Toyota - Tacoma Regular - Workshop Manual - 2000 - 2000

Page 1151 Page 502 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 3219 3. COMPRESS COIL SPRING Using SST, compress the coil spring. SST 09727-22011 (09727-23010, 09727-23020, 09727-23030, 09727-23040) HINT: When setting the fork, insert it to the center area of the coil spring and lower it by turning it along the coil spring. 4. DISCONNECT STABILIZER BAR a. Remove the nut, retainer, cushion and stabilizer bar link from the lower suspension arm. Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.) b. Remove the 2 stabilizer bar bracket set bolts. Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.) 5. REMOVE LOWER SUSPENSION ARM WITH STRUT BAR a. Support the upper suspension arm and steering knuckle securely. b. Remove the cotter pin and nut. Torque: 110 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°. 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 boot. 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 951 a) Remove the 2 water bypass pipe nuts. b) Remove the 2 timing chain cover bolts. c) Remove the 9 bolts and 2 nuts. d) Using a plastic faced hammer, loosen the chain cover and remove the timing chain cover and 3 gaskets. 15. REMOVE NO.1 TIMING CHAIN AND CAMSHAFT TIMING SPROCKET 16. REMOVE CRANKSHAFT TIMING SPROCKET HINT: If necessary, remove the sprocket with SST and crankshaft pulley bolt. SST 09950-40011 (09951-04010, 09952-04010, 09953-04010, 09954-04010, 09955-04061) Page 3060 Part 2 Of 2 DISASSEMBLY NOTICE: When using a vise, do not overtighten it. Page 823 4. Install the bearing caps in their proper locations. 5. Apply light coat of engine oil on the threads and under the heads of the bearing cap bolts. 6. Install and uniformly tighten the 10 bearing cap bolts in several passes. Torque: 15.5 Nm (160 kgf-cm, 12 ft. lbs.) 7. Remove the service bolt. 8. Check that the intake and exhaust camshafts turn smoothly. Page 1357 Ignition Switch: Testing and Inspection 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 1149 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 Page 3591 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 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 245 Page 1570 CHART 12 CHART 13 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 Ignition Cable: Testing and Inspection ON-VEHICLE INSPECTION Except California Spec.: INSPECT HIGH-TENSION CORDS a. Remove the air cleaner cap and MAF meter assembly. b. Remove the intake air connector. c. 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. d. Using an ohmmeter, measure the high-tension cord resistance. Maximum resistance: 25 kohms per cord If the resistance is greater than the maximum, check the terminals. If necessary, replace the high-tension cord. e. Reinstall the high-tension cords. Secure the high-tension cords with the clamps as shown in the illustration. f. Reinstall the intake air connector. g. Reinstall the air cleaner cap and MAF meter assembly. Page 3184 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 2518 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 4376 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. 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 651 TOY 730 - 73mm Toyota Oil Filter Wrench M 0219 - 74mm Oil Filter Wrench Page 1377 6. TROUBLESHOOTING If the CO/HC concentration does not comply with regulations, troubleshoot according in the order given. 1) Check heated oxygen sensor operation. 2) See the table for possible causes, then inspect and correct the applicable causes if necessary. Page 2450 Page 1573 CHART 16 CHART 17 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 the coil, closing the contacts of the EFI main relay (Marking: EFI) and supplying power to terminal +B of the ECM. WIRING DIAGRAM Page 2820 a. Using SST, remove the bearing cover (outside) and bearing. SST 09820-00021 NOTE: Be careful not to damage the fan. b. Remove the bearing cover (inside). c. Place the bearing cover (inside) on the rotor. d. Using SST and a press, press in a new bearing. SST 09820-00030 e. Using SST, push in the bearing cover (outside). SST 09285-76010 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 3292 Wheel Bearing: Service and Repair Disassembly and Reassembly DISASSEMBLY 1. CHECK HUB BEARINGS Clean the bearings and outer races and inspect them for wear or damage. Locations Fuse: Locations Relay Box / No. 2 Page 2346 Locations Ignition Switch and Key Unlock Warning Switch Page 3636 Page 3956 Page 3394 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 3153 a. Using SST, remove the oil seal from the bushing. SST 09527-20011, 09612-24014 (09613-22011) NOTICE: Be careful not to damage the bushing. b. Coat a new oil seal lip with power steering fluid. c. Using SST, press in the oil seal. SST 09950-60010 (09951-00240, 09951-00400, 09952-06010) NOTICE: Make sure to install the oil seal facing the correct direction. 5. IF NECESSARY, REPLACE TEFLON RING AND O-RING a. Using a screwdriver, remove the teflon ring and O-ring from the steering rack. NOTICE: Be careful not to damage the groove for the teflon ring. b. Coat a new O-ring with power steering fluid and install it. c. Expand a new teflon ring with your fingers. NOTICE: Be careful not to over-expand the ring. Diagram Information and Instructions Shift Indicator: 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 4001 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 1153 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 2813 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 AND VOLTAGE REGULATOR Remove the 5 screws, bush holder and voltage regulator. 3. REMOVE RECTIFIER HOLDER Remove the bolt, 4 screws and rectifier holder. 4. REMOVE PULLEY Page 946 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 683 Fluid - A/T: Service Precautions DO NOT over fill transmission beyond normal fluid level markings. Fluid foaming and transmission damage may occur. Page 3668 Page 3152 a. Using a brass bar and hammer, tap out the bearing from the rack housing. b. Using SST, press out the bearing from the rack housing. SST 09950-60010 (09951-00260), 09950-70010 (09951-07200) c. Coat a new bearing with molybdenum disulfide lithium base grease. d. Using SST, press in the bearing. SST 09950-60010 (09951-00310), 09950-70010 (09951-07200) e. Coat a new bearing with molybdenum disulfide lithium base grease. f. Using SST, press in the bearing. SST 09950-60010 (09951-00320), 09950-70010 (09951-07200) 4. IF NECESSARY, REPLACE OIL SEAL Page 954 NOTICE: Vernier calipers must contact the chain rollers for measuring. Minimum sprocket diameter with chain: If the diameter is less than minimum, replace the chain with the sprocket. 2. INSPECT CHAIN TENSIONER SLIPPER AND VIBRATION DAMPERS Measure the chain tensioner slipper and vibration damper wears. Maximum wear: 1.0 mm (0.039 inch) If the wear is greater than maximum, replace the slipper and/or dampers. 3. 2RZ-FE: INSPECT OIL JET Check the oil for damage or clogging. If necessary, replace the oil jet. 4. INSPECT NO.1 CHAIN TENSIONER 5. 3RZ-FE: INSPECT NO.2 CHAIN TENSIONER a) Inspect the chain tensioner 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 1613 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 3686 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 415 Vehicle Speed Sensor: Service and Repair ON-VEHICLE REPAIR 1. DISCONNECT VEHICLE SPEED SENSOR CONNECTOR Vehicle Speed Sensor NO.1 (A43D) 2. REMOVE VEHICLE SPEED SENSOR ASSEMBLY a. Remove the bolt and the vehicle speed sensor assembly. b. Remove the clip and the driven gear from the vehicle speed sensor. c. Remove the O-ring from the vehicle speed sensor. 3. INSTALL VEHICLE SPEED SENSOR ASSEMBLY a. Coat a new O-ring with ATF and install it to the vehicle speed sensor. b. Install the driven gear and the clip to the vehicle speed sensor. c. Install the vehicle speed sensor assembly with the bolt. Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.) 4. CONNECT VEHICLE SPEED SENSOR CONNECTOR 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 2453 Step 2 Step 3 INSPECTION PROCEDURE Page 1554 Oxygen Sensor: Technical Service Bulletins Engine Controls - O2 Sensor Monitor Threshold Values SPECIAL SERVICE TOOLS SS002-03 December 17, 2003 Title O2S TEST RESULTS (MODE 05) Models All '96 - '03, '04 Corolla, ECHO, Matrix, Sienna & Scion xA & xB Introduction This Service Bulletin contains Oxygen Sensor (O2S) Monitor threshold values for all models from 1996 to 2003 and some 2004 models. Starting in 2004, the O2S Monitor threshold values can be found in the repair manual. These values are used when analyzing the O2S test results to determine the O2S condition. Applicable Vehicles ^ All 1996 - 2003 model year Toyota vehicles. ^ 2004 model year Corolla, ECHO, Matrix and Sienna vehicles. ^ 2004 model year Scion xA and xB vehicles. Function Description Checking O2S Test Results To view O2S test results, the O2S Monitor must be completed and the test results must be checked within the same key cycle. If the ignition key is cycled OFF, the O2S test results will be set to the minimum or maximum limits, and all test results will be erased. The O2S test results are stored in the ECU (SAE term: Powertrain Control Module/PCM) when the monitor is completed. The test results are static and will not change once the monitor is complete. The process for checking 02S test results is described in the following three basic steps: 1. Completing the O2S Readiness Monitor. 2. Accessing O2S Test Results. 