side. If continuity is not as specified, replace the switch. 2. INSPECT PASSENGER AIRBAG MANUAL ON-OFF INDICATOR OPERATION a. Check that continuity exists between 5 and 6. b. Connect the positive (+) lead from the battery to terminal 1 and negative (-) lead to terminal 2. c. Check that the indicator light lights up. If the operation is not as specified, replace the indicator. Page 1582 CHART 11 Page 4037 reinstall plastic sheet against metal door panel. Confirm that there are no voids between sealer and plastic sheet and between sealer and metal door panel. 22. Flood all areas with water to confirm that there are no leaks into cab area. 23. If no leaks are present, reinstall door trim panel. Page 328 A/F and 02 Sensor Identification Page 2981 2. Using SST, tighten the nuts to the specified torque. SST 09810-38140 Torque: 17 Nm (173 kg.cm, 13 ft.lb) NOTE: If the nut is over tightened, it may cause cracks on the inside of the insulator. h. Clean the contact surfaces of the remaining contact plate and plunger with a dry shop rag. i. Reinstall the plunger, a new gasket, the end cover and lead clamp (1.8 kW) with the 3 bolts. Torque: 2.5 Nm (25 kg.cm, 22 in.lb) for 1.4 kW 3.6 Nm (37 kg.cm, 32 in.lb) for 1.8 kW Page 4652 Page 1173 D: Indicates related system. Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V). Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, 1H2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green O = Orange P = Pink R = Red SB = Sky Blue V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Page 207 Steps 2 - 3 INSPECTION PROCEDURE O/D Main Switch & O/D OFF Indicator Light Circuit Overdrive Switch: Testing and Inspection O/D Main Switch & O/D OFF Indicator Light Circuit CIRCUIT DESCRIPTION The O/D main switch is a momentary type switch. When pressing the O/D OFF main switch, the O/D OFF indicator light lights up and ECM prohibit shifting to O/D, and when pressing it again, the O/D OFF indicator light goes off and ECM allows shifting to O/D. Turning the IG switch OFF will reset the O/D OFF indicator light. Description and Operation ABS Light: Description and Operation Testing and Inspection Locations Page 2494 Drive/Propeller Shaft: Service and Repair REMOVAL HINT: Pre runner is the models described. RZN191L-TRPDKAB, RZN196L-CRPDKAB, VZN195L-CRPDKAB Page 2928 Battery: Testing and Inspection INSPECTION CAUTION: - Check that the battery cables are connected to the correct terminals. - Disconnect the battery cables when the battery is given a quick charge. - Do not perform tests with a high voltage insulation resistance tester. - Never disconnect the battery while the engine is running. 1. CHECK BATTERY ELECTROLYTE LEVEL Check the electrolyte quantity of each cell. Maintenance-Free Battery: If under the lower level, replace the battery (or add distilled water if possible) and check the charging system. Except Maintenance-Free Battery: If under the lower level, add distilled water. 2. Except Maintenance-Battery: CHECK BATTERY SPECIFIC GRAVITY Check the specific gravity of each cell. Standard specific gravity: 1.25- 1.29 at 20°C (68°F) If the specific gravity is less than specification, charge the battery. 3. Maintenance-Free Battery: CHECK BATTERY VOLTAGE a. After having driven the vehicle and in the case that 20 minutes have not passed after having stopped the engine, turn the ignition switch ON and turn on the electrical system (headlight, blower motor, rear defogger etc.) for 60 seconds to remove the surface charge. b. Turn the ignition switch OFF and turn off the electrical systems. c. Measure the battery voltage between the negative (-) and positive (+) terminals of the battery. Standard voltage: 12.5 - 12.9 V at 20°C (68 °F) If the voltage is less than specification, charge the battery. Component Tests and General Diagnostics Seat Belt Reminder Lamp: Component Tests and General Diagnostics INSPECT SEAT BELT WARNING LIGHT a. Remove the integration relay from the No.1 J/B. b. Ground terminal 9 on the junction block side connector. c. Turn the ignition switch ON and check that the warning light lights up. If the warning light does not light up, inspect the bulb or wire harness. Page 4487 Air Bag(s) Arming and Disarming: Service and Repair Release Method of Airbag Activation Prevention Mechanism Page 2074 Overdrive Indicator Lamp: Testing and Inspection O/D Main Switch & O/D OFF Indicator Light Circuit CIRCUIT DESCRIPTION The O/D main switch is a momentary type switch. When pressing the O/D OFF main switch, the O/D OFF indicator light lights up and ECM prohibit shifting to O/D, and when pressing it again, the O/D OFF indicator light goes off and ECM allows shifting to O/D. Turning the IG switch OFF will reset the O/D OFF indicator light. Page 2778 Brake Rotor/Disc: Testing and Inspection For information regarding the inspection of this component, please refer to Brake Caliper; Service and Repair; Disassembly and Reassembly. Page 3460 Blower Motor: Service and Repair Disassembly and Reassembly DISASSEMBLY REMOVE BLOWER MOTOR Remove the 3 screws and blower motor. REASSEMBLY Reassembly is in the reverse order of disassembly. Page 2217 Step 4 Page 3014 Auxiliary Power Outlet: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Page 1563 Applicable Vehicles Page 2028 Page 1436 Mass Air Flow Meter: Testing and Inspection INSPECTION 1. INSPECT MAF METER RESISTANCE Using an ohmmeter, measure the resistance between terminals THA and E2. If the resistance is not as specified, replace the MAF meter. Temperature Resistance at -20 °C (-4 °F) 13.6 - 18.4 Kohms at -20 °C (68 °F) 2.2 - 2.7 Kohms at -60 °C (140 °F) 0.5 - 0.7 Kohms 2. INSPECT MAF METER OPERATION a. Connect the MAF meter connector. b. Using a voltmeter, connect the positive (+) tester probe to terminal VG, and negative (-) tester probe to terminal E2G. c. Turn the ignition switch ON. d. Blow air into the MAF meter, and check that the voltage fluctuates. If operation is not as specified, replace the MAF meter. e. Turn the ignition switch OFF. f. Disconnect the MAF meter connector. Description and Operation Throttle Position Sensor: Description and Operation Throttle Position Sensor The throttle position sensor is mounted in the throttle body and detects the throttle valve opening angle. When the throttle valve is fully closed, a voltage of approximately 0.3 - 1 .0 V is applied to terminal VTA of the ECM. The voltage applied to terminals VTA of the ECM increases in proportion to the opening angle of the throttle valve and becomes approximately 2.7 - 5.2 V when the throttle valve is fully opened. The ECM ledges the vehicle driving conditions from these signals input from terminals VTA and uses them as one of the conditions to decide the air- fuel ratio correction, power increase correction and fuel-cut control etc. Page 3699 Air Bag(s) Arming and Disarming: Service and Repair Release Method of Airbag Activation Prevention Mechanism Page 554 d. Torque the front and/or rear adjusting cam nuts. Torque: 130 Nm (1,325 kgf-cm, 96 ft. lbs.) Measuring Point Reference 5. INSPECT TOE-IN Toe-In: If the toe-in is not within the specified value, adjust the rack ends. Locations Page 1393 Idle Speed: Testing and Inspection INSPECTION 1. INITIAL CONDITIONS a) Engine at normal operating temperature b) Air cleaner installed c) All pipes and hoses of air induction system connected d) All accessories switched OFF e) All vacuum lines properly connected f) SFI system wiring connectors fully plugged g) Ignition timing checked correctly h) Transmission in neutral position i) A/C switch is OFF 2. CONNECT TOYOTA HANDHELD TESTER OR OBDII SCAN TOOL 3. INSPECT IDLE SPEED a) Race the engine speed at 1,000 rpm for approx. 5 seconds. b) Check the idle speed. Idle speed: 700 ± 50 rpm If the idle speed is not as specified, check the IAC valve and air intake system. 4. DISCONNECT TOYOTA HANDHELD TESTER OR OBDII SCAN TOOL Page 2135 Step 1 Page 1264 Oxygen Sensor: Technical Service Bulletins Engine Controls - O2 Sensor Monitor Threshold Values SPECIAL SERVICE TOOLS SS002-03 December 17, 2003 Title O2S TEST RESULTS (MODE 05) Models All '96 - '03, '04 Corolla, ECHO, Matrix, Sienna & Scion xA & xB Introduction This Service Bulletin contains Oxygen Sensor (O2S) Monitor threshold values for all models from 1996 to 2003 and some 2004 models. Starting in 2004, the O2S Monitor threshold values can be found in the repair manual. These values are used when analyzing the O2S test results to determine the O2S condition. Applicable Vehicles ^ All 1996 - 2003 model year Toyota vehicles. ^ 2004 model year Corolla, ECHO, Matrix and Sienna vehicles. ^ 2004 model year Scion xA and xB vehicles. Function Description Checking O2S Test Results To view O2S test results, the O2S Monitor must be completed and the test results must be checked within the same key cycle. If the ignition key is cycled OFF, the O2S test results will be set to the minimum or maximum limits, and all test results will be erased. The O2S test results are stored in the ECU (SAE term: Powertrain Control Module/PCM) when the monitor is completed. The test results are static and will not change once the monitor is complete. The process for checking 02S test results is described in the following three basic steps: 1. Completing the O2S Readiness Monitor. 2. Accessing O2S Test Results. 3. Comparing O2S Test Results to Failure Thresholds. Required SSTs NOTE: Additional Diagnostic Tester Kits, Program Cards or other SSTs may be ordered by calling SPX-OTC at 1-800-933-8335. Warranty Information Completing O2S Readiness Monitor 1. Clear any stored Diagnostic Trouble Codes (DTCs) using the Toyota Diagnostic Tester. Locations Fuse Block: Locations Relay Box / No. 2 Page 1519 Step 3 Step 4 Step 5 Step 6 Page 1567 Oxygen Sensor: Technical Service Bulletins Engine Controls - O2 Sensor Monitor Threshold Values SPECIAL SERVICE TOOLS SS002-03 December 17, 2003 Title O2S TEST RESULTS (MODE 05) Models All '96 - '03, '04 Corolla, ECHO, Matrix, Sienna & Scion xA & xB Introduction This Service Bulletin contains Oxygen Sensor (O2S) Monitor threshold values for all models from 1996 to 2003 and some 2004 models. Starting in 2004, the O2S Monitor threshold values can be found in the repair manual. These values are used when analyzing the O2S test results to determine the O2S condition. Applicable Vehicles ^ All 1996 - 2003 model year Toyota vehicles. ^ 2004 model year Corolla, ECHO, Matrix and Sienna vehicles. ^ 2004 model year Scion xA and xB vehicles. Function Description Checking O2S Test Results To view O2S test results, the O2S Monitor must be completed and the test results must be checked within the same key cycle. If the ignition key is cycled OFF, the O2S test results will be set to the minimum or maximum limits, and all test results will be erased. The O2S test results are stored in the ECU (SAE term: Powertrain Control Module/PCM) when the monitor is completed. The test results are static and will not change once the monitor is complete. The process for checking 02S test results is described in the following three basic steps: 1. Completing the O2S Readiness Monitor. 2. Accessing O2S Test Results. 3. Comparing O2S Test Results to Failure Thresholds. Required SSTs NOTE: Additional Diagnostic Tester Kits, Program Cards or other SSTs may be ordered by calling SPX-OTC at 1-800-933-8335. Warranty Information Completing O2S Readiness Monitor 1. Clear any stored Diagnostic Trouble Codes (DTCs) using the Toyota Diagnostic Tester. Capacity Specifications Engine Oil: Capacity Specifications Engine Oil With filter .............................................................................................................................................. .......................................................... 5.7 Qts.(5.4L) Without filter ....................................................... ............................................................................................................................................ 5.4 Qts.(5.1L) DENSO Made Brake Switch (Cruise Control): Testing and Inspection DENSO Made CIRCUIT DESCRIPTION When the brake pedal is on depressed, battery positive voltage normally applies through the STOP fuse and stop light switch to terminal STP-of the ECU, and the ECU turns the cruise control off. A fail-safe function is provided so that cancel functions normally, even if there is a malfunction in the stop light signal circuit. If the harness connected to terminal STP-has an open circuit, terminal STP-will have battery positive voltage and the cruise control will be turned off. Also, when the brake is on, the magnetic clutch is cut mechanically by the stop light switch, turning the cruise control oft. (See operation of the magnetic clutch) Wiring Diagram Page 3661 - If the sensor has been dropped, or there are cracks, dents or other defects in the case, brackets or connector, replace the removed sensor with new one. - The front sensor is equipped with an electrical connection check mechanism. Be sure to lock this mechanism securely when connecting the connector. If the connector is not securely locked, a malfunction code will be detected by the diagnostic system. b. Connect the front airbag sensor connectors. 2. INSTALL BATTERY a. Install the battery carrier and battery. b. Install the battery clamp with the bolt. Page 3011 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Page 3301 c. Using a service-purpose wire harness tie down the steering wheel pad to the disc wheel. Wire harness: Stripped wire harness section 1.25 sq.mm or more (0.0019 sq.in. or more) CAUTION: If a wire harness which is too thin or some other thing is used to tie down the steering wheel pad, it may be snapped by the shock when the airbag is deployed. This is highly dangerous. Always use a wire harness for vehicle use which is at least 1.25 sq.mm (0.0019 sq.in). HINT: To calculate the square of the stripped wire harness section: Square = 3.14 x sq.(Diameter) divided by 4 1. Install the 2 bolts with washers in the 2 bolt holes in the steering wheel pad. Bolt: L: 35. mm (1.387 in.) M: 6.0 mm (0.236 in.) Pitch: 1.0 mm (0.039 in.) NOTE: Tighten the bolts by hand until the bolts become difficult to turn. - Do not tighten the bolts too much. Page 4346 Steps 3 - 4 INSPECTION PROCEDURE Page 1051 REMOVAL 1. REMOVE TIMING BELT 2. REMOVE WATER INLET AND THERMOSTAT 3. DISCONNECT NO.2 OIL COOLER HOSE FROM WATER PUMP 4. REMOVE WATER PUMP a) Remove the 7 bolts. b) Pry out the water pump. INSPECTION 1. INSPECT WATER PUMP a) Visually check the drain hole for coolant leakage. If leakage is found, replace the water pump. If engine coolant has leaked onto the timing belt, replace the timing belt. b) Turn the pulley, and check that the water pump bearing moves smoothly and quietly. If necessary, replace the water pump. 2. INSPECT FLUID COUPLING Specifications Firing Order: Specifications Firing Order 1 - 2 - 3 - 4 - 5 - 6 Page 2693 ABS Light: Testing and Inspection CIRCUIT DESCRIPTION If the ECU detects trouble, it lights the ABS warning light while at the same time prohibiting ABS control. At this time, the ECU records a DTC in memory. After removing the short pin of the DLC1, connect terminals Tc and E1 of the DLC1 to make the ABS warning light blink and output the DTC. WIRING DIAGRAM Step 1 Page 2258 Step 2 Step 3 INSPECTION PROCEDURE Page 416 Evaporative Vapor Pressure Sensor: Testing and Inspection Vapor Pressure Sensor 1. INSPECT POWER SOURCE VOLTAGE OF VAPOR PRESSURE SENSOR a. Disconnect the vapor pressure sensor connector. b. Turn the ignition switch ON. c. Using a voltmeter, measure the voltage between connector terminals VC and E2 of the wiring harness side. Voltage: 4.5 - 5.5 V d. Turn the ignition switch OFF. e. Reconnect the vapor pressure sensor connector. 2. INSPECT POWER OUTPUT OF VAPOR PRESSURE SENSOR a. Turn the ignition switch ON. b. Disconnect the vacuum hose from the vapor pressure sensor. c. Connect a voltmeter to terminals PTNK and E2 of the ECM, and measure the output voltage under ambient atmospheric pressure. 1. Apply vacuum (2.0 kpa, 15 mmHg, 0.59 in.Hg) to the vapor pressure sensor. Voltage: 1.3 - 2.1 V 2. Release the vacuum from the vapor pressure sensor. Voltage: 3.0 - 3.6 V 3. Apply pressure (1.5 kPa, 15 gf/Sq.cm, 0.22 psi) to the vapor pressure sensor. Voltage: 4.2 - 4.8 V d. Reconnect the vacuum hose to the vapor pressure sensor. Page 1120 Water Pump: Diagrams WATER PUMP REPLACEMENT W/ RELATED COMPONENTS Part 1 of 3 ABS/TCS - Zero Point Calibration Information Yaw Rate Sensor: Technical Service Bulletins ABS/TCS - Zero Point Calibration Information T-SB-0020-08 March 25, 2008 Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment Service Category Brake Section Brake Control/Dynamic Control System Market USA Applicability Introduction The purpose of this TSB is to provide information on when and how to perform the zero point calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting the battery is a necessary step for performing the zero point calibration. Warranty Information Required Tools & Equipment ^ Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE). ^ The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the service procedures listed in this bulletin. Preliminary Information Perform this procedure if any of these repairs have been performed on the vehicle: ^ Wheel alignment has been adjusted. ^ Any chassis components have been removed/installed or replaced. Testing and Inspection Fuel Gauge Sender: Testing and Inspection INSPECT FUEL SENDER GAUGE RESISTANCE Measure the resistance between terminals 2 and 3. 68 L 57 L If resistance value is not as specified, replace the sender gauge. Paint - Iron Rust Contamination Repair Paint: All Technical Service Bulletins Paint - Iron Rust Contamination Repair PAINT PA005-04 REVISED November 16, 2004 Title IRON PARTICLE RUST CONTAMINATION REPAIR Models '94 - Current Toyota & '04 - Current Scion TSB REVISION NOTICE: ^ December16, 2004: Text has been revised to more accurately describe cleaner (Auto Magic © Special Cleaner Concentrate is not an oxalic acid solution); Applicable Vehicles has been defined more clearly. The previous TSB should be discarded. Introduction The purpose of this bulletin is to provide information regarding the proper procedures to clean vehicles that may have been subjected to contamination by airborne iron particles such as rail dust. Applicable Vehicles ^ 1994 - Current model year Toyota vehicles. ^ 2004 - Current model year Scion vehicles. Condition During rail transportation or extended storage near industrial areas vehicles may occasionally be subjected to contamination by airborne iron particles shed from railroad tracks train wheels exposure to heavy machinery facilities gnnding welding etc. Inspection This type of contamination can be identified by the presence of small red or brown particles on the paint surface. These particles are often difficult to see on dark color paints but can be easily felt when brushing a hand across horizontal body surfaces such as hood roof or deck lid. Caution: Because of the abrasiveness of these small iron particles, polishing or buffing procedures should not be affempted to repair the paint surface of an affected vehicle. This will result in further paint damage and detract from vehicle appearance. Repair Washing the affected paint surfaces with Auto Magic © Special Cleaner Concentrate is the recommended method to dislodge embedded iron particles and remove the surrounding rust stains. The correct usage of Auto Magic © Special Cleaner Concentrate is described in this bulletin. Warranty Information Required Tools & Materials General Precautions Page 4916 Quarter Window Glass Diagram Information and Instructions Seat Belt Reminder Buzzer: Diagram Information and Instructions Key to Diagrams Key to Diagrams A: System Title. B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: (1) Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. Page 4632 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Page 736 Loosen/Tighten Bleeder Plug 3. CONNECT VINYL TUBE TO BRAKE CALIPER OR WHEEL CYLINDER BLEEDER PLUG Insert the other end of the tube in a half-full container of brake fluid. HINT: Begin air bleeding from the wheel cylinder with the longest hydraulic line. 4. BLEED BRAKE LINE a. Slowly depress the brake pedal several times. b. While an assistant depresses the pedal, loosen the bleeder plug until fluid starts to run out. Then tighten the bleeder plug. c. Repeat this procedure until there are no more air bubbles in the fluid. Torque: (bleeder plug) 11 Nm (110 kgf-cm, 8 ft. lbs.) 5. REPEAT PROCEDURE FOR EACH WHEEL ON-VEHICLE INSPECTION HINT: Pre runner is the described below. RZN191L-TRPDKAB, RZN196L-CRPDKAB, VZN195L-RPDKAB 1. SET REAR AXLE LOAD Rear axle load (includes vehicle weight): 2. INSTALL LSP & BV GAUGE (SST) AND BLEED AIR SST 09709-29018 3. RAISE FRONT BRAKE PRESSURE TO 7,845 kPa (80 kgf/cm2, 1,138 psi) AND CHECK REAR BRAKE PRESSURE Rear Brake Pressure: Page 2520 Step 2 Step 3 INSPECTION PROCEDURE Page 1747 Heated Oxygen Sensor Page 3263 NOTICE: Use SST 09922-10010 in the direction shown in the illustration. HINT: Use a torque wrench with a fulcrum length of 345 mm (13.58 inch). c. Using a brass bar and hammer, stake the washer. NOTICE: Avoid any impact to the rack. 12. INSTALL RH AND LH RACK BOOTS, CLAMPS AND CLIPS a. Install the rack boot. NOTICE: Be careful not to damage or twist the boot. b. Tighten a new clamp, as shown in the illustration. 13. INSTALL RH AND LH TIE ROD ENDS AND LOCK NUTS a. Screw the lock nut and tie rod end onto the rack end until the matchmarks are aligned. b. After adjusting toe-in, torque the nut. Torque: 54 Nm (550 kgf-cm, 40 ft. lbs.) Lower Valve Body Page 2247 Shift Indicator: Description and Operation Previous automatic transmissions have selected each gear shift using mechanically controlled throttle hydraulic pressure, governor hydraulic pressure and lock-up hydraulic pressure. The electronically controlled transmission, however, electrically controls the governor pressure and lock-up sensor through the solenoid valve. Control of the solenoid valve by the engine control module based on the input signals from each sensor makes smooth driving possible by shift selection for each gear which is most appropriate to the driving conditions at that time. 1. GEAR SHIFT OPERATION During driving, the engine control module selects the shift for each gear which is most appropriate to the driving conditions, based on input signals from the engine coolant temp. sensor to TERMINAL THW of the engine control module and also the input signals to TERMINAL SP2+ of the engine control module from the vehicle speed sensor devoted to the electronically controlled transmission. Current is then output to the electronically controlled transmission solenoid. When shifting to 1st speed, current flows from TERMINAL S1 of the engine control module to TERMINAL 1 of the electronically controlled transmission solenoid to GROUND, and continuity to the No.1 solenoid causes the shift. For 2nd speed, current flows from TERMINAL S1 of the engine control module to TERMINAL 1 of the electronically controlled transmission solenoid to GROUND, and from TERMINAL S2 of the engine control module to TERMINAL 2 of the electronically controlled transmission solenoid to GROUND. And continuity to solenoid No.1 and No.2 causes the shift. For 3rd speed, there is no continuity to No.1 solenoid, only to No.2 causing the shift. Shifting into 4th speed (Overdrive) takes place when there is no continuity to either No.1 or No.2 solenoid. 2. LOCK-UP OPERATION When the engine control module judges from each signal that lock-up operation conditions have been met, current flows from TERMINAL SL of the engine control module to TERMINAL 3 of the electronically controlled transmission solenoid to GROUND, causing continuity to the lock-up solenoid and causing lock-up operation. 3. STOP LIGHT SW CIRCUIT If the brake pedal is depressed (Stop light SW ON) when driving in lock-up condition, a signal is input to TERMINAL STP of the engine control module, the engine control module operates and continuity to the lock-up solenoid is cut. 4. OVERDRIVE CIRCUIT * O/D main SW ON When the O/D main SW is turned ON (SW point is open), a signal is input to TERMINAL ODMS of the engine control module and engine control module operation causes gear shift when the conditions for overdrive are met. * O/D main SW OFF When the O/D main SW is turned OFF (SW point is closed), a signal is input into TERMINAL ODMS of the engine control module, and turns on the O/D OFF indicator light. This activates the ECU, and the transmission system is controlled not to shift to overdrive. 5. A/T OIL TEMP. WARNING When the A/T oil temp. sensor affixed to the transmission case detects that the fluid temp. is 150 °C (302 °F) or more, the engine control module operates and the current flowing through the GAUGE fuse flows to the A/T oil temp. warning light to TERMINAL OILW of the engine control module to GROUND, so that the warning light lights up, informing that the oil temp. is high. When the oil temp. drops to 120 °C (248 °F) or less, the engine control module stops operating and the warning light goes out. Page 2230 Shift Indicator: Fuse and Fusible Link Locations Relay Box / No. 2 Page 4812 Splice Point J: Indicates a wiring Splice Point (Codes are "E"for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I 5 is indicated by the shaded section. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. N: Page No. How to Read Ground Points How to Read Ground Points Page 2010 Crankshaft Position Sensor: Testing and Inspection INSPECT CRANKSHAFT POSITION SENSOR a. Remove the sensor connector. b. Using an ohmmeter, measure the resistance between the terminals. Resistance: Cold 1,630 - 2,740 ohms Hot 2,065 - 3,225 ohms c. Reinstall the sensor. Page 1704 A/F and 02 Sensor Identification Description and Operation Transmission Mode Indicator - A/T: Description and Operation The ECM memory contains the shift programs for the NORMAL and POWER patterns, 2 position, L position and the lock-up patterns. Following the programs corresponding to the signals from the pattern select switch, the park/neutral position and other various sensors, the ECM switches the solenoid valves ON and OFF, and controls the transmission gear change and the lock-up clutch operation. Testing and Inspection Power Door Lock Switch: Testing and Inspection INSPECT DRIVER'S DOOR LOCK CONTROL SWITCH CONTINUITY If continuity is not as specified, replace the switch. INSPECT PASSENGER'S DOOR LOCK CONTROL SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 2803 3. REMOVE CALIPER Remove the 2 mounting bolts and caliper. Torque: 123 Nm (1,250 kgf-cm, 90 ft. lbs.) 4. REMOVE CLIP, 2 PINS AND ANTI-RATTLE SPRING 5. REMOVE 2 PADS WITH 4 ANTI-SQUEAL SHIMS INSTALLATION Installation is in the reverse order of removal. HINT: After installation, fill the brake reservoir with brake fluid, bleed brake system and check for leaks. See: Brake Bleeding Page 4656 Junction Box / No. 1 Page 2243 Specifications Brake Shoe: Specifications Lining Thickness: Standard 0.217 in Minimum 0.039 in Drum To Shoe Clearance 0.024 in Specifications Drive Belt: Specifications Alternator Belt New Belt ...................................................................................................................... .................................................................................... 160 +/- 20 lbf Used Belt .................................. .............................................................................................................................................................. .......... 100 +/- 20 lbf Power Steering Belt New Belt ............................................................................................................. ............................................................................................... 135 - 180 lbf Used Belt ........................ .............................................................................................................................................................. ....................... 85 - 120 lbf A/C Belt New Belt ................................................................................................................................ .......................................................................... 160 +/- 25 lbf Used Belt ............................................ .............................................................................................................................................................. 100 +/- 20 lbf Page 1281 CHART 14 Page 3853 c. Remove the 3 bolts and back panel trim. d. Using a screwdriver, remove the back panel lower garnish. HINT: Tape the screwdriver tip before use. e. Remove the 4 bolts and rear seat cushions. f. Remove the front and rear seat outer belt shoulder anchors. Using a screwdriver, open the covers, then unfasten the bolts and remove the front and rear seat outer belt shoulder anchors. HINT: Tape the screwdriver tip before use. g. Remove the lock handle. 1. Using a screwdriver, remove the cover. HINT: Tape the screwdriver tip before use. 2. Remove the 2 screws and lock handle. h. Remove the quarter trim. 1. Remove the 2 bolts and front and rear seat outer belt floor anchors. 2. Remove the screw and coat hook. 3. Using a screwdriver, remove the quarter trim. NOTE: Paying enough attention remove the clip on the quarter trim shown in the illustration. Otherwise, the quarter trim or the front pillar garnish might be broken. HINT: Tape the screwdriver tip before use. Page 2377 Page 3642 CAUTION: The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment. - Use gloves and safety glasses when handling a steering wheel pad with the deployed airbag. - Always wash your hands with water after completing the operation. - Do not apply water, etc. to a steering wheel pad with the deployed airbag. 1. Remove the steering wheel pad from the disc wheel. 2. Place the steering wheel pad in a vinyl bag, tie the end tightly and dispose of it in the same way as other general parts disposal. Disposing of Steering Wheel Pad With Airbag Deployed HINT: When scrapping vehicle equipped with an SRS or disposing of a steering wheel pad (with airbag), always first deploy the air bag in accordance with the procedure described. If any abnormality occurs with the airbag deployment, contact the SERVICE DEPT. of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION: - Never dispose of a steering wheel pad which has an undeployed airbag. - The airbag produces a sizeable exploding sound when it deploys, so perform the operation out-ofdoors and where it will not create a nuisance to nearby residents. - When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool). Perform the operation in a place away from electrical noise. SST 09082-00700 - When deploying an airbag, perform the operation at least 10 m (33 ft) away from the steering wheel pad. - The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment. - Use gloves and safety glasses when handling a steering wheel pad with the deployed airbag. - Always wash your hands with water after completing the operation. - Do not apply water, etc.to a steering wheel pad with the deployed airbag. CAUTION: - The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment. - When moving a vehicle for scrapping which has a steering wheel pad with the deployed airbag, use gloves and safety glasses. - Use gloves and safety glasses when handling a steering wheel pad with deployed airbag. - Always wash your hands with water after completing the operation. - Do not apply water, etc.to a steering wheel pad with deployed airbag. 1. Remove the steering wheel pad from the steering wheel. 2. Place the steering wheel pad in a vinyl bag, tie the end tightly and dispose of it in the same way as other general parts disposal. Page 2195 1. Loosen the nut on the control shaft lever. 2. Push the control shaft fully forward. 3. Return the control shaft lever 2 notches to N position. 4. Set the shift lever to N position. 5. While holding the shift lever lightly toward the R position side, adjust the control lever nut. 6. Tighten the control shaft lever nut. Torque: 13 Nm (130 kg.cm, 10 ft.lb) 7. Start the engine and make sure that the vehicle moves forward when shifting the lever from the N to D position and reverses when shifting it to the R position. g. Floor shift: Inspect and adjust the shift lever position. When shifting the shift lever from the N position to other positions, check that the lever can be shifted smoothly and accurately to each position and that the position indicator correctly indicates the position. If the indicator is not aligned with the correct position, carry out the following adjustment procedures. 1. Remove the nut on the shift lever. 2. Push the control shaft lever fully downward. 3. Return the control shaft lever 2 notches to N position. 4. Set the shift lever to N position. 5. While holding the shift lever lightly toward the R position side, adjust the control shaft lever nut. 6. Tighten the control shaft lever nut. Torque: 13 Nm (130 kg.cm, 10 ft.lb) 7. Start the engine and make sure that the vehicle moves forward when shifting the lever from the N to D position and reverses when shifting it to the R position. h. Inspect and adjust the park/neutral position. Page 4458 Cruise Control Indicator Lamp: Testing and Inspection FORD Made CIRCUIT DESCRIPTION When the cruise control main switch is turned ON, CRUISE MAIN indicator light lights up. Wiring Diagram Page 114 Airbag Sensor Assembly: Testing and Inspection Replacement Requirements REPLACEMENT REQUIREMENTS In the following cases, replace the airbag sensor assembly. - If the SRS has been deployed in a collision. - If the airbag sensor assembly has been found to be faulty in troubleshooting. - If the airbag sensor assembly has been dropped. CAUTION: For removal and installation of the airbag sensor assembly. Be sure to follow the correct procedure. Page 4734 Stop Light: Component Tests and General Diagnostics Stop Light System INSPECTION 1. w/o Cruise Control: INSPECT STOP LIGHT SWITCH CONTINUITY If continuity is not as specified, replace the switch. 2. W/ Cruise Control: INSPECT STOP LIGHT SWITCH CONTINUITY If continuity is not as specified, replace the switch. ABS/TCS - Zero Point Calibration Information Alignment: Technical Service Bulletins ABS/TCS - Zero Point Calibration Information T-SB-0020-08 March 25, 2008 Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment Service Category Brake Section Brake Control/Dynamic Control System Market USA Applicability Introduction The purpose of this TSB is to provide information on when and how to perform the zero point calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting the battery is a necessary step for performing the zero point calibration. Warranty Information Required Tools & Equipment ^ Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE). ^ The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the service procedures listed in this bulletin. Preliminary Information Perform this procedure if any of these repairs have been performed on the vehicle: ^ Wheel alignment has been adjusted. ^ Any chassis components have been removed/installed or replaced. Page 2428 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Page 2900 Steps 1 - 3 Page 194 Step 4 INSPECTION PROCEDURE Page 3791 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Specifications Drive Belt: Specifications Alternator Belt New Belt ...................................................................................................................... .................................................................................... 160 +/- 20 lbf Used Belt .................................. .............................................................................................................................................................. .......... 100 +/- 20 lbf Power Steering Belt New Belt ............................................................................................................. ............................................................................................... 135 - 180 lbf Used Belt ........................ .............................................................................................................................................................. ....................... 85 - 120 lbf A/C Belt New Belt ................................................................................................................................ .......................................................................... 160 +/- 25 lbf Used Belt ............................................ .............................................................................................................................................................. 100 +/- 20 lbf Testing and Inspection Backup Lamp Switch: Testing and Inspection INSPECT BACK-UP LIGHT SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 991 CAUTION: Put a shop towel under the delivery pipe. Slowly loosen the union bolt. e. Install SST (pressure gauge) to the delivery pipe with the 2 gaskets and SST (union and union bolt). SST 09268-45012 Torque: 34.3 Nm (350 kg.cm, 25 ft.lb) f. Wipe off any splattered gasoline. g. Connect a TOYOTA hand-held tester to the DLC3. (See step 1) h. Reconnect the negative (-) terminal cable to the battery. i. Turn the ignition switch ON. j. Measure the fuel pressure. Fuel pressure: 265-304 kPa (2.7-3.1 kg/Sq.cm,38 - 44 psi) If pressure is high, replace the fuel pressure regulator. If pressure is low, check the fuel hoses, fuel hose connections, fuel pump, fuel filter and fuel pressure regulator. k. Disconnect the TOYOTA hand-held tester from the DLC3. l. Reinstall the No.2 timing belt cover with the 6 bolts. Torque: 9 Nm (90 kg.cm, 80 in.lb) m. Start the engine. n. Disconnect the vacuum sensing hose from the fuel pressure regulator, and plug the hose end. o. Measure the fuel pressure at idle. Fuel pressure: 265 - 304 kPa (2.7 - 3.1 kg/Sq.cm, 38 - 44 psi) p. Reconnect the vacuum sensing hose to the fuel pressure regulator. q. Measure the fuel pressure at idle. Fuel pressure: 226 - 265 kPa (2.3 - 2.7 kg/Sq.cm, 33 - 38 psi) If pressure is not as specified, check the vacuum sensing hose and fuel pressure regulator and fuel pressure regulator. r. Stop the engine. s. Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped. Fuel pressure: 147 kPa (1.5 kg/Sq.cm, 21 psi) or more If pressure is not as specified, check the fuel pump, pressure regulator and/or injectors. t. After checking fuel pressure, disconnect the negative (-) terminal cable from the battery and carefully remove the SST to prevent gasoline from splashing. SST 09268-45012 Page 1939 2. REMOVE IAC VALVE Remove the 4 screws, IAC valve and gasket. HINT: At the time of installation, please refer to the following items. Place a new gasket on the throttle body. INSTALLATION Installation is in the reverse order of removal. Page 4779 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Page 3235 Key Reminder Switch: Description and Operation Current always flows to TERMINAL 12 of the integration relay through the DOME fuse. 1. SEAT BELT WARNING SYSTEM When the ignition SW is turned ON, current flows from the GAUGE fuse to TERMINAL 6 of the integration relay. At the same time, current flows to TERMINAL A 2 of the relay from the GAUGE fuse through the seat belt warning light. This current activates the integration relay and, for approx. 4-8 seconds, the current flowing through the warning light flows from TERMINAL A 2 of the relay to TERMINAL A 7 to GROUND, causing the warning light to light up. At the same time as the warning light lights up, a buckle SW ON signal is input to TERMINAL A 3 of the integration relay, the current flowing from TERMINAL 12 of the integration relay flows to TERMINAL A 7 to GROUND and the seat belt warning buzzer sounds for approx. 4 - 8 seconds. However, if the seat belt is put ON (Buckle SW OFF) during this period (while the buzzer is sounding), a signal input to TERMINAL A 3 of the integration relay stops and the current flowing from TERMINAL 12 of the integration relay to TERMINAL A 7 to GROUND is cut, causing the buzzer to stop. 2. KEY REMINDER SYSTEM With the ignition key inserted in the key cylinder (Unlock warning SW ON), the ignition SW still oft and front LH door open (Door courtesy SW ON), a signal is input to TERMINAL A 10, A 5 of the integration relay, the integration relay operates and current flows from TERMINAL 6 of the relay to TERMINAL A 7 to GROUND and the key reminder buzzer sounds. Lower Ball Joint: Specifications Lower Ball Joint Turning Torque 0.1-2.5 Nm (1.0-22.0 in.lb) Maximum Play 0.5 mm (0.020 in) Page 4654 Page 4497 Junction Box / No. 3 Capacity Specifications Power Steering Fluid: Capacity Specifications Power Steering Fluid: Total ..................................................................................................................................................... .......................................... 0.8 liters (0.9 US Qts.) Page 4889 Using an ammeter: INSPECT ONE TOUCH POWER WINDOW SYSTEM a. Disconnect the connector of the master switch. b. Connect the positive (+) lead from the ammeter to terminal 4 on the wire harness side connector and the negative (-) lead to negative terminal of the battery. c. Connect the positive (+) lead from the battery to terminal 9 on the wire harness side connector. d. As the window goes down, check that the current increases to approximately 7.0 A. e. Check that the current increases to approximately 14.5 A or more when the window stops going down. HINT: The circuit breaker opens for some 4 - 40 seconds after the window stops going down, so that the check must be done before the circuit breaker operates. If the operation is as specified, replace the master switch. Using an ammeter with a current - measuring probe: INSPECT ONE TOUCH POWER WINDOW SYSTEM a. Remove the master switch with the connector connected. b. Attach a current-measuring probe to terminal 3 of the wire harness. c. Turn the ignition switch ON and set the power window switch in the down position. d. As the window goes down, check that the current increases to approximately 7.0 A. Specifications Brake Drum: Specifications Inside Diameter: Standard 11.614 in Maximum 11.693 in Drum To Shoe Clearance 0.024 in Page 4332 f. Read the blinking pattern of the CRUISE MAIN indicator light. g. After performing the check, turn the main switch OFF. HINT: When 2 or more signals are input to the ECU, the lowest numbered code will be displayed first. Page 3171 j. With the engine idling and valve fully opened, turn the steering wheel to full lock. Minimum fluid pressure: 8,336 kPa (85 kgf/cm2, 1209 psi) NOTICE: ^ Do not maintain lock position for more than 10 seconds. ^ Do not let the fluid temperature become too high. k. Disconnect the SST l. Connect the pressure feed tube. m. 5VZ-FE Engine: Install the air cleaner and 3 bolts. n. Bleed the power steering system. Page 3283 f. Using SST and a torque wrench, tighten the cap until the preload is within specification. SST 09616-00010 Preload (turning): 0.5-1.7 Nm (4.7-17.2 kgf-cm, 4.1-14.9 inch lbs.) 12. INSTALL RACK GUIDE SPRING CAP LOCK NUT a. Apply sealant to 2 or 3 threads of the nut. Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent b. Holding the rack guide spring cap rotating, and using SST, torque the nut. SST 09922-10010 Torque: 51 Nm (521 kgf-cm, 38 ft. lbs.) NOTICE: Use SST 09922-10010 in the direction shown in the illustration. HINT: Use a torque wrench with a fulcrum length of 345 mm (13.58 inch). c. Recheck the total preload. Preload (turning): 0.5-1.7 Nm (4.7-17.2 kgf-cm, 4.1-14.9 inch lbs.) d. Remove the RH and LH rack ends. 13. INSTALL RH AND LH CLAW WASHERS AND RACK ENDS a. Install a new washer, and temporarily tighten the rack end. HINT: Align the claws of the washer with the steering rack grooves. Page 1886 Fuel Injector: Locations Page 691 Capacity: A340E: 1.6 liters (1.7 US qts, 1.4 Imp. qts) A340F: 2.0 liters (2.1 US qts, 1.8 Imp. qts) 4. Start the engine and shift the shift lever into all positions from P to L position and then shift into P position. 5. With the engine idling, check the fluid level. Add fluid up to the COOL level on the dipstick. 6. Check the fluid level at the normal operating temperature, 70 - 80 °C (158 - 176 °F), and add as necessary. NOTE: Do not overfill. d. Check the fluid leaks. Check for leaks in the transmission. If there are leaks, it is necessary to repair or replacements, FIPGs, oil seals, plugs or other parts. e. Inspect and adjust the throttle cable. 1. Check that the throttle valve is fully closed. 2. Check that the inner cable is not slack. 3. Measure the distance between the outer cable end and stopper on the cable. Standard distance: 0 - 1 mm (0 - 0.04 in.) If the distance is not standard, adjust the cable by the adjusting nuts. f. Column shift: Inspect and adjust the shift lever position. When shifting the shift lever from the N position to other positions, check that the lever can be shifted smoothly and accurately to each position and that the position indicator correctly indicates the position. If the indicator is not aligned with the correct position, carry out the following adjustment procedures. Diagram Information and Instructions Seat Belt Reminder Buzzer: Diagram Information and Instructions Key to Diagrams Key to Diagrams A: System Title. B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: (1) Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. Front Planetary Gear Page 2493 Drive/Propeller Shaft: Testing and Inspection PROBLEM SYMPTOMS TABLE Use the table to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace these parts. Page 464 - If the sensor has been dropped, or there are cracks, dents or other defects in the case, brackets or connector, replace the removed sensor with new one. - The front sensor is equipped with an electrical connection check mechanism. Be sure to lock this mechanism securely when connecting the connector. If the connector is not securely locked, a malfunction code will be detected by the diagnostic system. b. Connect the front airbag sensor connectors. 2. INSTALL BATTERY a. Install the battery carrier and battery. b. Install the battery clamp with the bolt. Page 2436 Diagram Legend Locations Page 1628 D: Indicates related system. Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V). Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, 1H2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green O = Orange P = Pink R = Red SB = Sky Blue V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Page 3710 Page 793 3. w/o Free wheel hub (4WD only): DISCONNECT DRIVE SHAFT a. Using a screwdriver, remove the grease cap. b. Remove the cotter pin and lock cap. HINT: At the time of installation, if the holes for the cotter pin are not aligned, tighten the nut further up to 60°. c. With applying the brakes, remove the lock nut. Torque: 235 Nm (2,400 kgf-cm, 174 ft. lbs.) 4. w/ Freewheel hub: DISCONNECT DRIVE SHAFT a. Remove the free wheel hub. b. Using a snap ring expander, remove the snap ring. c. Remove the spacer. 5. w/ ABS: DISCONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP FROM STEERING KNUCKLE Remove the 2 bolts and ABS speed sensor wire harness clamp from the steering knuckle. Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.) 6. REMOVE BRAKE CALIPER AND DISC a. Remove the union bolt and 2 gaskets from the caliper, then disconnect the flexible hose from the caliper. Torque: 30 Nm (310 kgf-cm, 22 ft. lbs.) HINT: At the time of installation, install the flexible hose lock securely in the lock hole in the caliper. b. Remove the 2 bolts, brake caliper and disc. Torque: 123 Nm (1,250 kgf-cm, 90 ft. lbs.) Page 1327 D: Indicates related system. Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V). Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, 1H2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green O = Orange P = Pink R = Red SB = Sky Blue V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Page 3754 e. Retract the whole belt, then pull out the belt until 200 mm (7.87 in.) of belt remains retracted. f. Tilt the retractor slowly. g. Make sure that the belt can be pulled out at a tilt of 15 degrees or less, and cannot be pulled out at over 45 degrees of tilt. If a problem is found, replace the assembly. 4. Manual type: TESTING a. Adjust the belt to the proper length. b. Apply a firm load to the belt. c. Make sure that the belt does not extend. Page 1882 D. Start the engine. After the engine has stalled, turn the ignition switch OFF. E. Disable the fuel return line by blocking the line or installing the appropriate plug in the return outlet, if applicable. NOTE: Do NOT clamp plastic lines. F. Install the device adapter to the fuel line and then secure the swivel fitting on the end of the hose. G. Make sure the ball valve on the device is turned OFF (valve handle is crosswise to device). Screw the can of EFI cleaner (P/N 00289-1PF14) onto the device can adapter. H. Open the valve on the device, start the vehicle, and allow it to run until the engine stalls. I. Turn the ball valve OFF and remove the empty can. J. Place a shop towel over the can adapter and slowly open the ball valve to depressurize the system. K. Remove supply and return line adapters, reconnect vehicle fuel supply and return lines (replacing any fuel line gaskets and seals), and connect the fuel pump electrical connector. L. Before starting the vehicle, pressurize the fuel system and check for leaks. Run the engine for 4 - 5 minutes, and then snap the throttle several times to dislodge any carbon that may remain in the system. 2. Add 1 can of Toyota Non-Pressurized Fuel Injector Cleaner Fuel Tank Additive (P/N 08813-0080DS) to the fuel tank. 3. Road test the vehicle to verify normal operation. Page 1629 Splice Point J: Indicates a wiring Splice Point (Codes are "E"for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I 5 is indicated by the shaded section. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. N: Page No. How to Read Ground Points How to Read Ground Points Page 1298 Page 1186 Engine Control Module: Connector Views Connectors (California Spec.) Part 1 Of 2 (California Spec.) Page 4930 a. Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G. b. When the primer is coated wrongly to the area other than the specified, wipe it off with a clean shop rag before the primer dries. NOTE: Let the primer coating dry for 3 minutes or more. - Do not keep any of the opened Primer G for later use. 8. APPLY ADHESIVE a. Cut off the tip of the cartridge nozzle. Part No. 08850-00801 or equivalent HINT: After cutting off the tip, use all adhesive within the time described in the table. b. Load the cartridge into the sealer gun. c. Coat the glass with adhesive, as shown in the illustration. Adhesive height: A: 8.0 - 10 mm (0.31 - 0.39 in.) 9. INSTALL GLASS Specifications Timing Belt: Specifications Timing Belt Replacement Interval .................................................................................................................................................. 90,000 mi. or 72 months Timing Belt Cover Torque .................................................................................................................... ........................................................................ 9 Nm Page 361 Page 2566 Step 2 Step 3 INSPECTION PROCEDURE Page 4446 Junction Box / No. 1 Page 4631 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Page 4107 The table contains all of the necessary information to correctly identify the type of system installed, and where to go to get programming procedures for each vehicle. NOTE: Should a vehicle having both VIP and Factory systems available (as identified in the following table) be brought in without any remotes (or one non-working remote), use the following tips to help determine which type of wireless system (O.E. or PIO/PIO) the vehicle has. ^ Look at the Trim Level of the vehicle. Higher-grade vehicles will tend to have O.E. systems, while entry-grade vehicles will tend to have VIP For example, the 2001 Camry XLE has Factory RKE, but the LE and CE grades have VIP. ^ Look for a "Status Monitor" with a glass breakage sensor and an LED externally installed into the dashboard or on the center console. Most VIP systems will have this. ^ Locate the ECU (refer to the applicable vehicle VIP Manual installation instructions for location). Once located, refer to the part label. ^ Attempt to perform the factory wireless programming procedure to get a response from the vehicle. Select the "confirmation mode" and see if any "Lock/Unlock" response is received, if so, the vehicle has a factory system. Page 383 INSPECTION 1. INSPECT HEATER RESISTANCE OF HEATED OXYGEN SENSOR a. Disconnect the sensor connector. b. Using an ohmmeter,measure the resistance between terminals +B and HT. Resistance: at 20 °C (68 °F) 11 - 16 ohms at 800 °C (1,472 °F) 23 - 32 ohms If the resistance is not as specified, replace the sensor. Torque: 20 Nm (200 kg.cm, 14 ft.lb) c. Reconnect the oxygen sensor connector. 2. Bank 1 Sensor 1: INSPECT OPERATION OF HEATED OXYGEN SENSOR 3. Bank 1 Sensor 2: INSPECT OPERATION OF HEATED OXYGEN SENSOR Page 4522 b. Disconnect the connector from the integration relay and inspect the connectors on the wire harness side. Body - Water Leaks to The Interior Front Door Panel: Customer Interest Body - Water Leaks to The Interior BODY BO026-00 Title: WATER LEAK FIELD-FIX REPAIR INSTRUCTIONS Models: '97 - '04 Tacoma October 27, 2000 TSB Revision Notice: ^ January 12, 2005: Applicable Vehicles has been updated to include 2004 model year. ^ August 25, 2003: VIN and Applicable Model Information has changed, and repair procedure has been expanded and clarified. ^ October 27, 2000: This TSB updates B0016-98 dated June 12, 1998. B016-98 is now obsolete and should be discarded. Previous versions of this TSB should be discarded. Introduction Use the following field-fix procedures if water is present on the floor carpeting and it can be confirmed that the water is leaking into the cab from either the upper cowl or side cowl seam, or moisture barrier behind the door trim panel. Applicable Vehicles 1997 - 2004 model year Tacoma vehicles. Required Materials Warranty Information Page 1474 Splice Point J: Indicates a wiring Splice Point (Codes are "E"for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I 5 is indicated by the shaded section. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. N: Page No. How to Read Ground Points How to Read Ground Points Page 4560 Testing and Inspection Power Mirror Switch: Testing and Inspection INSPECT MIRROR SWITCH CONTINUITY Left Side Left Side: Page 1722 CHART 14 Page 2156 On-Vehicle Inspection Drive Belt: Testing and Inspection On-Vehicle Inspection INSPECTION INSPECT DRIVE BELT a. Visually check the belt for excessive wear, frayed cords etc. If any defect has been found, replace the drive belt. HINT: Cracks on the rib side of a belt are considered acceptable. If the belt has chunks missing from the ribs, it should be replaced. b. Using a belt tension gauge, measure the belt tension. Belt tension gauge: DENSO BTG-20 (95506-00020) Borroughs No. BT-33-73F Drive belt tension: New belt: 135-180 lbs. Used belt: 85-120 lbs. If the belt tension is not as specified, adjust it. HINT: "New belt" refers to a belt which has been used less than 5 minutes on a running engine. - "Used belt" refers to a belt which has been used on a running engine for 5 minutes or more. - After installing a belt, check that it fits properly in the ribbed grooves. - Check with your hand to confirm that the belt has not slipped out of the groove on the bottom of the pulley. - After installing a new belt, run the engine for about 5 minutes and recheck the belt tension. Specifications Brake Fluid: Specifications Fluid Type FMVSS 116 DOT 3 Brake Fluid Page 4046 19. Flood R/F door glass area (spray water at door glass, belt-molding area). 20. Inspect sealer between plastic sheeting (moisture barrier) and metal door panel for voids/skips in sealer. If there are voids/skips between the plastic sheet and the door panel, it will need to be resealed. A. Using a heat gun, heat the butyl tape securing the plastic sheet to make removal easier. B. Use Kent Acrysol to clean the door panel and plastic sheet. NOTE: ^ Follow the directions provided by the cleaning agent. ^ To ensure proper sealing of the plastic sheeting, it is important that the door panel and plastic sheeting is extremely clean. C. Use 3M 8.0 mm butyl tape (P/N 08610) to reattach the plastic sheet to the door panel. Make sure there is a continuos solid bead sealing the plastic sheet to the door panel. 21. Inspect drain-back holes (small slits in metal door panel, near bottom of sealer) to determine if holes are covered by sealer material. If sealer covers drain-back holes (small slits in metal door panel) carefully pull up a portion of plastic sheet, clean out drain-back holes and reinstall plastic sheet against metal door panel. Confirm that there are no voids between sealer and plastic sheet and between sealer and metal door panel. 22. Flood all areas with water to confirm that there are no leaks into cab area. 23. If no leaks are present, reinstall door trim panel. Page 1612 Oxygen Sensor: Description and Operation Air / Fuel Sensor Air / Fuel Sensor To obtain a high purification rate for the CO, HC and NOx components of the exhaust gas, a three-way catalytic converter is used, but for the most efficient use of the three-way catalytic converter, the air-fuel ratio must be precisely controlled so that it is always close to the stoichiometric air-fuel ratio. The A/F sensor has the characteristic that provides output voltage* approximately proportional to the existing air-fuel ratio. The A/F sensor output voltage* is used to provide feedback for the ECM to control the air- fuel ratio. By the A/F sensor output, the ECM can determine the deviation amount from the stoichiometric air-fuel ratio and control the proper injection time immediately. If the A/F sensor is malfunctioning, ECM is unable to perform accurate air-fuel ratio control. The A/F sensor is equipped with a heater which heats the zirconia element. The heater is controlled by the ECM. When the intake air volume is low (the temp. of the exhaust gas is low), current flows to the heater to heat the sensor for accurate oxygen concentration detection. * The voltage value changes at the inside of the ECM only. Page 543 INSPECT REAR WIPER AND WASHER SWITCH CONTINUITY If continuity is not as specified, replace the switch. INSPECT WASHER LINKED OPERATION a. Connect the positive (+) lead from the battery to terminal 16 and the negative (-) lead to terminal 2. b. Connect the positive (+) lead from the voltmeter to terminal 7 and the negative (-) lead to terminal 2. c. Push in the washer switch, and check that the voltage changes as shown in the table. If operation is not as specified, replace the wiper and washer switch. Description and Operation Throttle Position Sensor: Description and Operation Throttle Position Sensor The throttle position sensor is mounted in the throttle body and detects the throttle valve opening angle. When the throttle valve is fully closed, a voltage of approximately 0.3 - 1 .0 V is applied to terminal VTA of the ECM. The voltage applied to terminals VTA of the ECM increases in proportion to the opening angle of the throttle valve and becomes approximately 2.7 - 5.2 V when the throttle valve is fully opened. The ECM ledges the vehicle driving conditions from these signals input from terminals VTA and uses them as one of the conditions to decide the air- fuel ratio correction, power increase correction and fuel-cut control etc. Page 4393 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 1129 REMOVAL 1. REMOVE TIMING BELT 2. REMOVE WATER INLET AND THERMOSTAT 3. DISCONNECT NO.2 OIL COOLER HOSE FROM WATER PUMP 4. REMOVE WATER PUMP a) Remove the 7 bolts. b) Pry out the water pump. INSPECTION 1. INSPECT WATER PUMP a) Visually check the drain hole for coolant leakage. If leakage is found, replace the water pump. If engine coolant has leaked onto the timing belt, replace the timing belt. b) Turn the pulley, and check that the water pump bearing moves smoothly and quietly. If necessary, replace the water pump. 2. INSPECT FLUID COUPLING Testing and Inspection Daytime Running Lamp Relay: Testing and Inspection Terminal Identification INSPECT DAYTIME RUNNING LIGHT RELAY CIRCUIT Disconnect the connector from the relay and inspect the connector on the wire harness side. If circuit is as specified, perform inspections. Page 1441 Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor The intake air temperature sensor is built into the air cleaner cap and senses the intake air temperature. A thermistor built in the sensor changes the resistance value according to the intake air temperature. The lower the intake air temperature, the greater the thermistor resistance value, and the higher the intake air temperature, the lower the thermistor resistance value. The intake air temperature sensor is connected to the ECM. The 5 V power source voltage in the ECM is applied to the intake air temperature sensor from the terminal THA via a resistor R. That is, the resistor R and the intake air temp. sensor are connected in series. When the resistance value of the intake air temp. sensor changes in accordance with changes in the intake air temperature, the potential at terminal THA also changes. Based on this signal, the ECM increases the fuel injection volume to improve driveability during cold engine operation. Page 1184 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Description and Operation Mass Air Flow Meter: Description and Operation Mass Air Flow Meter The mass air flow meter uses a platinum hot wire. The hot wire air flow meter consists of a platinum hot wire, thermistor and a control circuit installed in a plastic housing. The hot wire air flow meter works on the principle that the hot wire and thermistor located in the intake air bypass of the housing detect any changes in the intake air temperature. The hot wire is maintained at the set temperature by controlling the current flow through the hot wire. This current flow is then measured as the output voltage of the mass air flow meter. The circuit is constructed so that the platinum hot wire and thermistor provide a bridge circuit, with the power transistor controlled so that the potential of A and B remains equal to maintain the set temperature. Page 3019 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Removal and Installation Load Compensator: Service and Repair Removal and Installation REMOVAL 1. DISCONNECT SHACKLE NO. 2 FROM BRACKET a. Remove the nut and disconnect the shackle No. 2. b. Remove the cushion retainer, 2 cushions and collar. Paint - Paint Codes - All Paint: All Technical Service Bulletins Paint - Paint Codes - All COLLISION REPAIR INFORMATION CRIB98 TITLE: 2000 PAINT & REFINISH FORMULA CODES SECTION: REFINISH BULLETIN #98 MODELS: ALL TOYOTA DATE: NOVEMBER 1999 Attached for your reference is a list of all 2000 Toyota paint codes and the refinish formula codes for the following paint manufacturers: BASF, DuPont, PPG, Sherwin-Williams, Sikkens, Spies-Hecker, and ICI Autocolor. NOTE: The vehicle paint code is on the certification label which can be located on the drivers side door jamb or the lower section of the "B" pillar. Please contact your local paint representative for the actual paint mixing formulas or if you need help in color matching. 2000 TOYOTA PAINT CODES AND COLOR NAMES Specifications Case: Specifications Service Specifications Transmission Case Bushing, Maximum ........................................................................................................................................... 38.19 mm (1.5035 inch) Tightening Specifications Overdrive Support X Transmission Case ............................................................................................................................... 25 Nm (260 kg-cm, 19 ft. lbs.) Oil Pump X Transmission Case ............................................................................................................................................. 22 Nm (220 kg-cm, 16 ft. lbs.) Valve Body X Transmission Case ........................................................................................................................................... 10 Nm (100 kg-cm, 7 ft. lbs.) Oil Pan X Transmission Case .............................................................................................................................................. 7.4 Nm (75 kg-cm, 65 inch lbs.) Extension Housing X Transmission Case .............................................................................................................................. 36 Nm (370 kg-cm, 27 ft. lbs.) Transmission Housing: 10 mm Bolt .......................................................................................................................................... .............................. 34 Nm (345 kg-cm, 25 ft. lbs.) 12 mm Bolt ........................................................... ............................................................................................................. 57 Nm (580 kg-cm, 42 ft. lbs.) Union ................................................................................................................................................... .................................. 29 Nm (300 kg-cm, 22 ft. lbs.) Parking Lock Pawl Bracket ................................................................................................................................................. 7.4 Nm (75 kg-cm, 65 inch lbs.) Locations Fusible Link: Locations Relay Box / No. 2 Locations Page 3239 If circuit is as specified, try replacing the relay with a new one. If circuit is not as specified, inspect the circuits connected to other parts. Page 2628 Junction Box / No. 1 Page 3433 b. Using a chisel and hammer, stake the lock nut. 6. w/o Free wheel hub (4WD only): INSTALL BEARING SPACER Using SST and a press, install the bearing spacer. SST 09950-60010 (09951-00650), 09950-70010 (09951-07150) 7. 4WD: INSTALL NEW OIL SEAL (INSIDE) a. Using SST and a plastic hammer, install a new oil seal (inside). SST 09527-17011 HINT: Strike the SST on its circumference evenly. b. Coat the oil seal lip with MP grease. 8. PreRunner: INSTALL GREASE CAP Manual Steering Gear Steering Gear: Diagrams Manual Steering Gear Part 1 Of 2 Page 1700 Oxygen Sensor: Technical Service Bulletins Engine Controls - Bank 1/Bank 2 O2 Sensor identification ENGINE EG034-07 Title: ENGINE BANK 1 AND BANK 2 A/F AND O2 IDENTIFICATION Models: '93 - '08 Applicable Models June 28, 2007 The information contained in this TSB supercedes TSB No. EG037-04. TSB No. EG037-04 is now obsolete and should be discarded. Introduction This service bulletin provides information on the proper identification of engine bank 1 and engine bank 2 for correct A/F sensor and oxygen sensor replacement. This bulletin contains information that identifies engine bank 1 and engine bank 2 on the following engines: 1AZ-FE, 2AZ-FE, 2AZ-FE (PZEV), 1GR-FE, 2GR-FE, 2GR-FSE, 2JZ-GE, 1MZ-FE, 3MZ-FE, 1UR-FSE, 3UR-FE, 2UZ-FE, 3UZ-FE, 5VZ-FE, and 1ZZ-FE. ^ Bank 1 (B1) refers to the bank that includes cylinder No. 1. ^ Bank 2 (B2) refers to the bank opposite bank 1. ^ Sensor 1 (S1) refers to the sensor that is located before the catalytic converters. ^ Sensor 2 (S2) refers to the sensor that is located after the catalytic converters. Warranty Information Page 2476 c. Support the brake caliper securely. 7. DISCONNECT LOWER BALL JOINT Remove the 4 bolts and disconnect the lower ball joint. Torque: 80 Nm (820 kgf-cm, 59 ft. lbs.) 8. REMOVE STEERING KNUCKLE a. Remove the cotter pin and loosen the nut. Torque: 105 Nm (1,100 kgf-cm, 80 ft. lbs.) HINT: At the time of installation, if the holes for the cotter pin are not aligned, tighten the nut further up to 60°. b. Using SST, disconnect the steering knuckle. SST 09950-40011 (09951-04010, 09952-04010, 09553-04020, 09554-04010, 09955-04031, 09958-04011) c. Remove the nut and steering knuckle. NOTICE: 4WD: Be careful not to damage the oil seal and drive shaft boot. HINT: 4WD: When it is difficult to disconnect the drive shaft, tap the tip of the drive shaft with a plastic hammer. INSTALLATION Installation is in the reverse order of removal. HINT: After installation, bleed the brake system , check the front wheel alignment and ABS speed sensor signal. Component Tests and General Diagnostics Shift Indicator: Component Tests and General Diagnostics A/T.P. (Automatic Transmission Parking) Indicator Circuit CIRCUIT DESCRIPTION The propeller shaft and wheels are free even when the transmission shift lever is set to P as long as the transfer shift lever is in Neutral position. The A/T.P. indicator light lights up to warn the drive that the propeller shaft and wheels are not locked. If the A/T.P. indicator light goes on, the transfer shift lever should be shifted out of N position WIRING DIAGRAM Step 1 Paint - Paint Codes - All Paint: All Technical Service Bulletins Paint - Paint Codes - All COLLISION REPAIR INFORMATION CRIB98 TITLE: 2000 PAINT & REFINISH FORMULA CODES SECTION: REFINISH BULLETIN #98 MODELS: ALL TOYOTA DATE: NOVEMBER 1999 Attached for your reference is a list of all 2000 Toyota paint codes and the refinish formula codes for the following paint manufacturers: BASF, DuPont, PPG, Sherwin-Williams, Sikkens, Spies-Hecker, and ICI Autocolor. NOTE: The vehicle paint code is on the certification label which can be located on the drivers side door jamb or the lower section of the "B" pillar. Please contact your local paint representative for the actual paint mixing formulas or if you need help in color matching. 2000 TOYOTA PAINT CODES AND COLOR NAMES Page 3253 INSTALLATION 1. INSTALL MANUAL STEERING GEAR ASSEMBLY Torque the 2 gear assembly set bolts, nuts and washers. Torque: 201 Nm (2,050 kgf-cm, 148 ft. lbs.) 2. CONNECT INTERMEDIATE NO. 2 SHAFT 3. CONNECT RH AND LH TIE ROD ENDS 4. POSITION FRONT WHEELS FACING STRAIGHT AHEAD HINT: Do it with the front of the vehicle jacked up. 5. CENTER SPIRAL CABLE 6. INSTALL STEERING WHEEL a. Align the matchmarks on the wheel and steering column main shaft. b. Temporarily tighten the wheel set nut. c. Connect the connector. 7. CHECK STEERING WHEEL CENTER POINT 8. TORQUE STEERING WHEEL SET NUT Torque: 35 Nm (360 kgf-cm, 26 ft. lbs.) 9. INSTALL STEERING WHEEL PAD 10. CHECK FRONT WHEEL ALIGNMENT Disassembly and Reassembly Air/Fuel Ratio Sensor Oxygen Sensor: Testing and Inspection Air/Fuel Ratio Sensor Air-Fuel Ratio (A/F) Sensor COMPONENTS INSPECTION 1. INSPECT HEATER RESISTANCE OF A/F SENSOR a. Disconnect the sensor connector. b. Using an ohmmeter, measure the resistance between terminals +B and HT. Resistance: at 20 °C (68 °F) 0.8 - 1.4 ohms at 800 °C (1,472 °F) 1.8 - 3.2 ohms If the resistance is not as specified, replace the sensor. Torque: 20 Nm (200 kg.cm, 14 ft.lb) c. Connect the sensor connector. 2. INSPECT OPERATION OF A/F SENSOR Page 3790 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source How to Read Power Source Page 2341 Shift Interlock: Electrical Diagrams Page 3821 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Page 1337 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 254 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Page 4669 Junction Box / No. 3 Page 810 Wheel Fastener: Specifications Hub Nut ............................................................................................................................................... ................................................... 110 Nm (83 ft. lbs.) Page 2335 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Page 4636 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Page 2999 Connector Locations Page 1699 A/F and 02 Sensor Identification Page 60 3. Start the engine and warm it up to normal operating temperatures before test-driving. 4. Perform a thorough test drive with several accelerations from a stop with "light throttle" application until proper transmission shifting is verified. Reset Procedure 2 1. Disconnect the negative battery cable for 5 minutes. 2. Reconnect battery cable. 3. Start the engine and warm it up to normal operating temperatures before test-driving. 4. Perform a thorough test drive with several accelerations from a stop with "light throttle" application until proper transmission shifting is verified. Page 1067 5. REMOVE ECT SENSOR a. Disconnect the ECT sensor connector. b. Using a 19 mm dean socket wrench, remove the ECT sensor and gasket. 6. INSPECT ECT SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: Refer to the graph If the resistance is not as specified, replace the ECT sensor. 7. REINSTALL ECT SENSOR a. Install a new gasket to the ECT sensor. b. Using a 19 mm deep socket, install the ECT sensor. Torque: 20 Nm (200 kg.cm, 14 ft.lb) c. Connect the ECT sensor connector. 8. REINSTALL FUEL PIPE Install the fuel pipe with 4 new gaskets and the 2 union bolts. Torque: 34.3 Nm (350 kg. cm, 25 ft.lb) 9. REINSTALL NO.2 TIMING BELT COVER 10. RECONNECT UPPER RADIATOR HOSE TO WATER OUTLET 11. REFILL WITH ENGINE COOLANT Page 3252 Part 2 Of 2 REMOVAL 1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 2. REMOVE STEERING WHEEL PAD 3. REMOVE STEERING WHEEL 4. DISCONNECT RH AND LH TIE ROD ENDS 5. DISCONNECT INTERMEDIATE NO. 2 SHAFT 6. REMOVE MANUAL STEERING GEAR ASSEMBLY Remove the 2 gear assembly set bolts, nuts and washers. Page 3986 promoters. However, the application of adhesion promoters on earlier model bumpers made from PP/TPU (Polypropylene/Thermoplastic Urethane) and PUR (Polyurethane) is also recommended. Airbag(s) Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Airbag(s) Arming and Disarming CAUTION: * Work must be started 90 seconds after the ignition switch is turned to the "LOCK" position and the negative (-) terminal cable is disconnected from the battery. (The SRS is equipped with a back-up power source so that if work is started within 90 seconds of disconnecting the negative (-) terminal cable of the battery, the SRS may be deployed.) * When the negative (-) terminal cable is disconnected from the battery, the memory of the clock and audio system will be canceled. So before starting work, make a record of the contents memorized in the audio memory system. When work is finished, reset the audio systems as before and adjust the clock. To avoid erasing the memory of each memory system, never use a backup power supply from outside the vehicle. * Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during repairs. * Do not expose the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor directly to hot air or flames. AIR BAG SYSTEM DISARMING The Air Bag/Supplemental Restraint System (SRS) incorporates a backup energy source that maintains sufficient deployment voltage for up to 90 seconds after the ignition is turned Off and the battery has been disconnected. Before disconnecting battery, note radio station settings, since all vehicle memory will be lost. Never use a backup power source from outside the vehicle. 1. Turn ignition to Lock, then disconnect battery ground cable. 2. Wait at least 90 seconds after disconnection before beginning service or diagnostic procedures. AIR BAG SYSTEM ARMING 1. Ensure ignition is in Lock position. 2. Connect battery ground cable. 3. Wait at least 10 seconds before turning ignition from Lock position. 4. Turn ignition to ACC or On position and ensure SRS lamp lights, then goes off after approximately six seconds. If lamp remains lit, an SRS condition is indicated. Refer to Restraint Systems, Air Bag Systems, Testing And Inspection. See: Restraint Systems/Air Bag Systems/Testing and Inspection Page 2820 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Disassembly and Assembly DISASSEMBLY 1. DISCONNECT CONNECTOR 2. REMOVE ECU a. Using a E5 torx wrench, remove the 4 screws. Torque: 1.8 Nm (18.4 kgf-cm, 16 inch lbs.) b. Remove the ECU from the actuator. NOTICE: Protect the actuator in order to prevent sealing surface from getting dirty and causing damage on the valve body. If the dirt and the like is stuck to the sealing surface, use plastic tools or soft objects to remove the dirt. Do not use chemical solvents. REASSEMBLY Reassembly is in the reverse order of disassembly. Page 4817 Horn: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Page 1518 Step 1 Step 2 Page 3563 Control Module HVAC: Service and Repair REMOVAL 1. REMOVE GLOVE COMPARTMENT DOOR 2. REMOVE AMPLIFIER a. Disconnect the connector from the amplifier. b. Remove amplifier cover. c. Remove the amplifier from the cooling unit. INSTALLATION Installation is in the reverse order of removal. Page 5011 c. Connect the positive (+) lead from the battery to terminal 2 and the negative (-) lead from the battery to the motor body or terminal 4, and check that the motor stops running at the stop position after the motor operates again. If operation is not as specified, replace the motor. INSPECT WIPER MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 2 and the negative (-) lead to terminal 1, and check that the motor operates. NOTE: These tests must be performed quickly (within 20 seconds) to prevent the coil from burning out. If operation is not as specified, replace the motor. Page 2086 Page 1297 CHART 27 Testing and Inspection Igniter: Testing and Inspection ON-VEHICLE INSPECTION NOTE: "Cold" and "Hot" in these sentences express the temperature of the coils themselves. "Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F). INSPECT IGNITOR AND SPARK TEST Check that the spark occurs. 1. Disconnect high-tension cords from spark plug. 2. Remove the spark plug. 3. Install the spark plug to each high-tension cord. 4. Ground the spark plug. 5. Check if spark occurs while engine is being cranked. NOTE: To prevent excess fuel being injected from the injectors during this test, do not crank the engine for more 5 - 10 seconds at a time. If the spark does not occur, do the test as per the flow chart. 6. Using a 16 mm plug wrench, install the spark plugs. Torque: 18 N.m (195 kgf.cm, 15 ft.lbf) 7. Reinstall the ignition coil with ignitor. Specifications Output Shaft: Specifications Service Specifications Thrust Play .......................................................................................................................................... ...................... 