3. Comparing O2S Test Results to Failure Thresholds. Required SSTs NOTE: Additional Diagnostic Tester Kits, Program Cards or other SSTs may be ordered by calling SPX-OTC at 1-800-933-8335. Warranty Information Completing O2S Readiness Monitor 1. Clear any stored Diagnostic Trouble Codes (DTCs) using the Toyota Diagnostic Tester. Page 3519 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. Testing and Inspection Headlamp Dimmer Relay: Testing and Inspection INSPECT HEADLIGHT DIMMER RELAY CONTINUITY If continuity is not as specified, replace the relay. Page 3568 Page 237 Key Reminder Switch: Ground Locations Page 2974 Junction Box / No. 1 Details 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 2961 Page 457 b. Disconnect the connector from the integration relay and inspect the connectors on the wire harness side. Page 533 An AC voltage is generated in the No.2 vehicle speed sensor coil as the rotor mounted on the output shaft rotates, and this voltage is sent to the ECM. The gear shift point and lock-up timing are controlled by the ECM based on the signals from this vehicle speed sensor and the throttle position sensor signal. If the No.2 vehicle speed sensor malfunctions, the ECM uses input signals from the No.1 vehicle speed sensor as a back-up signal. Page 334 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 3611 Seat Belt: Diagrams Seat Belt 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 1470 Page 4188 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. 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 - 490 kPa (2.5 - 5.0 kgf/cm2, 36 - 71 psi) 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 1204 REPLACEMENT 1. REMOVE THROTTLE BODY 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: 5.4 Nm (55 kg.cm, 48 in.lb) b. Connect the sensor connector. 4. REINSTALL THROTTLE BODY Page 3090 Junction Box / No. 1 Page 3381 4. REMOVE WATER VALVE Remove the bolt and water valve. INSTALLATION Installation is in the reverse order of removal. Page 1468 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 2386 b. Loosen the 2 lower ball joint set bolts. c. Remove the cotter pin and loosen the nut. d. Using SST, disconnect the steering knuckle from the up per ball joint. SST 09628-62011 e. Remove the 2 lower ball joint set bolts. f. Remove the nut and steering knuckle. NOTICE: Do not remove the Jack. INSTALLATION 1. INSTALL STEERING KNUCKLE a. Support the lower suspension arm with a jack. b. Place the steering knuckle to the lower ball joint and temporarily install the 2 bolts. c. Push down the upper suspension arm and connect the upper ball joint to the steering knuckle and install the nut. Torque: 110 Nm (1,100 kgf-cm, 80 ft. lbs.) d. Install a new cotter pin. If the holes for the cotter pin are not aligned, tighten the nut further up to 60°. e. Torque the 2 lower ball joint bolts. Torque: 160 Nm (1,600 kgf-cm, 116 ft. lbs.) 2. INSTALL DUST COVER Install the dust cover with the 4 bolts. Torque: 8.3 Nm (85 kgf-cm, 74 inch lbs.) 3. INSTALL STABILIZER BAR LINK Install the bolt, 5 retainers, collar, 4 cushions and a new nut. 4. PACK BEARINGS WITH MP GREASE a. Place MP grease in the your palm. b. Pack grease into the bearing, continuing until the grease oozes out from the other side. c. Employ the same manner around the bearing circumference. 5. COAT INSIDE OF HUB AND CAP WITH MP GREASE 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 1410 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 INTAKE AIR CONNECTOR 3. Except California Spec.: DISCONNECT HIGH-TENSION CORDS FROM SPARK PLUGS NOTICE: Pulling on or bending the cords may damage the conductor inside. 4. California Spec.: REMOVE IGNITION COILS (WITH IGNITER) 5. REMOVE SPARK PLUGS 6. 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: 1,230 kPa (12.5 kgf/cm2, 178 psi) or more Minimum pressure: 880 kPa (9.0 kgf/cm2, 127 psi) Difference between each cylinder: 98 kPa (1.0 kgf/cm2, 14 psi) or less e) If the cylinder compression in one or more cylinders is low, pour 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, chances are that the piston rings and/or cylinder bore are worn or damage. - If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket. 7. REINSTALL SPARK PLUGS Torque: 19 Nm (200 kgf-cm, 14 ft. lbs.) 8. Except California Spec.: REINSTALL HIGH-TENSION CORDS TO SPARK PLUGS 9. California Spec.: REINSTALL IGNITION COILS (WITH IGNITER) 10. REINSTALL INTAKE AIR CONNECTOR Page 2674 Brake Fluid: Testing and Inspection Check for fluid leakage from actuator or hydraulic lines. Page 1016 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 2957 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 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 1061 Radiator: Service and Repair Removal and Installation Part 1 Of 2 Locations 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. Collision / Non-Collision Inspections Impact Sensor: Testing and Inspection Collision / Non-Collision Inspections INSPECTION 1. VEHICLES NOT INVOLVED IN COLLISION Do a diagnostic system check. * 2. VEHICLES INVOLVED IN COLLISION a. Do a diagnostic system check. * b. If the front fender of the car or its periphery is damaged, do a visual check for damage to the front airbag sensor, which includes the following items even if the airbag was not deployed: Check the bracket deformation. - Check the paint peeling off the bracket. - Check the cracks, dents or chips in the case. - Check the cracks, dents, chipping and scratches in the connector. - Check the peeling off of the label or damage to the serial number. * Refer to SRS Warning Light Check, and How to Display and Read Diagnostic Trouble Codes. See: Restraint Systems/Air Bag Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Displaying & Reading Trouble Codes Page 4243 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 1314 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 1143 Page 650 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 950 11. REMOVE OIL PAN a) Remove the 16 bolts and 2 nuts. b) Insert the blade of SST between the cylinder block and oil pan, cut off applied sealer and remove the oil pan. SST 09032-00100 NOTICE: Be careful not to damage the oil pan flanges of the oil pan and cylinder block. 12. REMOVE OIL STRAINER Remove the bolt, 2 nuts, oil strainer and gasket. 13. REMOVE CRANKSHAFT PULLEY a) w/ A/C: Remove the 4 bolts, No.2 and No.3 crankshaft pulleys. b) Using SST, remove the pulley bolt. SST 09213-54015, 09330-00021 c) Remove the crankshaft pulley. HINT: If necessary, remove the pulley with SST and crankshaft pulley bolt. SST 09950-50012 (09951-05010, 09952-05010, 09953-05010, 09954-05020) 14. REMOVE TIMING CHAIN COVER Page 2684 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 743 Junction Box / No. 1 Details Front Page 2509 Junction Box / No. 3 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 3011 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 948 REMOVAL 1. REMOVE ENGINE UNDER COVER 2. DRAIN ENGINE OIL 3. 4WD: REMOVE FRONT DIFFERENTIAL AND DRIVE SHAFTS ASSEMBLY REMOVE DRIVE BELT FOR GENERATOR, FAN WITH FLUID COUPLING AND WATER PUMP PULLEY REMOVE CYLINDER HEAD ASSEMBLY 6. DISCONNECT A/C COMPRESSOR AND BRACKET a) Remove the 4 bolts, and disconnect the compressor from the bracket. HINT: Put aside the compressor, and suspend it. b) Remove the 4 bolts and A/C compressor bracket. Page 3658 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 1855 Fuel Pressure: Testing and Inspection 1. INSPECT FUEL PUMP OPERATION a. Connect the TOYOTA hand-held tester to the DLC3. b. Turn the ignition switch ON and push the 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. f. Check that there is pressure in the 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. 2. CHECK FUEL PRESSURE a. Check that the battery positive voltage is above 12V. b. Disconnect the negative (-) terminal cable from the battery. c. Remove the union bolt and 2 gaskets, and disconnect the fuel inlet pipe from the delivery pipe. CAUTION: Put a suitable container or shop rag under the delivery pipe. Page 2898 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 2235 Transmission Speed Sensor: Service and Repair VEHICLE SPEED SENSOR ON-VEHICLE REPAIR Vehicle Speed Sensor NO.1(A43D) 1. DISCONNECT VEHICLE SPEED SENSOR CONNECTOR 2. REMOVE VEHICLE SPEED SENSOR ASSEMBLY (a) Remove the bolt and the vehicle speed sensor assembly. (b) Remove the clip and the driven gear from the vehicle speed sensor. (c) Remove the o-ring from the vehicle speed sensor. 3. INSTALL VEHICLE SPEED SENSOR ASSEMBLY (a) Coat a new o-ring with ATF and install it to the vehicle speed sensor. (b) Install the driven gear and the clip to the vehicle speed sensor. (c) Install the vehicle speed sensor assembly with the bolt. Torque: 16 Nm (160 kgf.cm, 12 ft.lbf) 4. CONNECT VEHICLE SPEED SENSOR CONNECTOR Page 2960 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 2313 Steps 1 - 2 Page 1027 Part 2 Of 2 REMOVAL 1. REMOVE ENGINE UNDER COVER 2. DRAIN ENGINE COOLANT 3. DISCONNECT AIR PIPE Remove the 2 bolts and disconnect the air pipe from the fan shroud. 4. DISCONNECT UPPER RADIATOR HOSE FROM RADIATOR 5. REMOVE OIL DIPSTICK GUIDE a) Remove the bolt, dipstick guide and engine wire bracket. b) Remove the O-ring from the dipstick guide. HINT: At the time of installation, please refer to the following items. Use a new O-ring. 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 1577 CHART 21 Page 980 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 HINT: All vacuum hoses for EGR system, etc. should be properly connected. f) SFI system wiring connectors fully plugged g) Ignition timing check correctly h) Transmission in neutral position 2. CONNECT TOYOTA HANDHELD TESTER OR OBDII SCAN TOOL 3. INSPECT IDLE SPEED a) Race the engine speed at 2,500 rpm for approx. 90 seconds. b) Check the idle speed. Idle speed: 650 - 750 rpm If the idle speed is not as specified, check the IAC valve, intake air leakage and SFI system. 