0.27 - 0.86 mm (0.0106 - 0.0339 inch) Page 1598 CHART 26 Page 4672 Specifications Wheel Bearing: Specifications On models with serviceable wheel bearings, use a Lithium Multipurpose Grease. Page 1506 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Page 3091 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Page 3799 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 4981 6. Mask-off wiper motor opening. 7. Attach Kent(TM) 12" extension tube (P/N 90175) to the nozzle on the can of Leak-Chek(TM) (P/N 50087). NOTE: Direct Leak-Chek(TM) spray material approximately 1 inch above seam. Spray force is very strong - make several test passes before actually spraying material into seam. 8. Spray Leak-Chek(TM) through the wiper motor opening. a. Spray material inside upper cowl, beginning in lower corner, and continuing toward the centerline of vehicle. b. Remove wand from the wiper motor opening and insert it into larger cowl openings on the right hand side. Continue spraying material along entire seam until seam is filled from R/F fender to L/F fender area. Spray Leak-Chek(TM) into seam a total of 3 times, allowing Leak-Chek(TM) to flash dry for 30-45 minutes between applications. (Drying time increases as outside temperature decreases.) 9. After final application of Leak-Chek(TM) has been allowed to dry for approximately one hour, flood area with water for 5-10 minutes. NOTE: Hold garden hose at top right front corner of windshield and point hose downward toward lower right hand corner of windshield as shown. 10. Check inside cab behind Heater/Air Conditioner box for evidence of water leakage during water leak check. 11. Carefully inspect "T" joint on right and left sides (close to heater motor box, and brake booster) for evidence of water leaks. 12. If no leaks are found, cowl area leak repair is complete. Reinstall wiper motor, cowl trim panel, wiper arms, and hood. Wiper Arm Torque: 20 N.m (205 kgf.cm, 15 ft.lbf) If water leaks are still present and are coming in from the cowl area, remove right front fender and proceed as follows: 13. Seal around entire perimeter of "L" bracket with Kent High Tech(TM) Clear Seam Sealer (see drawing for location of "L" bracket). 14. Using a flashlight, look through the 2" x 3" rectangular hole on side of vertical cowl panel and locate vertical seam that connects side of cowl to front cowl. Page 75 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 3706 4. Install the bracket assembly, according to the directions in the Owner's Manual. Tighten the bolt to 16.5 - 24.7 N-m, (1.68-2.52 kgf-m, 12.2 - 18.2 ft-lbf). ^ Assure the top strap is attached to the child seat, according to the child seat manufacturer's instructions. ^ Assure the child seat is installed in the vehicle according to the Toyota Owner's Manual (seat section). Owner's Manual Installation Reference Information Page 2445 a. Using a chisel and hammer, loosen the staked part of the nut. b. Using SST to hold the flange, remove the nut. SST 09330-00021 c. Using SST, remove the companion flange. SST 09950-30011 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020, 09956-03050) 4. REMOVE OIL SEAL Using SST, remove the oil seal. SST 09350-32014 (09308-10010) 5. Except 3RZ-FE, 5VZ-FE w/o Diff. lock: REMOVE OIL SLINGER 6. REMOVE FRONT BEARING Using SST, remove the front bearing from the drive pinion. SST 09556-22010 Page 1072 4. REMOVE WATER VALVE Remove the bolt and water valve. INSTALLATION Installation is in the reverse order of removal. Page 4541 Step 1 Step 2 Description and Operation Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor The crankshaft position sensor, which detects the engine speed and crankshaft angle signal (NE signal), has been installed on the oil pump body. The NE signal plate has 34 teeth. The NE signal sensor generates 34 signals at every engine revolution. The ECM detects the standard crankshaft angle based on the G signal, and the actual crankshaft angle and the engine speed by the NE signal. Page 1738 CHART 27 Front Page 1084 Radiator: Service and Repair Removal and Installation REMOVAL 1. DRAIN ENGINE COOLANT 2. REMOVE FRONT BUMPER FILLER 3. REMOVE RADIATOR GRILLE a) Remove the 4 screws and clearance lights. Valve Cover Oil Baffle - Damage Prevention Valve Cover: Technical Service Bulletins Valve Cover Oil Baffle - Damage Prevention ENGINE EG007-02 Title: GENERAL MAINTENANCE TIP Models: All '93 - '03 Models March 22, 2002 Introduction To help prevent unnecessary complications during the oil fill process, no undue load should be placed on the oil baffle attached to the inside of the valve cover (see illustration). This baffle is designed to deflect oil and should not be used to support the weight of heavy oil fill devices. These devices can place stress on the baffle, and bend or break it during the oil fill process. Applicable Vehicles ^ All 1993 - 2003 model year Toyota vehicles. Oil Filling Procedure Please take measures to ensure that the baffle is not damaged during the oil fill process. If it does become damaged, repair it before any collateral damage occurs. Warranty Information Page 344 CHART 2 CHART 3 CHART 4 Page 3814 Seat Belt Reminder Lamp: Ground Locations Page 726 Refrigerant: Fluid Type Specifications Type R-134a Page 4676 Shift Indicator: Description and Operation Previous automatic transmissions have selected each gear shift using mechanically controlled throttle hydraulic pressure, governor hydraulic pressure and lock-up hydraulic pressure. The electronically controlled transmission, however, electrically controls the governor pressure and lock-up sensor through the solenoid valve. Control of the solenoid valve by the engine control module based on the input signals from each sensor makes smooth driving possible by shift selection for each gear which is most appropriate to the driving conditions at that time. 1. GEAR SHIFT OPERATION During driving, the engine control module selects the shift for each gear which is most appropriate to the driving conditions, based on input signals from the engine coolant temp. sensor to TERMINAL THW of the engine control module and also the input signals to TERMINAL SP2+ of the engine control module from the vehicle speed sensor devoted to the electronically controlled transmission. Current is then output to the electronically controlled transmission solenoid. When shifting to 1st speed, current flows from TERMINAL S1 of the engine control module to TERMINAL 1 of the electronically controlled transmission solenoid to GROUND, and continuity to the No.1 solenoid causes the shift. For 2nd speed, current flows from TERMINAL S1 of the engine control module to TERMINAL 1 of the electronically controlled transmission solenoid to GROUND, and from TERMINAL S2 of the engine control module to TERMINAL 2 of the electronically controlled transmission solenoid to GROUND. And continuity to solenoid No.1 and No.2 causes the shift. For 3rd speed, there is no continuity to No.1 solenoid, only to No.2 causing the shift. Shifting into 4th speed (Overdrive) takes place when there is no continuity to either No.1 or No.2 solenoid. 2. LOCK-UP OPERATION When the engine control module judges from each signal that lock-up operation conditions have been met, current flows from TERMINAL SL of the engine control module to TERMINAL 3 of the electronically controlled transmission solenoid to GROUND, causing continuity to the lock-up solenoid and causing lock-up operation. 3. STOP LIGHT SW CIRCUIT If the brake pedal is depressed (Stop light SW ON) when driving in lock-up condition, a signal is input to TERMINAL STP of the engine control module, the engine control module operates and continuity to the lock-up solenoid is cut. 4. OVERDRIVE CIRCUIT * O/D main SW ON When the O/D main SW is turned ON (SW point is open), a signal is input to TERMINAL ODMS of the engine control module and engine control module operation causes gear shift when the conditions for overdrive are met. * O/D main SW OFF When the O/D main SW is turned OFF (SW point is closed), a signal is input into TERMINAL ODMS of the engine control module, and turns on the O/D OFF indicator light. This activates the ECU, and the transmission system is controlled not to shift to overdrive. 5. A/T OIL TEMP. WARNING When the A/T oil temp. sensor affixed to the transmission case detects that the fluid temp. is 150 °C (302 °F) or more, the engine control module operates and the current flowing through the GAUGE fuse flows to the A/T oil temp. warning light to TERMINAL OILW of the engine control module to GROUND, so that the warning light lights up, informing that the oil temp. is high. When the oil temp. drops to 120 °C (248 °F) or less, the engine control module stops operating and the warning light goes out. Seat Belts - Shoulder Belt Particle (Dirt) Buildup Seat Belt: All Technical Service Bulletins Seat Belts - Shoulder Belt Particle (Dirt) Buildup BODY BO019-01 August 10, 2001 Title: SHOULDER BELT ANCHOR TAPE SET Models: All Applicable Models Introduction To assist customers in preventing particle buildup and preserve the appearance of the shoulder belt anchor, the following procedure has been developed. Applicable Vehicles ^ 1996-2001 model year 4Runner*1 vehicles. ^ 1996-2001 model year Land Cruiser vehicles. ^ 1996-2001 model year RAV4*2 vehicles. ^ 2001 model year Sequoia vehicles. ^ 1996-1998 model year T100 trucks. ^ 1996-2001 model year Tacoma*1 trucks. ^ 2000-2001 model year Tundra trucks. *1 Except rear seat belt. *2 Except rear seat belt of soft top models. Parts Information Warranty Information Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Installation Procedure 1. CLEAN SHOULDER BELT ANCHOR NOTE: ^ Do not install the tape when the vehicle temperature is below the freezing point. ^ Do not re-use removed fluorocarbon resin tape. Page 2904 Steps 3 - 4 INSPECTION PROCEDURE Page 1918 Fuel Return Line: Testing and Inspection COMPONENTS CAUTION: - Always use new gaskets when replacing the fuel tank or component parts. - Apply the proper torque to all tightened Darts. INSPECTION INSPECT FUEL TANK AND LINE Page 4824 Horn: Electrical Diagrams Service Hints HORN RELAY [J/B NO.1] 2-3 : Closed with horn SW ON Page 694 Fluid - A/T: Service and Repair a. Check the fluid level. HINT: Drive the vehicle so that the engine and transmission are at normal operating temperature. Fluid temp.: 70 - 80 °C (158 - 176 °F) - Only use the COOL range on the dipstick as a rough reference when the fluid is replaced or the engine does not run. 1. Park the vehicle on a level surface and set the parking brake. 2. With the engine idling and the brake pedal depressed, shift the shift lever into all positions from P to L position and return to P position. 3. Pull out the dipstick and wipe it clean. 4. Push it back fully into the pipe. 5. Pull it out and check that the fluid level is in the HOT range. If the level is not within the range, add new fluid. Fluid type: ATF ID-II or DEXRON(R)III (DEXRON(R)II) NOTE: Do not overfill. b. Check the fluid condition. If the fluid smells burnt or is black, replace it. c. Replace the ATF. 1. Remove the drain plug and drain the fluid. 2. Reinstall the drain plug securely. 3. With the engine OFF add new fluid through the oil filler pipe. Fluid type: ATF ID-II or DEXRON(R)III (DEXRON(R)II) Component Tests and General Diagnostics Key Reminder Switch: Component Tests and General Diagnostics Ignition Switch and Key Unlock Warning Switch INSPECTION 1. INSPECT IGNITION SWITCH CONTINUITY If continuity is not as specified, replace the switch. 2. INSPECT KEY UNLOCK WARNING SWITCH CONTINUITY If continuity is not as specified, replace the switch. 3. Key Unlock Warning System: INSPECT INTEGRATION RELAY OPERATION Page 3837 Seat Belt Reminder Lamp: Pinout Values and Diagnostic Parameters B 6 BUCKLE SW 1-2 : Open with driver's seat belt in use D 15 DOOR COURTESY SW LH 1-GROUND : Closed with LH door open I 15-A SEAT BELT WARNING RELAY [INTEGRATION RELAY] 6-GROUND : Approx. 12 volts with ignition SW ON 12-GROUND : Always approx. 12 volts A-7-GROUND : Always continuity A-5-GROUND : Continuity with LH door open A-10-GROUND: Approx. 12 volts with ignition key in cylinder A-2-GROUND : 0 Volts for 4 - 8 seconds with ignition SW ON and 12 volts 4 - 8 seconds after ignition SW ON Electrical Specifications Oxygen Sensor: Electrical Specifications Air/Fuel Ratio Sensor Resistance: at 20°C (68°F): 0.8 - 1.4 ohms at 800°C (1,472°F): 1.8 - 3.2 ohms Heated Oxygen Sensor Resistance Between Terminals +B and HT: at 20°C (68°F) 11 - 16 Ohms at 800°C (1,472°F) 23 - 32 Ohms Page 4440 Cigarette Lighter: Testing and Inspection C 4 CIGARETTE LIGHTER 2-GROUND : Approx. 12 volts with ignition SW at ON and ACC position 1-GROUND : Always continuity C 7 CLOCK 1-GROUND : Always approx. 12 volts (Power for clock) 4-GROUND : Approx. 12 volts with ignition SW at ON or ACC position (Power for indication) 3-GROUND : Approx. 12 volts with light control SW at TAIL or HEAD position (Signal of indication) 2-GROUND : Always continuity Page 2056 7. REMOVE WATER BYPASS PIPE AND KNOCK SENSOR WIRE 8. REMOVE KNOCK SENSORS Using SST, remove the knock sensor. SST 09817-16011 9. INSPECT KNOCK SENSORS Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor. 10. REINSTALL KNOCK SENSORS Using SST, install the knock sensor. SST 09817-16011 Torque: 39 Nm (400 kg.cm, 29 ft.lb) 11. REINSTALL WATER BYPASS PIPE AND KNOCK SENSOR WIRE 12. REINSTALL INTAKE MANIFOLD ASSEMBLY 13. REINSTALL FUEL PRESSURE REGULATOR 14. REINSTALL INTAKE AIR CONNECTOR ASSEMBLY 15. REINSTALL NO.2 TIMING BELT COVER 16. REINSTALL AIR CLEANER HOSE 17. REFILL WITH ENGINE COOLANT Page 4567 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Locations Page 2306 Step 1 Step 2 Page 2320 Transmission Speed Sensor: Description and Operation CIRCUIT DESCRIPTION The speed sensor for ABS detects the wheel speed and sends the appropriate signals to the ABS ECU. The ECU converts these signals into a pulse signal and outputs it to the combination meter. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. Page 3215 Junction Box / No. 3 Page 3783 Seat Belt Extender Worksheet Page 342 O2S Application Table O2S Failure Threshold Charts Page 2391 c. Disconnect the throttle cable from the cam. d. Remove the valve body. NOTICE: Be careful not to drop the check ball body and spring. 10. REMOVE SHIFT SOLENOID VALVE a. Remove the solenoid valve mounting bolts. b. Remove the 3 solenoid valves. c. Remove the 3 O-rings from the solenoid valves. 11. INSTALL SHIFT SOLENOID VALVE a. Coat the 3 new O-rings with ATE b. Install the 3 O-rings to the shift solenoid valves. c. Install the 3 shift solenoid valves with the 3 bolts. Torque: 10 Nm (100 kgf-cm, 7 ft. lbs.) 12. INSTALL VALVE BODY a. Align the groove of the manual valve to the pin of the lever. b. Connect the throttle cable to the cam. Page 753 Engine Room R/B # 2 Engine Room R/B # 2 Locations Fusible Link: Locations Relay Box / No. 2 Diagrams Specifications Quarter Window Glass 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 1383 Fuel Pressure: Testing and Inspection 1. CHECK FUEL PUMP OPERATION a. Connect a TOYOTA hand-held tester to the DLC3. b. Turn the ignition switch ON and push TOYOTA hand-held tester main switch ON. NOTE: Do not start the engine. c. Select the ACTIVE TEST mode on the TOYOTA hand-held tester. d. Please refer to the TOYOTA hand-held tester operator's manual for further details. e. If you have no TOYOTA hand-held tester, connect the positive (+) and negative (-) leads from the battery to the fuel pump connector. (See step 4) f. Check that there is pressure in the fuel inlet hose from the fuel filter. HINT: If there is fuel pressure, you will hear the sound of fuel flowing. If there is no pressure, check the M-fuse, fuses, EFI main relay,fuel pump, ECM and wiring connections. g. Turn the ignition switch OFF. h. Disconnect the TOYOTA hand-held tester from the DLC3. 2. CHECK FUEL PRESSURE a. Check the battery positive voltage is above 12 V. b. Disconnect the negative (-) terminal cable from the battery. c. Remove the 6 bolts, and disconnect the No.2 timing belt cover. d. Remove the union bolt holding the fuel pipe to the delivery pipe and gasket. Component Locations Shift Indicator: Component Locations Page 2092 Shift Indicator: Ground Locations Page 1683 Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor The intake air temperature sensor is built into the air cleaner cap and senses the intake air temperature. A thermistor built in the sensor changes the resistance value according to the intake air temperature. The lower the intake air temperature, the greater the thermistor resistance value, and the higher the intake air temperature, the lower the thermistor resistance value. The intake air temperature sensor is connected to the ECM. The 5 V power source voltage in the ECM is applied to the intake air temperature sensor from the terminal THA via a resistor R. That is, the resistor R and the intake air temp. sensor are connected in series. When the resistance value of the intake air temp. sensor changes in accordance with changes in the intake air temperature, the potential at terminal THA also changes. Based on this signal, the ECM increases the fuel injection volume to improve driveability during cold engine operation. Page 4804 Page 1279 CHART 11 Page 1641 Engine Control Module: Connector Views Connectors (California Spec.) Part 1 Of 2 (California Spec.) Page 2193 Fluid - A/T: Service and Repair a. Check the fluid level. HINT: Drive the vehicle so that the engine and transmission are at normal operating temperature. Fluid temp.: 70 - 80 °C (158 - 176 °F) - Only use the COOL range on the dipstick as a rough reference when the fluid is replaced or the engine does not run. 1. Park the vehicle on a level surface and set the parking brake. 2. With the engine idling and the brake pedal depressed, shift the shift lever into all positions from P to L position and return to P position. 3. Pull out the dipstick and wipe it clean. 4. Push it back fully into the pipe. 5. Pull it out and check that the fluid level is in the HOT range. If the level is not within the range, add new fluid. Fluid type: ATF ID-II or DEXRON(R)III (DEXRON(R)II) NOTE: Do not overfill. b. Check the fluid condition. If the fluid smells burnt or is black, replace it. c. Replace the ATF. 1. Remove the drain plug and drain the fluid. 2. Reinstall the drain plug securely. 3. With the engine OFF add new fluid through the oil filler pipe. Fluid type: ATF ID-II or DEXRON(R)III (DEXRON(R)II) Page 3851 e. Dispose of front seat outer belt (with seat belt pretensioner). CAUTION: The front seat outer belt is very hot when the seat belt pretensioner is activated, so leave it alone for at least 30 minutes after activation. - Use gloves and safety glasses when handling a front seat outer belt with activated seat belt pretensioner. - Always wash your hands with water after completing the operation. - Do not apply water, etc. to a front seat outer belt with activated seat belt pretensioner. 1. Remove the disc wheel and SST. 2. Place the front seat outer belt in a vinyl bag, tie the end tightly and dispose of it in the same way as other general parts. Page 4102 Keyless Entry Transmitter: Technical Service Bulletins Keyless Entry - Transmitter Programming & Identification ELECTRICAL EL008-02 REVISED December 20, 2002 Title: WIRELESS TRANSMITTER & PROGRAMMING GUIDE Models: All Applicable TSB REVISION NOTICE: Page 1428 HINT: Apply SST (B) at a slight angle on the side marked with "9" or "7", at the position shown in the illustration. - When SST (B) is inserted too deeply, it will get pinched by the shim. To prevent it from being stuck, insert it gently from the intake side, at a slight angle. 4) Using a small screwdriver and magnetic finger, remove the adjusting shim. b) Determine the replacement adjusting shim size by following the Formula or Charts: 1) Using a micrometer, measure the thickness of the removed shim. 2) Calculate the thickness of a new shim so the valve clearance comes within the specified value. T Thickness of used shim A Measured valve clearance N Thickness of new shim Intake: N = T + (A - 0.18 mm (0.007 inch)) Exhaust: N = T + (A - 0.32 mm (0.013 inch)) Page 1773 Page 3241 Key Reminder Switch: Pinout Values and Diagnostic Parameters B 6 BUCKLE SW 1-2 : Open with driver's seat belt in use D 15 DOOR COURTESY SW LH 1-GROUND : Closed with LH door open I 15-A SEAT BELT WARNING RELAY [INTEGRATION RELAY] 6-GROUND : Approx. 12 volts with ignition SW ON 12-GROUND : Always approx. 12 volts A 7-GROUND : Always continuity A 5-GROUND : Continuity with LH door open A 10-GROUND: Approx. 12 volts with ignition key in cylinder A 2-GROUND : 0 Volts for 4 - 8 seconds with ignition SW ON and 12 volts 4 - 8 seconds after ignition SW ON Page 1048 If necessary, replace the fluid coupling. c) Reinstall the fan to the fluid coupling with the 4 nuts. Torque: 7.4 Nm (75 kgf-cm, 65 inch lbs.) 3. INSPECT FAN PULLEY BRACKET Check the turning smoothness of the fan pulley. If necessary, replace the pulley bracket. 4. INSPECT TIMING BELT COMPONENTS Page 3491 Control Assembly: Testing and Inspection On-Vehicle Inspection INSPECT HEATER CONTROL LEVER AND DIALS OPERATION Move the control lever and dials left and right check for stiffness and binding the full range of the lever and dials. Page 3036 Engine Compartment Instrument Panel Locations Page 1601 Page 365 CHART 26 Page 3545 Refrigerant: Fluid Type Specifications Type R-134a Page 3064 Auxiliary Power Outlet: Connector Locations Junction Box / No. 3 Page 4724 Stop Light: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Page 1278 CHART 10 Diagram Information and Instructions Data Link Connector: Diagram Information and Instructions Key to Diagrams Key to Diagrams A: System Title. B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: (1) Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. Page 1578 CHART 5 CHART 6 Page 4100 Page 2525 Step 4 Specifications Camshaft Gear/Sprocket: Specifications Tightening Torque Crankshaft Pulley ................................................................................................................................ ..................................................... 250 Nm (184 ft.lb) Camshaft Timing Pulley ................................... .......................................................................................................................................... 110 Nm (81 ft.lb) Page 3404 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 1511 Engine Control Module: Connector Views Connectors (California Spec.) Part 1 Of 2 (California Spec.) Description and Operation Brake Switch - TCC: Description and Operation Stop Light Switch Signal Engine This signal is used to detect when the brakes have been applied. The STP signal voltage is the same as the voltage supplied to the stop lights. The STP signal is used mainly to control the fuel cut-off engine speed (The fuel cut-off engine speed is reduced slightly when the vehicle is braking.). Automatic Transaxle The purpose of this circuit is to prevent the engine from stalling, while driving in lock-up condition, when brakes are suddenly applied. When the brake pedal is operated, this switch sends a signal to ECM. Then the ECM cancels operation of the lock-up clutch while braking is in progress. Capacity Specifications Fluid - Differential: Capacity Specifications Differential Fluid Rear Short wheel base with locker ...................................................................................................... .................................................................................. 2.8 Qt Short wheel base without locker ............ .............................................................................................................................................................. ......... 2.7 Qt Extra long wheel base with locker .................................................................................. .............................................................................................. 3.1 Qt Extra long wheel base without locker ................................................................................................................................................... ........................ 2.6 Qt Page 1678 Crankshaft Position Sensor: Testing and Inspection INSPECT CRANKSHAFT POSITION SENSOR a. Remove the sensor connector. b. Using an ohmmeter, measure the resistance between the terminals. Resistance: Cold 1,630 - 2,740 ohms Hot 2,065 - 3,225 ohms c. Reinstall the sensor. Diagram Information and Instructions Seat Belt Reminder Lamp: Diagram Information and Instructions Key to Diagrams Key to Diagrams A: System Title. B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: (1) Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. Input Signal Check Cruise Control Switch: Testing and Inspection Input Signal Check DENSO Made HINT: 1. For check No.1 - No.2: Turn the ignition switch ON. 2. For check No.3: - Turn ignition switch ON. - Shift to D position. 3. For check No.4: - Jack up the vehicle. - Start the engine. - Shift to D position. a. Press the control switch to SET/COAST or RES/ACC position and hold it down or hold it up "1". b. Push the main switch ON "2". c. Check that the CRUISE MAIN indicator light blinks twice or 3 times repeatedly after 3 seconds. d. Turn the SET/COAST or RES/ACC switch OFF. e. Operate each switch as listed in the table. Page 4105 Page 737 HINT: The brake pedal should not be depressed twice and/or returned while setting to the specified pressure. Read the value of rear brake pressure 2 seconds after adjusting the specified fluid pressure. If the brake pressure is incorrect, adjust the fluid pressure. 4. IF NECESSARY, ADJUST FLUID PRESSURE a. Adjust the length of the No. 2 shackle. Low pressure - Lengthen A High pressure - Shorten A Initial Set: Adjustment Range: HINT: One turn of the nut changes the fluid pressure as shown in the following table. Rear Brake Pressure: b. If the pressure cannot be adjusted by the No. 2 shackle, raise or lower the valve body. Low pressure - Lower body High pressure - Raise body c. Torque the nuts. Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.) d. Adjust the length of the No. 1 shackle again. If it cannot be adjusted, inspect the valve housing. Page 2282 Step 5 INSPECTION PROCEDURE Page 1448 Camshaft Position Sensor: Testing and Inspection INSPECT CAMSHAFT POSITION SENSOR a. Disconnect the sensor connector. b. Using an ohmmeter, measure the resistance between the terminals. Resistance: cold 835 - 1,400 ohms Hot 1,060 - 1,645 ohms If the resistance is not as specified, replace the sensor. c. Reconnect the camshaft position sensor connector. Page 3315 Steering Wheel: Service and Repair Airbag Assembly Connectors DISCONNECTION a. Place a finger on the slider. b. Slide the slider to release lock. c. Disconnect the connector. CONNECTION a. Align a lock part of male connector and a slider of female connector in the same direction as shown in the illustration, fit in them without rubbing. b. Make sure to insert until they are locked. After fitting in pull them slightly to check that they are locked. (When locked, make sure that the outer returns to its original position and sound at the time of fitting in can be heard.) HINT: As the slider slides, do not touch it. - Be careful not to deform the release board. If the release board is deformed, replace it with a new one. Testing and Inspection Starter Relay: Testing and Inspection INSPECTION 1. REMOVE STARTER RELAY (Marking: ST) 2. INSPECT STARTER RELAY a. Inspect the relay continuity. 1. Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. 2. Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. b. Inspect the relay operation. 1. Apply battery positive voltage across terminals 1 and 2. Page 1892 4. CONNECT FUEL INLET PIPE a. Temporarily install the inlet pipe with 2 new gaskets, union bolt and bolt. b. Tighten the clamp bolt. Torque: 8 Nm (80 kg.cm, 71 in.lb) c. Tighten the union bolt. Torque: 34.3 Nm (350 kg.cm, 25 ft.lb) 5. INSTALL FUEL PRESSURE REGULATOR 6. INSPECT AIR ASSIST LINES AND CONNECTIONS Visually check for loose connections, sharp bends or damage. 7. INSTALL INTAKE AIR CONNECTOR ASSEMBLY 8. INSTALL AIR CLEANER HOSE 9. CHECK FOR FUEL LEAKS Description and Operation Transmission Mode Indicator - A/T: Description and Operation The ECM memory contains the shift programs for the NORMAL and POWER patterns, 2 position, L position and the lock-up patterns. Following the programs corresponding to the signals from the pattern select switch, the park/neutral position and other various sensors, the ECM switches the solenoid valves ON and OFF, and controls the transmission gear change and the lock-up clutch operation. Page 1336 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 3793 Locations Relay Box: Locations Relay Box / No. 2 Page 847 Connecting Rod: Specifications Torque Specifications Tightening Torque Step 1 .................................................................................................................................................. ................................................... 25 Nm (18 ft lb) Step 2 .................................................................... ................................................................................................................... Tighten an additional 90° Page 3397 3. w/o Free wheel hub (4WD only): DISCONNECT DRIVE SHAFT a. Using a screwdriver, remove the grease cap. b. Remove the cotter pin and lock cap. HINT: At the time of installation, if the holes for the cotter pin are not aligned, tighten the nut further up to 60°. c. With applying the brakes, remove the lock nut. Torque: 235 Nm (2,400 kgf-cm, 174 ft. lbs.) 4. w/ Freewheel hub: DISCONNECT DRIVE SHAFT a. Remove the free wheel hub. b. Using a snap ring expander, remove the snap ring. c. Remove the spacer. 5. w/ ABS: DISCONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP FROM STEERING KNUCKLE Remove the 2 bolts and ABS speed sensor wire harness clamp from the steering knuckle. Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.) 6. REMOVE BRAKE CALIPER AND DISC a. Remove the union bolt and 2 gaskets from the caliper, then disconnect the flexible hose from the caliper. Torque: 30 Nm (310 kgf-cm, 22 ft. lbs.) HINT: At the time of installation, install the flexible hose lock securely in the lock hole in the caliper. b. Remove the 2 bolts, brake caliper and disc. Torque: 123 Nm (1,250 kgf-cm, 90 ft. lbs.) Page 2992 Page 4988 ^ Using wipers instead of an ice scraper to remove frost and ice from the windshield during a car warm up can dull, nick, or tear the rubber. ^ Banging wiper on the glass to remove ice & snow can cause the blade to bend and rubber to come out of the blade providing the potential to scratch the glass. ^ Ice forms in wiper blade pin joints, which causes streaking and unwiped areas. To remove ice from pin joints, compress the blade and rubber with your hand to loosen the frozen joints. To prevent this condition, use winter blades with a rubber cover. Page 3757 D. Check to be sure that the male pin of the tongue plate stopper has become deformed evenly in the hole of the female part and is firmly held to the belt webbing. Page 2133 Step 5 INSPECTION PROCEDURE Diagram Information and Instructions Key Reminder Switch: Diagram Information and Instructions Key to Diagrams Key to Diagrams A: System Title. B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: (1) Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. Page 529 e. Check that the current increases to approximately 14.5 A or more when the window stops going down. HINT: The circuit breaker opens for some 4 - 40 seconds after the window stops going down, so that the check must be done before the circuit breaker operates. If operation is as specified, replace the master switch. Page 2787 Brake Shoe: Service and Repair For information regarding the service and repair of this component and the system that it is a part of, please refer to Drum Brake System; Service and Repair. Page 4342 Steps 1 - 2 Page 4807 Junction Box / No. 1 Paint - Gray Bumper Paint Colors Paint: All Technical Service Bulletins Paint - Gray Bumper Paint Colors PAINT PA001-03 January 23, 2003 Title 1995-2003 GRAY BUMPER PAINT CODES Models '95- '03 Tacoma & '00 - '03 Tundra Introduction Following are color codes for gray painted steel bumpers installed on the 1995 - 2003 model year Tacoma and 2000 - 2003 model year Tundra. These bumpers are factory installed usually on base trim level models. Applicable Vehicles ^ 1995 - 2003 model year Tacoma vehicles. ^ 2000 - 2003 model year Tundra vehicles. Parts Information Warranty Information Page 1108 W/ Tachometer W/o Tachometer HINT: Connect the test leads so that the current from the ohmmeter can flow according to the above order. This circuit includes the diode. If resistance value is not as specified, replace the receiver gauge. Page 4726 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Page 4665 Page 3306 - The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment. - Use gloves and safety glasses when handling a steering wheel pad with the deployed airbag. - Always wash your hands with water after completing the operation. - Do not apply water, etc. to a steering wheel pad with the deployed airbag. AIRBAG DEPLOYMENT WHEN SCRAPPING VEHICLE HINT: Have a battery ready as the power source to deploy the airbag. a. Check functioning of the SST. CAUTION: When deploying the airbag, always use the specified SST: SRS Airbag Deployment Tool. SST 09082-00700 1. Connect the SST to the battery. Connect the red clip of the SST to the battery positive (+) terminal and the black clip to the battery negative (-) terminal. HINT: Do not connect the yellow connector which will be connected with the supplemental restraint system. 2. Check functioning of the SST. Press the SST activation switch, and check that the LED of the SST activation switch lights up. CAUTION: If the LED lights up when the activation switch is not being pressed, SST malfunction is probable, so definitely do not use the Page 2521 Overdrive Indicator Lamp: Testing and Inspection O/D Main Switch & O/D OFF Indicator Light Circuit CIRCUIT DESCRIPTION The O/D main switch is a momentary type switch. When pressing the O/D OFF main switch, the O/D OFF indicator light lights up and ECM prohibit shifting to O/D, and when pressing it again, the O/D OFF indicator light goes off and ECM allows shifting to O/D. Turning the IG switch OFF will reset the O/D OFF indicator light. Page 1398 c. When connecting the flare nut on the high pressure pipe union, observe these procedures: 1. Apply a light coat of engine oil to the flare and tighten the flare nut by hand. 2. Using SST, tighten the flare nut to the specified torque. SST 09631-22020 Torque: 28 Nm (285 kg.cm, 21 ft.lb) HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). d. Observe these precautions when removing and installing the injectors. 1. Never reuse the O-ring. 2. When placing a new O-ring on the injector, take care not to damage it in any way. 3. Coat a new O-ring with spindle oil or gasoline before installing-never use engine, gear or brake oil. e. Install the injector to the delivery pipe and intake manifold, as shown in the illustration. f. Check that there are no fuel leaks after doing maintenance anywhere on the fuel system. 1. Connect a TOYOTA hand-held tester to the DLC3. Page 1896 Page 3747 CAUTION For this procedure, do not use pliers. They may damage the webbing. C. Tighten the c-clamp until the space between its jaws are 4.5 - 5.0 mm (0.18 in. -0.20 in.) Figures 5&6 Page 3186 1. CHECK OIL CLEARANCE BETWEEN VANE RUMP SHAFT AND BUSHING Using a micrometer and caliper gauge, measure the oil clearance. Standard clearance: 0.03-0.05 mm (0.0012-0.0020 inch) Maximum clearance: 0.07 mm (0.0028 inch) If it is more than the maximum, replace the front housing and vane pump shaft. 2. INSPECT VANE PUMP ROTOR AND VANE PLATES a. Using a micrometer, measure the height, thickness and length of the 10 plates. Minimum height: 8.6 mm (0.339 inch) Minimum thickness: 1.397 mm (0.0550 inch) Minimum length: 14.991 mm (0.5902 inch) b. Using a feeler gauge, measure the clearance between the rotor groove and plate. Maximum clearance: 0.035 mm (0.0014 inch) Page 4312 Steps 3 - 4 INSPECTION PROCEDURE Page 98 Fuel Pump Relay: Testing and Inspection 1. REMOVE CIRCUIT OPENING RELAY 2. INSPECT CIRCUIT OPENING RELAY a. Inspect the relay continuity. 1. Using an ohmmeter, check that there is no continuity between terminals 1 and 2. If there is continuity, replace the relay. 2. Check that there is continuity between terminals 2 and 4. If there is no continuity, replace the relay. 3. Check that there is continuity between terminals 5 and 5. If there is no continuity, replace the relay. Page 1805 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Component Tests and General Diagnostics Shift Indicator: Component Tests and General Diagnostics A/T.P. (Automatic Transmission Parking) Indicator Circuit CIRCUIT DESCRIPTION The propeller shaft and wheels are free even when the transmission shift lever is set to P as long as the transfer shift lever is in Neutral position. The A/T.P. indicator light lights up to warn the drive that the propeller shaft and wheels are not locked. If the A/T.P. indicator light goes on, the transfer shift lever should be shifted out of N position WIRING DIAGRAM Step 1 Page 626 17. SET NO.1 CYLINDER AT TDC/COMPRESSION a) Temporarily install the crankshaft pulley bolt to the crankshaft. b) Turn the crankshaft, and align the timing marks of the crankshaft timing pulley and oil pump body. NOTICE: Always turn the crankshaft clockwise. c) Check that the timing marks of the camshaft timing pulleys and No.3 timing belt cover are aligned. If not, turn the crankshaft pulley 1 revolution (360°). d) Remove the crankshaft pulley bolt. 18. IF REUSING TIMING BELT, CHECK INSTALLATION MARKS ON TIMING BELT Check that there are 3 installation marks and front mark on the timing belt. If the installation and front marks have disappeared, before removing the timing belt, place 3 new installation marks on the timing belt to match the timing marks of the timing pulleys, and place a new front mark on the timing belt. 19. REMOVE TIMING BELT TENSIONER Alternately loosen the 2 bolts, and remove them, the belt tensioner and dust boot. 20. REMOVE TIMING BELT 21. REMOVE RH CAMSHAFT TIMING PULLEY a) Using SST, loosen the pulley bolt. SST 09960-10010 (09962-01000, 09963-01000) b) Remove the bolt, knock pin and timing pulley. Page 3427 3. w/o Free wheel hub (4WD only): DISCONNECT DRIVE SHAFT a. Using a screwdriver, remove the grease cap. b. Remove the cotter pin and lock cap. HINT: At the time of installation, if the holes for the cotter pin are not aligned, tighten the nut further up to 60°. c. With applying the brakes, remove the lock nut. Torque: 235 Nm (2,400 kgf-cm, 174 ft. lbs.) 4. w/ Freewheel hub: DISCONNECT DRIVE SHAFT a. Remove the free wheel hub. b. Using a snap ring expander, remove the snap ring. c. Remove the spacer. 5. w/ ABS: DISCONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP FROM STEERING KNUCKLE Remove the 2 bolts and ABS speed sensor wire harness clamp from the steering knuckle. Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.) 6. REMOVE BRAKE CALIPER AND DISC a. Remove the union bolt and 2 gaskets from the caliper, then disconnect the flexible hose from the caliper. Torque: 30 Nm (310 kgf-cm, 22 ft. lbs.) HINT: At the time of installation, install the flexible hose lock securely in the lock hole in the caliper. b. Remove the 2 bolts, brake caliper and disc. Torque: 123 Nm (1,250 kgf-cm, 90 ft. lbs.) Page 1690 COMPONENTS INSPECTION 1. DRAIN ENGINE COOLANT 2. REMOVE AIR CLEANER HOSE 3. REMOVE NO.2 TIMING BELT COVER 4. REMOVE INTAKE AIR CONNECTOR ASSEMBLY 5. REMOVE FUEL PRESSURE REGULATOR 6. REMOVE INTAKE MANIFOLD ASSEMBLY Testing and Inspection Fuel Gauge Sender: Testing and Inspection INSPECT FUEL SENDER GAUGE RESISTANCE Measure the resistance between terminals 2 and 3. 68 L 57 L If resistance value is not as specified, replace the sender gauge. Keyless Entry - Remote Transmitter Programming Guide Keyless Entry Transmitter: Technical Service Bulletins Keyless Entry - Remote Transmitter Programming Guide ELECTRICAL EL010-07 REVISED Title: WIRELESS TRANSMITTER & PROGRAMMING GUIDE Models: '90 - '08 Applicable Toyota November 9, 2007 TSB REVISION NOTICE: ^ November 10, 2007: A TSB reference has been updated in the Programming column of the Application Chart. Previous versions of this TSB should be discarded. TSB UPDATE NOTICE: The information contained in this TSB supersedes TSB No. EL008-02. TSB No. EL008-02 is now obsolete and should be discarded. Introduction Difficulties during Remote Keyless Entry (RKE) Transmitter Programming can arise due to confusion between Toyota Factory Wireless systems and Toyota Port/Dealer installed systems. This bulletin will assist in identifying the system/correct remote transmitters for each vehicle, and provide the location of the most accurate programming procedure for each system. Applicable Vehicles ^ 1990 - 2008 model year applicable Toyota vehicles. Warranty Information System Identification The Application Chart contains all of the necessary information to correctly identify the type of system installed, and where to go to get programming procedures for each vehicle. Should a vehicle having both VIP and Factory systems available (as identified in the Application Chart) be brought in without any remotes (or one non-working remote), use the following tips to help determine which type of wireless system (O.E. or PIO/DIO) the vehicle has. ^ Look at the Trim Level of the vehicle. Higher-grade vehicles will tend to have O.E. systems, while entry-grade vehicles will tend to have VIR For example, the 2001 Camry XLE has Factory WRKE, but the LE and CE grades have VIR ^ Look for a "Status Monitor" with a glass breakage sensor and an LED externally installed into the dashboard or on the center console. Most VIP systems will have this. ^ Locate the ECU (refer to the applicable vehicle VIP Manual installation instructions for location). Once located, refer to the part label. ^ Attempt to perform the factory wireless programming procedure to get a response from the vehicle. Select the "confirmation mode" and see if any "Lock/Unlock" response is received, if so, the vehicle has a factory system. Testing and Inspection Oil Filter: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Engine Lubrication; Testing and Inspection. Testing and Inspection Oil Pressure Warning Lamp/Indicator: Testing and Inspection INSPECT LOW OIL PRESSURE WARNING LIGHT a. Disconnect the connector from the warning switch and ground terminal on the wire harness side connector. b. Turn the ignition switch ON and check that the warning light lights up. If the warning light does not light up, test the bulb. Page 1228 4. REINSTALL NO.2 TIMING BELT COVER Page 4931 a. Position the glass so that the reference marks are lined up, and press it in gently along the rim. b. Using a spatula, apply adhesive on the glass rim. c. Use a scraper to remove any excess or protruding adhesive. d. Hold the glass in place securely with a protective tape or equivalent until the adhesive hardened. NOTE: Take care not to drive the vehicle during the time described in the table. 10. INSPECT FOR LEAKS AND REPAIR a. Conduct a leak test after the hardening time has elapsed. b. Seal any leak with sealant. Part No. 08833-00030 or equivalent 11. APPLY ADHESIVE TO MOULDING INSTALLATION AREA Coat the glass with adhesive at the moulding installation area. Part No. 08833-00030 or equivalent 12. INSTALL NEW WINDSHIELD OUTSIDE UPPER MOULDING Place new moulding into the body and tap it by hand. 13. INSTALL WIPER ARMS Page 2280 Step 3 Page 3495 3. DISCONNECT HATER CONTROL CABLES HINT: After connection, adjust the control cables. 4. REMOVE HEATER CONTROL ASSEMBLY Remove the 2 screws and pull out the heater control assembly, then disconnect the connector. INSTALLATION Installation is in the reverse order of removal. HINT: After installation, adjust the heater control cables. a. Set hater control assembly in these conditions: 1. Set heater control assembly at "FRESH" position. 2. Mode control dial at "FACE" position 3. Temperature control dial at "COOL" position b. Adjust air inlet control cable. Pull the mode control link at "FRESH" position, connect the control cable and lock the clamp. HINT: Lock the clamp during lightly pushing the outer cable in the direction, as shown in the illustration. c. Adjust mode control cable. Pull the mode control link at "FACE" position, connect the control cable and lock the clamp. HINT: Lock the clamp during lightly pushing the outer cable in the direction, as shown in the illustration. Specifications Compression Check: Specifications Compression Pressure ........................................................................................................................ ..................................................... 1,200 kPa or More Minimum Pressure .......................................... ....................................................................................................................................................... 1,000 kPa Difference Between Each Cylinder ..................................................................................... .......................................................................... 100 kPa or Less Page 1780 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Page 3456 Blower Motor: Testing and Inspection INSPECT BLOWER MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal 2, then check that the motor operations smoothly. If operation is not as specified, replace the blower motor. Page 411 Vehicle Speed Sensor: Testing and Inspection INSPECT VEHICLE SPEED SENSOR OPERATION a. Connect the positive (+) lead from the battery to terminal 1 and negative (-) lead to terminal 2. b. Connect the positive (+) lead from the tester to terminal 3 and the negative (-) lead to terminal 2. c. Rotate the shaft. d. Check that there is voltage change from approx. 0 V to 11 V or more between terminals 2 and 3. HINT: The voltage change should be performed 4 times for every revolution of the speed sensor shaft. If operation is not as specified, replace the sensor. Page 1579 CHART 7 Page 2136 Step 2 Step 3 INSPECTION PROCEDURE Page 1093 1. Remove coolant and any foreign material on rubber points "A," "B," and "C." 2. Check that points "A," "B " and "C" are not deformed, cracked, or swollen. 3. Check that points "C" and "D" are not stuck together. 4. Apply engine coolant to points "B" and "C" before using the radiator cap tester. ^ Radiator Cap Tester: Snap-On/Sun P/N SVTS262A (or equivalent) 5. Before installing the radiator cap tester, use the applicable radiator cap adaptor provided in the following SST kits in conjunction with the radiator cap tester: ^ SST P/N 09230-00030-01 (09231-10080-01) or 09230-00020-01 (09231-10060-01) or 09230-00050-01(09231-10110-01 6. When using the radiator cap tester, tilt it more than 30 degrees. 7. Pump the radiator cap tester several times, and check the maximum pressure. Pumping speed: 1 pump/second HINT: Stop pumping when the valve opens and read the gauge. The gauge must be within the standard values listed below when the pressure valve opens. The cap is considered OK when the pressure holds steady or falls very slowly, but holds within the standard values listed below for one minute. Specification: If the maximum pressure is less than the minimum standard value, replace the radiator cap sub-assembly. Type: Compact Cap, 88 kPa Vehicle - Long Term Storage Guidelines Paint: All 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 3987 Rear Bumper Cover / Fascia: Technical Service Bulletins Paint - Refinishing Bumper Cover PAINT PA003-02 REVISED June 4, 2002 Title REFINISHING REPLACEMENT BUMPER COVERS Models All '83 - '05 Models TSB REVISION NOTICE: ^ February 14, 2005: Applicable Vehicles now includes 2004 - 2005 model years. Previous versions of this TSB should be discarded. Introduction In cases where a bumper cover is being replaced a special preparation process is necessary to assure the refinish is customer acceptable. This bulletin provides the recommended refinishing procedure for new bumper covers. Applicable Vehicles ^ All 1983 - 2005 model year Toyota vehicles. Required Tools & Material Note:Please visit www.3m.comlautomotive to find the nearest store that sells 3M automotive products. Warranty Information Refinishing Procedure 1. Mix a solution of mild soap (car wash soap with no wax additives) and clean water. Note: Carefully follow mixing instructions on the soap container. Too much soap or too much water may cause surface contamination or rinsing difficulty. Paint - Chip Protection Tape Paint: Customer Interest Paint - Chip Protection Tape Bulletin Number: BO001-00 Date: January 7, 2000 Title: REAR QUARTER PANEL PAINT CHIP PROTECTION Models: '95 - '00 Tacoma Introduction: A new anti-chip tape has been developed to help prevent repeat occurrences of paint chipping on the rear quarter panels of Tacoma compact pick-up trucks caused by the impact of road debris. Applicable Vehicles: All 1995 - 2000 model year Tacoma vehicles. Parts Information Repair Procedure: NOTE: This repair is to be used in conjunction with repainting of the truck bed due to excessive chipping of the rear quarter panel. NOTE: Apply anti-chipping tape only after the surface has been repainted, cured, and is not hotter than 38° C (100° F). Apply the anti-chipping tape directly to the painted surface of the rear quarter panel between the front edge of the rear quarter panels and the rear tires as shown. Warranty Information Page 1654 Part 2 Of 2 (Except California Spec.) *1: A/T *2: M/T Page 4235 For additional information about color matching Toyota vehicles refer to the repainting section of the Toyota Fundamental Painting procedure manual (part # 00400-BR024) or contact your regional office to obtain information about Toyota Collision Repair and Refinish Training Programs. Component Locations Auxiliary Power Outlet: Component Locations Page 3403 b. Using a chisel and hammer, stake the lock nut. 6. w/o Free wheel hub (4WD only): INSTALL BEARING SPACER Using SST and a press, install the bearing spacer. SST 09950-60010 (09951-00650), 09950-70010 (09951-07150) 7. 4WD: INSTALL NEW OIL SEAL (INSIDE) a. Using SST and a plastic hammer, install a new oil seal (inside). SST 09527-17011 HINT: Strike the SST on its circumference evenly. b. Coat the oil seal lip with MP grease. 8. PreRunner: INSTALL GREASE CAP Specifications Water Pump: Specifications Water Pump W/ Bolts 20 Nm Page 2425 Description and Operation Mass Air Flow Meter: Description and Operation Mass Air Flow Meter The mass air flow meter uses a platinum hot wire. The hot wire air flow meter consists of a platinum hot wire, thermistor and a control circuit installed in a plastic housing. The hot wire air flow meter works on the principle that the hot wire and thermistor located in the intake air bypass of the housing detect any changes in the intake air temperature. The hot wire is maintained at the set temperature by controlling the current flow through the hot wire. This current flow is then measured as the output voltage of the mass air flow meter. The circuit is constructed so that the platinum hot wire and thermistor provide a bridge circuit, with the power transistor controlled so that the potential of A and B remains equal to maintain the set temperature. Page 681 Coolant: Testing and Inspection INSPECTION 1. CHECK ENGINE COOLANT LEVEL AT RESERVOIR TANK The engine coolant level should be between the "LOW" and "FULL" lines. When the engine is cold. If low, check for leaks and add "TOYOTA Long Life Coolant" or equivalent up to the "FULL" line. 2. CHECK ENGINE COOLANT QUALITY a) Remove the radiator cap. CAUTION: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure. b) There should not be any excessive deposits of rust or scale around the radiator cap or water outlet filler hole, and the coolant should be free from oil. If they are excessively dirty, clean the coolant passages and replace the coolant. c) Reinstall the radiator cap. Page 1116 a) Immerse the thermostat in water and gradually heat the water. b) Check the valve opening temperature. Valve opening temperature: 80 - 84°C (176 - 183°F) If the valve opening temperature is not as specified, replace the thermostat. c) Check the valve lift. Valve lift: 8.5 mm (0.335 inch) or more at 95°C (203°F) If the valve lift is not as specified, replace the thermostat. d) Check that the valve is fully closed when the thermostat is at low temperatures (below 40°C (104°F)). If not closed, replace the thermostat. INSTALLATION 1. INSTALL THERMOSTAT a) Place a new gasket to the thermostat. b) Install the thermostat with the jiggle valve downward. c) Install the water inlet with the 3 nuts. Torque: 20 Nm (200 kgf-cm, 14 ft. lbs.) 2. CONNECT LOWER RADIATOR HOSE 3. FILL WITH ENGINE COOLANT 4. START ENGINE AND CHECK FOR LEAKS Service and Repair Truck Bed: Service and Repair Toyota does not provide any procedures nor do they recommend sectioning any part of the bed of the vehicle. Beginning with the 2005 Model Year, the Tacoma has been equipped with a Sheet Molded Compound (SMC) pick-up bed tub. The SMC bed offers rugged performance and utility attributes but, like all body components can sustain damage as a result of a collision. While materials are available to repair SMC, they typically require reinforcing, sanding, priming, and top-coating. SMC repairs of this type will lack the original Tacoma quality and appearance, and may not function as intended under future operating conditions and subsequent collisions. Therefore it is recommended to replace collision damaged SMC beds with genuine new original equipment replacement parts only. Page 445 COMPONENTS INSPECTION 1. DRAIN ENGINE COOLANT 2. REMOVE AIR CLEANER HOSE 3. REMOVE NO.2 TIMING BELT COVER 4. REMOVE INTAKE AIR CONNECTOR ASSEMBLY 5. REMOVE FUEL PRESSURE REGULATOR 6. REMOVE INTAKE MANIFOLD ASSEMBLY Page 508 Step 5 INSPECTION PROCEDURE Engine/Transmission Controls - Resetting ECM Memory Engine Control Module: Technical Service Bulletins Engine/Transmission Controls - Resetting ECM Memory TRANSMISSION & CLUTCH TC002-03 REVISED Title: ECM RESET MEMORY FUNCTION Models: '00 - '05 All Models June 10, 2003 TSB REVISION NOTICE: ^ December 20, 2004: Applicable Vehicles section has been updated - 2004 and 2005 model years added, models and model years updated for various models; and Reset Procedure 2 has been revised. ^ January 16, 2004: Tundra vehicles were added to the Applicable Vehicles chart. ^ December 17, 2003: T-100 vehicles were removed from the Applicable Vehicles chart. Previous versions of this TSB should be discarded. Introduction Whenever an automatic transmission is replaced, overhauled or individual components are replaced, use this procedure to clear Engine Control Module (ECM, SAE term: Powertrain Control Module, PCM) "Learned Values" to minimize subsequent performance concerns. CAUTION: Failure to follow the procedure below may lengthen the time to readjust the ECM "Learned Values," potentially resulting in performance concerns. Required SSTs Warranty Information Applicable Vehicles Page 1961 Mass Air Flow Meter: Service and Repair REMOVAL 1. REMOVE AIR CLEANER CASE a. Disconnect the air cleaner hose. b. Disconnect the MAF meter connector. c. Remove the 3 bolts and air cleaner case. 2. REMOVE MAF METER a. Remove the 2 screws and MAF meter. b. Remove the O-ring from the MAF meter. INSTALLATION 1. INSTALL MAF METER a. Install the O-ring to the MAF meter. b. Install the MAF meter with the 2 screws. 2. INSTALL AIR CLEANER CASE a. Install the air cleaner case with the 3 bolts. b. Connect the MAF meter connector. c. Connect the air cleaner hose. Page 822 Page 2512 Flex Plate: Service and Repair For further information regarding this component and the system that it is a part of, please refer to Torque Converter; Service and Repair. Page 2166 No. 52 .................................................................................................................................................. .............................................. 4.6 mm (0.181 inch) No. 53 .................................................................. .............................................................................................................................. 4.4 mm (0.173 inch) No. 54 ......................................................................................................................................... ....................................................... 4.2 mm (0.165 inch) No. 55 ......................................................... ....................................................................................................................................... 4.0 mm (0.157 inch) Page 4973 If seam is not sealed properly, clean vertical and horizontal seam area with Acrysol(TM) cleaner. Use an air hose to dry all seams before applying sealer. NOTE: Hole is located behind fender. 15. Attach a 12 to 18 inch length of plastic tubing to tip of Kent High Tech(TM) Clear Seam Sealer. 16. Seal entire vertical joint with High Tech(TM) clear seam sealer. Allow sealer to dry according to instructions on tube. NOTE: Seams are inside boxed area and accessed through the square hole as shown. 17. Flood cowl area with water to confirm that there are no cowl seam leaks into cab. If water leaks are still present and there are no cowl area seam leaks, reinstall front fender and inspect for water entry along lower edge of interior door trim panel; then proceed as follows: 18. Remove door trim panel. 19. Flood R/F door glass area (spray water at door glass, belt-molding area). 20. Inspect sealer between plastic sheeting (moisture barrier) and metal door panel for voids/skips in sealer. If there are voids/skips between the plastic sheet and the door panel, it will need to be resealed. A. Using a heat gun, heat the butyl tape securing the plastic sheet to make removal easier. B. Use Kent Acrysol to clean the door panel and plastic sheet. NOTE: ^ Follow the directions provided by the cleaning agent. ^ To ensure proper sealing of the plastic sheeting, it is important that the door panel and plastic sheeting is extremely clean. C. Use 3M 8.0 mm butyl tape (P/N 08610) to reattach the plastic sheet to the door panel. Make sure there is a continuos solid bead sealing the plastic sheet to the door panel. 21. Inspect drain-back holes (small slits in metal door panel, near bottom of sealer) to determine if holes are covered by sealer material. If sealer covers drain-back holes (small slits in metal door panel) carefully pull up a portion of plastic sheet, clean out drain-back holes and Locations Page 2773 Brake Pad: Service and Repair REPLACEMENT 1. REMOVE FRONT WHEEL 2. INSPECT PAD LINING THICKNESS Check the pad thickness and replace pads if not within specification. Minimum thickness: 1.0 mm (0.039 inch) 3. REMOVE CLIP, 2 PINS AND ANTI-RATTLE SPRING 4. REMOVE 2 PADS AND 4 ANTI-SQUEAL SHIMS NOTICE: The anti-rattle spring can be used again provided that they have sufficient rebound, no deformation, cracks or wear, and have had all rust, dirt and foreign particles cleaned off. 5. CHECK DISC THICKNESS AND RUNOUT Page 1568 2. Start the engine. 3. Perform the drive pattern to run and complete the Oxygen Sensor (O2S) Monitor. HINT: The 02S Monitor is completed when the following conditions are met: ^ Two (2) minutes or more passed after the engine start. ^ The Engine Coolant Temperature (ECT) is 167°F (75°C) or more. ^ Cumulative running time at 30 mph (48 km/h) or more exceeds 6 minutes. ^ Vehicle is in closed loop. ^ The fuel-cut is operated for 8 seconds or more (for Rear O2S Monitor). A. Allow the engine to idle for two minutes. B. Warm up the engine until the Engine Coolant Temperature (ECT) reaches 167°F (75°C). C. Drive the vehicle over 30 mph (48 km/h) for more than 40 seconds. D. Stop the vehicle and allow the engine to idle for more than 20 seconds. E. Repeat steps C and D at least 8 times in one driving cycle. (Do not cycle the ignition key.) In addition, perform the following steps for the Rear O2S Readiness Monitor: A. Select second gear. B. Allow the vehicle to run at 30 mph (48 km/h) or more. C. Keep the accelerator pedal "off-idle" for more than 10 seconds. D. Immediately after step C, release the accelerator pedal for at least 10 seconds without depressing the brake pedal (to execute the fuel-cut). E. Decelerate the vehicle until the vehicle speed reaches less than 6mph (10km/h). F. Repeat steps B - E at least twice in one driving cycle. Accessing O2S Test Results 1. On the Diagnostic Tester* screen, select the following menus: ^ DIAGNOSTICS ^ CARB OBD II Page 4513 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 1652 Part 2 Of 2 (California Spec.) *1: Only for A/T *2: The ECM terminal voltage is fixed regardless of the output voltage from the sensor. Connectors (Except California Spec.) Page 4571 Seat Belt Reminder Buzzer: Testing and Inspection INSPECT INTEGRATION RELAY SEAT BELT WARNING SYSTEM OPERATION a. Connect the positive (+) lead from the battery to terminal 12 and negative (-) lead from the battery to terminal 7. b. Connect the terminal 2 to terminal 5 through the 3.4 W test bulb. c. Connect the negative (-) lead from the battery to terminal 3. d. Check that the bulb lights and the chime sounds for 4 - 8 seconds. e. Return to step (a) and operate the chime again. f. Check that the buzzer does not sound when disconnecting terminal 3 from the negative (-) lead. g. Check that the chime stops sounding. HINT: Check the chime within a period of 4 to 8 seconds. If operation is not as specified, replace the relay. Page 3520 Heater Control Valve: Service and Repair REMOVAL 1. DRAIN ENGINE COOLANT FROM RADIATOR HINT: It is not necessary to drain out all the coolant. 2. DISCONNECT WATER VALVE CONTROL CABLE FROM WATER VALVE HINT: At the time of installation, please refer to the following item. For installing the control cable, refer to "INSTALLATION" of HEATER CONTROL ASSEMBLY. 3. DISCONNECT WATER HOSES a. Using pliers, grip the claws of the clip and slide the clip along the hose. b. Disconnect the water hose. HINT: At the time of installation, please refer to the following item. Install the hose clip in the position, as shown in the illustration. Page 461 Impact Sensor: Service and Repair Airbag Sensor Connectors DISCONNECTION a. While holding both flank sides of the outer, slide the outer to the direction shown by an arrow. b. Lock of the connectors is released, then disconnect the connectors. HINT: Make sure to hold both flank sides of the outer. If holding the top and bottom sides, it will obstruct disconnection. CONNECTION a. Align the male connector (of the side of sensor) and female connector in the same direction as shown in the illustration and fit in them without rubbing. b. As they are fitted in, the outer slides rearward. Press it until the outer returns to its original position again. If fitting stops half way, connectors will separate. c. Make sure to insert until they are locked. After fitting in, pull them slightly to check that they are locked. (When locked, make sure that the outer returns to its original position and sound at the time of fitting in can be heard.) HINT: Do not fit in while holding the outer. - When fitting in, the outer slides. Do not touch it. Page 1242 Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor The intake air temperature sensor is built into the air cleaner cap and senses the intake air temperature. A thermistor built in the sensor changes the resistance value according to the intake air temperature. The lower the intake air temperature, the greater the thermistor resistance value, and the higher the intake air temperature, the lower the thermistor resistance value. The intake air temperature sensor is connected to the ECM. The 5 V power source voltage in the ECM is applied to the intake air temperature sensor from the terminal THA via a resistor R. That is, the resistor R and the intake air temp. sensor are connected in series. When the resistance value of the intake air temp. sensor changes in accordance with changes in the intake air temperature, the potential at terminal THA also changes. Based on this signal, the ECM increases the fuel injection volume to improve driveability during cold engine operation. Page 3224 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Tightening Specifications Fluid Pump: Specifications Tightening Specifications Stator Shaft X Oil Pump Body ................................................................................................................................................ 10 Nm (100 kg-cm, 7 ft. lbs.) Oil Pump X Transmission Case ............................................................................................................................................. 22 Nm (220 kg-cm, 16 ft. lbs.) Collision / Non-Collision Inspections Impact Sensor: Testing and Inspection Collision / Non-Collision Inspections INSPECTION 1. VEHICLES NOT INVOLVED IN COLLISION Do a diagnostic system check. * 2. VEHICLES INVOLVED IN COLLISION a. Do a diagnostic system check. * b. If the front fender of the car or its periphery is damaged, do a visual check for damage to the front airbag sensor, which includes the following items even if the airbag was not deployed: Check the bracket deformation. - Check the paint peeling off the bracket. - Check the cracks, dents or chips in the case. - Check the cracks, dents, chipping and scratches in the connector. - Check the peeling off of the label or damage to the serial number. * Refer to SRS Warning Light Check, and How to Display and Read Diagnostic Trouble Codes. See: Air Bag Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Displaying & Reading Trouble Codes Page 4066 Page 1702 Page 1797 Splice Point J: Indicates a wiring Splice Point (Codes are "E"for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I 5 is indicated by the shaded section. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. N: Page No. How to Read Ground Points How to Read Ground Points Electrical Specifications Generator: Electrical Specifications Testing - Voltage/Amperage Testing - Voltage/Amperage Regulating Voltage 13.7 to 14.7 V at 77 deg F 13.2 to 14.0 V at 239 deg F Rated - Voltage/Amperage Rated - Voltage/Amperage Rated Output 70 A at 12 V Rotor Coil Resistance 2.1 to 2.5 ohms Page 2140 Transmission Position Switch/Sensor: Service and Repair ON-VEHICLE REPAIR 1. DISCONNECT 2 OIL COOLER PIPES 2. DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 3. REMOVE PARK/NEUTRAL POSITION SWITCH a. Pry off the lock washer and remove the nut. b. Remove the bolt and pull out the park/neutral position switch. 4. INSTALL AND ADJUST PARK/NEUTRAL POSITION SWITCH Torque: Nut: 6.9 Nm (70 kgf-cm, 61 inch lbs.) Bolt: 13 Nm (130 kgf-cm, 9 ft. lbs.) 5. CONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 6. CONNECT 2 OIL COOLER PIPES Page 1538 Idle Up Control Valve: Testing and Inspection INSPECTION 1. TURN AIR CONDITIONING SWITCH OFF 2. CHECK IDLE-UP a. Start engine and run it at idle. b. Fully turn the steering wheel. c. Check that the engine rpm decreases when the vacuum hose of the air control valve is pinched. d. Check that the engine rpm increases when the hose is released. Page 370 CHART 29 Page 4558 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source How to Read Power Source Page 2477 Wheel Bearing: Service and Repair Disassembly and Reassembly DISASSEMBLY Page 2405 Steps 1 - 3 Page 690 Fluid - A/T: Testing and Inspection a. Check the fluid level. HINT: Drive the vehicle so that the engine and transmission are at normal operating temperature. Fluid temp.: 70 - 80 °C (158 - 176 °F) - Only use the COOL range on the dipstick as a rough reference when the fluid is replaced or the engine does not run. 1. Park the vehicle on a level surface and set the parking brake. 2. With the engine idling and the brake pedal depressed, shift the shift lever into all positions from P to L position and return to P position. 3. Pull out the dipstick and wipe it clean. 4. Push it back fully into the pipe. 5. Pull it out and check that the fluid level is in the HOT range. If the level is not within the range, add new fluid. Fluid type: ATF ID-II or DEXRON(R)III (DEXRON(R)II) NOTE: Do not overfill. b. Check the fluid condition. If the fluid smells burnt or is black, replace it. c. Replace the ATF. 1. Remove the drain plug and drain the fluid. 2. Reinstall the drain plug securely. 3. With the engine OFF add new fluid through the oil filler pipe. Fluid type: ATF ID-II or DEXRON(R)III (DEXRON(R)II) Page 1431 c) Install a new adjusting shim. 1) Place a new adjusting shim on the valve lifter, with imprinted numbers facing down. 2) Using SST (A), press down the valve lifter and remove SST (B). SST 09248-55040 (09248-05410, 09248-05420) d) Recheck the valve clearance. 6. REINSTALL CYLINDER HEAD COVERS 7. REINSTALL INTAKE AIR CONNECTOR Specifications Engine Oil Pressure: Specifications Oil Pressure At idle ................................................................................................................................................... .............. 29 kPa (0.3 kgf/cm2, 4.3 psi) or More At 3,000 rpm ............................................................................................................................................. 245 - 520 kPa (2.5 - 5.3 kgf/cm2, 36 - 75 psi) Page 3097 Engine Compartment Instrument Panel Locations Page 2386 Page 3620 3. REMOVE AIRBAG SENSOR ASSEMBLY a. Disconnect the connector. NOTE: Remove the connector with the sensor assembly installed. b. Using a torx wrench remove the 3 screws and airbag sensor assembly. Torx wrench: T40 (Part No.09042-00020 or locally manufactured tool) INSTALLATION NOTE: - Never use SRS parts from another vehicle. When replacing parts, replace with new parts. - Never reuse the airbag sensor assembly involved in a collision when the airbag has deployed. - Never repair a sensor in order to reuse it. 1. INSTALL AIRBAG SENSOR ASSEMBLY a. Using a torx wrench, install the airbag sensor assembly with the 3 screws. Torx wrench: T40 (Part No.09042-00020 or locally manufactured tool) Torque: 20 Nm (205 kg.cm, 15 ft.lb) b. Connect the connector. NOTE: Installation of the connector is done after the sensor assembly has been installed. - Make sure the sensor assembly is installed to the specified torque. - If the sensor assembly has been dropped, or there are cracks, dents or other defects in the case, bracket or connector, replace the sensor assembly with a new one. - When installing the airbag sensor assembly, take care that the SRS wiring does not interfere with other parts and is not pinched between other parts. - After installation, shake the sensor assembly to check that there is no looseness. 2. INSTALL REMOVED PARTS Page 2576 Installation is in the reverse order of removal. HINT: After installation, do the road test. Heated Oxygen Sensor Oxygen Sensor: Description and Operation Heated Oxygen Sensor Heated Oxygen Sensor The ECM observes the waveform of the heated oxygen sensor located behind the catalyst to determine whether the catalyst performance has deteriorated. If the catalyst is functioning normally, the waveform of the heated oxygen sensor located behind the catalyst switches back and forth between rich and lean much more slowly. When the waveform of the heated oxygen sensor located behind the catalyst alternates flutteringly between rich and lean, it indicates that catalyst performance has deteriorated. Page 391 Transmission Position Switch/Sensor: Service and Repair ON-VEHICLE REPAIR 1. DISCONNECT 2 OIL COOLER PIPES 2. DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 3. REMOVE PARK/NEUTRAL POSITION SWITCH a. Pry off the lock washer and remove the nut. b. Remove the bolt and pull out the park/neutral position switch. 4. INSTALL AND ADJUST PARK/NEUTRAL POSITION SWITCH Torque: Nut: 6.9 Nm (70 kgf-cm, 61 inch lbs.) Bolt: 13 Nm (130 kgf-cm, 9 ft. lbs.) 5. CONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 6. CONNECT 2 OIL COOLER PIPES Page 2480 1. INSTALL NEW BEARING a. Using SST and a press, install a new bearing to the steering knuckle. SST 09527-17011, 09950-60020 (09951-00910) b. Using snap ring pliers, install a snap ring. 2. INSTALL NEW OIL SEAL (OUTSIDE) a. Using SST and a plastic hammer, install a new oil seal (outside). SST 09223-15030, 09527-17011 b. Coat the oil seal lip with MP grease. 3. INSTALL AXLE HUB TO STEERING KNUCKLE a. Install the dust cover to the steering knuckle with the 4 bolts. Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.) b. Using SST and a press, install the axle hub to the steering knuckle. SST 09649-17010 4. INSTALL ABS SPEED SENSOR ROTOR/SPACER NOTICE: Do not scratch the serration of the speed sensor rotor. 5. w/ Freewheel hub: INSTALL NEW LOCK NUT a. Using SST, install and torque a new lock nut to the axle hub. SST 09318-12010 Torque: 274 Nm (2,800 kgf-cm, 203 ft. lbs.) Page 477 Steps 1 - 3 Locations Timing Component Alignment Marks: Locations CAUTION: Incorrect removal or installation of the timing belt can result in damage to internal engine components. For complete Timing Belt Removal and Installation information, please refer to Timing Belt; Service and Repair. See: Timing Belt/Service and Repair INSTALL TIMING BELT NOTICE: The engine should be cold. a) Remove any oil or water on the pulleys, and keep them clean. NOTICE: Only wipe the pulleys; do not use any cleansing agent. b) Face the front mark on the timing belt forward. c) Install the timing belt to the LH camshaft timing pulley. Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley. d) Install the timing belt to the No.2 idler pulley. e) Install the timing belt to the RH camshaft timing pulley. Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley. f) Install the timing belt to the water pump pulley. g) Install the timing belt to the crankshaft timing pulley. Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley. h) Install the timing belt to the No.1 idler pulley. Page 1208 b. Inspect the relay operation. 1. Apply battery positive voltage across terminals 3 and 5. 2. Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. 3. Apply battery positive voltage across terminals 2 and 4. 4. Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. 3. REINSTALL CIRCUIT OPENING RELAY Page 3013 Page 2095 Page 23 If circuit is as specified, try replacing the amplifier with a new one. If the circuit is not as specified, inspect the circuits connected to other parts. Page 3792 Testing and Inspection Blower Motor Relay: Testing and Inspection INSPECT HEATER MAIN RELAY (Making: HTR) CONTINUITY If continuity is not as specified, replace the relay. Page 1712 Page 2651 Step 2 Step 3 INSPECTION PROCEDURE Page 79 Part 1 Of 2 (Except California Spec.) Page 1725 CHART 18 CHART 19 Page 1933 Idle Air Control Valve: Description and Operation Intake Air Control Valve The rotary solenoid type IAC valve is located on the throttle body and intake air bypassing the throttle valve is directed to the IAC valve through a passage. In this way the intake air volume bypassing the throttle valve is regulated, controlling the engine speed. The ECM operates only the IAC valve to perform idle-up and provide feedback for the target idling speed. Page 2085 Testing and Inspection Hazard Warning Switch: Testing and Inspection Turn Signal And Hazard Warning System Reference INSPECT HAZARD WARNING SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 4026 6. Mask-off wiper motor opening. 7. Attach Kent(TM) 12" extension tube (P/N 90175) to the nozzle on the can of Leak-Chek(TM) (P/N 50087). NOTE: Direct Leak-Chek(TM) spray material approximately 1 inch above seam. Spray force is very strong - make several test passes before actually spraying material into seam. 8. Spray Leak-Chek(TM) through the wiper motor opening. a. Spray material inside upper cowl, beginning in lower corner, and continuing toward the centerline of vehicle. b. Remove wand from the wiper motor opening and insert it into larger cowl openings on the right hand side. Continue spraying material along entire seam until seam is filled from R/F fender to L/F fender area. Spray Leak-Chek(TM) into seam a total of 3 times, allowing Leak-Chek(TM) to flash dry for 30-45 minutes between applications. (Drying time increases as outside temperature decreases.) 9. After final application of Leak-Chek(TM) has been allowed to dry for approximately one hour, flood area with water for 5-10 minutes. NOTE: Hold garden hose at top right front corner of windshield and point hose downward toward lower right hand corner of windshield as shown. 10. Check inside cab behind Heater/Air Conditioner box for evidence of water leakage during water leak check. 11. Carefully inspect "T" joint on right and left sides (close to heater motor box, and brake booster) for evidence of water leaks. 12. If no leaks are found, cowl area leak repair is complete. Reinstall wiper motor, cowl trim panel, wiper arms, and hood. Wiper Arm Torque: 20 N.m (205 kgf.cm, 15 ft.lbf) If water leaks are still present and are coming in from the cowl area, remove right front fender and proceed as follows: 13. Seal around entire perimeter of "L" bracket with Kent High Tech(TM) Clear Seam Sealer (see drawing for location of "L" bracket). 14. Using a flashlight, look through the 2" x 3" rectangular hole on side of vertical cowl panel and locate vertical seam that connects side of cowl to front cowl. Page 1924 Fuel Supply Line: Testing and Inspection COMPONENTS CAUTION: - Always use new gaskets when replacing the fuel tank or component parts. - Apply the proper torque to all tightened Darts. INSPECTION INSPECT FUEL TANK AND LINE Page 1548 Knock Sensor: Testing and Inspection Testing and Inspection Lights On Warning: Testing and Inspection Headlight And Taillight System Light-ON Warning System HINT: The tables will be useful for you in troubleshooting these electrical problems. The most likely causes of the malfunction are shown in the order of their probability. Inspect each part in the order shown, and replace the part when it is found to be faulty. Light-On Warning System: INSPECT INTEGRATION RELAY OPERATION a. Connect the positive (+) lead from the battery to terminal 12 and the negative (-) lead to terminal 7. b. Connect the positive (+) lead from the battery to terminal 4 and the negative (-) lead to terminal 5. c. Check that the buzzer does not sound when terminal 4 or 5 is connected to the positive (+) lead. d. Check that the buzzer does not sound when disconnecting terminal 4 or 5. If operation is not as specified, replace the relay. Page 4586 D: Indicates related system. Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V). Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, 1H2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green O = Orange P = Pink R = Red SB = Sky Blue V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Page 4820 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 3581 *Some Toyota vehicles are equipped with a Passenger Airbag Manual On-Off Switch, and other Toyota models may have a retrofit passenger airbag switch installed at the dealership. To analyze the condition of the manual on-off switch technicians must follow specific inspection procedures which are outlined in this bulletin. However complete airbag manual on-off switch inspection and repair procedures can be found in vehicle-specific Toyota Repair Manuals. Note - for all Toyota vehicles Following all collisions when the SRS does NOT deploy inspect: ^ Steering wheel pad ^ Side airbags and seat frames ^ Front & side airbag sensors ^ Wiring harness and connectors ^ Front passenger airbag assembly ^ Malfunction indicator lamp for correct operation Component Replacement Notes Note 1 - Replace the Steering Wheel Pad: ^ If the airbag has been deployed or dropped ^ If the steering wheel pad is diagnosed as needing replacement when troubleshooting or during inspection Note 2 - Inspect and if necessary replace the Spiral Cable: ^ If the spiral cable is diagnosed as needing replacement when troubleshooting or during inspection Page 1321 Transmission Position Switch/Sensor: Service and Repair ON-VEHICLE REPAIR 1. DISCONNECT 2 OIL COOLER PIPES 2. DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 3. REMOVE PARK/NEUTRAL POSITION SWITCH a. Pry off the lock washer and remove the nut. b. Remove the bolt and pull out the park/neutral position switch. 4. INSTALL AND ADJUST PARK/NEUTRAL POSITION SWITCH Torque: Nut: 6.9 Nm (70 kgf-cm, 61 inch lbs.) Bolt: 13 Nm (130 kgf-cm, 9 ft. lbs.) 5. CONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 6. CONNECT 2 OIL COOLER PIPES Testing and Inspection Hazard Warning Flasher: Testing and Inspection Turn Signal And Hazard Warning System INSPECT TURN SIGNAL FLASHER OPERATION a. Connect the positive (+) lead from the battery to terminal 2 and the negative (-) lead to terminal 3. b. Connect the 2 turn signal light bulbs parallel to each other to terminals 1 and 3, check that the bulbs flash. HINT: The turn signal lights should flash 60 or 120 times per minute. If one of the front or rear turn signal lights has an open circuit, the number of flashers will be more than 140 per minute. If operation is not as specified, replace the flasher. Page 755 Interior J/B # 1 Page 239 Key Reminder Switch: Splice Locations Page 1740 CHART 28 Page 2088 Junction Box / No. 1 Description and Operation Braking Sensor/Switch: Description and Operation Stop Light Switch This stop light switch senses whether the brake pedal is depressed or released, and sends the signal to the ECU. O/D Main Switch & O/D OFF Indicator Light Circuit Overdrive Switch: Testing and Inspection O/D Main Switch & O/D OFF Indicator Light Circuit CIRCUIT DESCRIPTION The O/D main switch is a momentary type switch. When pressing the O/D OFF main switch, the O/D OFF indicator light lights up and ECM prohibit shifting to O/D, and when pressing it again, the O/D OFF indicator light goes off and ECM allows shifting to O/D. Turning the IG switch OFF will reset the O/D OFF indicator light. Page 4587 Splice Point J: Indicates a wiring Splice Point (Codes are "E"for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I 5 is indicated by the shaded section. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. N: Page No. How to Read Ground Points How to Read Ground Points Page 185 Steps 3 - 4 INSPECTION PROCEDURE Page 4467 An airbag activation prevention mechanism is built into the connector for the squib circuit of the SRS. When release of the airbag activation prevention mechanism is directed in the troubleshooting procedure, as shown in the illustration of the connectors on the next pages, insert paper which has the same thickness as the male terminal between the terminal and the short spring. CAUTION: Never release the airbag activation prevention mechanism on the squib connector. NOTE: - Do not release the airbag activation prevention mechanism unless specifically directed by the troubleshooting procedure. - If the inserted paper is too thick the terminal and short spring may be damaged, so always use paper with the same thickness as the male terminal. Page 4602 Seat Belt Reminder Lamp: Description and Operation General Description SRS Warning Light The SRS warning light is located on the combination meter. It goes on to alert the driver of trouble in the system when a malfunction is detected in the airbag sensor assembly self-diagnosis. In normal operating conditions when the ignition switch is turned to the ACC or ON position, the light goes on for about 6 seconds and then goes OFF. Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Key to Diagrams Key to Diagrams A: System Title. B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: (1) Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. Page 4391 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 2810 Brake Fluid: Testing and Inspection Check for fluid leakage from actuator or hydraulic lines. Page 1094 1. Remove coolant and any foreign material on rubber points "A," "B," and "C." 2. Check that points "A" and "B" are not deformed, cracked, or swollen. 3. Check that points "B" and "C" are not stuck together. 4. Apply engine coolant to point "B" before using the radiator cap tester. ^ Radiator Cap Tester: Snap-On/Sun P/N SVTS262A (or equivalent) 5. Before installing the radiator cap tester, use the applicable radiator cap adaptor provided in the following SST kits in conjunction with the radiator cap tester: ^ SST P/N 09230-00030-01 (09231-10080-01) or 09230-00020-01 (09231-10060-01) or 09230-00050-01(09231-10110-01 6. When using the radiator cap tester, tilt it more than 30 degrees. 7. Pump the radiator cap tester several times, and check the maximum pressure. Pumping speed: 1 pump/second HINT: Stop pumping when the valve opens and read the gauge. The gauge must be within the standard values listed below when the pressure valve opens. The cap is considered OK when the pressure holds steady or falls very slowly, but holds within the standard values listed below for one minute. Page 771 Engine Compartment Instrument Panel Locations Page 3012 Page 4246 4. REMOVE REMOVABLE ROOF AUXILIARY CATCH Remove the screw and auxiliary catch. 5. REMOVE INNER WEATHERSTRIP 6. REMOVE SLIDING ROOF OPENING TRIM 7. REMOVE ASSIST GRIP 8. REMOVE SUN VISORS AND HOLDERS 9. REMOVE INNER REAR VIEW MIRROR 10. REMOVE QUARTER TRIM a. Remove the clip on the quarter trim as shown in the illustration. b. Employ the same manner described above to the other side. NOTE: Paying enough attention remove the clip. Otherwise, the quarter trim or the front pillar garnish might be broken. 11. REMOVE FRONT PILLAR GARNISH 12. REMOVE FRONT SIDE OF ROOF HEADLINING 13. REMOVE REMOVABLE ROOF HINGE CASE a. Remove the 2 bolts and hinge case. Torque: 3.4 N.m (35 kgf.cm, 30 in.lbf) b. Employ the same manner described above to the other side. INSTALLATION Installation Is In the reverse order of removal. Page 2631 Shift Indicator: Fuse and Fusible Link Locations Relay Box / No. 2 Page 2079 Step 5 INSPECTION PROCEDURE Page 1615 Oxygen Sensor: Testing and Inspection Heated Oxygen Sensor Heated Oxygen Sensor COMPONENTS Page 260 If circuit is as specified, try replacing the relay with a new one. If circuit is not as specified, inspect the circuits connected to other parts. Page 2942 Generator: Service and Repair Disassembly and Reassembly DISASSEMBLY 1. REMOVE REAR END COVER a. Remove the nut and terminal insulator. b. Remove the 3 nuts and end cover. 2. REMOVE BRUSH HOLDER a. Remove the 2 screws, brush holder and cover. b. Remove the brush holder cover from the brush holder. 3. REMOVE VOLTAGE REGULATOR Remove the 3 screws and voltage regulator. 4. REMOVE RECTIFIER HOLDER Page 1758 Throttle Position Sensor: Service and Repair Refer to Fuel Delivery and Air Induction / Throttle Body / Service and Repair, for removal and installation of this component. Page 2770 ^ Type "A": Has a projection on the upper and lower side of the brake pad. (See illustration.) ^ Type "B": Has a flat upper and lower edge on the brake pad backing plate. Type "A" Brake Pad A. Remove the anti-squeal spring, clip and pad guide pin. B. Remove the brake pads with the anti-squeal shims. C. Clean any dust from the brake pads. D. Apply a small amount of the disc brake caliper grease (1-2 mm thick) to the areas indicated in the illustration. NOTE: Do NOT apply grease to the friction surfaces of the brake pads or the disc rotor. E. Install the brake pads with the anti-squeal shims. NOTE: Clean excess grease from the brake pads and caliper. F. Install the pad guide pin, clip and anti-squeal spring. G. Install the wheel assembly. Page 4538 Step 2 Step 3 INSPECTION PROCEDURE Page 968 13. REMOVE FAN BRACKET a) Remove the nut and PS pump adjusting strut. b) Remove the bolt, nut and fan bracket. 14. REMOVE CRANKSHAFT PULLEY a) Using SST, loosen the pulley bolt. SST 09213-54015 (90119-08216), 09330-00021 b) Remove the SST, pulley bolt and pulley. HINT: If necessary, remove the pulley with SST and a service bolt. SST 09950-50011 (09951-05010, 09952-05010, 09953-05020, 09954-05030) 15. REMOVE STARTER WIRE BRACKET AND NO.1 TIMING BELT COVER a) Remove the 2 bolts and starter wire bracket. b) Remove the 4 bolts and timing belt cover. 16. REMOVE TIMING BELT GUIDE 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 1583 CHART 12 CHART 13 Page 4302 reinstall plastic sheet against metal door panel. Confirm that there are no voids between sealer and plastic sheet and between sealer and metal door panel. 22. Flood all areas with water to confirm that there are no leaks into cab area. 23. If no leaks are present, reinstall door trim panel. Page 4832 INSPECT DAYTIME RUNNING LIGHT NO.4 RELAY CONTINUITY If continuity is not as specified, replace the relay. Service Specifications Valve Body: Specifications Service Specifications VALVE BODY SPRING SPECIFICATIONS UPPER VALVE BODY LOWER VALVE BODY On-Vehicle Inspection Throttle Body: Testing and Inspection On-Vehicle Inspection 1. INSPECT THROTTLE BODY Check that the throttle linkage moves smoothly. 2. INSPECT THROTTLE POSITION SENSOR a. Apply vacuum to the throttle opener. b. Disconnect the sensor connector. c. Using an ohmmeter, measure the resistance between each terminal. Page 4371 Step 2 Step 3 INSPECTION PROCEDURE Troubleshooting in accordance with the chart for each trouble symptom. Page 3076 Page 4352 Step 4 INSPECTION PROCEDURE Page 3767 Rear Seat Belt Extender Applications Page 568 Fuel Pressure: Testing and Inspection 1. CHECK FUEL PUMP OPERATION a. Connect a TOYOTA hand-held tester to the DLC3. b. Turn the ignition switch ON and push TOYOTA hand-held tester main switch ON. NOTE: Do not start the engine. c. Select the ACTIVE TEST mode on the TOYOTA hand-held tester. d. Please refer to the TOYOTA hand-held tester operator's manual for further details. e. If you have no TOYOTA hand-held tester, connect the positive (+) and negative (-) leads from the battery to the fuel pump connector. (See step 4) f. Check that there is pressure in the fuel inlet hose from the fuel filter. HINT: If there is fuel pressure, you will hear the sound of fuel flowing. If there is no pressure, check the M-fuse, fuses, EFI main relay,fuel pump, ECM and wiring connections. g. Turn the ignition switch OFF. h. Disconnect the TOYOTA hand-held tester from the DLC3. 2. CHECK FUEL PRESSURE a. Check the battery positive voltage is above 12 V. b. Disconnect the negative (-) terminal cable from the battery. c. Remove the 6 bolts, and disconnect the No.2 timing belt cover. d. Remove the union bolt holding the fuel pipe to the delivery pipe and gasket. Page 2226 Shift Indicator: Connector Locations Page 1339 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Page 2772 Brake Pad: Specifications Thickness: Standard 0.453 in Minimum 0.039 in Page 2843 REASSEMBLY Reassembly is in the reverse order of disassembly. NOTICE: Apply lithium soap base glycol grease to the rubber parts indicated by the arrows. Paint - Gray Bumper Paint Colors Paint: All Technical Service Bulletins Paint - Gray Bumper Paint Colors PAINT PA001-03 January 23, 2003 Title 1995-2003 GRAY BUMPER PAINT CODES Models '95- '03 Tacoma & '00 - '03 Tundra Introduction Following are color codes for gray painted steel bumpers installed on the 1995 - 2003 model year Tacoma and 2000 - 2003 model year Tundra. These bumpers are factory installed usually on base trim level models. Applicable Vehicles ^ 1995 - 2003 model year Tacoma vehicles. ^ 2000 - 2003 model year Tundra vehicles. Parts Information Warranty Information Testing and Inspection Power Window Relay: Testing and Inspection INSPECT POWER MAIN RELAY CONTINUITY If continuity is not as specified, replace the relay. Page 3906 Testing and Inspection Refrigerant Pressure Sensor / Switch: Testing and Inspection 1. SET ON MANIFOLD GAUGE SET 2. REMOVE GLOVE COMPARTMENT DOOR 3. DISCONNECT CONNECTOR FROM COOLING UNIT 4. SET VEHICLE IN THESE CONDITIONS: a. Running engine at 2,000 rpm b. Blower speed control switch at HI c. Temperature control lever MAX. COOL d. A/C switch ON 5. INSPECT PRESSURE SWITCH OPERATION a. Connect the positive (+) lead from the ohmmeter to terminal 1 and negative (-) lead to terminal 4. b. Check continuity between terminals when refrigerant pressure is changed, as shown in the illustration. If operation is not as specified, replace the pressure switch. Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Key to Diagrams Key to Diagrams A: System Title. B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: (1) Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. Locations Knock Sensor: Locations Page 1847 CAUTION: Put a shop towel under the delivery pipe. Slowly loosen the union bolt. e. Install SST (pressure gauge) to the delivery pipe with the 2 gaskets and SST (union and union bolt). SST 09268-45012 Torque: 34.3 Nm (350 kg.cm, 25 ft.lb) f. Wipe off any splattered gasoline. g. Connect a TOYOTA hand-held tester to the DLC3. (See step 1) h. Reconnect the negative (-) terminal cable to the battery. i. Turn the ignition switch ON. j. Measure the fuel pressure. Fuel pressure: 265-304 kPa (2.7-3.1 kg/Sq.cm,38 - 44 psi) If pressure is high, replace the fuel pressure regulator. If pressure is low, check the fuel hoses, fuel hose connections, fuel pump, fuel filter and fuel pressure regulator. k. Disconnect the TOYOTA hand-held tester from the DLC3. l. Reinstall the No.2 timing belt cover with the 6 bolts. Torque: 9 Nm (90 kg.cm, 80 in.lb) m. Start the engine. n. Disconnect the vacuum sensing hose from the fuel pressure regulator, and plug the hose end. o. Measure the fuel pressure at idle. Fuel pressure: 265 - 304 kPa (2.7 - 3.1 kg/Sq.cm, 38 - 44 psi) p. Reconnect the vacuum sensing hose to the fuel pressure regulator. q. Measure the fuel pressure at idle. Fuel pressure: 226 - 265 kPa (2.3 - 2.7 kg/Sq.cm, 33 - 38 psi) If pressure is not as specified, check the vacuum sensing hose and fuel pressure regulator and fuel pressure regulator. r. Stop the engine. s. Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped. Fuel pressure: 147 kPa (1.5 kg/Sq.cm, 21 psi) or more If pressure is not as specified, check the fuel pump, pressure regulator and/or injectors. t. After checking fuel pressure, disconnect the negative (-) terminal cable from the battery and carefully remove the SST to prevent gasoline from splashing. SST 09268-45012 Page 2499 d. Using SST to hold the flange, press the bearing into position by tightening down a new nut. SST 09330-00021 Torque: 181 Nm (1,850 kgf-cm, 134 ft. lbs.) e. Loosen the nut. f. Torque the nut again. Torque: 69 Nm (700 kgf-cm, 51 ft. lbs.) g. Using a chisel and hammer, stake the nut. 3. 3-joint type: CONNECT PROPELLER SHAFT AND INTERMEDIATE SHAFT a. Align the matchmarks on the flanges and connect the flanges with the 4 bolts, washers and nuts. HINT: If replacing either the center flange or intermediate shaft, reassemble them so that the front flange yoke of the intermediate shaft and the rear flange yoke of the propeller shaft are facing in the same direction. b. Torque the nuts. Torque: 74 Nm (750 kgf-cm, 54 ft. lbs.) 4. INSERT SLEEVE YOKE INTO PROPELLER SHAFT a. Apply grease to the propeller shaft spline and sleeve yoke sliding surface. Grease: Molybdenum disulfide lithium base chassis grease, NLGI No. 2. b. Install the dust cover to the shaft. c. Align the matchmarks on the yoke and propeller shaft. INSTALLATION Installation is in the reverse order of removal. HINT: Propeller shaft (pre runner) and rear propeller shaft (4WD) of 3-joint type: Center bearing center line and the center bearing housing center line must be adjusted within 0 ± 1 mm (0 ± 0.04 inch) of each other in the vehicles front and rear direction when the vehicle is unloaded. - Propeller shaft (pre runner) and rear propeller shaft (4WD) of 3-joint type: When adjusting the center bearing housing center line, it should be perpendicular to the axis of front propeller shaft. - With a grease gun, pump grease into each fitting until it begins to flow around the oil seal. Grease: Spiders: Lithium base chassis grease, NLGI No. 2. Sleeve yoke and double cardan joint: Molybdenum disulfide lithium base chassis grease, NLGI No. 2. Page 3098 Fuse: Application and ID Engine Room R/B # 2 Page 4426 D: Indicates related system. Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V). Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, 1H2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green O = Orange P = Pink R = Red SB = Sky Blue V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Page 2955 Steps 1 - 3 Testing and Inspection Door Lamp: Testing and Inspection INSPECT DOOR COURTESY SWITCH CONTINUITY a. Check that continuity exists between terminal and the switch body in the ON position (switch pin released opened door). b. Check that no continuity exists between terminal and the switch body in the OFF position (switch pin pushed in closed door). If operation is not as specified, replace the switch. Page 4353 Clutch Switch: Testing and Inspection FORD Made CIRCUIT DESCRIPTION When the clutch pedal is depressed, the clutch switch sends a signal to the cruise control ECU. When the signal is input to the cruise control ECU during cruise control driving, the cruise control ECU cancels cruise control. Wiring Diagram Page 3932 NOTE: After "Dinghy" Towing, or at the recommended distance limits, let the Engine idle for more than 3 minutes before operating the vehicle or resuming towing. NOTE: Vehicles that are Dinghy towable will not sustain internal damage to the transmission or transfer components, as long as speed/distance limits are observed. The transmission must be placed in the "neutral" position when Dinghy towing. Dinghy towing these vehicles does not eliminate the possibility of damage to other vehicle systems (Body, Chassis, Electrical Systems, etc.). Page 2541 Shift Indicator: Locations Component Locations Page 1871 Fuel: Specifications Fuel Type Unleaded Gasoline Octane Rating 87 Octane or Higher Page 2475 3. w/o Free wheel hub (4WD only): DISCONNECT DRIVE SHAFT a. Using a screwdriver, remove the grease cap. b. Remove the cotter pin and lock cap. HINT: At the time of installation, if the holes for the cotter pin are not aligned, tighten the nut further up to 60°. c. With applying the brakes, remove the lock nut. Torque: 235 Nm (2,400 kgf-cm, 174 ft. lbs.) 4. w/ Freewheel hub: DISCONNECT DRIVE SHAFT a. Remove the free wheel hub. b. Using a snap ring expander, remove the snap ring. c. Remove the spacer. 5. w/ ABS: DISCONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP FROM STEERING KNUCKLE Remove the 2 bolts and ABS speed sensor wire harness clamp from the steering knuckle. Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.) 6. REMOVE BRAKE CALIPER AND DISC a. Remove the union bolt and 2 gaskets from the caliper, then disconnect the flexible hose from the caliper. Torque: 30 Nm (310 kgf-cm, 22 ft. lbs.) HINT: At the time of installation, install the flexible hose lock securely in the lock hole in the caliper. b. Remove the 2 bolts, brake caliper and disc. Torque: 123 Nm (1,250 kgf-cm, 90 ft. lbs.) Testing and Inspection Oil Pressure Warning Lamp/Indicator: Testing and Inspection INSPECT LOW OIL PRESSURE WARNING LIGHT a. Disconnect the connector from the warning switch and ground terminal on the wire harness side connector. b. Turn the ignition switch ON and check that the warning light lights up. If the warning light does not light up, test the bulb. Page 1603 CHART 29 Page 2804 Brake Caliper: Service and Repair Disassembly and Assembly DISASSEMBLY 1. REMOVE CYLINDER BOOT SET RINGS AND BOOTS Using a screwdriver, remove the 4 cylinder boot set rings and boots. 2. REMOVE PISTONS FROM CYLINDER Page 1673 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection COMPONENTS INSPECTION 1. DRAIN ENGINE COOLANT 2. DISCONNECT UPPER RADIATOR HOSE FROM WATER OUTLET 3. REMOVE NO.2 TIMING BELT COVER 4. REMOVE FUEL PIPE Remove the 2 union bolt, 4 gaskets and fuel pipe. Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions Key to Diagrams Key to Diagrams A: System Title. B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: (1) Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. Page 376 Heated Oxygen Sensor Page 3413 Page 2957 Clutch Switch: Testing and Inspection FORD Made Clutch Switch Circuit CIRCUIT DESCRIPTION When the clutch pedal is depressed, the clutch switch sends a signal to the cruise control ECU. When the signal is input to the cruise control ECU during cruise control driving, the cruise control ECU cancels cruise control. Wiring Diagram Page 3217 Key Reminder Switch: Ground Locations Page 1834 2. INSPECT HOSES, CONNECTIONS AND GASKETS Visually check for cracks, leaks or damage. Page 2522 WIRING DIAGRAM Trailer Harness - Updated Design/Diagnostics Trailer Adapter Kit: Technical Service Bulletins Trailer Harness - Updated Design/Diagnostics ACCESSORIES AX006-02 October 18, 2002 Title: TRAILER WIRE HARNESS Models: 4Runner, Highlander, land Cruiser, RAV4, Sienna, Tacoma & Tundra Introduction Beginning in 2000, the accessory trailer wire harness supplier was changed and a new design was adopted which incorporated in-line fuses in the tow wire harness in addition to the vehicle fuse. This bulletin identifies the fuse location to supplement dealer diagnostics troubleshooting. In the future please reference the accessory trailer wire harness Owner's Guide for the vehicle specific diagnostic procedures. As a general note please place the towing wire harness Owner's Guide in glove box after every DIO installation. Applicable Vehicles ^ 4Runner, Highlander, Land Cruiser, RAV4, Sienna, Tacoma, and Tundra vehicles using the Accessory Towing Receiver Hitch and factory Towing Receiver Hitch option. (See table below for applicable model years.) Accessory Wire Harness Kit Information Warranty Information Page 3332 Ball Joint: Specifications Upper Ball Joint Turning Torque 0.7-4.4 Nm (6.0-39.0 in.lb) Page 71 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Page 282 If continuity is not as specified, replace the switch. Page 2062 Spark Plug: Application and ID Recommended Spark Plugs ND K16TR11 NGK BKR5EKB-11 Locations Vehicle Lifting: Locations Airbag(s) Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Airbag(s) Arming and Disarming CAUTION: * Work must be started 90 seconds after the ignition switch is turned to the "LOCK" position and the negative (-) terminal cable is disconnected from the battery. (The SRS is equipped with a back-up power source so that if work is started within 90 seconds of disconnecting the negative (-) terminal cable of the battery, the SRS may be deployed.) * When the negative (-) terminal cable is disconnected from the battery, the memory of the clock and audio system will be canceled. So before starting work, make a record of the contents memorized in the audio memory system. When work is finished, reset the audio systems as before and adjust the clock. To avoid erasing the memory of each memory system, never use a backup power supply from outside the vehicle. * Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during repairs. * Do not expose the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor directly to hot air or flames. AIR BAG SYSTEM DISARMING The Air Bag/Supplemental Restraint System (SRS) incorporates a backup energy source that maintains sufficient deployment voltage for up to 90 seconds after the ignition is turned Off and the battery has been disconnected. Before disconnecting battery, note radio station settings, since all vehicle memory will be lost. Never use a backup power source from outside the vehicle. 1. Turn ignition to Lock, then disconnect battery ground cable. 2. Wait at least 90 seconds after disconnection before beginning service or diagnostic procedures. AIR BAG SYSTEM ARMING 1. Ensure ignition is in Lock position. 2. Connect battery ground cable. 3. Wait at least 10 seconds before turning ignition from Lock position. 4. Turn ignition to ACC or On position and ensure SRS lamp lights, then goes off after approximately six seconds. If lamp remains lit, an SRS condition is indicated. Refer to Restraint Systems, Air Bag Systems, Testing And Inspection. See: Air Bag Systems/Testing and Inspection Testing and Inspection EFI Main Relay: Testing and Inspection 1. REMOVE EFI MAIN RELAY (Marking: EFI) 2. INSPECT EFI MAIN RELAY a. Inspect the relay continuity. 1. Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. 2. Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. b. Inspect the relay operation. 1. Apply battery positive voltage across terminals 1 and 2. 2. Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. 3. REINSTALL EFI MAIN RELAY Page 3257 a. Using a screwdriver and hammer, stake back the washer. NOTICE: Avoid any Impact to the steering rack. b. Using a spanner to hold the steering rack steady, and using SST, remove the rack end. SST 09922-10010 NOTICE: ^ Use SST 09922-10010 in the direction shown in the illustration. ^ Mark the RH and LH rack ends. 5. REMOVE RACK HOUSING NO.2 BRACKET AND GROMMET a. Place matchmarks, on the bracket and rack housing. b. Remove the bolt. 6. REMOVE RACK GUIDE SPRING CAP LOCK NUT Using SST, remove the nut. SST 09922-10010 NOTICE: Use SST 09922-10010 in the direction shown in the illustration. DENSO Made Actuator Control Cable: Testing and Inspection DENSO Made Step 1 INSPECTION PROCEDURE Page 972 b) Hold the tensioner with both hands and push the push rod strongly as shown to check that it doesn't move. If the push rod moves, replace the tensioner. NOTICE: Never hold the tensioner push rod facing downward. c) Measure the protrusion of the push rod from the housing end. Protrusion: 10.0 - 10.8 mm (0.394 - 0.425 inch) If the protrusion is not as specified, replace the tensioner. INSTALLATION 1. INSTALL CRANKSHAFT TIMING PULLEY a) Align the pulley set key with the key groove of the timing pulley and slide on the timing pulley. b) Slide on the timing pulley, facing the flange side inward. 2. INSTALL NO.1 IDLER PULLEY a) Using a 10 mm hexagon wrench, install the plate washer and idler pulley with bolt. Torque: 35 Nm (350 kgf-cm, 26 ft. lbs.) b) Check that the pulley bracket moves smoothly. 3. INSTALL NO.2 IDLER PULLEY a) Install the idler pulley with the bolt. Torque: 40 Nm (400 kgf-cm, 30 ft. lbs.) b) Check that the idler pulley moves smoothly. Page 4321 Steps 3 - 4 INSPECTION PROCEDURE Page 2618 Step 4 Testing and Inspection Instrument Panel Relay: Testing and Inspection INSPECT BULB CHECK RELAY OPERATION a. Connect the positive (+) lead from the battery to terminal C through a 1.4 W test bulb and the negative (-) lead to terminal B, check that the test bulb does not light up. b. Connect the positive (+) lead from the battery to terminal A and check that the test bulb lights up. If operation is not as specified, replace the relay. Testing and Inspection Temperature Gauge: Testing and Inspection INSPECT ENGINE COOLANT TEMPERATURE RECEIVER GAUGE OPERATION a. Disconnect the connector from the sender gauge. b. Turn the ignition switch ON and check that the receiver gauge needle indicates COOL. c. Ground terminal on the wire harness side connector through a 3.4 W test bulb. d. Turn the ignition switch ON, and check that the bulb lights up and the receiver gauge needle moves to the hot side. If operation is as specified, replace the sender gauge. Then, recheck the system. If operation is not as specified, measure the receiver gauge resistance. INSPECT ENGINE COOLANT TEMPERATURE RECEIVER GAUGE RESISTANCE Measure the resistance between terminals. Page 4902 Using an ammeter: INSPECT ONE TOUCH POWER WINDOW SYSTEM a. Disconnect the connector of the master switch. b. Connect the positive (+) lead from the ammeter to terminal 4 on the wire harness side connector and the negative (-) lead to negative terminal of the battery. c. Connect the positive (+) lead from the battery to terminal 9 on the wire harness side connector. d. As the window goes down, check that the current increases to approximately 7.0 A. e. Check that the current increases to approximately 14.5 A or more when the window stops going down. HINT: The circuit breaker opens for some 4 - 40 seconds after the window stops going down, so that the check must be done before the circuit breaker operates. If the operation is as specified, replace the master switch. Using an ammeter with a current - measuring probe: INSPECT ONE TOUCH POWER WINDOW SYSTEM a. Remove the master switch with the connector connected. b. Attach a current-measuring probe to terminal 3 of the wire harness. c. Turn the ignition switch ON and set the power window switch in the down position. d. As the window goes down, check that the current increases to approximately 7.0 A. Page 4757 Page 3602 An airbag activation prevention mechanism is built into the connector for the squib circuit of the SRS. When release of the airbag activation prevention mechanism is directed in the troubleshooting procedure, as shown in the illustration of the connectors on the next pages, insert paper which has the same thickness as the male terminal between the terminal and the short spring. CAUTION: Never release the airbag activation prevention mechanism on the squib connector. NOTE: - Do not release the airbag activation prevention mechanism unless specifically directed by the troubleshooting procedure. - If the inserted paper is too thick the terminal and short spring may be damaged, so always use paper with the same thickness as the male terminal. 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 4661 Locations Testing and Inspection Power Mirror Motor: Testing and Inspection INSPECT MIRROR MOTOR OPERATION a. Connect the positive (+) lead from the battery to terminal 3 and negative (-) lead to terminal 1. Check that the mirror turns to left side. b. Remove the polarity and check that the mirror turns to right side. c. Connect the positive (+) lead from the battery to terminal 2 and the negative (-) lead to terminal 1. Check that the mirror turns upward. d. Reverse the polarity, check that the mirror turns downward. If operation is not as specified, replace the mirror assembly. Page 247 Intake Manifold Assembly Intake Manifold: Specifications Intake Manifold Assembly Intake Manifold Maximum Warpage .................................................................................................... ................................................................... 0.10 mm Intake Manifold W/ Bolts, Washers and Nuts Torque .......................................................................... ............................................................................................................................................... 18 Nm Intake Manifold Stay W/ Bolts Torque ................................................................................................. ........................................................................................................................ 18 Nm Page 3092 Auxiliary Power Outlet: Electrical Diagrams Service Hints P 13, P 14 POWER OUTLET 2-GROUND : Approx. 12 volts with the ignition SW at ACC or ON position 1-GROUND : Always continuity Page 2272 Step 4 Page 252 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 138 INSPECT DRIVER'S DOOR UNLOCK DETECTION SWITCH CONTINUITY If continuity is not as specified, replace the switch. INSPECT PASSENGER'S DOOR UNLOCK DETECTION SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 3184 Part 2 Of 2 DISASSEMBLY NOTICE: When using a vise, do not overtighten it. Description and Operation Transmission Mode Indicator - A/T: Description and Operation The ECM memory contains the shift programs for the NORMAL and POWER patterns, 2 position, L position and the lock-up patterns. Following the programs corresponding to the signals from the pattern select switch, the park/neutral position and other various sensors, the ECM switches the solenoid valves ON and OFF, and controls the transmission gear change and the lock-up clutch operation. Page 4503 D: Indicates related system. Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V). Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, 1H2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green O = Orange P = Pink R = Red SB = Sky Blue V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Page 2481 b. Using a chisel and hammer, stake the lock nut. 6. w/o Free wheel hub (4WD only): INSTALL BEARING SPACER Using SST and a press, install the bearing spacer. SST 09950-60010 (09951-00650), 09950-70010 (09951-07150) 7. 4WD: INSTALL NEW OIL SEAL (INSIDE) a. Using SST and a plastic hammer, install a new oil seal (inside). SST 09527-17011 HINT: Strike the SST on its circumference evenly. b. Coat the oil seal lip with MP grease. 8. PreRunner: INSTALL GREASE CAP Page 2601 Transmission Speed Sensor: Description and Operation CIRCUIT DESCRIPTION The speed sensor for ABS detects the wheel speed and sends the appropriate signals to the ABS ECU. The ECU converts these signals into a pulse signal and outputs it to the combination meter. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. Page 1772 Page 1484 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 1988 4. REMOVE THROTTLE BODY a. Disconnect the throttle position sensor connector. b. Disconnect the IAC valve connector. c. Disconnect the vacuum hose for the throttle opener. d. Disconnect the water bypass hose (from water bypass pipe). e. Disconnect the water hose (from intake manifold). f. Disconnect the air assist hose. g. Remove the 2 bolts, 2 nuts, throttle body and gasket. Torque: 18 Nm (180 kg.cm, 13 ft.lb) HINT: At the time of installation, please refer to the following items. Place a new gasket on the air intake chamber facing the protrusion upward. INSTALLATION Installation Is in the reverse order of removal. Page 1650 Step 7 Step 8 INSPECTION PROCEDURE Testing and Inspection Seat Belt Buckle Switch: Testing and Inspection INSPECT BUCKLE SWITCH CONTINUITY a. Check that continuity exists between terminals on the switch side connector with the switch ON (belt unfastened). b. Check that no continuity exists between terminals on the switch side connector with the switch OFF (belt fastened). If operation is not as specified, replace the seat belt inner. Page 1951 Fuel Pump Relay: Testing and Inspection 1. REMOVE CIRCUIT OPENING RELAY 2. INSPECT CIRCUIT OPENING RELAY a. Inspect the relay continuity. 1. Using an ohmmeter, check that there is no continuity between terminals 1 and 2. If there is continuity, replace the relay. 2. Check that there is continuity between terminals 2 and 4. If there is no continuity, replace the relay. 3. Check that there is continuity between terminals 5 and 5. If there is no continuity, replace the relay. Page 3383 2. INSTALL NEW BUSHING Using SST and a press, install a new bushing. SST 09506-35010, 09632-36010 HINT: Do not apply grease or oil to the bushing. REASSEMBLY 1. INSTALL COIL SPRING TO SHOCK ABSORBER a. Using SST, compress the coil spring. SST 09727-30021 NOTICE: ^ To avoid damage to SST, set SST arms to allow clearance to hold a 8-roll coil between them. ^ Do not compress the coil spring more than necessary. ^ Do not use an impact wrench. It will damage the SST. b. Install the coil spring to the shock absorber. HINT: Fit the lower end of the coil spring into the gap of the spring seat of the shock absorber. 2. INSTALL SUSPENSION SUPPORT a. Install the 2 cushions, 3 retainers and suspension support to the rod. b. Temporarily tighten a new suspension support center nut. c. Position the suspension support so that a line drawn between the 2 bolts would be parallel to the direction of the lower bushing. d. Remove the SST. SST 09727-30021 HINT: After removing the SST, again check the direction of the suspension support. e. Torque the suspension center nut. Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.) Page 1714 CHART 1 Page 3819 Splice Point J: Indicates a wiring Splice Point (Codes are "E"for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I 5 is indicated by the shaded section. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. N: Page No. How to Read Ground Points How to Read Ground Points Bleeding the Brake System Brake Bleeding: Service and Repair Bleeding the Brake System BRAKE FLUID BLEEDING HINT: If any work is done on the brake system or if air is suspected in the brake lines, bleed the air from the system. NOTICE: Do not let brake fluid remain on a painted surface. Wash it off immediately. 1. FILL BRAKE RESERVOIR WITH BRAKE FLUID Check the fluid level in the reservoir after bleeding each wheel. Add fluid, if necessary. Fluid: SAE J1703 or FMVSS No. 116 DOT 3 2. BLEED MASTER CYLINDER HINT: If the master cylinder has been disassembled or if the reservoir becomes empty, bleed the air from the master cylinder. a. Disconnect the brake lines from the master cylinder. b. Slowly depress the brake pedal and hold it. c. Block off the outlet plug with your finger, and release the brake pedal. d. Repeat (b) and (c) 3 or 4 times. Page 4419 Junction Box / No. 1 Junction Box / No. 3 Page 3810 Seat Belt Reminder Lamp: Connector Locations Locations Fuse: Locations Relay Box / No. 2 Page 553 c. How to read adjustment chart. 1. Find the wheel alignment standard value applicable for the particular model. 