4. DISCONNECT TOYOTA HAND-HELD TESTER OR OBDII SCAN TOOL Page 3307 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 1302 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 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 3136 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. Description and Operation Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor Crankshaft position sensor (NE signal) consists of and pickup coil. The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor generates 34 signals at every engine revolution. The ECM detects the standard crankshaft angle based on the G signal, and the actual crankshaft angle and the engine speed by the NE signal. Page 2249 HINT: Mark the position of the torque converter clutch to ensure correct installation. Page 3020 Front shim thickness: -1.7 mm (0.067 inch) Rear shim thickness: +11.6 mm (0.063 inch) d. Torque the upper suspension arm set bolts. Torque: 130 Nm (1,300 kgf-cm, 94 ft. lbs.) HINT: If the steering axis inclination is not as specified value after the camber and caster have been correctly adjusted, recheck the steering knuckle and front wheel for distortion or looseness. NOTICE: Adjust the shim thickness to 7 mm (4-11 mm), and adjust the difference between the front and rear of the upper suspension arm shaft to within 4 mm. Measuring Point Reference 5. INSPECT TOE-IN Toe-In: If the toe-in is not within the specified value, adjust the rack ends. 6. ADJUST TOE-IN 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: 54 Nm (550 kgf-cm, 40 ft. lbs.) f. Place the boots on the seats and install the clips. HINT: Make sure that the boots are not twisted. Page 3960 Page 2428 Junction Box / No. 1 Page 2892 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 1170 Part 1 Of 2 (Except California Spec.) Page 2793 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 2529 Page 1641 Part 2 Of 2 (California Spec.) *1: Only for A/T *2: Only for 3RZ-FE *3: The ECM terminal voltage is fixed regardless of the output voltage from the sensor. Connectors (Except California Spec.) Page 859 a) Check only the valves indicated. 1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft. 2) Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim. Valve clearance (Cold): b) Turn the crankshaft pulley 1 revolution (360°) and align its groove with timing mark "O" of the timing chain cover. c) Check only the valves indicated as shown. Measure the valve clearance. (See procedure in step (a)) 9. ADJUST VALVE CLEARANCE a) Remove the adjusting shim. 1) Turn the crankshaft to position the cam lobe of the camshaft on the adjusting valve upward. 2) Position the notch of the valve lifter toward the spark plug side. 3) Using SST (A), press down the valve lifter and place SST (B) between the camshaft and valve lifter flange. Remove SST (A). SST 09248-55040 (09248-05410, 09248-05420) HINT: Apply SST (B) at slight angle on the side marked with "9", at the position shown in the illustration. Page 2949 Junction Box / No. 3 Fuse and Fusible Link Locations 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 3140 Steering Gear: Service and Repair With Power Steering Removal and Installation Part 1 Of 3 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. Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Crankshaft Pulley Bolt Torque Using SST ........................................................................................... ...................................................................................................................... 260 Nm No. 3 and No. 2 Crankshaft Pulley Bolts (4) Torque (W/ A/C) ............................................................. ............................................................................................................................................ 25 Nm 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 3976 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. Electrode Gap Specification Spark Plug: Specifications Electrode Gap Specification Electrode Gap Correct Gap ......................................................................................................................................... ........................................................................ 0.8 mm Page 3125 Part 3 Of 3 POWER STEERING GEAR REPLACEMENT AND OVERHAUL W/ RELATED COMPONENTS Page 1156 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 319 Knock Sensor: Testing and Inspection 1. REMOVE STARTER 2. REMOVE FUEL FILTER SET BOLTS 3. REMOVE KNOCK SENSOR a. Disconnect the knock sensor connector. b. Using SST, remove the knock sensor. SST 09816-30010 4. INSPECT KNOCK SENSOR Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor. 5. REINSTALL KNOCK SENSOR a. Using SST, install the knock sensor. SST 09816 - 30010 Torque: 44 Nm (450 kg.cm, 33 ft.lb) b. Connect the knock sensor connector. 6. REINSTALL FUEL FILTER SET BOLTS Torque: 20 Nm (200 kg.cm, 14 ft.lb) 7. REINSTALL STARTER Page 3731 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. 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. 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 ECM will be erased when the battery negative (-) terminal cable is removed from the battery. Therefore, if necessary, read the diagnostic trouble code(s) 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 a new gasket. 2. Tighten the union bolt by hand. 3. Tighten the union bolt to the specified torque. Torque: 29 Nm (300 kg.cm, 22 ft.lb) 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. REINSTALLER MAIN RELAY Page 1877 Mass Air Flow Meter: Service and Repair COMPONENTS REMOVAL 1. REMOVE AIR CLEANER CAP WITH MAF METER a. Disconnect the MAF meter connector and wire clamp. b. Loosen the air cleaner hose clamp. c. Disconnect the air hose from air cleaner cap. d. Loosen the 4 clips, and remove the air cleaner cap together with the MAF meter. 2. REMOVE MAF METER FROM AIR CLEANER CAP Page 1439 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 intake camshaft. 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. 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 1699 Page 3115 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 2697 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.) Page 1057 Part 2 Of 2 Part 2 of 2 Page 2418 Flywheel: Service and Repair For further information regarding this component and the system that it is a part of please refer to Cylinder Block; Service and Repair. 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 3728 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. 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 3770 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 4094 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: 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 3366 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 2209 Parking Pawl: Service and Repair ON-VEHICLE REPAIR 1. REMOVE DRAIN PLUG AND DRAIN ATF 2. REMOVE VALVE BODY 3. REMOVE PARKING LOCK PAWL BRACKET Remove the 2 bolts, wave washers and parking lock pawl bracket. 4. REMOVE PARKING LOCK PAWL a. Remove the spring from parking lock pawl pivot pin. b. Remove the pivot pin and parking lock pawl. c. Remove the E-ring from the pivot pin. 5. INSTALL PARKING LOCK PAWL a. Install the E-ring to the pivot pin. b. Install the parking lock pawl, pivot pin and spring. 6. INSTALL PARKING LOCK PAWL BRACKET Install the bracket and tighten the 2 bolts with the wave washers. Torque: 7.4 Nm (75 kgf-cm, 65 inch lbs.) HINT: Push the parking lock rod fully forward. Page 4379 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 3235 Stabilizer Bar: Service and Repair REMOVAL 1. REMOVE FRONT WHEELS Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.) 2. REMOVE STABILIZER BAR a. Hold the bolt with a wrench, then remove the nut, 5 retainers, collar, 4 cushions and bolt. Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.) b. Employ the same manner described above to the other side. c. Remove the 4 bolts and stabilizer bar with the cushions and brackets. Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.) d. Remove the brackets and cushions from the stabilizer bar. HINT: At the time of installation, install the cushion to the portion inside the paint line. INSTALLATION Installation is in the reverse order of removal. Specifications Brake Shoe: Specifications Lining Thickness: Standard 0.236 in Minimum 0.039 in Drum To Shoe Clearance 0.024 in Page 1466 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 2304 a. Check that there is no continuity when connecting the positive (+) lead from the ohmmeter to terminal 2 and the negative (-) lead to terminal 1. b. Check that there is no continuity when connecting the positive (+) lead from the ohmmeter to terminal 3 and the negative (-) lead to terminal 1. c. Check the there is no continuity between terminals 2 and 3. If the continuity is not as specified, replace the clutch start cancel switch. 9. CHECK OPERATION OF CLUTCH START CANCEL SWITCH a. Connect positive (+) lead from the battery to terminal 3 and connect negative (-) lead to terminal 1. b. Check that there is no continuity when connecting the positive (+) lead from the ohmmeter to terminal 2 and the negative (-) lead to terminal 1. c. When pushing the switch and check that the indicator light comes on and there is continuity between terminal 1 and 2. Page 1743 c. Connect the sensor connector. 2. INSPECT OPERATION OF A/F SENSOR Page 1406 g. Using a 16 mm plug wrench, reinstall the 4 spark plug. Torque: 20 Nm (200 kg.cm, 14 ft.lb) h. Except California Spec.: Reconnect the high-tension cords to the spark plugs. i. California Spec.: Reinstall the ignition coil. Page 3631 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 595 NOTE: Always pinch the hose. Avoid bending as it may cause to hose to crack. 7. Turn the ignition switch OFF. 8. Disconnect the TOYOTA hand-held tester from the DLC3. Page 3502 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 1937 INSPECT FUEL TANK AND LINE a. Check the fuel lines for cracks or leakage, and all connections for deformation. b. Check the fuel tank vapor vent system hoses and connections for looseness, sharp bends or damage. c. Check the fuel tank for defamation, cracks, fuel leakage or tank band looseness. d. Check the filler neck for damage or fuel leakage. e. Hose and tube connections are as shown in the illustration. If a problem is found, repair or replace the part as necessary. Page 1029 INSPECTION 1. INSPECT WATER PUMP a) Visually check the air hole and drain hole for coolant leakage. If leakage is found, replace the water pump. 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 the fluid coupling for damage and silicon oil leakage. If necessary, replace the fluid coupling. c) Install the fan and fluid coupling with the 4 nuts. Torque: 5.5 Nm (55 kgf-cm, 49 inch lbs.) INSTALLATION Installation is in the reverse order of removal. Page 777 * For vehicle capacity weight. ** For reduced loads (1 to 4 passengers). *** For trailer towing. Page 69 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 1710 CHART 12 CHART 13 Page 3598 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 1194 Mass Air Flow Meter: Testing and Inspection 1. INSPECT MAF METER RESISTANCE Using an ohmmeter, measure the resistance between terminals THA and E3. Temperature Resistance -20 °C (-4 °F) 10 - 20 Kohms 0 °C (32 °F) 4 - 7 Kohms 20 °C (68 °F) 2 - 3 Kohms 40 °C (104 °F) 0.9 - 1.3 Kohms 60 °C (140 °F) 0.4 - 0.7 Kohms 80 °C (176 °F) 0.2 - 0.4 Kohms If the resistance is not as specified, replace the MAF meter. 2. INSPECT MAF METER OPERATION a. Connect the negative (-) terminal cable to the battery. b. Turn the ignition switch ON. c. Connect the MAF meter connector. d. Using a voltmeter, connect the positive (+) tester probe to terminal VG, and negative (-) tester probe to terminal E3. e. Blow air into the MAF meter, and check that the voltage fluctuates. If operation is not as specified, replace the MAF meter. f. Turn the ignition switch OFF. g. Disconnect the negative (-) terminal cable from the battery. h. Disconnect the MAF meter connector. Page 2447 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 Firing Order: Specifications Firing Order Firing Order Firing Order 1 - 3 - 4 - 2 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. Page 1582 CHART 24 Page 1256 CHART 18 CHART 19 Page 2438 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 1075 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. Specifications Camshaft Gear/Sprocket: Specifications Tightening Torque Camshaft Timing Gear x Intake Camshaft ................................................................................................................................................ 73.5 Nm (54 ft.lb) Crankshaft Pulley x Crankshaft ...................................................................................... ......................................................................... 260 Nm (193 ft.lb) Page 2817 f. 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) g. Remove the generator from SST (C). h. Turn SST (B), and remove SST (A and B). 5. INSTALL RECTIFIER HOLDER Install the rectifier holder with the bolt and 4 screws. Torque: 1.96 Nm (20 kg.cm, 17.4 in.lb) for screw 3.9 Nm (40 kg.cm, 34.7 in.lb) for bolt 6. INSTALL VOLTAGE REGULATOR AND BRUSH HOLDER a. Install the brush holder cover to the brush holder. NOTE: Be careful of the holder installation direction. b. Place the voltage regulator together with the brush holder horizontally on the rectifier end frame. Page 4441 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 1037 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 radiator reservoir until it is "FULL" line. 3. CHECK ENGINE COOLANT FOR LEAKS 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 2247 ^ 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. 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 4306 Clock: Ground Locations Page 3608 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 1972 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. Pressure Specification Fuel Pressure: Specifications Fuel Pressure No Vacuum 38 to 44 psi Page 1795 Page 436 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 4192 Steps 2 - 3 INSPECTION PROCEDURE Page 4359 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. 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 2967 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. 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 3101 Page 1803 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor NO.1 Vehicle Speed Sensor NO.1 Circuit Description The vehicle speed sensor outputs a 4-pulse signal for every revolution of the rotor shaft, which is rotated by the transmission output shaft via the driven gear. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. Vehicle Speed Sensor NO.2 Vehicle Speed Sensor NO.2 Circuit Description The No.2 vehicle speed sensor detects the rotation speed of the transmission output shaft and sends signals to the ECM. The ECM determines the vehicle speed based on these signals. Page 3638 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 1266 Page 412 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor NO.1 Vehicle Speed Sensor NO.1 Circuit Description The vehicle speed sensor outputs a 4-pulse signal for every revolution of the rotor shaft, which is rotated by the transmission output shaft via the driven gear. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. Vehicle Speed Sensor NO.2 Vehicle Speed Sensor NO.2 Circuit Description The No.2 vehicle speed sensor detects the rotation speed of the transmission output shaft and sends signals to the ECM. The ECM determines the vehicle speed based on these signals. Specifications Brake Fluid: Specifications Fluid Type FMVSS 116 DOT 3 Brake Fluid 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 1370 Fuel Pressure: Specifications Volume Specification Information not supplied by the manufacturer. 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 2958 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 1566 CHART 7 Page 4208 Step 4 INSPECTION PROCEDURE Page 4284 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 789 2. REMOVE BEARING OUTER RACES Using SST, a brass bar and hammer, remove the inside and out side of the bearing outer races. SST 09527-17011 NOTICE: Be careful not to damage the ABS speed sensor rotor. REASSEMBLY INSTALL NEW BEARING OUTER RACES a. Using SST and a press, install a new inside of the bearing outer race. SST 09527-17011, 09950-60010 (09951-00640), 09950-70010 (09951-07150) b. Using SST and a press, install a new outside of the bearing race. SST 09527-17011, 09950-60010 (09951-00490), 09950-70010 (09951-07150) NOTICE: Be careful not to damage the ABS speed sensor rotor. Page 3707 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. Description and Operation Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor Crankshaft position sensor (NE signal) consists of and pickup coil. The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor generates 34 signals at every engine revolution. The ECM detects the standard crankshaft angle based on the G signal, and the actual crankshaft angle and the engine speed by the NE signal. Page 3154 d. Coat the ring with power steering fluid. e. Install the ring to the steering rack, and settle it down with your fingers. 6. 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 teflon ring. b. Expand 4 new teflon rings with your fingers. NOTICE: Be careful not to over-expand the teflon 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 rings fit to the steering rack. SST 09631-20081 NOTICE: Be careful not to damage the rings. 7. IF NECESSARY, REPLACE UNION SEATS a. Using a screw extractor, remove the 2 seats from the control valve housing. Page 3582 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 3616 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.]) 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 1551 Page 3708 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 3332 Electrical - SRS And HV Wiring Repairs Air Bag Harness: Technical Service Bulletins Electrical - SRS And HV Wiring Repairs TITLE: SRS & HV WIRING REPAIRS SECTION: ELECTRICAL BULLETIN # 156 MODELS: ALL TOYOTA LEXUS and SCION MODELS DATE: AUGUST 2007 There are no approved repairs to Supplemental Restraint System (SRS) or High Voltage (HV) wiring or connectors. SRS system wiring and connectors are color coded yellow and HV wiring is orange however vehicle-specific wiring diagrams are the best source for identifying wiring in these circuits. Wiring diagrams are available through the Technical Information System (TIS) www.techinfo.toyota.com. If SRS or HV wiring or connectors are suspected of damage they should be inspected thoroughly. Damaged wiring and/or connectors require replacement of the affected harness. Follow all precautions and procedures outlined in model-specific repair manuals for replacing SRS wiring or components. Only Certified Hybrid Service Technicians are qualified to replace HV system wiring and components. Page 787 f. Using a dial indicator near the center of the axle hub and measure the backlash in the bearing shaft direction. Maximum: 0.05 mm (0.0020 inch) or less 9. INSTALL LOCK CAP, COTTER PIN AND GREASE CAP a. Install the lock cap and a new cotter pin. If the holes for the cotter pin are not aligned, tighten the nut further up to 60°. b. Install the grease cap. 10. INSTALL BRAKE CALIPER Install the brake caliper with the 2 bolts. Torque: 108 Nm (1,100 kgf-cm, 80 ft. lbs.) 11. w/ ABS: CONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP TO STEERING KNUCKLE Connect the ABS speed sensor and wire harness clamp with the 2 bolts. Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.) 12. INSTALL FRONT WHEEL Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.) 13. DEPRESS BRAKE PEDAL SEVERAL TIMES 14. CHECK FRONT WHEEL ALIGNMENT 15. w/ ABS: CHECK ABS SPEED SENSOR SIGNAL Page 1935 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. 