2. Mark the selected standard value on the adjustment chart. Example: Camber: 0°10' (0.17°) Caster: 1°40' (1.67°) 3. Mark the alignment value measured when the vehicle was non-loaded on the adjustment chart. Example: Camber: -0°10'(-0.17°) Caster: 1°40' (1.67°) 4. As shown in the chart, read the distance from the measured value to the standard value, and adjust the front and/or rear adjusting cams accordingly. Example: Front cam: -(Shorter) 2.8 Rear cam: -(Shorter) 2.8 Page 2279 Step 1 Step 2 Page 4420 Junction Box / No. 3 Fuse and Fusible Link Locations Page 3774 Owner Instructions Failure to follow the recommendations indicated below could result in reduced effectiveness of the seat belt restraint system in case of vehicle collision, causing personal injury. The Seat Belt Extender must not be used: a. By anyone other than for whom it was provided (name recorded on seat belt extender). b. In any vehicle and/or seat position other than the one for which it was provided. c. When the Seat Belt Extender is provided for rear seat positions (with automatic locking retractor), make sure the retractor is locked when in use. If your seat belt cannot be fastened securely because it is not long enough, a personalized Seat Belt Extender is available from your Toyota dealer free of charge. Please contact your local Toyota dealer so that the dealer can order the proper required length for the extender. Bring the heaviest coat you expect to wear for proper measurement and selection of length. Additional ordering information is available at your Toyota dealer. CAUTION: When using the Seat Belt Extender, observe the following. Failure to follow these instructions could result in reduced effectiveness of the seat belt restraint system in case of vehicle accident, increasing the chance of personal injury. ^ Never use the Seat Belt Extender if you can COMFORTABLY fasten the seat belt without it. ^ The Seat Belt Extender must never be used with any child safety seats. ^ Remember that the extender provided for you may not be safe when used on a; different vehicle, or for another person or at a different seating position than the one originally intended for. To connect the extender to the seat belt, insert the tab into the seat belt buckle so that the "PRESS" signs on the buckle-release buttons of the extender Service and Repair Fuel Pressure Release: Service and Repair 1. BEFORE WORKING ON FUEL SYSTEM, DISCONNECT NEGATIVE (-) TERMINAL CABLE FROM BATTERY HINT: Any diagnostic trouble code retained by the computer will be erased when the negative (-) terminal cable is removed from the battery. Therefore, if necessary, read the diagnosis before removing the negative (-) terminal cable from the battery. 2. DO NOT SMOKE OR WORK NEAR AN OPEN FLAME WHEN WORKING ON FUEL SYSTEM 3. KEEP GASOLINE AWAY FROM RUBBER OR LEATHER PARTS 4. FUEL SYSTEM a. When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe these procedures: 1. Disconnect the fuel pump connector. 2. Start the engine. After the engine has stopped on its own, turn the ignition switch OFF. 3. Put a container under the connection. 4. Slowly loosen the connection. 5. Disconnect the connection. 6. Plug the connection with a rubber plug. b. When connecting the union bolt on the high pressure pipe union, observe these procedures: 1. Always use 2 new gaskets. 2. Tighten the union bolt by hand. 3. Tighten the union bolt to the specified torque. Torque: 34.3 Nm (350 kg.cm, 25 ft.lb) Page 4763 Dome Lamp: Splice Locations Page 692 1. Loosen the nut on the control shaft lever. 2. Push the control shaft fully forward. 3. Return the control shaft lever 2 notches to N position. 4. Set the shift lever to N position. 5. While holding the shift lever lightly toward the R position side, adjust the control lever nut. 6. Tighten the control shaft lever nut. Torque: 13 Nm (130 kg.cm, 10 ft.lb) 7. Start the engine and make sure that the vehicle moves forward when shifting the lever from the N to D position and reverses when shifting it to the R position. g. Floor shift: Inspect and adjust the shift lever position. When shifting the shift lever from the N position to other positions, check that the lever can be shifted smoothly and accurately to each position and that the position indicator correctly indicates the position. If the indicator is not aligned with the correct position, carry out the following adjustment procedures. 1. Remove the nut on the shift lever. 2. Push the control shaft lever fully downward. 3. Return the control shaft lever 2 notches to N position. 4. Set the shift lever to N position. 5. While holding the shift lever lightly toward the R position side, adjust the control shaft lever nut. 6. Tighten the control shaft lever nut. Torque: 13 Nm (130 kg.cm, 10 ft.lb) 7. Start the engine and make sure that the vehicle moves forward when shifting the lever from the N to D position and reverses when shifting it to the R position. h. Inspect and adjust the park/neutral position. Page 223 Refrigerant Pressure Sensor / Switch: Service and Repair REMOVAL 1. REMOVE EVAPORATOR 2. REMOVE PRESSURE SWITCH FROM LIQUID TUBE Disconnect the connector and remove the pressure switch. Torque: 10 Nm (100 kg.cm, 7 ft.lb) HINT: Lock the switch mounted on the tube with an open end wrench, being careful not to deform the tube and remove the switch. - At the time of installation, please refer to the following item. Lubricate a new O-ring with the compressor oil and install the switch. INSTALLATION Installation is in the reverse order of removal. Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Key to Diagrams Key to Diagrams A: System Title. B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: (1) Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. Page 4025 Applicable Warranty*: This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Repair Procedure 1. Remove Wiper Arms, Plastic Cowl Cover and Wiper Motor (store wiper links up against bottom of windshield). NOTE: Mark wiper arm linkage attached to wiper motor and wiper motor splined shaft prior to removing the 12 mm retaining nut. 2. Spray Acrysol(TM) under entire lip of 1/2" pinch weld and wipe dry with a clean paper towel. FOLLOW DIRECTIONS ON SIDE OF CAN CAREFULLY. Dry open seam with compressed air prior to applying sealer. NOTE: Do not use a red shop towel to wipe surfaces because shop towels are contaminated with silicone. 3. Apply a small bead of Kent High Tech(TM) Clear Seam Sealer to underside front edge of the pinch weld from fender to fender as shown. 4. Apply Kent High Tech(TM) Clear Seam Sealer on all spot welds located on the floor of cowl panel. 5. Apply Kent High Tech(TM) Clear Seam Sealer around outside base of hood safety stops, and seal outside corner, under the "L" bracket as shown. Testing and Inspection Ignition Cable: Testing and Inspection ON-VEHICLE INSPECTION INSPECT HIGH-TENSION CORDS a. Remove the air cleaner hose. b. Disconnect the high-tension cords at the rubber boot. Do not pull on the high-tension cords. NOTE: Pulling on or bending the cords may damage the conductor inside. c. Using an ohmmeter, measure the high-tension cord resistance. Maximum resistance: 25 kohms per cord If the resistance is greater than maximum, check the terminals. If necessary, replace the high-tension cord. Page 1430 3) Select a new shim with a thickness as close as possible to the calculated values. HINT: Shims are available in 17 sizes in increments of 0.050 mm (0.0020 inch), from 2.500 mm (0.0984 inch) to 3.300 mm (0.1299 inch). Locations Page 1493 Refer to Reset Procedure 2 for the vehicles with Electronically Controlled Automatic Transmissions: Reset Procedure 1 1. Connect the Toyota Diagnostic Tester to the vehicle. 2. Reset the ECM (PCM). Refer to the procedures below. DENSO Made Clutch Switch: Testing and Inspection DENSO Made CIRCUIT DESCRIPTION When the clutch pedal is depressed, the clutch switch sends a signal to the cruise control ECU. When the signal is input to the cruise control ECU during cruise control driving, the cruise control ECU cancels cruise control. Wiring Diagram Diagrams Brake Master Cylinder: Diagrams Locations Page 3729 Warranty Information APPLICABLE WARRANTY ^ This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. ^ Warranty application is limited to correction of a problem based upon a customer's specific complaint. Parts Information Repair Procedure 1. Shift the tongue plate to the upper portion of the tongue plate stopper and temporarily hold it with a clip or tape. 2. Remove any pieces of the original tongue plate stopper in the webbing with a pair of diagonal pliers. NOTE Be careful not to damage the webbing, since this may compromise the safety of this seatbelt. CAUTION Damaged or weakened seat belts may break in an accident and injure the occupant. The seat belt assembly MUST be replaced if: ^ The webbing is cut, frayed, worn, or damaged. ^ It has been used during a severe impact (inspect the label to ensure no impact damage has occurred) Page 542 W/ Intermittent w/ INTERMITTENT: If continuity is not as specified, replace the switch. INSPECT INTERMITTENT OPERATION a. Turn the wiper switch to INT position. b. Turn the intermittent time control switch to FAST position. c. Connect the positive (+) lead from the battery to terminal 16 and the negative (-) lead to terminal 2. d. Connect the positive (+) lead from the voltmeter to terminal 7 and the negative (-) lead to terminal 2, check that the meter needle indicates battery positive voltage. If operation is not as specified, replace the wiper and washer switch. Body - Water Leaks to The Interior Wiper Motor: Customer Interest Body - Water Leaks to The Interior BODY BO026-00 Title: WATER LEAK FIELD-FIX REPAIR INSTRUCTIONS Models: '97 - '04 Tacoma October 27, 2000 TSB Revision Notice: ^ January 12, 2005: Applicable Vehicles has been updated to include 2004 model year. ^ August 25, 2003: VIN and Applicable Model Information has changed, and repair procedure has been expanded and clarified. ^ October 27, 2000: This TSB updates B0016-98 dated June 12, 1998. B016-98 is now obsolete and should be discarded. Previous versions of this TSB should be discarded. Introduction Use the following field-fix procedures if water is present on the floor carpeting and it can be confirmed that the water is leaking into the cab from either the upper cowl or side cowl seam, or moisture barrier behind the door trim panel. Applicable Vehicles 1997 - 2004 model year Tacoma vehicles. Required Materials Warranty Information Page 4385 The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. Page 2860 b. Set the SST on the gasket, and lower the pin until its tip slightly touches the piston. SST 09737-00010 c. Turn the SST upside down, and set it on the booster. SST 09737-00010 d. Measure the clearance between the booster push rod and pin head (SST). Clearance: 0 mm (0 inch) e. Adjust the booster push rod length until the push rod lightly touches the pin head. 3. INSTALL MASTER CYLINDER 4. CONNECT VACUUM HOSE TO BRAKE BOOSTER 5. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM See: Brake Bleeding 6. CHECK FOR FLUID LEAKAGE 7. CHECK AND ADJUST BRAKE PEDAL DO OPERATIONAL CHECK See: Brake Pedal Assy/Testing and Inspection See: Testing and Inspection Page 4218 Warning: Auto Magic © Special Cleaner Concentrate is a corrosive material. Appropriate personal protection equipment must be worn to protect persons performing the contamination removal procedure. Please refer to the precautions on the product prior to use. Caution: Consult local or state regulations regarding the handling, use, and disposal of Auto Magic © Special Cleaner Concentrate prior to use. Under no circumstances should contamination removal be performed in direct sunlight or contamination removal solution be allowed to dry on vehicle surfaces, as staining of plastic, rubber, or painted parts may result. Repair Procedure 1. Move vehicle out of direct sunlight. Initially rinse with cool water then wash with liquid car wash detergent. Rinse again thoroughly with fresh water. 2. Dilute the mixture to a 1:8 ratio for painted surfaces. Use the recommended dilution ratio when applying to any other surface. Apply the diluted cleaner so that it evenly covers the affected area. Use an appropriate mitt or sponge to agitate the surface. 3. Thoroughly rinse vehicle with fresh water. 4. Inspect vehicle carefully both visually and by feel to determine if all iron particles have been removed. Repeat the wash several times if necessary to achieve complete removal. 5. Dry vehicle with a soft terry cloth towel and apply a non-abrasive non-silicone glaze to obtain a high-gloss finish. Page 4417 Cigarette Lighter: Locations Component Locations Connector Locations Page 2072 Step 1 Page 1175 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source How to Read Power Source Page 5000 reinstall plastic sheet against metal door panel. Confirm that there are no voids between sealer and plastic sheet and between sealer and metal door panel. 22. Flood all areas with water to confirm that there are no leaks into cab area. 23. If no leaks are present, reinstall door trim panel. Page 463 2. REMOVE FRONT AIRBAG SENSOR RH a. Disconnect the front airbag sensor connector. NOTE: Disconnect the connector with the front airbag sensor installed. b. Remove the 2 nuts and front airbag sensor RH. 3. REMOVE FRONT AIRBAG SENSOR LH a. Disconnect the front airbag sensor connector. NOTE: Disconnect the connector with the front airbag sensor installed. b. Remove the 2 bolts and front airbag sensor LH. INSTALLATION 1. INSTALL FRONT AIRBAG SENSOR LH AND RH a. Install the front airbag sensor with the 2 bolts and 2 nuts with the arrows on the sensors facing toward the front of the vehicle. Torque: 20 Nm (205 kg.cm, 15 ft.lb) NOTE: Connection of the connector is done after the sensor has been installed. - Make sure the sensor is installed with the specified torque. Page 1588 CHART 20 Page 335 2. Start the engine. 3. Perform the drive pattern to run and complete the Oxygen Sensor (O2S) Monitor. HINT: The 02S Monitor is completed when the following conditions are met: ^ Two (2) minutes or more passed after the engine start. ^ The Engine Coolant Temperature (ECT) is 167°F (75°C) or more. ^ Cumulative running time at 30 mph (48 km/h) or more exceeds 6 minutes. ^ Vehicle is in closed loop. ^ The fuel-cut is operated for 8 seconds or more (for Rear O2S Monitor). A. Allow the engine to idle for two minutes. B. Warm up the engine until the Engine Coolant Temperature (ECT) reaches 167°F (75°C). C. Drive the vehicle over 30 mph (48 km/h) for more than 40 seconds. D. Stop the vehicle and allow the engine to idle for more than 20 seconds. E. Repeat steps C and D at least 8 times in one driving cycle. (Do not cycle the ignition key.) In addition, perform the following steps for the Rear O2S Readiness Monitor: A. Select second gear. B. Allow the vehicle to run at 30 mph (48 km/h) or more. C. Keep the accelerator pedal "off-idle" for more than 10 seconds. D. Immediately after step C, release the accelerator pedal for at least 10 seconds without depressing the brake pedal (to execute the fuel-cut). E. Decelerate the vehicle until the vehicle speed reaches less than 6mph (10km/h). F. Repeat steps B - E at least twice in one driving cycle. Accessing O2S Test Results 1. On the Diagnostic Tester* screen, select the following menus: ^ DIAGNOSTICS ^ CARB OBD II Page 2798 5. IF NECESSARY, CHECK VALVE BODY a. Assemble the valve body in the uppermost position. HINT: When the brakes are applied, the position will move down about 0.8 mm (0.03 inch). Even at this time, the piston should not make contact with or move the load sensing spring. b. In this position, check the rear brake pressure. If the measured value is not within the standard, replace the valve body. Page 1288 CHART 22 Page 3616 Airbag Sensor Assembly: Testing and Inspection Replacement Requirements REPLACEMENT REQUIREMENTS In the following cases, replace the airbag sensor assembly. - If the SRS has been deployed in a collision. - If the airbag sensor assembly has been found to be faulty in troubleshooting. - If the airbag sensor assembly has been dropped. CAUTION: For removal and installation of the airbag sensor assembly. Be sure to follow the correct procedure. Page 4730 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Page 481 Steps 3 - 4 INSPECTION PROCEDURE Page 4912 c. Employ the same manner described above to the other side. REASSEMBLY Reassembly is in the reverse order of disassembly. Page 3868 Impact Sensor: Testing and Inspection Replacement Requirements REPLACEMENT REQUIREMENTS In the following cases, replace the front airbag sensor. - If the SRS has been deployed in a collision. (Replace both the left and right airbag sensors.) - If the front airbag sensor has been found to be faulty in troubleshooting. - If the front airbag sensor has been found to be faulty during checking items. - If the front airbag sensor has been dropped. CAUTION: Be sure to follow the correct procedure for removal and installation of the front airbag sensor. Page 3712 The illustrations shown contain a reference information chart. This chart contain. ^ Owner's Manual page(s) that provide the illustration showing available top strap bracket location(s). The information goes back to 1983 model year. 2001 models and newer already had the bracket installed by the factory. Installation notes, such as bracket spacer sizes for each specific child seat location. Page 4229 Paint Codes & Color Names NOTE: Please contact your local paint representative for the actual paint mixing formulas or if you need help in color matching. Page 422 Mass Air Flow Meter: Service and Repair REMOVAL 1. REMOVE AIR CLEANER CASE a. Disconnect the air cleaner hose. b. Disconnect the MAF meter connector. c. Remove the 3 bolts and air cleaner case. 2. REMOVE MAF METER a. Remove the 2 screws and MAF meter. b. Remove the O-ring from the MAF meter. INSTALLATION 1. INSTALL MAF METER a. Install the O-ring to the MAF meter. b. Install the MAF meter with the 2 screws. 2. INSTALL AIR CLEANER CASE a. Install the air cleaner case with the 3 bolts. b. Connect the MAF meter connector. c. Connect the air cleaner hose. Page 1035 HINT: Apply SST (B) at a slight angle on the side marked with "9" or "7", at the position shown in the illustration. - When SST (B) is inserted too deeply, it will get pinched by the shim. To prevent it from being stuck, insert it gently from the intake side, at a slight angle. 4) Using a small screwdriver and magnetic finger, remove the adjusting shim. b) Determine the replacement adjusting shim size by following the Formula or Charts: 1) Using a micrometer, measure the thickness of the removed shim. 2) Calculate the thickness of a new shim so the valve clearance comes within the specified value. T Thickness of used shim A Measured valve clearance N Thickness of new shim Intake: N = T + (A - 0.18 mm (0.007 inch)) Exhaust: N = T + (A - 0.32 mm (0.013 inch)) Page 3585 NOTICE: Take care not to damage the SST wire harness. (6) Connect the SST red clip to the battery positive (+) terminal and the black clip to the nnegative(-) terminal. (c) Deploy the airbag. (1) Confirm that no one is inside the vehicle or within 10m (33ft) area around the vehicle. (2) Press the SST activation switch and deploy the airbag. HINT: The airbag deploys simultaneously as the LED of the SST activation switch lights up. (d) Dispose of the steering wheel pad (with airbag). CAUTION: - The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment. - Use gloves and safety glasses when handling a steering wheel pad with the deployed airbag. - Always wash your hands with water after completing the operation. - Do not apply water; etc. to a steering wheel pad with the deployed airbag. (1) When scrapping a vehicle, deploy the airbag and scrap the vehicle with the steering wheel pad still installed. (2) When moving a vehicle for scrapping which has a steering wheel pad with deployed airbag, use gloves and safety glasses. PASSENGER AIRBAG MANUAL ON-OFF SWITCH INSPECTION 1. INSPECT PASSENGER AIRBAG MANUAL ON-OFF SWITCH CONTINUITY HINT: Release the activation prevention mechanism of the passenger airbag manual on-off switch connector on the airbag sensor assembly side. Testing and Inspection Instrument Panel Relay: Testing and Inspection INSPECT BULB CHECK RELAY OPERATION a. Connect the positive (+) lead from the battery to terminal C through a 1.4 W test bulb and the negative (-) lead to terminal B, check that the test bulb does not light up. b. Connect the positive (+) lead from the battery to terminal A and check that the test bulb lights up. If operation is not as specified, replace the relay. Page 652 c. When connecting the flare nut on the high pressure pipe union, observe these procedures: 1. Apply a light coat of engine oil to the flare and tighten the flare nut by hand. 2. Using SST, tighten the flare nut to the specified torque. SST 09631-22020 Torque: 28 Nm (285 kg.cm, 21 ft.lb) HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). d. Observe these precautions when removing and installing the injectors. 1. Never reuse the O-ring. 2. When placing a new O-ring on the injector, take care not to damage it in any way. 3. Coat a new O-ring with spindle oil or gasoline before installing-never use engine, gear or brake oil. e. Install the injector to the delivery pipe and intake manifold, as shown in the illustration. f. Check that there are no fuel leaks after doing maintenance anywhere on the fuel system. 1. Connect a TOYOTA hand-held tester to the DLC3. Page 3273 a. Using a screwdriver and hammer, stake back the washer. NOTICE: Avoid any impact to the steering rack. b. Using a spanner to hold the steering rack steady, and using SST, remove the rack end. SST 09922-10010 NOTICE: Use SST 09922-10010 in the direction shown in the illustration. Mark the RH and LH rack ends. 6. REMOVE RACK GUIDE SPRING CAP LOCK NUT Using SST, remove the nut. SST 09922-10010 NOTICE: Use SST 09922-10010 in the direction shown in the illustration. 7. REMOVE RACK GUIDE SPRING CAP 8. REMOVE RACK GUIDE SPRING AND RACK GUIDE 9. REMOVE DUST COVER 10. REMOVE CONTROL VALVE HOUSING WITH CONTROL VALVE ASSEMBLY a. Place matchmarks on the valve housing and rack housing. b. Remove the 2 bolts. c. Pull out the control valve assembly with the valve housing. Page 1533 Idle Air Control Valve: Service and Repair COMPONENTS REMOVAL 1. REMOVE THROTTLE BODY Electrode Gap Specification Spark Plug: Specifications Electrode Gap Specification Electrode Gap Correct Gap ......................................................................................................................................... ........................................................................ 1.1 mm Page 2466 The design of the rear axle seal has been changed from a flat face to an angled face for part number 90310-50006 and part number 90310-56002. Installation Procedure Sequoia To properly install Rear Axle Oil Seal part number 90310-56002, use the following SSTs and a hammer to install the new oil seal: ^ SST P/N 09950-60020-01 (09951-00730-01) - Replacer 73 ^ SST P/N 09951-70010-01 (09951-07150-01) - Handle Tacoma & Tundra To properly install Rear Axle Oil Seal part number 90310-56006, use the following SSTs and a hammer to install the new oil seal: ^ SST P/N 09950-60020-01 (09951-00710) - Replacer 71 ^ SST P/N 09951-70010-01 (09951-07150-01) - Handle Page 2978 2. REPLACE REAR BEARING a. Using SST, remove the bearing. SST 09286-46011 b. Using SST and a press, press in a new bearing. NOTE: Be careful of the bearing Installation direction. SST 09820-00030 3. REPLACE MAGNETIC SWITCH TERMINAL KIT PARTS a. Remove the 3 bolts, lead clamp (1.8 kw) end cover, gasket and plunger. b. Using vernier calipers, measure the contact plate for depth of wear. Maximum wear: 0.9 mm (0.035 in.) Page 1232 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection COMPONENTS INSPECTION 1. DRAIN ENGINE COOLANT 2. DISCONNECT UPPER RADIATOR HOSE FROM WATER OUTLET 3. REMOVE NO.2 TIMING BELT COVER 4. REMOVE FUEL PIPE Remove the 2 union bolt, 4 gaskets and fuel pipe. Page 4115 LH RH INSPECT DOOR KEY LOCK AND UNLOCK SWITCH CONTINUITY If continuity is not as specified, replace the switch. If continuity is not as specified, replace the switch. Page 4777 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Locations Page 3152 Repair Procedure 1. Disconnect the cable from the negative (-) battery terminal for MORE THAN two (2) seconds. 2. Reconnect the cable to the negative (-) battery terminal. 3. Perform the applicable zero point calibration of the yaw rate sensor and/or the steering angle sensor. HINT Refer to the applicable TSB or Repair Manual for the zero point calibration procedure. 4. Re-initialize all applicable systems available on the vehicle (power window sunroof power lift door etc.). Page 689 Fluid - A/T: Fluid Type Specifications Transmission Fluid .............................................................................................................................. ................................................. ATF Dexron II or III Page 1742 CHART 30 Page 1338 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Testing and Inspection Power Door Lock Actuator: Testing and Inspection INSPECT DRIVER'S DOOR LOCK MOTOR OPERATION a. Connect the positive (+) lead from the battery to terminal 7 and the negative (-) lead to terminal 3, and check that the door lock link moves to UNLOCK position. b. Remove the polarity and check that the door lock link moves to LOCK position. If operation is not as specified, replace the door lock assembly. INSPECT PASSENGER'S DOOR LOCK MOTOR OPERATION a. Connect the positive (+) lead from the battery to terminal 6 and the negative (-) lead to terminal 2, and check that the door lock moves to UNLOCK position. b. Remove the polarity and check that the door lock link moves to LOCK position. If operation is not as specified, replace the door lock assembly. Page 2421 Splice Point J: Indicates a wiring Splice Point (Codes are "E"for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I 5 is indicated by the shaded section. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. N: Page No. How to Read Ground Points How to Read Ground Points Page 3826 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Page 2191 1. Loosen the nut on the control shaft lever. 2. Push the control shaft fully forward. 3. Return the control shaft lever 2 notches to N position. 4. Set the shift lever to N position. 5. While holding the shift lever lightly toward the R position side, adjust the control lever nut. 6. Tighten the control shaft lever nut. Torque: 13 Nm (130 kg.cm, 10 ft.lb) 7. Start the engine and make sure that the vehicle moves forward when shifting the lever from the N to D position and reverses when shifting it to the R position. g. Floor shift: Inspect and adjust the shift lever position. When shifting the shift lever from the N position to other positions, check that the lever can be shifted smoothly and accurately to each position and that the position indicator correctly indicates the position. If the indicator is not aligned with the correct position, carry out the following adjustment procedures. 1. Remove the nut on the shift lever. 2. Push the control shaft lever fully downward. 3. Return the control shaft lever 2 notches to N position. 4. Set the shift lever to N position. 5. While holding the shift lever lightly toward the R position side, adjust the control shaft lever nut. 6. Tighten the control shaft lever nut. Torque: 13 Nm (130 kg.cm, 10 ft.lb) 7. Start the engine and make sure that the vehicle moves forward when shifting the lever from the N to D position and reverses when shifting it to the R position. h. Inspect and adjust the park/neutral position. Component Tests and General Diagnostics Engine Control Module: Component Tests and General Diagnostics CIRCUIT DESCRIPTION When the ignition switch is turned ON, battery positive voltage is applied to coil, closing the contacts of the EFI main relay (Marking: EFI) and supplying power to terminal +B of the ECM. WIRING DIAGRAM Page 1465 Crankshaft Position Sensor: Service and Repair REPLACEMENT 1. REMOVE ENGINE UNDER COVER 2. REMOVE CRANKSHAFT POSITION SENSOR a. Disconnect the sensor connector. b. Remove the bolt and sensor. Torque: 7.8 Nm (80 kg.cm, 69 in.lb) 3. REINSTALL NEW CRANKSHAFT POSITION SENSOR a. Install the sensor with the bolt. b. Connect the sensor connector. 4. REINSTALL ENGINE UNDER COVER Testing and Inspection Dimmer Switch: Testing and Inspection W/ Tachometer (DLX Grade M/T Vehicle) INSPECT LIGHT CONTROL RHEOSTAT a. Turn the rheostat knob OFF and check that no continuity exists between terminals (Rheostat knob turned to fully counterclockwise). b. Gradually, turn the rheostat knob from the dark side to bright side and check that the resistance decreases from 10 to 0 Ohm. (Rheostat knob turned to clockwise) If operation is not as specified, replace the rheostat. ELECTRICAL TYPE (W/ All A/T Vehicle and SR5 Grade M/T Vehicle): INSPECT LIGHT CONTROL RHEOSTAT a. Connect terminals 1 and 3 through a 3.4 W test bulb. b. Connect the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal 2. c. Turn the rheostat knob to fully counterclockwise and check that the test bulb goes out. d. Gradually turn the rheostat knob to clockwise and check that the test bulb brightness changes from dark to bright. If operation is not as specified, replace the rheostat. Page 4459 Steps 1 - 2 INSPECTION PROCEDURE Page 4106 Page 1642 Part 2 Of 2 (California Spec.) *1: Only for A/T *2: The ECM terminal voltage is fixed regardless of the output voltage from the sensor. Connectors (Except California Spec.) Page 4398 Audible Warning Device: Description and Operation Component Description VSC Buzzer The VSC buzzer sounds while the accumulator pressure is abnormally low or an abnormality casing low fluid pressure occurs VSC is activated. BRAKE Warning Buzzer The BRAKE warning buzzer sounds when the accumulator pressure is abnormally low or an abnormality casing low fluid pressure occurs. Page 2273 Step 5 INSPECTION PROCEDURE Page 2736 5. IF NECESSARY, CHECK VALVE BODY a. Assemble the valve body in the uppermost position. HINT: When the brakes are applied, the position will move down about 0.8 mm (0.03 inch). Even at this time, the piston should not make contact with or move the load sensing spring. b. In this position, check the rear brake pressure. If the measured value is not within the standard, replace the valve body. Page 1238 Crankshaft Position Sensor: Service and Repair REPLACEMENT 1. REMOVE ENGINE UNDER COVER 2. REMOVE CRANKSHAFT POSITION SENSOR a. Disconnect the sensor connector. b. Remove the bolt and sensor. Torque: 7.8 Nm (80 kg.cm, 69 in.lb) 3. REINSTALL NEW CRANKSHAFT POSITION SENSOR a. Install the sensor with the bolt. b. Connect the sensor connector. 4. REINSTALL ENGINE UNDER COVER Page 2456 Part 2 Of 2 HINT: PreRunner is the model described below. RZN191L-TRPDKAB, RZN196L-CRPDKAB, VZN195L-CRPDKAB 1. REMOVE REAR WHEEL AND BRAKE DRUM Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.) 2. CHECK BEARING BACKLASH AND AXLE SHAFT DEVIATION a. Using a dial indicator, check the backlash in the bearing shaft direction. Maximum: 0.7 mm (0.028 inch) If the backlash exceeds the maximum, replace the bearing. b. Using a dial indicator, check the deviation at the surface of the axle shaft outside the hub bolt. Maximum: 0.1 mm (0.0039 inch) If the deviation exceeds the maximum, replace the axle shaft. 3. w/ ABS: REMOVE ABS SPEED SENSOR FROM REAR AXLE HOUSING Remove the bolt and ABS speed sensor. Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.) 4. REMOVE REAR BRAKE ASSEMBLY Connector Locations Key Reminder Switch: Connector Locations Page 3363 3. REMOVE STABILIZER BAR a. Remove the 4 bracket set bolts and stabilizer bar with the cushions and brackets. Torque: 25 Nm (260 kgf-cm, 19 ft. lbs.) b. Remove the brackets and cushions from the stabilizer bar. 4. REMOVE STABILIZER BAR LINKS a. Hold the stabilizer bar link, remove the nut, retainers and bushings. Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.) b. Employ the same manner described above to the other side. INSPECTION INSPECT STABILIZER BAR LINK BALL JOINT FOR ROTATION CONDITION a. As shown in the illustration, flip the ball joint stud back and forth 5 times before installing the nut. b. Using a torque wrench, turn the nut continuously 1 turn each 2-4 seconds and take the torque reading on the 5th turn. Turning torque: 0.05-2.0 Nm (0.5-20 kgf-cm, 0.4-17 inch lbs.) INSTALLATION Installation is in the reverse order of removal. Page 880 2. Turn the ignition switch ON and push TOYOTA hand-held tester main switch ON. NOTE: Do not start the engine. 3. Select the ACTIVE TEST mode on the TOYOTA hand-held tester. 4. Please refer to the TOYOTA hand-held tester operator's manual for further details. 5. If you have no TOYOTA hand-held tester, connect the positive (+) and negative (-) leads from the battery to the fuel pump connector. 6. Pinch the fuel return hose. The pressure in the high pressure line will rise to approx. 400 kPa (4 kg/Sq.cm, 57 psi). In this state, check to see that there are no leaks from any part of the fuel system. NOTE: Always pinch the hose. Avoid bending as it may cause the hose to crack. 7. Turn the ignition switch OFF. 8. Disconnect the TOYOTA hand-held tester from the DLC3. Page 4257 INSPECT DRIVER'S DOOR UNLOCK DETECTION SWITCH CONTINUITY If continuity is not as specified, replace the switch. INSPECT PASSENGER'S DOOR UNLOCK DETECTION SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 408 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2216 Step 3 Page 3974 promoters. However, the application of adhesion promoters on earlier model bumpers made from PP/TPU (Polypropylene/Thermoplastic Urethane) and PUR (Polyurethane) is also recommended. Page 4974 reinstall plastic sheet against metal door panel. Confirm that there are no voids between sealer and plastic sheet and between sealer and metal door panel. 22. Flood all areas with water to confirm that there are no leaks into cab area. 23. If no leaks are present, reinstall door trim panel. Page 3824 Seat Belt Reminder Lamp: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Page 3589 panel. CAUTION: Be sure to follow the correct procedure for removal and installation of the front passenger airbag assembly. 3. VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED a. Do a diagnostic system check. b. Do a visual check which includes the following items with the airbag assembly removed from the vehicle. - Check for deformation of the instrument panel, instrument panel reinforcement and glove compartment door. - Check for damage to the connector and wire harness. HINT: If the instrument panel or instrument panel reinforcement is deformed, never repair it. Always replace it with a new one. - There should be no interference between the instrument panel and front passenger airbag door, or the glove compartment and front passenger airbag door. The clearance should be uniform all the way around when the new airbag assembly is installed on the instrument panel. REPLACEMENT REQUIREMENTS In the following cases, replace the front passenger airbag assembly, instrument panel or instrument panel reinforcement. CAUTION: Be sure to follow the correct procedure for replacement of the front passenger airbag assembly. STEERING WHEEL PAD AND SPIRAL CABLE 1. VEHICLE NOT INVOLVED IN COLLISION a. Do a diagnostic system check . b. Do a visual check which includes the following item with the steering wheel pad (with airbag) installed in the vehicle. Check cuts, minute cracks or marked discoloration on the steering wheel pad top surface and in the grooved portion. 2. VEHICLE INVOLVED IN COLLISION AND AIRBAG IS NOT DEPLOYED a. Do a diagnostic system check . DENSO Made Clutch Switch: Testing and Inspection DENSO Made Clutch Switch Circuit CIRCUIT DESCRIPTION When the clutch pedal is depressed, the clutch switch sends a signal to the cruise control ECU. When the signal is input to the cruise control ECU during cruise control driving, the cruise control ECU cancels cruise control. Wiring Diagram Page 36 INSPECT DAYTIME RUNNING LIGHT NO.4 RELAY CONTINUITY If continuity is not as specified, replace the relay. Page 4725 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Page 2648 Shift Indicator: Description and Operation Previous automatic transmissions have selected each gear shift using mechanically controlled throttle hydraulic pressure, governor hydraulic pressure and lock-up hydraulic pressure. The electronically controlled transmission, however, electrically controls the governor pressure and lock-up sensor through the solenoid valve. Control of the solenoid valve by the engine control module based on the input signals from each sensor makes smooth driving possible by shift selection for each gear which is most appropriate to the driving conditions at that time. 1. GEAR SHIFT OPERATION During driving, the engine control module selects the shift for each gear which is most appropriate to the driving conditions, based on input signals from the engine coolant temp. sensor to TERMINAL THW of the engine control module and also the input signals to TERMINAL SP2+ of the engine control module from the vehicle speed sensor devoted to the electronically controlled transmission. Current is then output to the electronically controlled transmission solenoid. When shifting to 1st speed, current flows from TERMINAL S1 of the engine control module to TERMINAL 1 of the electronically controlled transmission solenoid to GROUND, and continuity to the No.1 solenoid causes the shift. For 2nd speed, current flows from TERMINAL S1 of the engine control module to TERMINAL 1 of the electronically controlled transmission solenoid to GROUND, and from TERMINAL S2 of the engine control module to TERMINAL 2 of the electronically controlled transmission solenoid to GROUND. And continuity to solenoid No.1 and No.2 causes the shift. For 3rd speed, there is no continuity to No.1 solenoid, only to No.2 causing the shift. Shifting into 4th speed (Overdrive) takes place when there is no continuity to either No.1 or No.2 solenoid. 2. LOCK-UP OPERATION When the engine control module judges from each signal that lock-up operation conditions have been met, current flows from TERMINAL SL of the engine control module to TERMINAL 3 of the electronically controlled transmission solenoid to GROUND, causing continuity to the lock-up solenoid and causing lock-up operation. 3. STOP LIGHT SW CIRCUIT If the brake pedal is depressed (Stop light SW ON) when driving in lock-up condition, a signal is input to TERMINAL STP of the engine control module, the engine control module operates and continuity to the lock-up solenoid is cut. 4. OVERDRIVE CIRCUIT * O/D main SW ON When the O/D main SW is turned ON (SW point is open), a signal is input to TERMINAL ODMS of the engine control module and engine control module operation causes gear shift when the conditions for overdrive are met. * O/D main SW OFF When the O/D main SW is turned OFF (SW point is closed), a signal is input into TERMINAL ODMS of the engine control module, and turns on the O/D OFF indicator light. This activates the ECU, and the transmission system is controlled not to shift to overdrive. 