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 1578 CHART 22 Page 4248 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 4434 Page 1794 Page 3678 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 - 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 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. Page 205 Wiring Diagram Step 1 Page 579 - Slowly loosen the union bolt. d. Install the fuel inlet pipe and SST (pressure gauge) to the delivery pipe with the 3 gaskets and SST (union bolt). SST 09268-45012 Torque: 29 Nm (300 kg.cm, 22 ft.lb) e. Wipe off any splattered gasoline. f. Connect the TOYOTA hand-held tester to the DLC3. g. Turn the ignition switch ON and push the TOYOTA hand-held tester main switch ON. NOTE: Do not start the engine. h. Select the active test mode on the TOYOTA hand-held tester. i. Please refer to the TOYOTA hand-held tester operator's manual for further details. j. If you have no TOYOTA hand-held tester, connect the positive (+) and negative (-) leads from the battery to the fuel pump connector. k. Reconnect the negative (-) terminal cable to the battery. l. Turn the ignition switch ON. m. 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. n. Remove the TOYOTA hand-held tester. o. Start the engine. p. Measure the fuel pressure at idle. Fuel pressure: 206 - 255 kPa (2.1 - 2.6 kg/Sq.cm, 31 - 37 psi) If pressure is not as specified, check the vacuum sensing hose and fuel pressure regulator. q. Stop the engine. r. 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 injector. s. After checking fuel pressure, disconnect the negative (-) terminal cable from the battery and carefully remove the SST to prevent gasoline from splashing. Page 1629 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 161 Page 1282 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 3886 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 3691 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 1306 Page 338 Page 1478 Data Link Connector: Description and Operation The vehicle's ECM uses the ISO 9141-2 communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 9141-2 format. Page 1193 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 Camshaft Gear/Sprocket: Specifications Tightening Torque Camshaft Timing Gear x Intake Camshaft ................................................................................................................................................ 73.5 Nm (54 ft.lb) Crankshaft Pulley x Crankshaft ...................................................................................... ......................................................................... 260 Nm (193 ft.lb) Page 3635 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 2724 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 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. 1. Apply MP grease to the thrust portion of the intake camshaft. 2. Place the intake camshaft with knock pin facing upward of camshaft angle on the cylinder head. 3. Install the bearing caps in their proper locations. 4. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts. 5. Install and uniformly tighten the 10 bearing cap bolts in several passes. Torque: 15.5 Nm (160 kgf-cm, 12 ft. lbs.) b. Install the exhaust camshaft. 1. Apply MP grease to the thrust portion of the exhaust camshaft. 2. Engage the exhaust camshaft gear to the intake camshaft gear by matching the timing marks (1 and 2 dots) on each gear. NOTICE: There are, also timing marks (for TDC) on each gear. Do not use these marks. 3. Roll down the exhaust camshaft onto the bearing journals while engaging gears with each other. Page 2516 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 2968 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 292 Mass Air Flow Meter: Service and Repair COMPONENTS REMOVAL 1. REMOVE AIR CLEANER CAP WITH MAF METER a. Disconnect the MAF meter connector and wire clamp. b. Loosen the air cleaner hose clamp. c. Disconnect the air hose from air cleaner cap. d. Loosen the 4 clips, and remove the air cleaner cap together with the MAF meter. 2. REMOVE MAF METER FROM AIR CLEANER CAP 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 ECM will be erased when the battery negative (-) terminal cable is removed from the battery. Therefore, if necessary, read the diagnostic trouble code(s) 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 a new gasket. 2. Tighten the union bolt by hand. 3. Tighten the union bolt to the specified torque. Torque: 29 Nm (300 kg.cm, 22 ft.lb) Page 162 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 2819 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 SST and a press, press out the bearing. SST 09950-60010 (09951-00260, 09952-06010) c. Using SST and a press, press in a new bearing. SST 09950-60010 (09951-00500) Install the bearing retainer with the 4 screws. Torque: 2.6 Nm (26.5 kg.cm, 23 in.lb) 3. REPLACE REAR BEARING Page 3565 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). Page 1905 Fuel Injector: Service and Repair COMPONENTS REMOVAL 1. REMOVE AIR CLEANER HOSE WITH RESONATOR AND INTAKE AIR CONNECTOR Page 3180 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 1604 Oxygen Sensor: Testing and Inspection Heated Oxygen Sensor Heated Oxygen Sensor Page 724 Refrigerant Oil: Fluid Type Specifications Type ND-OIL 8 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 HINT: All vacuum hoses for EGR systems, etc. should be properly connected. f) SFI system wiring connectors fully plugged g) Ignition timing check 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 HINT: When doing the 2 mode (idle and 2,500 rpm) test, these measurement order prescribed by the applicable local regulations. Page 3206 Ball Joint: Specifications Lower Ball Joint Turning Torque 0.5-3.5 Nm (4.0-30.0 in.lb) Maximum Play 0.5 mm (0.020 in) Page 1214 Crankshaft Position Sensor: Service and Repair REPLACEMENT 1. REMOVE ENGINE UNDER COVER 2. REMOVE GENERATOR 3. REMOVE GENERATOR BRACKET Remove the 3 bolts and bracket. 4. REMOVE CRANKSHAFT POSITION SENSOR a. Disconnect the sensor connector. b. Disconnect the sensor connector from the connector bracket. c. Remove the 2 bolts and crankshaft position sensor. d. Remove the O-ring. 5. REINSTALL NEW CRANKSHAFT POSITION SENSOR a. Install a new O-ring to the sensor. b. Install the sensor with the 2 bolts. Torque: 8.5 Nm (85 kg.cm, 74 in.lb) c. Reinstall the sensor connector to the connector bracket. d. Reconnect the sensor connector. 6. REINSTALL GENERATOR BRACKET Install the bracket with the 3 bolts Torque: Bolt A: 74.5 Nm (760 kg.cm, 55 ft.lb) Bolt B: 18 Nm (180 kg.cm, 13 ft.lb) 7. REINSTALL GENERATOR 8. REINSTALL ENGINE UNDER COVER Locations Camshaft Position Sensor: Locations Page 89 Part 2 Of 2 (Except California Spec.) *:Only for A/T Page 2270 a. Remove the eight bolts and lower valve body cover. b. Remove the two gaskets and plate. c. Remove the four check balls. d. Remove the retainer and three pins. 4. Remove lower valve body plate. Page 1062 Part 2 Of 2 REMOVAL 1. DRAIN ENGINE COOLANT 2. REMOVE RADIATOR GRILLE a) Remove the 4 screws, 2 clips and clearance lights. b) Remove the 2 filler. c) Remove the 11 clips and radiator grille. Page 3521 - 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 3356 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 1146 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 Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor Crankshaft position sensor (NE signal) consists of and pickup coil. The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor generates 34 signals at every engine revolution. The ECM detects the standard crankshaft angle based on the G signal, and the actual crankshaft angle and the engine speed by the NE signal. Page 494 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 382 c. Connect the sensor connector. 2. INSPECT OPERATION OF A/F SENSOR Page 2373 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 4431 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 4449 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 Specifications Wheel Bearing: Specifications On models with serviceable wheel bearings, use a Lithium Multipurpose Grease. 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 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 2413 Flex Plate: Specifications Drive Plate Bolts 74 Nm (54 ft.lb) 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 - 0.8 V is applied to terminal VTA of the ECM. The voltage applied to the terminals VTA of the ECM increases in proportion to the opening angle of the throttle valve and becomes approximately 3.2 - 4.9 V when the throttle valve is fully opened. The ECM judges the vehicle driving conditions from these signals input from terminal VTA, uses it as one of the conditions to decide the air-fuel ratio correction, power increase correction and fuel cut control etc. Locations Relay Box: Locations Relay Box / No. 2 Page 881 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 2175 Shift Indicator: Connector Locations Locations Page 2405 e. Remove the spacer. 3. 3-joint type: REMOVE CENTER SUPPORT BEARING FROM INTERMEDIATE SHAFT INSPECTION NOTICE: Be careful not to grip the propeller shaft tube too tightly in a vise as this will cause deformation. 1. INSPECT PROPELLER SHAFT AND INTERMEDIATE SHAFT FOR DAMAGE OR RUNOUT 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. REASSEMBLY NOTICE: Be careful not to grip the propeller shaft tube too tightly in a vise as this will cause deformation. Page 2427 Shift Indicator: Connector Locations Page 1801 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 563 RZN140L Model RZN150L Model VZN150L 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 upper suspension arm set bolts. b. Adjust the camber and caster by adding or removing shims (See adjustment chart). Shim Thickness: HINT: Try to adjust the camber and caster to the center of the specified values. Page 578 Fuel Pressure: Testing and Inspection 1. INSPECT FUEL PUMP OPERATION a. Connect the TOYOTA hand-held tester to the DLC3. b. Turn the ignition switch ON and push the 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. f. Check that there is pressure in the 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. 2. CHECK FUEL PRESSURE a. Check that the battery positive voltage is above 12V. b. Disconnect the negative (-) terminal cable from the battery. c. Remove the union bolt and 2 gaskets, and disconnect the fuel inlet pipe from the delivery pipe. CAUTION: Put a suitable container or shop rag under the delivery pipe. 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 start 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. Page 1689 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 3107 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 2266 LOWER VALVE BODY Page 1895 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 2233 Transmission Speed Sensor: Description and Operation Vehicle Speed Sensor NO.1 Vehicle Speed Sensor NO.1 Circuit Description The vehicle speed sensor outputs a 4-pulse signal for every revolution of the rotor shaft, which is rotated by the transmission output shaft via the driven gear. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. Vehicle Speed Sensor NO.2 Vehicle Speed Sensor NO.2 Circuit Description The No.2 vehicle speed sensor detects the rotation speed of the transmission output shaft and sends signals to the ECM. The ECM determines the vehicle speed based on these signals. Page 1632 Part 2 Of 2 (California Spec.) *1: Only for A/T *2: Only for 3RZ-FE *3: The ECM terminal voltage is fixed regardless of the output voltage from the sensor. Connectors (Except California Spec.) Page 2668 Brake Caliper: Service and Repair Disassembly and Assembly DISASSEMBLY 1. REMOVE PISTON AND CYLINDER BOOT a. Put a piece of cloth or an equivalent between the piston and caliper. b. Use compressed air to remove the piston and cylinder boot from the caliper. CAUTION: Do not place your fingers in front of the piston when using compressed air. 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 299 Camshaft Position Sensor: Testing and Inspection INSPECTION 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 2796 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. 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 1457 Crankshaft Position Sensor: Service and Repair REPLACEMENT 1. REMOVE ENGINE UNDER COVER 2. REMOVE GENERATOR 3. REMOVE GENERATOR BRACKET Remove the 3 bolts and bracket. 4. REMOVE CRANKSHAFT POSITION SENSOR a. Disconnect the sensor connector. b. Disconnect the sensor connector from the connector bracket. c. Remove the 2 bolts and crankshaft position sensor. d. Remove the O-ring. 5. REINSTALL NEW CRANKSHAFT POSITION SENSOR a. Install a new O-ring to the sensor. b. Install the sensor with the 2 bolts. Torque: 8.5 Nm (85 kg.cm, 74 in.lb) c. Reinstall the sensor connector to the connector bracket. d. Reconnect the sensor connector. 6. REINSTALL GENERATOR BRACKET Install the bracket with the 3 bolts Torque: Bolt A: 74.5 Nm (760 kg.cm, 55 ft.lb) Bolt B: 18 Nm (180 kg.cm, 13 ft.lb) 7. REINSTALL GENERATOR 8. REINSTALL ENGINE UNDER COVER Page 3834 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 493 Step 4 INSPECTION PROCEDURE 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 744 Engine Compartment Instrument Panel Locations Page 1537 Knock Sensor: Testing and Inspection 1. REMOVE STARTER 2. REMOVE FUEL FILTER SET BOLTS 3. REMOVE KNOCK SENSOR a. Disconnect the knock sensor connector. b. Using SST, remove the knock sensor. SST 09816-30010 4. INSPECT KNOCK SENSOR Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor. 5. REINSTALL KNOCK SENSOR a. Using SST, install the knock sensor. SST 09816 - 30010 Torque: 44 Nm (450 kg.cm, 33 ft.lb) b. Connect the knock sensor connector. 6. REINSTALL FUEL FILTER SET BOLTS Torque: 20 Nm (200 kg.cm, 14 ft.lb) 7. REINSTALL STARTER Page 1791 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 622 a) Check only the valves indicated. 1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft. 2) Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim. Valve clearance (Cold): b) Turn the crankshaft pulley 1 revolution (360°) and align its groove with timing mark "O" of the timing chain cover. c) Check only the valves indicated as shown. Measure the valve clearance. (See procedure in step (a)) 9. ADJUST VALVE CLEARANCE a) Remove the adjusting shim. 1) Turn the crankshaft to position the cam lobe of the camshaft on the adjusting valve upward. 2) Position the notch of the valve lifter toward the spark plug side. 3) Using SST (A), press down the valve lifter and place SST (B) between the camshaft and valve lifter flange. Remove SST (A). SST 09248-55040 (09248-05410, 09248-05420) HINT: Apply SST (B) at slight angle on the side marked with "9", at the position shown in the illustration. Page 2579 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 3435 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 4290 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 3492 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 3684 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 2150 Fluid - A/T: Service Precautions DO NOT over fill transmission beyond normal fluid level markings. Fluid foaming and transmission damage may occur. Page 363 Page 1086 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 113 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 385 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 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. 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 1979 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 1104 INSPECTION 1. INSPECT WATER PUMP a) Visually check the air hole and drain hole for coolant leakage. If leakage is found, replace the water pump. 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 the fluid coupling for damage and silicon oil leakage. If necessary, replace the fluid coupling. c) Install the fan and fluid coupling with the 4 nuts. Torque: 5.5 Nm (55 kgf-cm, 49 inch lbs.) INSTALLATION Installation is in the reverse order of removal. Page 343 CHART 2 CHART 3 CHART 4 Page 3446 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. Page 2079 Shift Indicator: Ground Locations Front Page 2194 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 2294 2. REMOVE PUSH ROD Pull back the boot, and using snap ring pliers, remove the snap ring. 3. REMOVE PISTON REASSEMBLY 1. COAT PARTS WITH LITHIUM SOAP BASE GLYCOL GREASE, AS SHOWN 2. INSERT PISTON INTO CYLINDER 3. INSTALL PUSH ROD ASSEMBLY WITH SNAP RING 4. INSTALL RESERVOIR TANK a. Install the reservoir tank and a new grommet. b. Using a pin punch and hammer, drive in the slotted spring pin. INSTALLATION Installation is in the reverse order of removal. HINT: After installation, bleed the system and adjust the clutch pedal. Page 561 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.). 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. Page 362 CHART 25 Page 2062 Spark Plug: Specifications Torque Specification Spark Plug x Cylinder Head ................................................................................................................ ......................................................................... 20 Nm Page 2809 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 4361 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 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). 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 3156 b. Coat SST with power steering fluid. c. Install the rack into the rack housing. d. Remove the SST. 4. INSTALL BUSHING a. Coat a new O-ring with power steering fluid and install it to the bushing. b. To prevent oil seal lip damage, wind vinyl tape on the steering rack end, and apply power steering fluid. c. Install the bushing. NOTICE: ^ Make sure to install the bushing facing the correct direction. ^ Be careful not to damage the oil seal lip. 5. INSTALL CYLINDER END STOPPER a. Align the installation hole for the wire of the stopper with the slot of the rack housing. b. Install a new wire into the stopper. c. Using SST, turn the stopper clockwise 450 ± 500 . SST 09631-10021 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. Page 4105 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 3450 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 2930 Engine Compartment Instrument Panel Locations Page 80 Part 2 Of 2 (Except California Spec.) *:Only for A/T Page 2688 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. Page 1035 Coolant: Fluid Type Specifications Coolant Type "Toyota Long Life Coolant" or Equivelant Coolant Do Not use alcohol type antifreezs or plain water alone. Diagrams Airbag(s) Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Airbag(s) Arming and Disarming CAUTION: * Work must be started 90 seconds after the ignition switch is turned to the "LOCK" position and the negative (-) terminal cable is disconnected from the battery. (The SRS is equipped with a back-up power source so that if work is started within 90 seconds of disconnecting the negative (-) terminal cable of the battery, the SRS may be deployed.) * When the negative (-) terminal cable is disconnected from the battery, the memory of the clock and audio system will be canceled. So before starting work, make a record of the contents memorized in the audio memory system. When work is finished, reset the audio systems as before and adjust the clock. To avoid erasing the memory of each memory system, never use a backup power supply from outside the vehicle. * Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during repairs. * Do not expose the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor directly to hot air or flames. AIR BAG SYSTEM DISARMING The Air Bag/Supplemental Restraint System (SRS) incorporates a backup energy source that maintains sufficient deployment voltage for up to 90 seconds after the ignition is turned Off and the battery has been disconnected. Before disconnecting battery, note radio station settings, since all vehicle memory will be lost. Never use a backup power source from outside the vehicle. 1. Turn ignition to Lock, then disconnect battery ground cable. 2. Wait at least 90 seconds after disconnection before beginning service or diagnostic procedures. AIR BAG SYSTEM ARMING 1. Ensure ignition is in Lock position. 2. Connect battery ground cable. 3. Wait at least 10 seconds before turning ignition from Lock position. 