5. A/T OIL TEMP. WARNING When the A/T oil temp. sensor affixed to the transmission case detects that the fluid temp. is 150 °C (302 °F) or more, the engine control module operates and the current flowing through the GAUGE fuse flows to the A/T oil temp. warning light to TERMINAL OILW of the engine control module to GROUND, so that the warning light lights up, informing that the oil temp. is high. When the oil temp. drops to 120 °C (248 °F) or less, the engine control module stops operating and the warning light goes out. Page 2389 4. A340E: REMOVE OIL STRAINER NOTICE: Be careful as some fluid will come out of the oil strainer. a. Separate the solenoid wire. b. Remove the 3 bolts, oil strainer and 2 gaskets. 5. A340F: REMOVE OIL STRAINER NOTICE: Be careful as some fluid will come out of the oil strainer. a. Remove the 11 bolts, oil strainer from the oil strainer case. b. Remove the 3 gaskets from the oil strainer. c. Remove the 5 bolts and oil strainer case. 6. A340E: REMOVE OIL PIPE Pry up both pipe ends with a large screwdriver and remove the 2 pipes. Specifications Crankshaft Gear/Sprocket: Specifications Crankshaft Pulley Torque .................................................................................................................... ...................................................................... 300 Nm Page 2658 Page 2612 Step 1 Page 4643 b. Disconnect the connector from the integration relay and inspect the connectors on the wire harness side. Page 2542 Page 2255 Transmission Mode Indicator - A/T: Testing and Inspection CIRCUIT DESCRIPTION The ECM memory contains the shift programs for the NORMAL and POWER patterns, 2 position, L position and the lock-up patterns. Following the programs corresponding to the signals from the pattern select switch, the park/neutral position and other various sensors, the ECM switches the solenoid valves ON and OFF, and controls the transmission gear change and the lock-up clutch operation. Testing and Inspection Heater Control Valve: Testing and Inspection Water Valve 1. WARM UP ENGINE 2. DISCONNECT WATER VALVE CONTROL CABLE 3. INSPECT WATER VALVE OPERATION a. Check that warm air blown out the vent when the water valve lever is moved to "WARM" position. b. Check that cool air blown out when the water valve is moved to the "COOL" position. If operation is not as specified, replace the water valve. 4. CONNECT WATER VALVE CONTROL CABLE After connection, adjust the control cable. Page 4621 Key Reminder Switch: Splice Locations Service Data Connecting Rod: Specifications Service Data Connecting Rod Thrust Clearance Standard ....................................................................................... .............................................................................................................. 0.150 - 0.330 mm Maximum . .............................................................................................................................................................. ................................................ 0.380 mm Connecting Rod Alignment Maximum Bend ........................................................................................ ........................................................................................... 0.05 mm per 100 mm Maximum Twist .... .............................................................................................................................................................. ................. 0.15 mm per 100 mm Connecting Rod Bolts Standard Outer Diameter ................................................................................. .......................................................................................... 7.860 - 8.000 mm Minimum Outer Diameter .............................................................................................................................................. ........................................ 7.600 mm Connecting Rod Cap Torque ............................................................................................................... .......................................................................................................... 25 Nm Page 4655 Shift Indicator: Connector Locations Page 1804 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Pressure Specification Fuel Pressure: Specifications Fuel Pressure No Vacuum 38 to 44 psi Page 2108 Shift Indicator: Description and Operation Previous automatic transmissions have selected each gear shift using mechanically controlled throttle hydraulic pressure, governor hydraulic pressure and lock-up hydraulic pressure. The electronically controlled transmission, however, electrically controls the governor pressure and lock-up sensor through the solenoid valve. Control of the solenoid valve by the engine control module based on the input signals from each sensor makes smooth driving possible by shift selection for each gear which is most appropriate to the driving conditions at that time. 1. GEAR SHIFT OPERATION During driving, the engine control module selects the shift for each gear which is most appropriate to the driving conditions, based on input signals from the engine coolant temp. sensor to TERMINAL THW of the engine control module and also the input signals to TERMINAL SP2+ of the engine control module from the vehicle speed sensor devoted to the electronically controlled transmission. Current is then output to the electronically controlled transmission solenoid. When shifting to 1st speed, current flows from TERMINAL S1 of the engine control module to TERMINAL 1 of the electronically controlled transmission solenoid to GROUND, and continuity to the No.1 solenoid causes the shift. For 2nd speed, current flows from TERMINAL S1 of the engine control module to TERMINAL 1 of the electronically controlled transmission solenoid to GROUND, and from TERMINAL S2 of the engine control module to TERMINAL 2 of the electronically controlled transmission solenoid to GROUND. And continuity to solenoid No.1 and No.2 causes the shift. For 3rd speed, there is no continuity to No.1 solenoid, only to No.2 causing the shift. Shifting into 4th speed (Overdrive) takes place when there is no continuity to either No.1 or No.2 solenoid. 2. LOCK-UP OPERATION When the engine control module judges from each signal that lock-up operation conditions have been met, current flows from TERMINAL SL of the engine control module to TERMINAL 3 of the electronically controlled transmission solenoid to GROUND, causing continuity to the lock-up solenoid and causing lock-up operation. 3. STOP LIGHT SW CIRCUIT If the brake pedal is depressed (Stop light SW ON) when driving in lock-up condition, a signal is input to TERMINAL STP of the engine control module, the engine control module operates and continuity to the lock-up solenoid is cut. 4. OVERDRIVE CIRCUIT * O/D main SW ON When the O/D main SW is turned ON (SW point is open), a signal is input to TERMINAL ODMS of the engine control module and engine control module operation causes gear shift when the conditions for overdrive are met. * O/D main SW OFF When the O/D main SW is turned OFF (SW point is closed), a signal is input into TERMINAL ODMS of the engine control module, and turns on the O/D OFF indicator light. This activates the ECU, and the transmission system is controlled not to shift to overdrive. 5. A/T OIL TEMP. WARNING When the A/T oil temp. sensor affixed to the transmission case detects that the fluid temp. is 150 °C (302 °F) or more, the engine control module operates and the current flowing through the GAUGE fuse flows to the A/T oil temp. warning light to TERMINAL OILW of the engine control module to GROUND, so that the warning light lights up, informing that the oil temp. is high. When the oil temp. drops to 120 °C (248 °F) or less, the engine control module stops operating and the warning light goes out. Page 494 Repair Procedure 1. Disconnect the cable from the negative (-) battery terminal for MORE THAN two (2) seconds. 2. Reconnect the cable to the negative (-) battery terminal. 3. Perform the applicable zero point calibration of the yaw rate sensor and/or the steering angle sensor. HINT Refer to the applicable TSB or Repair Manual for the zero point calibration procedure. 4. Re-initialize all applicable systems available on the vehicle (power window sunroof power lift door etc.). Page 2455 Axle Shaft: Service and Repair REMOVAL Part 1 Of 2 Page 1592 Page 3831 Wheels - Tire Inflation & Wheel Lug Torque Chart Tires: Technical Service Bulletins Wheels - Tire Inflation & Wheel Lug Torque Chart October 1, 1999 TIRE INFLATION & WHEEL LUG TORQUE REFERENCE CHART PG031-99 Introduction Proper tire inflation is important to maximize tire life and vehicle ride comfort. 2000 MY Toyota vehicles are available with a wide variety of wheel sizes and tire profiles. Prior to customer vehicle delivery, refer to the following table to identify the appropriate tire pressure setting. Adjust tire pressures accordingly. Applicable Vehicles All 2000 Models Tire Pressure Settings * Recommended tire inflation pressure under high load capacity. Locations Page 298 4. REINSTALL NO.2 TIMING BELT COVER Page 4619 Key Reminder Switch: Fuse and Fusible Link Locations Relay Box / No. 2 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 1283 CHART 16 CHART 17 Page 551 2. INSTALL CAMBER-CASTER-KING PIN GAUGE OR POSITION VEHICLE ON WHEEL ALIGNMENT TESTER Follow the specific instructions of the equipment manufacturer. 3. INSPECT CAMBER, CASTER AND STEERING AXIS INCLINATION Camber, caster and steering axis inclination: RZN161L Model RZN1171L Model RZN191L model RZN196L model VZN170L model Front Page 4924 ^ Allow recommended cure time for urethane bond before delivering vehicle. ^ Always use OEM or manufacturers approved replacement glass and equivalent bonding materials. Page 2922 Battery Charging Procedure If the battery requires charging, follow the procedures below using the GR8 Battery Diagnostic Station (P/N 00002-MCGR8). 1. Connect the charger cables to the positive (+) and negative (-) battery terminals. 2. Plug the charger into the 110V outlet and turn the switch to the ON position. 3. Select appropriate USER ID (if applicable) and press the NEXT soft key. 4. Enter USER PIN (if applicable) and press the NEXT soft key. NOTE: For details on defining USER ID or PIN, refer to the GR8 Instruction Manual. 5. Press the NEXT soft key when the HELLO screen appears to proceed to the Main Menu. Page 996 If the CO/HC concentration does not comply with regulations, troubleshoot in the order given. 1) Check the A/F sensor or heated oxygen sensor operation. 2) See the table for possible causes, and then inspect and correct the applicable causes if necessary. O/D Main Switch & O/D OFF Indicator Light Circuit Overdrive Switch: Testing and Inspection O/D Main Switch & O/D OFF Indicator Light Circuit CIRCUIT DESCRIPTION The O/D main switch is a momentary type switch. When pressing the O/D OFF main switch, the O/D OFF indicator light lights up and ECM prohibit shifting to O/D, and when pressing it again, the O/D OFF indicator light goes off and ECM allows shifting to O/D. Turning the IG switch OFF will reset the O/D OFF indicator light. Description and Operation Brake Switch - TCC: Description and Operation Stop Light Switch Signal Engine This signal is used to detect when the brakes have been applied. The STP signal voltage is the same as the voltage supplied to the stop lights. The STP signal is used mainly to control the fuel cut-off engine speed (The fuel cut-off engine speed is reduced slightly when the vehicle is braking.). Automatic Transaxle The purpose of this circuit is to prevent the engine from stalling, while driving in lock-up condition, when brakes are suddenly applied. When the brake pedal is operated, this switch sends a signal to ECM. Then the ECM cancels operation of the lock-up clutch while braking is in progress. Page 24 Control Module HVAC: Service and Repair REMOVAL 1. REMOVE GLOVE COMPARTMENT DOOR 2. REMOVE AMPLIFIER a. Disconnect the connector from the amplifier. b. Remove amplifier cover. c. Remove the amplifier from the cooling unit. INSTALLATION Installation is in the reverse order of removal. Collision / Non-Collision Inspections Airbag Sensor Assembly: Testing and Inspection Collision / Non-Collision Inspections VEHICLE NOT INVOLVED IN COLLISION Check a diagnostic system. VEHICLE INVOLVED IN COLLISION WITH AIRBAG NOT DEPLOYED Check a diagnostic system. * VEHICLE INVOLVED IN COLLISION WITH AIRBAG DEPLOYED Replace the airbag sensor assembly. * * Refer to SRS Warning Light Check, and How to Display and Read Diagnostic Trouble Codes. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Displaying & Reading Trouble Codes Page 3852 Seat Belt Tensioner: Removal and Replacement SEAT BELT PRETENSIONER REMOVAL NOTE: - If the wiring connector of the seat belt pretensioner is disconnected with the ignition switch at ON or ACC, diagnostic trouble codes will be recorded. - Never use seat belt pretensioner from another vehicle. When replacing parts, replace them with new parts. 1. Regular cab: REMOVE FRONT SEAT OUTER BELT a. Remove the bolt and front seat outer belt floor anchor. b. Using a screwdriver, open the cover, then unfasten the bolt and remove the front seat outer belt shoulder anchor. HINT: Tape the screwdriver tip before use. c. Remove the clip and retractor cover. d. Remove the retractor of front seat outer belt. CAUTION: Never disassemble the front seat outer belt. NOTE: When removing the retractor of front seat outer belt, take care not to pull the seat belt pretensioner wire harness. 1 Disconnect the pretensioner connector as shown in the illustration. CAUTION: When removing the seat belt pretensioner, work must be started 90 seconds after the ignition switch is turned to the "LOCK" position and the negative (-) terminal cable is disconnected from the battery. 2. Remove the 2 bolts and retractor of front seat outer belt. 2. Extra cab: REMOVE FRONT SEAT OUTER BELT a. Remove the 4 screws and door scuff plate. b. Using a screwdriver, remove the back panel upper garnish. HINT: Tape the screwdriver tip before use. Specifications Brake Fluid: Specifications Fluid Type FMVSS 116 DOT 3 Brake Fluid O/D Cancel Signal Circuit Overdrive Indicator Lamp: Testing and Inspection O/D Cancel Signal Circuit CIRCUIT DESCRIPTION While driving uphill with cruise control activated, in order to minimize gear shifting and provide smooth cruising O/D may be prohibited temporarily under some conditions. The cruise control ECU sends O/D cut signals to the ECM as necessary and the ECM cancels O/D shifting until these signals are discontinued. WIRING DIAGRAM Page 2619 Step 5 INSPECTION PROCEDURE Locations Page 1809 Vehicle Speed Sensor: Description and Operation CIRCUIT DESCRIPTION The speed sensor for ABS detects the wheel speed and sends the appropriate signals to the ABS ECU. The ECU converts these signals into a pulse signal and outputs it to the combination meter. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. Page 2430 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Testing and Inspection Low Fuel Lamp/Indicator: Testing and Inspection INSPECT FUEL LEVEL WARNING LIGHT a. Disconnect the connector from the sender gauge. b. Connect terminals 1 and 3 on the wire harness side connector. c. Turn the ignition switch ON and check that the warning light lights up. If the warning light does not light up, test the bulb. INSPECT FUEL LEVEL WARNING SWITCH a. Apply battery positive voltage between terminals 1 and 3, and through a 3.4 W test bulb, and check that the bulb lights up. HINT: It will take a short time for bulb to light up. b. Submerge the switch in fuel and check that the bulb goes out. If operation is not as specified, replace the sender gauge. Page 4746 INSPECT DAYTIME RUNNING LIGHT NO.4 RELAY CONTINUITY If continuity is not as specified, replace the relay. Vehicle - Long Term Storage Guidelines Paint: All 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 3584 (2) Check the functioning of the SST. Press the SST activation switch, and check that the LED of the SST activation switch lights up. CAUTION: If the LED lights up when the activation switch is not being pressed, SST malfunction is probable, so definitely do not use the SST. (b) Install the SST. CAUTION: Check that there is no looseness in the steering wheel and steering wheel pad. (1) Remove the steering column lower cover. (2) Disconnect the airbag connector of the spiral cable. (3) Connect the SST connector to the airbag connector of the spiral cable. SST 09082-00700 (4) Move the SST at least 10m (33ft) away from the front of the vehicle. (5) Close all the doors and windows of the vehicle. Page 537 W/ Intermittent w/ INTERMITTENT: If continuity is not as specified, replace the switch. INSPECT INTERMITTENT OPERATION a. Turn the wiper switch to INT position. b. Turn the intermittent time control switch to FAST position. c. Connect the positive (+) lead from the battery to terminal 16 and the negative (-) lead to terminal 2. d. Connect the positive (+) lead from the voltmeter to terminal 7 and the negative (-) lead to terminal 2, check that the meter needle indicates battery positive voltage. If operation is not as specified, replace the wiper and washer switch. Page 3265 Part 2 Of 3 Page 3802 Seat Belt Reminder Buzzer: Description and Operation Current always flows to TERMINAL 12 of the integration relay through the DOME fuse. 1. SEAT BELT WARNING SYSTEM When the ignition SW is turned ON, current flows from the GAUGE fuse to TERMINAL 6 of the integration relay. At the same time, current flows to TERMINAL A 2 of the relay from the GAUGE fuse through the seat belt warning light. This current activates the integration relay and, for approx. 4-8 seconds, the current flowing through the warning light flows from TERMINAL A 2 of the relay to TERMINAL A 7 to GROUND, causing the warning light to light up. At the same time as the warning light lights up, a buckle SW ON signal is input to TERMINAL A 3 of the integration relay, the current flowing from TERMINAL 12 of the integration relay flows to TERMINAL A 7 to GROUND and the seat belt warning buzzer sounds for approx. 4 - 8 seconds. However, if the seat belt is put ON (Buckle SW OFF) during this period (while the buzzer is sounding), a signal input to TERMINAL A 3 of the integration relay stops and the current flowing from TERMINAL 12 of the integration relay to TERMINAL A 7 to GROUND is cut, causing the buzzer to stop. 2. KEY REMINDER SYSTEM With the ignition key inserted in the key cylinder (Unlock warning SW ON), the ignition SW still oft and front LH door open (Door courtesy SW ON), a signal is input to TERMINAL A 10, A 5 of the integration relay, the integration relay operates and current flows from TERMINAL 6 of the relay to TERMINAL A 7 to GROUND and the key reminder buzzer sounds. Page 1272 O2S Application Table O2S Failure Threshold Charts Page 2169 Page 874 3) Select a new shim with a thickness as close as possible to the calculated values. HINT: Shims are available in 17 sizes in increments of 0.050 mm (0.0020 inch), from 2.500 mm (0.0984 inch) to 3.300 mm (0.1299 inch). Page 2118 Page 2920 8. Select the appropriate model and press the NEXT soft key. 9. Select OEM battery type and press the NEXT soft key. 10. Choose the correct battery (model number and CCA) and press the NEXT soft key. 11. Aim the infrared (IR) temperature measurement sensor at the negative (-) battery post and press the NEXT soft key. Page 3000 Junction Box / No. 3 Fuse and Fusible Link Locations Specifications Crankshaft: Specifications Crankshaft Thrust Clearance Standard ............................................................................................... ...................................................................................................... 0.020 - 0.220 mm Maximum ......... .............................................................................................................................................................. ........................................ 0.300 mm Thrust Washer Thickness .......................................................... ................................................................................................................. 2.440 - 2.490 mm Cylinder Block Main Journal Bore Diameter Mark 1 ............................................................................ ........................................................................................................................ 68.010 - 68.016 mm Mark 2 .................................................................................................................................................. .................................................. 68.016 - 68.022 mm Mark 3 ............................................................. ....................................................................................................................................... 68.022 68.028 mm Crankshaft Main Journal Diameter Mark 0 .......................................................................................... .......................................................................................................... 63.996 - 64.000 mm Mark 1 ..... .............................................................................................................................................................. ................................. 63.990 - 63.996 mm Mark 2 .............................................................................. ...................................................................................................................... 63.985 - 63.980 mm Main Journal Diameter STD ................................................................................................................ ........................................................................................ 63.985 - 64.000 mm U/S 0.25 .................... .............................................................................................................................................................. ............... 63.745 - 63.755 mm Crank Pin Diameter STD ..................................................................................................................... ................................................................................... 54.987 - 55.000 mm U/S 0.25 ......................... .............................................................................................................................................................. .......... 54.745 - 54.755 mm Maximum Taper Out-Of-Round ........................................................................................................... .................................................................... 0.02 mm Page 2531 Replacement Requirements Impact Sensor: Service and Repair Replacement Requirements REPLACEMENT REQUIREMENTS In the following cases, replace the front airbag sensor. - If the SRS has been deployed in a collision. (Replace both the left and right airbag sensors.) - If the front airbag sensor has been found to be faulty in troubleshooting. - If the front airbag sensor has been found to be faulty during checking items. - If the front airbag sensor has been dropped. CAUTION: Be sure to follow the correct procedure for removal and installation of the front airbag sensor. Page 2358 Page 261 b. Disconnect the connector from the integration relay and inspect the connectors on the wire harness side. Page 2406 Step 4 INSPECTION PROCEDURE Page 2205 Page 4593 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Page 4511 B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) D. Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. E. Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). How to Replace Terminal HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Special Tool 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. A: For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. Page 2571 ^ If there are 2 alignment pins present the transmissionltransaxle assembly may be installed following the applicable Repair Manual procedure. NOTE: A missing alignment pin may result in failure of the transmissionltransaxle assembly. 2. Install the missing alignment pin(s). ^ Refer to the applicable Repair Manual procedure for location of the cylinder block rear side alignment pins. NOTE In the Repair Manual, the alignment pin is referred to as a "straight pin." Page 1663 Mass Air Flow Meter: Service and Repair REMOVAL 1. REMOVE AIR CLEANER CASE a. Disconnect the air cleaner hose. b. Disconnect the MAF meter connector. c. Remove the 3 bolts and air cleaner case. 2. REMOVE MAF METER a. Remove the 2 screws and MAF meter. b. Remove the O-ring from the MAF meter. INSTALLATION 1. INSTALL MAF METER a. Install the O-ring to the MAF meter. b. Install the MAF meter with the 2 screws. 2. INSTALL AIR CLEANER CASE a. Install the air cleaner case with the 3 bolts. b. Connect the MAF meter connector. c. Connect the air cleaner hose. Page 3256 1. SECURE MANUAL STEERING GEAR IN VISE Using SST and 2 bolts, secure the gear assembly in a vise, as shown in the illustration. SST 09612-00012 Reference: Bolt: 90105-10017 Nut: 90170-10198 HINT: Use 2 of the same type of SST. 2. REMOVE RH AND LH TIE ROD ENDS AND LOCKNUTS Place matchmarks on the tie rod end and rack end. 3. REMOVE RH AND LH CLIPS, RACK BOOTS AND CLAMPS Using a screwdriver, loosen the clamp. NOTICE: ^ Be careful not to damage the boot. ^ Mark the RH and LH boots. 4. REMOVE RH AND LH RACK ENDS AND CLAW WASHERS Page 3778 Procedure and Sample Label Procedure: 1. Owner requests a Seat Belt Extender from dealer. 2. Dealer verifies the need for a Seat Belt Extender and obtains a current copy of this TSB and copies the Worksheet. 3. Dealer measures the customer and completes the Worksheet. Dealer determines the correct part number and places a Critical Order for the part through the TDN Parts Network. 4. Dealer receives Seat Belt Extender and calls the customer in to check fit of the part. 5. If the Seat Belt Extender fit is good, dealership personnel completes the Customer Information Label on the part, explains usage of the part, and gives the customer a copy of the completed Worksheet. 6. Dealer places a copy of the completed Worksheet in the customer's records. Sample Seat Belt Extender Customer Information Label Application Charts Page 1275 CHART 5 CHART 6 Page 2175 Page 2021 4. REINSTALL NEW IGNITION COILS a. Connect a new ignition coil to the spark plug, and attach the ignition coil to the cylinder head cover. b. Install the ignition coil with the bolt. Torque: 7.8 Nm (80 kg.cm, 69 in.lb) 5. RECONNECT HIGH-TENSION CORDS TO IGNITION COILS 6. REINSTALL AIR CLEANER HOSE Page 1781 Vehicle Speed Sensor: Description and Operation CIRCUIT DESCRIPTION The speed sensor for ABS detects the wheel speed and sends the appropriate signals to the ABS ECU. The ECU converts these signals into a pulse signal and outputs it to the combination meter. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. Pressure Specification Fuel Pressure: Specifications Fuel Pressure No Vacuum 38 to 44 psi Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Key to Diagrams Key to Diagrams A: System Title. B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: (1) Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. Diagrams Page 3047 Engine Compartment Instrument Panel Locations Page 3820 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source How to Read Power Source Testing and Inspection Control Module HVAC: Testing and Inspection Air Conditioning Amplifier INSPECT AMPLIFIER CIRCUIT a. Remove the glove compartment door. b. Disconnect the amplifier connector and inspect the connector on wire harness side, as shown in the chart. Test conditions: - Turn ignition switch to ON - Blower speed switch HI If the circuit is not as specified, inspect the circuits connected to other parts. c. Connect the connector to amplifier and inspect wire harness side connector from the back side, as shown in the chart. Test conditions - Running engine at idle speed - Blower speed switch at "HI" position - A/C switch ON - Temperature control lever at "COOL" position - Set on manifold gauge set Page 3828 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. DENSO Made Clutch Switch: Testing and Inspection DENSO Made CIRCUIT DESCRIPTION When the clutch pedal is depressed, the clutch switch sends a signal to the cruise control ECU. When the signal is input to the cruise control ECU during cruise control driving, the cruise control ECU cancels cruise control. Wiring Diagram Page 3260 a. Using SST, press out the oil seal from the pinion bearing adjusting screw. SST 09950-60010 (09951-00250), 09950-70010 (09951-07100) b. Coat a new oil seal lip with molybdenum disulfide lithium base grease. c. Using SST press in the oil seal until it surface is flush with the pinion bearing adjusting screw. SST 09950-60010 (09951-00250), 09950-70010 (09951-07100) NOTICE: Make sure to install the oil seal facing the correct direction. REASSEMBLY NOTICE: When using a vise, do not overtighten it. 1. COAT WITH MOLYBDENUM DISULFIDE LITHIUM BASE GREASE 2. INSTALL STEERING RACK a. Install the rack into the rack housing. NOTICE: Install the rack to the steering pinion housing side of the rack housing as shown. b. Set the rack notched side so that the pinion can be positioned inside. 3. INSTALL STEERING PINION ASSEMBLY a. Line up the cutout portion of the steering rack with the pinion assembly. Page 4599 Page 2474 HINT: PreRunner is the model described below. RZN191L-TRPDKAB, RZN196L-CRPDKAB, VZN195L-CRPDKAB 1. REMOVE FRONT WHEEL Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.) 2. REMOVE SHOCK ABSORBER Testing and Inspection Refrigerant Pressure Sensor / Switch: Testing and Inspection 1. SET ON MANIFOLD GAUGE SET 2. REMOVE GLOVE COMPARTMENT DOOR 3. DISCONNECT CONNECTOR FROM COOLING UNIT 4. SET VEHICLE IN THESE CONDITIONS: a. Running engine at 2,000 rpm b. Blower speed control switch at HI c. Temperature control lever MAX. COOL d. A/C switch ON 5. INSPECT PRESSURE SWITCH OPERATION a. Connect the positive (+) lead from the ohmmeter to terminal 1 and negative (-) lead to terminal 4. b. Check continuity between terminals when refrigerant pressure is changed, as shown in the illustration. If operation is not as specified, replace the pressure switch. Page 2328 D: Indicates related system. Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V). Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, 1H2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green O = Orange P = Pink R = Red SB = Sky Blue V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. A/T - Fluid Requirements Fluid - CVT: Technical Service Bulletins A/T - Fluid Requirements TRANSMISSION & CLUTCH TC001-02 May 24, 2002 Title: AUTOMATIC TRANSMISSION FLUID REQUIREMENTS Models: All '00 - '02 Models & '03 Corolla & Matrix Introduction Please refer to the table for correct application of Dexron(R) III (Dexron(R) II) and Toyota Type T-IV Automatic Transmission Fluids or equivalent. Parts Information Warranty Information Page 1741 CHART 29 Description and Operation Mass Air Flow Meter: Description and Operation Mass Air Flow Meter The mass air flow meter uses a platinum hot wire. The hot wire air flow meter consists of a platinum hot wire, thermistor and a control circuit installed in a plastic housing. The hot wire air flow meter works on the principle that the hot wire and thermistor located in the intake air bypass of the housing detect any changes in the intake air temperature. The hot wire is maintained at the set temperature by controlling the current flow through the hot wire. This current flow is then measured as the output voltage of the mass air flow meter. The circuit is constructed so that the platinum hot wire and thermistor provide a bridge circuit, with the power transistor controlled so that the potential of A and B remains equal to maintain the set temperature. Page 4098 Application Chart Collision / Non-Collision Inspections Clockspring Assembly / Spiral Cable: Testing and Inspection Collision / Non-Collision Inspections 1. VEHICLE NOT INVOLVED IN COLLISION a. Do a diagnostic system check . b. Do a visual check which includes the following item with the steering wheel pad (with airbag) installed in the vehicle. Check cuts, minute cracks or marked discoloration on the steering wheel pad top surface and in the grooved portion. 2. VEHICLE INVOLVED IN COLLISION AND AIRBAG IS NOT DEPLOYED a. Do a diagnostic system check . b. Do a visual check which includes the following items with the steering wheel pad (with airbag) removed from the vehicle. - Check cuts, minute cracks or marked discoloration on the steering wheel pad top surface and in the grooved portion. - Check cuts and cracks in wire harness, and chipping in connectors. - Check the deformation of the horn button contact plate of the steering wheel. HINT: If the horn button contact plate of the steering wheel is deformed, never repair it. Always replace the steering wheel assembly with a new one. - There should be no interference between the steering wheel pad and steering wheel, and the clearance should be uniform all the way around when the new steering wheel pad is installed on the steering wheel. Page 2774 6. INSTALL NEW PADS NOTICE: When replacing worn pads, the anti-squeal shims must be replaced together with the pads. a. Draw out a small amount of brake fluid from the reservoir. b. Press in the pistons with a monkey wrench handle or equivalent. HINT: ^ Tape the monkey wrench handle before use. ^ Always change the pad on one wheel at a time as there is a possibility of the opposite piston flying out. ^ If the piston is difficult to push in, loosen the bleeder plug and push in the piston while letting some brake fluid escape. c. Install the anti-squeal shims to new pads. HINT: Apply disc brake grease to both sides of inner anti-squeal shims. d. Install the 2 pads. NOTICE: Do not allow oil or grease to get on the rubbing face. 7. INSTALL ANTI-RATTLE SPRING AND 2 PINS 8. INSTALL CLIP 9. INSTALL FRONT WHEEL Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.) 10. DEPRESS BRAKE PEDAL SEVERAL TIMES 11. CHECK THAT FLUID LEVEL IS AT MAX LINE Page 3031 Interior Fuse Box Interior Panel Fuse Details Page 2669 WIRING DIAGRAM Page 974 7. INSTALL TIMING BELT NOTICE: The engine should be cold. a) Remove any oil or water on the pulleys, and keep them clean. NOTICE: Only wipe the pulleys; do not use any cleansing agent. b) Face the front mark on the timing belt forward. c) Install the timing belt to the LH camshaft timing pulley. Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley. d) Install the timing belt to the No.2 idler pulley. e) Install the timing belt to the RH camshaft timing pulley. Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley. f) Install the timing belt to the water pump pulley. g) Install the timing belt to the crankshaft timing pulley. Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley. h) Install the timing belt to the No.1 idler pulley. 8. SET TIMING BELT TENSIONER a) Using a press, slowly press in the push rod using 981 - 9,807 N (100 - 1,000 kgf, 200 - 2,205 lbs.) of pressure. b) Align the holes of the push rod and housing, pass a 1.27 mm hexagon wrench through the holes to keep the setting position of the push rod. c) Release the press. d) Install the dust boot to the tensioner. Page 443 Knock Sensor: Description and Operation Knock Sensor Each knock sensor is fitted to the right bank and left bank of the cylinder block to detect engine knocking. This sensor contains a piezoelectric element which generates a voltage when it becomes deformed, which occurs when the cylinder block vibrates due to knocking. If engine knocking occurs, ignition timing is retarded to suppress it. Page 4430 Page 1549 COMPONENTS INSPECTION 1. DRAIN ENGINE COOLANT 2. REMOVE AIR CLEANER HOSE 3. REMOVE NO.2 TIMING BELT COVER 4. REMOVE INTAKE AIR CONNECTOR ASSEMBLY 5. REMOVE FUEL PRESSURE REGULATOR 6. REMOVE INTAKE MANIFOLD ASSEMBLY Page 4184 Page 3809 Page 331 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 1594 Page 2675 Step 1 Testing and Inspection Oil Pressure Warning Lamp/Indicator: Testing and Inspection INSPECT LOW OIL PRESSURE WARNING LIGHT a. Disconnect the connector from the warning switch and ground terminal on the wire harness side connector. b. Turn the ignition switch ON and check that the warning light lights up. If the warning light does not light up, test the bulb. Capacity Specifications Power Steering Fluid: Capacity Specifications Power Steering Fluid: Total ..................................................................................................................................................... .......................................... 0.8 liters (0.9 US Qts.) Page 4578 Seat Belt Reminder Lamp: Connector Locations Page 1513 Part 1 Of 2 (Except California Spec.) Page 4034 Applicable Warranty*: This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. Repair Procedure 1. Remove Wiper Arms, Plastic Cowl Cover and Wiper Motor (store wiper links up against bottom of windshield). NOTE: Mark wiper arm linkage attached to wiper motor and wiper motor splined shaft prior to removing the 12 mm retaining nut. 2. Spray Acrysol(TM) under entire lip of 1/2" pinch weld and wipe dry with a clean paper towel. FOLLOW DIRECTIONS ON SIDE OF CAN CAREFULLY. Dry open seam with compressed air prior to applying sealer. NOTE: Do not use a red shop towel to wipe surfaces because shop towels are contaminated with silicone. 3. Apply a small bead of Kent High Tech(TM) Clear Seam Sealer to underside front edge of the pinch weld from fender to fender as shown. 4. Apply Kent High Tech(TM) Clear Seam Sealer on all spot welds located on the floor of cowl panel. 5. Apply Kent High Tech(TM) Clear Seam Sealer around outside base of hood safety stops, and seal outside corner, under the "L" bracket as shown. Pressure Specification Fuel Pressure: Specifications Fuel Pressure No Vacuum 38 to 44 psi Page 3001 Relay Box / No. 2 Ground Locations Page 4097 Locations Vehicle Speed Sensor: Locations CIRCUIT DESCRIPTION The speed sensor for ABS detects the wheel speed and sends the appropriate signals to the ABS ECU. The ECU converts these signals into a pulse signal and outputs it to the combination meter. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. Page 738 5. IF NECESSARY, CHECK VALVE BODY a. Assemble the valve body in the uppermost position. HINT: When the brakes are applied, the position will move down about 0.8 mm (0.03 inch). Even at this time, the piston should not make contact with or move the load sensing spring. b. In this position, check the rear brake pressure. If the measured value is not within the standard, replace the valve body. Page 2884 Page 1726 CHART 20 Page 1478 Page 1635 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Page 4664 Page 3429 Wheel Bearing: Service and Repair Disassembly and Reassembly DISASSEMBLY Page 330 Applicable Vehicles Page 2063 Spark Plug: Testing and Inspection INSPECT SPARK PLUGS a. Disconnect the 3 high-tension cords. b. Remove the 3 ignition coils. c. Using a 16 mm plug wrench, remove the 6 spark plugs. d. Clean the spark plugs. If the electrode has traces of wet carbon, allow it to dry and then clean with a spark plug cleaner. Air pressure: Below 588 kPa (6 kg/Sq.cm, 85 psi) Duration: 20 seconds or less HINT: If there are traces of oil, remove it with gasoline before using the spark plug cleaner. e. Visually check the spark plug for thread damage and insulator damage. If abnormal, replace the spark plug. Recommended spark plug: DENSO made K16TR11 NGK made BKR5EKB-11 Page 2762 ^ Type "A": Has a projection on the upper and lower side of the brake pad. (See illustration.) ^ Type "B": Has a flat upper and lower edge on the brake pad backing plate. Type "A" Brake Pad A. Remove the anti-squeal spring, clip and pad guide pin. B. Remove the brake pads with the anti-squeal shims. C. Clean any dust from the brake pads. D. Apply a small amount of the disc brake caliper grease (1-2 mm thick) to the areas indicated in the illustration. NOTE: Do NOT apply grease to the friction surfaces of the brake pads or the disc rotor. E. Install the brake pads with the anti-squeal shims. NOTE: Clean excess grease from the brake pads and caliper. F. Install the pad guide pin, clip and anti-squeal spring. G. Install the wheel assembly. Page 4778 Terminal Retainer Push the terminal retainer down to the temporary lock position. c. Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR a. Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2510 ^ 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. Wheels - Tire Inflation & Wheel Lug Torque Chart Wheel Fastener: Technical Service Bulletins Wheels - Tire Inflation & Wheel Lug Torque Chart October 1, 1999 TIRE INFLATION & WHEEL LUG TORQUE REFERENCE CHART PG031-99 Introduction Proper tire inflation is important to maximize tire life and vehicle ride comfort. 2000 MY Toyota vehicles are available with a wide variety of wheel sizes and tire profiles. Prior to customer vehicle delivery, refer to the following table to identify the appropriate tire pressure setting. Adjust tire pressures accordingly. Applicable Vehicles All 2000 Models Tire Pressure Settings * Recommended tire inflation pressure under high load capacity. Locations Fuse Block: Locations Relay Box / No. 2 Locations Page 61 Page 1257 Engine Bank Identification Restraints - Seat Belt Tongue Plate Stopper Replacement Seat Belt: All Technical Service Bulletins Restraints - Seat Belt Tongue Plate Stopper Replacement T-SB-0258-08 September 2, 2008 Seat Belt Tongue Plate Stopper Replacement Service Category Vehicle Interior Section Seat Belt Market USA Applicability TSB SUPERSESSION NOTICE The information contained in this TSB supersedes TSB No. BO017-07. ^ Applicability has been updated to include 2008 model year vehicles. TSB No. BO017-07 is Obsolete and any printed versions should be discarded. Be sure to review the entire content of this service bulletin before proceeding. Introduction For situations where only the seat belt stopper is broken a new service part has been developed to eliminate the need to replace the entire seat belt assembly. Follow the installation procedure below to utilize this new part. Page 4498 Key Reminder Switch: Fuse and Fusible Link Locations Relay Box / No. 2 Page 1866 Mass Air Flow Meter: Service and Repair REMOVAL 1. REMOVE AIR CLEANER CASE a. Disconnect the air cleaner hose. b. Disconnect the MAF meter connector. c. Remove the 3 bolts and air cleaner case. 2. REMOVE MAF METER a. Remove the 2 screws and MAF meter. b. Remove the O-ring from the MAF meter. INSTALLATION 1. INSTALL MAF METER a. Install the O-ring to the MAF meter. b. Install the MAF meter with the 2 screws. 2. INSTALL AIR CLEANER CASE a. Install the air cleaner case with the 3 bolts. b. Connect the MAF meter connector. c. Connect the air cleaner hose. Page 3903 Page 1148 Applicable Warranty*: This repair is covered under the Federal Emissions Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in service date. *Warranty application is limited to correction of a problem based upon a customer's specific complaint. Page 3246 Part 2 Of 2 MANUAL STEERING GEAR REPLACEMENT AND OVERHAUL W/ RELATED COMPONENTS Page 2054 Knock Sensor: Testing and Inspection Page 2296 Page 2099 Page 2833 1. ASSEMBLE LOAD SENSING SPRING a. Install the load sensing valve boot and load sensing spring boot. b. Install the 2 rubber plates, 2 collars and 4 bushings. HINT: ^ Apply lithium soap-base glycol grease to all rubbing areas. ^ Do not mistake the valve side for the shackle side of the load sensing spring. 2. INSTALL SHACKLE NO. 1 AND NO. 2 a. Install the lock nut and shackle No. 1 to the shackle No. 2. b. Torque the nut. Torque: 24 Nm (250 kgf-cm, 18 ft. lbs.) 3. INSTALL LOAD SENSING SPRING TO SHACKLE NO. 1 a. Install the load sensing spring and 2 plate washers to the shackle No. 1. b. Install the bolt and nut. Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.) 4. INSTALL LOAD SENSING SPRING TO VALVE BODY Install the load sensing spring to the load sensing valve with the clip. 5. INSTALL VALVE BRACKET a. 2WD: Install the set plate to the valve assembly through the valve bracket and temporarily tighten the 2 valve body mounting nuts with flexible hose bracket. b. 4WD and Pre runner: Install the set plate to the valve assembly through the valve bracket and temporarily tighten the 2 valve body mounting nuts. c. Install the bolt and nut with the 2 plate washers. Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.) Locations Page 4159 2. Scrub the bumper covers with the soap and water solution, making sure all difficult-to-reach areas are thoroughly cleaned. 3. Rinse the entire bumper cover with clean deionized water, making sure all difficult-to-reach areas are thoroughly rinsed. 4. Dry the surface with a clean towel before water dries on the surface. Clean, dry compressed air from an oil-less compressor may be substituted for drying with a towel. 5. Degrease the surface with a wax, grease, and silicone remover. Note: Lacquer thinner or brake cleaner will NOT remove silicone. You MUST use a wax, grease, and silicone remover. Carefully follow application instructions on the container label. Fish eyes or other paint irregularities may result from not following instructions. 6. Apply a generous amount of sanding paste with a gray 3M ScotchBrite pad. Only a gray pad should be used during the sanding process. Sand the entire bumper cover surface. Be sure all difficult-to-reach areas are thoroughly sanded. 7. Clean the entire bumper cover with car wash soap and water. Be sure all difficult-to-reach areas are thoroughly cleaned. 8. Rinse the entire bumper with clean deionized water. Be sure all difficult-to-reach areas are thoroughly rinsed. 9. Degrease the surface with an anti-static plastic parts cleaner and a white body shop towel or paper towel. Note: Never use a red shop towel to wipe the surface (contains silicone). 10. Assure the bumper is firmly held in place to a steady fixture. 11. Apply a plastic parts adhesion promoter to the surface, according to the manufacturer's recommendations. 12. Apply plastic parts primer to the surface, according to the paint manufacturer's recommendations. 13. Since bumpers are made of flexible plastic urethane material, use a two-part urethane finish paint system with plasticizer (flex agent) for all bumper and cladding repairs. Apply the appropriate top coat to the surface, according to the paint manufacturer's recommendations. 14. If heat is applied to cure the paint, assure the surface temperature does not exceed 80°C (176°F.) For additional information concerning the refinish process for plastic bumpers/cladding, please contact your respective refinish paint manufacturer's local representative. Page 3592 VEHICLE INVOLVED IN COLLISION WITH AIRBAG DEPLOYED Replace the airbag sensor assembly. * * Refer to SRS Warning Light Check, and How to Display and Read Diagnostic Trouble Codes. REPLACEMENT REQUIREMENTS In the following cases, replace the airbag sensor assembly. - If the SRS has been deployed in a collision. - If the airbag sensor assembly has been found to be faulty in troubleshooting. - If the airbag sensor assembly has been dropped. CAUTION: For removal and installation of the airbag sensor assembly. Be sure to follow the correct procedure. AIRBAG SENSOR FRONT INSPECTION 1. VEHICLES NOT INVOLVED IN COLLISION Do a diagnostic system check. * 2. VEHICLES INVOLVED IN COLLISION a. Do a diagnostic system check. * b. If the front fender of the car or its periphery is damaged, do a visual check for damage to the front airbag sensor, which includes the following items even if the airbag was not deployed: Check the bracket deformation. - Check the paint peeling off the bracket. - Check the cracks, dents or chips in the case. - Check the cracks, dents, chipping and scratches in the connector. - Check the peeling off of the label or damage to the serial number. * Refer to SRS Warning Light Check, and How to Display and Read Diagnostic Trouble Codes. REPLACEMENT REQUIREMENTS In the following cases, replace the front airbag sensor. - If the SRS has been deployed in a collision. (Replace both the left and right airbag sensors.) - If the front airbag sensor has been found to be faulty in troubleshooting. - If the front airbag sensor has been found to be faulty during checking items. - If the front airbag sensor has been dropped. CAUTION: Be sure to follow the correct procedure for removal and installation of the front airbag sensor. Page 3856 i. Install the back panel trim with the3 bolts. Torque: 9.8 N.m (100 kgf.cm, 7 ft.lbf) j. Install the back panel upper garnish. k. Install the door scuff plate with the 4 screws. 2. Regular cab: INSTALL FRONT SEAT OUTER BELT a. Install the retractor of front seat outer belt. 1. Install the retractor of front seat outer belt with the 2 bolts. Torque: Upper bolt: 4.9 N.m (50 kgf.cm, 43 in.lbf) Lower bolt: 43 N.m (440 kgf.cm, 32 ft.lbf) 2. Connect the pretensioner connector as shown in the illustration. b. Install the retractor cover with the clip. c. Install the front seat outer belt shoulder anchor with the bolt. Torque: 43 N.m (440 kgf.cm, 32 ft.lbf) d. Install the front seat outer belt floor anchor with the bolt. Torque: 43 N.m (440 kgf.cm, 32 ft.lbf) Page 2087 Shift Indicator: Connector Locations Electrical Specifications Oxygen Sensor: Electrical Specifications Air/Fuel Ratio Sensor Resistance: at 20°C (68°F): 0.8 - 1.4 ohms at 800°C (1,472°F): 1.8 - 3.2 ohms Heated Oxygen Sensor Resistance Between Terminals +B and HT: at 20°C (68°F) 11 - 16 Ohms at 800°C (1,472°F) 23 - 32 Ohms Description and Operation Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Sensor A thermistor that is built into the engine coolant temperature sensor changes the resistance value according to the engine coolant temperature. The lower the engine coolant temperature sensor, the greater the thermistor resistance value, and the higher the engine coolant temperature sensor temperature, the lower the thermistor resistance value. The engine coolant temperature sensor is connected to the ECM. The 5 V power source voltage in the ECM is applied to the engine coolant temperature sensor from the terminal THA via a resistor R. That is, the resistor R and the engine coolant temperature sensor are connected in series. When the resistance value of the engine coolant temperature sensor changes in accordance with changes in the engine coolant temperature, the potential at terminal THA also changes. Based on this signal, the ECM increases the fuel injection volume to improve driveability during cold engine operation. Page 3782 wear for proper measurement and selection of length. Additional ordering information is available at your Toyota dealer. CAUTION: When using the Seat Belt Extender, observe the following. Failure to follow these instructions could result in reduced effectiveness of the seat belt restraint system in case of vehicle accident, increasing the chance of personal injury. ^ Never use the Seat Belt Extender if you can COMFORTABLY fasten the seat belt without it. ^ The Seat Belt Extender must never be used with any child safety seats. ^ Remember that the extender provided for you may not be safe when used on a different vehicle, or for another person or at a different seating position than the one originally intended for. To connect the extender to the seat belt, insert the tab into the seat belt buckle so that the "PRESS" signs on the buckle-release buttons of the extender and the seat belt are both facing outward as shown. You will hear a click when the tab locks into the buckle. When releasing the seat belt, press on the buckle-release button on the extender, not on the seat belt. This helps prevent damage to the vehicle interior and extender itself. When not in use, remove the extender and store in the vehicle for future use. Seat Belt Extender Worksheet Page 3638 HINT: When scrapping vehicle equipped with an SRS or disposing of a steering wheel pad (with airbag), always first deploy the airbag in accordance with the procedure described. If any abnormality occurs with the airbag deployment, contact the SERVICE DEPT. of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION: - Never dispose of a steering wheel pad which has an undeployed airbag. - The airbag produces a sizeable exploding sound when it deploys, so perform the operation out-of-doors and where it will not create a nuisance to nearby residents. - When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool). Perform the operation in a place away from electrical noise. SST 09082-00700 - When deploying an airbag, perform the operation at least 10 m (33 ft) away from the steering wheel pad. - The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment. - Use gloves and safety glasses when handling a steering wheel pad with the deployed airbag. - Always wash your hands with water after completing the operation. - Do not apply water, etc. to a steering wheel pad with the deployed airbag. NOTE: - When disposing of the steering wheel pad (with airbag) only, never use the customers vehicle to deploy the airbag. - Be sure to follow the procedure given below when deploying the airbag. HINT: Have a battery ready as the power source to deploy the airbag. a. Remove the steering wheel pad. CAUTION: When removing the steering wheel pad, work must be started 90 seconds after the ignition switch is turned to the "LOCK" position and the negative (-) terminal cable is disconnected from the battery. - When storing the steering wheel pad, keep the upper surface of the pad facing upward. b. Fix the steering wheel pad to the disc wheel with tire. 1. Install the 2 bolts with washers in the 2 bolt holes in the steering wheel pad. Bolt: L: 35. mm (1.387 in.) Page 3312 Inner diameter: 360 mm (14.17 in.) CAUTION: Do not use tires with disc wheels. NOTE: The tires may be marked by the airbag deployment, so use the redundant tires. f. Deploy the airbag. 1. Connect the SST red clip to the battery positive (+) terminal and the black clip to the battery negative (-) terminal. 2. Check that no one is within 10 m (33 ft) area around the disc wheel which the steering wheel pad is tied to. 3. Press the SST activation switch and deploy the air- bag. HINT: The airbag deploys simultaneously as the LED of the SST activation switch lights up. g. Dispose the steering wheel pad (with airbag). CAUTION: The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment. - Use gloves and safety glasses when handling a steering wheel pad with the deployed airbag. - Always wash your hands with water after completing the operation. - Do not apply water, etc. to a steering wheel pad with the deployed airbag. 1. Remove the steering wheel pad from the disc wheel. 2. Place the steering wheel pad in a vinyl bag, tie the end tightly and dispose of it in the same way as other general parts disposal. Disposing of Steering Wheel Pad With Airbag Deployed DISPOSAL HINT: When scrapping vehicle equipped with an SRS or disposing of a steering wheel pad (with airbag), always first deploy the air-bag in accordance with the procedure described below. If any abnormality occurs with the airbag deployment, contact the SERVICE DEPT of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION: - Never dispose of a steering wheel pad which has an undeployed airbag. - The airbag produces a sizeable exploding sound when it deploys, so perform the operation out-of-doors and where it will not create a nuisance to nearby residents. Connector Locations Key Reminder Switch: Connector Locations Page 1528 Idle Air Control Valve: Description and Operation Intake Air Control Valve The rotary solenoid type IAC valve is located on the throttle body and intake air bypassing the throttle valve is directed to the IAC valve through a passage. In this way the intake air volume bypassing the throttle valve is regulated, controlling the engine speed. The ECM operates only the IAC valve to perform idle-up and provide feedback for the target idling speed. Page 1638 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. A/T - Fluid Requirements Fluid - A/T: Technical Service Bulletins A/T - Fluid Requirements TRANSMISSION & CLUTCH TC001-02 May 24, 2002 Title: AUTOMATIC TRANSMISSION FLUID REQUIREMENTS Models: All '00 - '02 Models & '03 Corolla & Matrix Introduction Please refer to the table for correct application of Dexron(R) III (Dexron(R) II) and Toyota Type T-IV Automatic Transmission Fluids or equivalent. Parts Information Warranty Information Page 2504 d. Using SST, install new bearings on the spider. SST 09332-25010 e. Using SST, adjust both bearings so that the snap ring grooves are at maximum and equal widths. 7. INSTALL SNAP RING a. Install 2 new snap rings of equal thickness which will allow 0 - 0.05 mm (0 - 0.0020 inch) axial play. HINT: Do not reuse the snap rings. TMC made: DANA made: b. Using a hammer, tap the yoke until there is no clearance between the bearing outer race and snap ring. Description and Operation Throttle Position Sensor: Description and Operation Throttle Position Sensor The throttle position sensor is mounted in the throttle body and detects the throttle valve opening angle. When the throttle valve is fully closed, a voltage of approximately 0.3 - 1 .0 V is applied to terminal VTA of the ECM. The voltage applied to terminals VTA of the ECM increases in proportion to the opening angle of the throttle valve and becomes approximately 2.7 - 5.2 V when the throttle valve is fully opened. The ECM ledges the vehicle driving conditions from these signals input from terminals VTA and uses them as one of the conditions to decide the air- fuel ratio correction, power increase correction and fuel-cut control etc. Page 1507 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 4592 Seat Belt Reminder Lamp: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Page 2329 Splice Point J: Indicates a wiring Splice Point (Codes are "E"for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I 5 is indicated by the shaded section. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. N: Page No. How to Read Ground Points How to Read Ground Points O/D Cancel Signal Circuit Overdrive Indicator Lamp: Testing and Inspection O/D Cancel Signal Circuit CIRCUIT DESCRIPTION While driving uphill with cruise control activated, in order to minimize gear shifting and provide smooth cruising O/D may be prohibited temporarily under some conditions. The cruise control ECU sends O/D cut signals to the ECM as necessary and the ECM cancels O/D shifting until these signals are discontinued. WIRING DIAGRAM Page 307 Crankshaft Position Sensor: Testing and Inspection INSPECT CRANKSHAFT POSITION SENSOR a. Remove the sensor connector. b. Using an ohmmeter, measure the resistance between the terminals. Resistance: Cold 1,630 - 2,740 ohms Hot 2,065 - 3,225 ohms c. Reinstall the sensor. Page 166 Wheel Speed Sensor: Service and Repair Speed Sensor, Rear REMOVAL REMOVE SPEED SENSOR a. Disconnect the speed sensor connector, and pull out the sensor wire harness with grommet. b. Remove the 5 resin clips, 2 clamp set bolts and 2 nuts holding the sensor wire harness from the side rail, fuel tank and axle housing. Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.) c. Remove the 2 mounting bolts and speed sensor. Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.) NOTICE: At the time of installation, please refer to the following items. ^ There are no objects on the sensor or the part of the axle end to which the sensor is to be installed. ^ The sensor is installed flat against the axle end when you tighten the bolt. ^ When installing the resin clips, use new ones. INSTALLATION Installation is in the reverse order of removal. NOTICE: After installation, check the speed sensor signal. Page 2112 Shift Indicator: Pinout Values and Diagnostic Parameters E 2 ELECTRONICALLY CONTROLLED TRANSMISSION SOLENOID 1, 2, 3-GROUND : Approx. 13 Ohm P 1 PARK/NEUTRAL POSITION SW 4-GROUND : Approx. 12 volts with ignition SW ON (Floor A/T), ACC (Column A/T) position O 4-A, S 4-B O/D MAIN SW A-1-A-3,B-5-B-10 : Open with O/D main SW at ON position Closed with O/D main SW at OFF position S 5-A,B STOP LIGHT SW A-1-A-2,B-1-B-2 : Closed with brake pedal depressed E 5-A, E 6-B, E 7-C, E 8-D ENGINE CONTROL MODULE S1-E1 : 9 - 14 volts S2,SL-E1 : 0 - 1.5 volts STP-E1 : 7.5 - 14 volts with brake pedal depressed : 0 - 1.5 volts with brake pedal released THW-E2 : 0.2 - 1.0 volts with coolant temp. 80 °C (176 °F) OIL-E2 : 4 - 5 volts with fluid temp. 20 °C (68 °F) VTA-E2 : 0.3 - 0.6 volts with throttle valve fully closed : 3.2 - 4.9 volts with throttle valve fully open VC-E2 : 4.5 - 5.5 volts OD1-E1 : 4.5 - 5.5 volts ODMS-E1 : 9 - 14 volts O/D main SW turned ON : 0 volts O/D main SW turned OFF SP1-E1 : Pulse generation with vehicle moving 2-E1 : 10 - 14 volts with shift lever at 2 position : 0-2 volts with shift lever at except 2 position L-E1 : 10 - 14 volts with shift lever at L position : 0 - 2 volts with shift lever at except L position OILW-E1 : 0.1 - 4.9 volts +B-E1 : 9 - 14 volts BATT-E1 : 9 - 14 volts Page 1634 Engine Control Module: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Page 3788 D: Indicates related system. Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V). Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, 1H2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green O = Orange P = Pink R = Red SB = Sky Blue V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Page 1604 CHART 30 Page 706 Fluid - Differential: Fluid Type Specifications Differential Fluid Grade ................................................................................................................................................... .................................................... GL-5 or equivalent Above -18° C (0° F) ......................................... .......................................................................................................................................................... SAE 90 Below -18° C (0° F) ................................................................................................................ ............................................................. SAE 85W-90 or 80W Page 157 Repair Procedure 1. Disconnect the cable from the negative (-) battery terminal for MORE THAN two (2) seconds. 2. Reconnect the cable to the negative (-) battery terminal. 3. Perform the applicable zero point calibration of the yaw rate sensor and/or the steering angle sensor. HINT Refer to the applicable TSB or Repair Manual for the zero point calibration procedure. 4. Re-initialize all applicable systems available on the vehicle (power window sunroof power lift door etc.). Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Key to Diagrams Key to Diagrams A: System Title. B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: (1) Indicates Relay Block No.1 C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. Page 2974 REMOVE STARTER a. Disconnect the starter connector. b. Remove the nut, and disconnect the starter wire. Torque: 8.8 Nm (90 kg.cm, 70 in.lb) c. Remove the 2 bolts and starter. Torque: 39 Nm (400 kg.cm, 29 ft.lb) INSTALLATION Installation is in the reverse order of removal. Page 574 If the CO/HC concentration does not comply with regulations, troubleshoot in the order given. 1) Check the A/F sensor or heated oxygen sensor operation. 2) See the table for possible causes, and then inspect and correct the applicable causes if necessary. Page 1131 Torque: 20 Nm (200 kgf-cm, 14 ft. lbs.) 2. CONNECT NO.2 OIL COOLER HOSE 3. INSTALL THERMOSTAT AND WATER INLET 4. INSTALL TIMING BELT Page 353 CHART 16 CHART 17 Page 2532 Locations Relay Box: Locations Relay Box / No. 2 Page 1096 7. Pump the radiator cap tester several times, and check the maximum pressure. Pumping speed: 1 pump/second HINT: Stop pumping when the valve opens and read the gauge. The gauge must be within the standard values listed below when the pressure valve opens. The cap is considered OK when the pressure holds steady or falls very slowly, but holds within the standard values listed below for one minute. Specification: If the maximum pressure is less than the minimum standard value, replace the radiator cap sub-assembly. Type: Plastic Cap, 108 kPa 1. Remove coolant and any foreign material on 0-ring "A." 2. Check that 0-ring "A" is not deformed, cracked, or swollen. 3. Apply engine coolant to 0-ring "A" and rubber point "B" before using the radiator cap tester. ^ Radiator Cap Tester: Snap-On/Sun P/N SVTS262A (or equivalent) 4. Before installing the radiator cap tester, use the applicable radiator cap adaptor provided in the following SST kits in conjunction with the radiator cap tester: ^ SST P/N 09230-00030-01 (09231-10080-01) or 09230-00020-01 (09231-10060-01) or 09230-00050-01(09231-10110-01 Recall 01E041000: Trailer Wire Harness Converter Defect Trailer Connector: All Technical Service Bulletins Recall 01E041000: Trailer Wire Harness Converter Defect Equipment Description: Trailer towing wire harness converters which integrates the vehicle's tail lights, brake lights, and turn signal lights with those equipped on the trailer. Manufactured between May 1, 1999, and August 31, 2000, these converters were sold for installation on 1999-2000 Toyota Tundra and Tacoma vehicles. Affected part numbers are: PT207-34000, PT207-34002, PT207-04981, and PT214-04985. In the Tundra vehicles, the circuitry utilized in the converter was inadequate to properly manage vehicle and/or trailer-side voltage spikes. If the converter is exposed to a voltage spike, it may cause an electrical short or open circuit within the converter. Tacoma vehicles, due to deficient waterproofing and improper installation location of the converter, which is mounted in the lower portion of the tailgate cavity of the vehicle, an electrical short circuit will occur if water enters the converter housing. An electrical short or open circuit can cause a fault in the converter and a non-operational condition of the trailer lights. A vehicle crash can occur, possibly resulting in personal injury or death, if the vehicle is driven without operational trailer lights. Dealers will notify the customers and install a redesigned trailer towing wire harness converter free of charge. Owner notification is expect to begin August 2001. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Toyota at 1-800-331-4331. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Page 2363 Transmission Position Switch/Sensor: Service and Repair ON-VEHICLE REPAIR 1. DISCONNECT 2 OIL COOLER PIPES 2. DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 3. REMOVE PARK/NEUTRAL POSITION SWITCH a. Pry off the lock washer and remove the nut. b. Remove the bolt and pull out the park/neutral position switch. 4. INSTALL AND ADJUST PARK/NEUTRAL POSITION SWITCH Torque: Nut: 6.9 Nm (70 kgf-cm, 61 inch lbs.) Bolt: 13 Nm (130 kgf-cm, 9 ft. lbs.) 5. CONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 6. CONNECT 2 OIL COOLER PIPES Page 351 CHART 14 Page 90 Part 2 Of 2 (Except California Spec.) *1: A/T *2: M/T Page 1196 Engine Control Module: Pinout Values and Diagnostic Parameters Connectors (California Spec.) Part 1 Of 2 (California Spec.) Page 1668 Camshaft Position Sensor: Service and Repair COMPONENTS REPLACEMENT 1. REMOVE NO.2 TIMING BELT COVER 2. REMOVE CAMSHAFT POSITION SENSOR a. Disconnect the sensor connector. b. Remove the bolt and sensor. 3. REINSTALL NEW CAMSHAFT POSITION SENSOR a. Install a new sensor with the bolt. Torque: 7.8 Nm (80 kg.cm, 69 in.lb) b. Connect the sensor connector. Page 3080 Splice Point J: Indicates a wiring Splice Point (Codes are "E"for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of splice Point I 5 is indicated by the shaded section. K: Indicates a shielded cable. L: Indicates the pin number of the connector. The numbering system is different for female and male connectors. M: Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. N: Page No. How to Read Ground Points How to Read Ground Points Page 693 Check that the engine can be started with the shift lever only in the N or P position, but not in other positions. If it is not as stated above, carry out the following adjustment procedure. 1. Loosen the park/neutral position switch bolt and set the shift lever to the N position. 2. Align the groove and neutral basic line. 1. Hold the switch in position and tighten the bolt. Torque: 13 Nm (130 kg.cm, 10 ft.lb) For continuity inspection of the park/neutral position switch. i. Check the idle speed. Connect OBD II scan tool or TOYOTA hand-held tester to the DLC 3 and inspect the idle speed. idle speed (in N position and air conditioner OFF): 3RZ-FE: 700 ± 50 rpm 5VZ-FE: 700 ± 50 rpm Testing and Inspection Power Door Lock Switch: Testing and Inspection INSPECT DRIVER'S DOOR LOCK CONTROL SWITCH CONTINUITY If continuity is not as specified, replace the switch. INSPECT PASSENGER'S DOOR LOCK CONTROL SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 1332 Specifications Accumulator: Specifications Accumulator Spring Tacoma, 4 Runner: Page 341 Page 3349 4. DISCONNECT SHOCK ABSORBER a. Remove the shock absorber lower nut and washer. Torque: 135 Nm (1,400 kgf-cm, 101 ft. lbs.) HINT: At the time of installation, after stabilizing the suspension, torque the nut. b. With lowering the lower suspension arm, remove the bolt and disconnect the shock absorber. 5. DISCONNECT LOWER BALL JOINT a. Support the upper suspension arm and steering knuckle securely. b. Remove the cotter pin and nut from the lower ball joint. Torque: 140 Nm (1,450 kgf-cm, 103 ft. lbs.) HINT: At the time of installation, if the holes for the cotter pin are not aligned, tighten the nut further up to 60°. c. Using SST, disconnect the lower ball joint from the lower suspension arm. SST 09628-62011 NOTICE: Be careful not to damage the lower ball joint. HINT: At the time of installation, face the cotter pin hole of the lower ball joint forward. 6. REMOVE LOWER SUSPENSION ARM a. Place matchmarks on the front and rear adjusting cams. b. Remove the nuts, adjusting cams, bolt and lower suspension arm. Torque: 130 Nm (1,325 kgf-cm, 96 ft. lbs.) Page 3017 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Page 3141 2. INSTALL CAMBER-CASTER-KING PIN GAUGE OR POSITION VEHICLE ON WHEEL ALIGNMENT TESTER Follow the specific instructions of the equipment manufacturer. 3. INSPECT CAMBER, CASTER AND STEERING AXIS INCLINATION Camber, caster and steering axis inclination: RZN161L Model RZN1171L Model RZN191L model RZN196L model VZN170L model Page 3018 Waterproof Type Connector B: For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Waterproof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 794 c. Support the brake caliper securely. 7. DISCONNECT LOWER BALL JOINT Remove the 4 bolts and disconnect the lower ball joint. Torque: 80 Nm (820 kgf-cm, 59 ft. lbs.) 8. REMOVE STEERING KNUCKLE a. Remove the cotter pin and loosen the nut. Torque: 105 Nm (1,100 kgf-cm, 80 ft. lbs.) HINT: At the time of installation, if the holes for the cotter pin are not aligned, tighten the nut further up to 60°. b. Using SST, disconnect the steering knuckle. SST 09950-40011 (09951-04010, 09952-04010, 09553-04020, 09554-04010, 09955-04031, 09958-04011) c. Remove the nut and steering knuckle. NOTICE: 4WD: Be careful not to damage the oil seal and drive shaft boot. HINT: 4WD: When it is difficult to disconnect the drive shaft, tap the tip of the drive shaft with a plastic hammer. INSTALLATION Installation is in the reverse order of removal. HINT: After installation, bleed the brake system , check the front wheel alignment and ABS speed sensor signal. Testing and Inspection Oil Pressure Sender: Testing and Inspection INSPECT LOW OIL PRESSURE SWITCH a. Disconnect the connector from the switch. b. Check that continuity exists between terminal and ground with the engine stopped. c. Check that no continuity exists between terminal and ground with the engine running. HINT: Oil pressure should be over 49 kPa (0.5 kg/sq.cm, 7.1 psi). If operation is not as specified, replace the switch. Page 1732 Page 1796 D: Indicates related system. Wiring Harness Connector E: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows (V). Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, 1H2), this indicates the same type of wiring harness and wiring harness connector. F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Wiring Color I: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green O = Orange P = Pink R = Red SB = Sky Blue V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Page 4354 Steps 1 - 2 Page 4515 b. Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR Disconnection of Male and Female Connectors Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. Page 3815 Seat Belt Reminder Lamp: Splice Locations Page 3277 5. INSPECT BEARING a. Check the bearing rotation condition and check for abnormal noise. If the bearing is worn or damaged, replace the control valve assembly. b. Coat the bearing with molybdenum disulfide lithium base grease. 6. INSPECT BUSHING a. Check the inside of the bushing of the cylinder end stopper for cracks. If faulty, replace the bushing. b. Coat the inside of the bushing with molybdenum disulfide lithium base grease. 7. IF NECESSARY, REPLACE BUSHING a. Using a screwdriver, remove the bushing from the cylinder end stopper. NOTICE: Be careful not to damage the cylinder end stopper. b. Coat the inside of a new bushing with molybdenum disulfide lithium base grease. c. Install the bushing. 8. IF NECESSARY, REPLACE TEFLON RING AND 0RING a. Using a screwdriver, remove the teflon ring and O-ring from the steering rack. NOTICE: Be careful not to damage the groove for the ring. b. Coat a new O-ring with power steering fluid and install it. Page 4590 Page 1782 Vehicle Speed Sensor: Testing and Inspection INSPECT VEHICLE SPEED SENSOR OPERATION a. Connect the positive (+) lead from the battery to terminal 1 and negative (-) lead to terminal 2. b. Connect the positive (+) lead from the tester to terminal 3 and the negative (-) lead to terminal 2. c. Rotate the shaft. d. Check that there is voltage change from approx. 0 V to 11 V or more between terminals 2 and 3. HINT: The voltage change should be performed 4 times for every revolution of the speed sensor shaft. If operation is not as specified, replace the sensor. Page 1486 Data Link Connector: Description and Operation The vehicle's ECM uses the ISO 9141-2 communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 9141-2 format. Heated Oxygen Sensor Oxygen Sensor: Description and Operation Heated Oxygen Sensor Heated Oxygen Sensor The ECM observes the waveform of the heated oxygen sensor located behind the catalyst to determine whether the catalyst performance has deteriorated. If the catalyst is functioning normally, the waveform of the heated oxygen sensor located behind the catalyst switches back and forth between rich and lean much more slowly. When the waveform of the heated oxygen sensor located behind the catalyst alternates flutteringly between rich and lean, it indicates that catalyst performance has deteriorated. Page 2935 Generator: Mechanical Specifications STD Minimum Slip Ring Diameter 14.2 to 14.4 mm 12.8 mm Brush Exposed Length 9.5 to 11.5 mm 1.5 mm Page 2944 NOTE: To prevent damage to the rotor shaft, do not loosen the pulley nut more than on-half of a turn. e. Remove the generator with SST (A) and (B) from SST (C). f. Turn SST (B) and remove SST (A) and (B). g. Remove the pulley nut and pulley. 6. REMOVE RECTIFIER END FRAME a. Remove the 4 nuts. b. Using SST, remove the rectifier end frame. SST 09286-46011 c. Using snap ring pliers, remove the generator washer from the rectifier end frame. 7. REMOVE ROTOR FROM DRIVE END FRAME REASSEMBLY 1. INSTALL ROTOR TO DRIVE END FRAME a. Place the rectifier end frame on the pulley. b. Install the rotor to the rectifier end frame. 2. INSTALL RECTIFIER END FRAME a. Place the generator washer on the rotor. Page 2311 Step 1 Page 625 13. REMOVE FAN BRACKET a) Remove the nut and PS pump adjusting strut. b) Remove the bolt, nut and fan bracket. 14. REMOVE CRANKSHAFT PULLEY a) Using SST, loosen the pulley bolt. SST 09213-54015 (90119-08216), 09330-00021 b) Remove the SST, pulley bolt and pulley. HINT: If necessary, remove the pulley with SST and a service bolt. SST 09950-50011 (09951-05010, 09952-05010, 09953-05020, 09954-05030) 15. REMOVE STARTER WIRE BRACKET AND NO.1 TIMING BELT COVER a) Remove the 2 bolts and starter wire bracket. b) Remove the 4 bolts and timing belt cover. 16. REMOVE TIMING BELT GUIDE Locations Page 2565 Airbag - Inspect, Replacement & Disposal After Collision Repairs and Inspections Required After a Collision: Technical Service Bulletins Airbag - Inspect, Replacement & Disposal After Collision COLLISION REPAIR INFORMATION CRIB99 TITLE: SRS AIRBAG COMPONENT REPLACEMENT & DISPOSAL PROCEDURES SECTION: ELECTRICAL BULLETIN #99 MODELS: TOYOTA DATE: APRIL 2000 The SRS Airbag system is an important safety feature of Toyota vehicles. It supplements the vehicle seat belt system by providing additional protection to vehicle occupants in the event of a severe frontal or side collision (it equipped with side airbags). In order to assure correct system operation it is necessary to replace certain components of the airbag system following a collision. In order to assist technicians in determining which components should be inspected tested or replaced the repair manual information has been organized in the attached matrix and replacement notes. Even in cases of a minor collision where the SRS does not deploy, the steering wheel pad, front passenger airbag assembly, side airbag assembly, airbag sensor assembly, and side airbag sensor assembly should be inspected and diagnostic tests should be performed. Always refer to the Toyota service repair manual for the correct diagnostic and repair procedures. The attached SRS airbag component replacement information includes: ^ A matrix indicating components requiring replacement inspection or testing after the deployment of the driver and/or passenger SRS airbag. ^ Component replacement notes. ^ A sample repair manual page outlining airbag deployment procedures when scrapping a vehicle. Please refer to the specific vehicle repair manual for procedures to deploy an airbag that has been removed from the vehicle. ^ A sample repair manual page outlining passenger airbag manual on-off switch inspection procedures. CAUTION: SRS Airbag service work can only be performed AFTER 90 seconds from the time the ignition switch is turned to the "lock" position and the negative (-) terminal cable is disconnected from the battery.