4. Turn ignition to ACC or On position and ensure SRS lamp lights, then goes off after approximately six seconds. If lamp remains lit, an SRS condition is indicated. Refer to Restraint Systems, Air Bag Systems, Testing And Inspection. See: Restraint Systems/Air Bag Systems/Testing and Inspection Locations Fusible Link: Locations Relay Box / No. 2 Page 1588 Page 333 Oxygen Sensor: Technical Service Bulletins Engine Controls - O2 Sensor Monitor Threshold Values SPECIAL SERVICE TOOLS SS002-03 December 17, 2003 Title O2S TEST RESULTS (MODE 05) Models All '96 - '03, '04 Corolla, ECHO, Matrix, Sienna & Scion xA & xB Introduction This Service Bulletin contains Oxygen Sensor (O2S) Monitor threshold values for all models from 1996 to 2003 and some 2004 models. Starting in 2004, the O2S Monitor threshold values can be found in the repair manual. These values are used when analyzing the O2S test results to determine the O2S condition. Applicable Vehicles ^ All 1996 - 2003 model year Toyota vehicles. ^ 2004 model year Corolla, ECHO, Matrix and Sienna vehicles. ^ 2004 model year Scion xA and xB vehicles. Function Description Checking O2S Test Results To view O2S test results, the O2S Monitor must be completed and the test results must be checked within the same key cycle. If the ignition key is cycled OFF, the O2S test results will be set to the minimum or maximum limits, and all test results will be erased. The O2S test results are stored in the ECU (SAE term: Powertrain Control Module/PCM) when the monitor is completed. The test results are static and will not change once the monitor is complete. The process for checking 02S test results is described in the following three basic steps: 1. Completing the O2S Readiness Monitor. 2. Accessing O2S Test Results. 3. Comparing O2S Test Results to Failure Thresholds. Required SSTs NOTE: Additional Diagnostic Tester Kits, Program Cards or other SSTs may be ordered by calling SPX-OTC at 1-800-933-8335. Warranty Information Completing O2S Readiness Monitor 1. Clear any stored Diagnostic Trouble Codes (DTCs) using the Toyota Diagnostic Tester. Page 3333 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. Page 3476 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 1440 Camshaft Position Sensor: Testing and Inspection INSPECTION 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. DENSO Made Actuator Control Cable: Testing and Inspection DENSO Made Step 1 INSPECTION PROCEDURE Page 1158 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 3572 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 3651 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 455 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 2707 REASSEMBLY Reassembly is in the reverse order of disassembly. NOTICE: Apply lithium soap base glycol grease to the rubber parts indicated by the arrows. Page 1771 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 3135 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 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 2037 Page 3231 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.). 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 1416 4) Remove the adjusting shim with a small screwdriver and magnetic finger. b) Determine the replacement adjusting shim size by these Formula or Charts: 1) Using a micrometer, measure the thickness of the removed shim. 2) Calculate the thickness of a new shim so that the valve clearance comes within the specified value. T Thickness of removed shim A Measured valve clearance N Thickness of new shim Intake: N = T + (A - 0.20 mm (0.008 inch) Exhaust: N = T + (A - 0.30 mm (0.012 inch) Page 3733 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 - 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 1902 g. Install the O-ring to the injector. h. Connect SST (union and hose) to the injector, and hold the injector and union with SST (clamp). SST 09268-41047 (09268-41110 for Except California Spec., 09268-41300 for California Spec.) i. Put the injector into a graduated cylinder. HINT: Install a suitable vinyl hose onto the injector to prevent gasoline from splashing out. j. Connect the TOYOTA hand-held tester to the DLC3. k. 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: Except California Spec: 69-88 Cu.cm (4.2 - 5.4 Cu in.) per 15 seconds California Spec: 71 - 86 Cu.cm (4.3 - 5.3 Cu in.) per 15 seconds Difference between each injector: Except California Spec: 5 Cu.cm (0.3 Cu in.) or less California Spec: 15 Cu.cm 1.0 Cu in.) or less If the injection volume is not as specified, replace the injector. Page 1514 Part 1 Of 2 (Except California Spec.) Page 1073 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 258 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. 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 293 Remove the 4 nuts, MAF meter and gasket. INSTALLATION 1. INSTALL MAF METER TO AIR CLEANER CAP a. Place a new gasket on the air cleaner cap. b. Install the MAF meter with the 4 nuts. Torque: 8.5 Nm (85 kg.cm, 74 in.lb) 2. INSTALL MAF METER WITH AIR CLEANER CAP Page 638 Assenmacher Specialty Tools 1-800-525-2943 Page 2038 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 intake camshaft. 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. 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 2888 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 4364 Page 1405 Spark Plug: Testing and Inspection INSPECT SPARK PLUGS a. Except California Spec.: Disconnect the high-tension cords from the spark plugs. b. California Spec.: Remove the ignition coils. c. Using a 16 mm plug wrench, remove the 4 spark plug. d. Using a spark plug cleaner or wire brush, clean the spark plug. e. Check the spark plug for electrode wear, threads damage and insulator damage. If abnormal, replace the plugs. Recommended spark plug: Except California Spec. DENSO made K16R-U NGK made BKR5EYA California Spec. DENSO made K16R-U11 NGK made BKR5EYA-U f. Adjust the electrode gap. Carefully bend the outer electrode to obtain the correct electrode gap. Correct electrode gap: Except California Spec. 1.1 mm (0.043 in.) California Spec. 0.8 mm (0.031 in.) Page 1569 CHART 11 Page 3223 c. Using SST, disconnect the steering knuckle from the up per ball joint. SST 09628-62011 d. Remove the nut and disconnect the steering knuckle from upper ball joint. NOTICE: Do not remove the jack. HINT: Support the steering knuckle securely. 5. REMOVE UPPER SUSPENSION ARM a. Loosen the 2 bolts and remove the front and rear alignment adjusting shims. Torque: 130 Nm (1,300 kgf-cm, 94 ft. lbs.) HINT: Make a note of the number and thickness of the front and rear shims. b. Remove the 2 bolts and upper suspension arm. 6. REMOVE UPPER BALL JOINT Remove the 4 bolts, nuts and upper ball joint from the upper suspension arm. Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.) INSPECTION INSPECT UPPER BALL JOINT FOR ROTATION CONDITION a. As shown in the illustration, flip the ball joint stud back and forth 5 times, before installing the nut. b. Using a torque wrench, turn the nut continuously 1 turn each 2-4 seconds and take the torque reading on the 5th turn. Turning torque: 0.5-3.5 Nm (5-35 kgf-cm, 4-30 inch lbs.) REPLACEMENT REPLACE UPPER SUSPENSION ARM SHAFT AND BUSHINGS a. Remove the lock bolts. Remove the 2 bolts and retainers from the arm shaft. b. Remove bushings. Cut off the shaded portions shown in the illustration to expose the edge of the tubes. Locations Vehicle Speed Sensor NO.1 (A43D) Page 3145 Part 2 Of 3 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. 2. Using an ohmmeter, check that there is continuity between terminals 3 and 5. 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 1698 Page 1303 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 2028 Knock Sensor: Testing and Inspection 1. REMOVE STARTER 2. REMOVE FUEL FILTER SET BOLTS 3. REMOVE KNOCK SENSOR a. Disconnect the knock sensor connector. b. Using SST, remove the knock sensor. SST 09816-30010 4. INSPECT KNOCK SENSOR Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor. 5. REINSTALL KNOCK SENSOR a. Using SST, install the knock sensor. SST 09816 - 30010 Torque: 44 Nm (450 kg.cm, 33 ft.lb) b. Connect the knock sensor connector. 6. REINSTALL FUEL FILTER SET BOLTS Torque: 20 Nm (200 kg.cm, 14 ft.lb) 7. REINSTALL STARTER Removal and Installation Wheel Bearing: Service and Repair Removal and Installation REMOVAL 1. REMOVE FRONT WHEEL 2. w/ ABS: DISCONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP FROM STEERING KNUCKLE Remove the 2 bolts and disconnect the ABS speed sensor and wire harness clamp from the steering knuckle. Page 248 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 1825 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 Page 340 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 405 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. 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. Specifications Axle Nut: Specifications - INSTALL AXLE HUB WITH DISC a. Place the axle hub on the spindle. b. Install a new outer bearing and claw washer. - ADJUST PRELOAD a. Install and torque the nut. Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.) b. Turn the hub several times to make the bearing more smoothly. c. Loosen the nut until it can be turned by hand. d. Using a spring tension gauge, measure and make a note down of the frictional force of the oil seal. HINT: Make sure to check preload in the direction of rotation. e. Tighten the nut until the preload is within the specified value. Preload (at starting): Frictional force plus 6 - 18 N (0.6 - 1.8 kgf, 1.3 - 4.0 ft. lbs.) HINT: Make sure to check preload in the direction of rotation. f. Using a dial indicator near the center of the axle hub and measure the backlash in the bearing shaft direction. Maximum: 0.05 mm (0.0020 inch) or less Page 2138 Page 236 Key Reminder Switch: Fuse and Fusible Link Locations Relay Box / No. 2 Page 2165 c. Remove the lock ball and snap ring. 7. REMOVE GOVERNOR BODY FROM OUTPUT SHAFT a. Using a large screwdriver, remove the retaining clip. b. Using a screwdriver unstake the lock plate, and remove the bolt and lock plate. c. Remove the governor body from the output shaft. 8. INSTALL GOVERNOR BODY TO OUTPUT SHAFT a. Place the governor body on the output shaft. HINT: Align the governor body and bolt hole on the output shaft. b. While lifting the retaining clip with a screwdriver, slide the governor body and insert the retaining clip end into the hole on the output shaft. c. Install a new lock plate with the bolt. Torque: 3.9 Nm (40 kgf-cm, 35 inch lbs.) Page 1102 Part 2 Of 2 REMOVAL 1. REMOVE ENGINE UNDER COVER 2. DRAIN ENGINE COOLANT 3. DISCONNECT AIR PIPE Remove the 2 bolts and disconnect the air pipe from the fan shroud. 4. DISCONNECT UPPER RADIATOR HOSE FROM RADIATOR 5. REMOVE OIL DIPSTICK GUIDE a) Remove the bolt, dipstick guide and engine wire bracket. b) Remove the O-ring from the dipstick guide. HINT: At the time of installation, please refer to the following items. Use a new O-ring. Page 3155 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 OIL SEAL a. Coat a new oil seal lip with power steering fluid. b. Using SST, press in the oil seal. SST 09950-60010 (09951-00250, 09951-00420, 09952-06010), 09950-70010 (09951-07360) NOTICE: ^ Make sure to install the oil seal facing the correct direction. ^ Take care that the oil seal does not get reversed as you install it. 3. INSTALL STEERING RACK a. Install SST to the rack. SST 09631-20102 HINT: If necessary, scrape the burrs off the rack teeth end and burnish. 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 2841 Page 1700 Page 1255 CHART 16 CHART 17 Page 2359 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.) Page 3110 Page 3428 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 1875 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 177 3. INSPECT ECT SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: Refer to the chart graph If the resistance is not as specified, replace the ECT sensor. 4. REINSTALL ECT SENSOR a. Install a new gasket to the ECT sensor. b. Using a 19 mm deep socket wrench, install the ECT sensor. Torque: 20 Nm (200 kg.cm, 14 ft.lb) c. Connect the ECT sensor connector. d. Install the engine wire protector to the 3 brackets. 5. REFILL WITH ENGINE COOLANT Capacity Specifications Refrigerant Oil: Capacity Specifications When Replacing, Add: Receiver 20 cc Condenser 40 cc Evaporator 40 to 50 cc Page 1082 3. INSPECT ECT SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: Refer to the chart graph If the resistance is not as specified, replace the ECT sensor. 4. REINSTALL ECT SENSOR a. Install a new gasket to the ECT sensor. b. Using a 19 mm deep socket wrench, install the ECT sensor. Torque: 20 Nm (200 kg.cm, 14 ft.lb) c. Connect the ECT sensor connector. d. Install the engine wire protector to the 3 brackets. 5. REFILL WITH ENGINE COOLANT Page 2814 a. 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) b. Check that SST (A) is secured to the rotor shaft. c. Mount SST (C) in a vise. d. Install the generator to SST (C). e. To loosen the pulley nut, turn SST (A) in the direction shown in the illustration. NOTE: To prevent damage to the rotor shaft, do not loosen the pulley nut more than on-half of a turn. f. Remove the generator from SST (C). g. Turn SST (B) and remove SST (A and B). h. Remove the pulley nut and pulley. 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 4308 #2 HINT: Troubleshoot the clock according to the table below. Page 3441 *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 1558 Page 2442 Shift Indicator: 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 Crankshaft Gear/Sprocket: Specifications Crankshaft Pulley Bolt Torque Using SST ........................................................................................... ...................................................................................................................... 260 Nm No. 3 and No. 2 Crankshaft Pulley Bolts (4) Torque (W/ A/C) ............................................................. ............................................................................................................................................ 25 Nm Diagram Information and Instructions Shift Indicator: 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 1023 Part 2 Of 2 Part 2 of 2 Specifications Clutch Fluid: Specifications Fluid Type FMVSS 116 DOT 3 Brake Fluid Page 3172 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 141 Right Side Right Side: If continuity is not as specified, replace the switch. 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 Vehicle Speed Sensor NO.1 (A43D) Page 1276 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 3710 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 2444 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 2332 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 347 CHART 10 Page 3144 Part 1 Of 3 Locations Page 713 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 1231 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 4287 Page 1579 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 3208 Ball Joint: Testing and Inspection INSPECTION INSPECT LOWER BALL JOINT EXCESSIVE PLAY 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) Locations Page 2891 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 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 3473 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 2857 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. 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. REINSTALLER MAIN RELAY Page 2670 Maximum disc runout: 0.07 mm (0.0028 inch) If the runout is greater than the maximum, replace the disc or grind it on a "On-Car" brake lathe. HINT: Before measuring the runout, confirm that the front hub bearing play is within the specification. 4. IF NECESSARY, REPLACE DISC a. Remove the torque plate from the knuckle. b. Remove the axle hub. c. Remove the disc from the axle hub. d. Install a new disc and torque the bolts. Torque: 64 Nm (650 kgf-cm, 47 ft. lbs.) e. Install the axle hub and adjust the front bearing preload. f. Install the torque plate onto the knuckle. Torque: 108 Nm (1,100 kgf-cm, 80 ft. lbs.) REASSEMBLY Reassembly is in the reverse order of disassembly. NOTICE: Apply lithium soap base glycol grease to the parts indicated by the arrows. Page 492 Steps 1 - 3 Page 1287 Heated Oxygen Sensor COMPONENTS 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. Page 682 Fluid - A/T: Fluid Type Specifications Transmission Fluid .............................................................................................................................. ................................................. ATF Dexron II or III 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 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 HINT: All vacuum hoses for EGR systems, etc. should be properly connected. f) SFI system wiring connectors fully plugged g) Ignition timing check 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 HINT: When doing the 2 mode (idle and 2,500 rpm) test, these measurement order prescribed by the applicable local regulations. Page 1013 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 PCV HOSES 3. Except California Spec.: DISCONNECT HIGH-TENSION CORDS FROM SPARK PLUGS 4. California Spec.: REMOVE IGNITION COILS (WITH IGNITER) NOTICE: Pulling on or bending the cords may damage the conductor inside. 5. DISCONNECT ENGINE WIRE a) w/ A/C: Disconnect the A/C compressor connector. b) Disconnect the oil pressure sensor connector. c) Disconnect the ECT sender gauge connector. d) Except California Spec.: Disconnect the ignition coil connector. e) Disconnect the 4 engine wire clamps and engine wire. 6. REMOVE CYLINDER HEAD COVER Remove the 10 bolts, 10 seal washers, cylinder head cover and gasket. 7. SET NO.1 CYLINDER TO TDC/COMPRESSION a) Turn the crankshaft pulley clockwise and align its groove with the "0" mark on the timing chain cover. b) Check that the timing marks (1 and 2 dots) of the camshaft drive and driven gears are in straight line on the cylinder head surface as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) and align the marks as above. 8. INSPECT VALVE CLEARANCE Page 374 Oxygen Sensor: Locations Air-Fuel Ratio (A/F) Sensor Page 1417 Page 1240 Page 3609 Seat Belt: Specifications Seat Belt Page 4024 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 1271 CHART 28 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. 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 2335 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 4286 Page 1653 Mass Air Flow Meter: Service and Repair COMPONENTS REMOVAL 1. REMOVE AIR CLEANER CAP WITH MAF METER a. Disconnect the MAF meter connector and wire clamp. b. Loosen the air cleaner hose clamp. c. Disconnect the air hose from air cleaner cap. d. Loosen the 4 clips, and remove the air cleaner cap together with the MAF meter. 2. REMOVE MAF METER FROM AIR CLEANER CAP Page 3687 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 1800 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 4420 Page 3721 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 4355 Key Reminder Switch: Ground Locations Page 1796 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 3157 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. 8. INSTALL OIL SEAL a. Coat a new oil seal lip with power steering fluid. b. Using SST, press in the oil seal. SST 09612-22011 NOTICE: Make sure to install the oil seal facing the correct direction. 9. INSTALL CONTROL VALVE HOUSING WITH CONTROL VALVE ASSEMBLY a. Place a new gasket on the rack housing. b. Align the matchmarks on the valve housing and rack housing. c. Torque the 2 bolts. Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.) 10. INSTALL SELF-LOCKING NUT Using SST to stop the control valve shaft rotating, torque a new nut. SST 09616-00010 Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.) 11. INSTALL DUST COVER Page 1258 Specifications Brake Drum: Specifications Inside Diameter: Standard 10.000 in Maximum 10.079 in Drum To Shoe Clearance 0.024 in Page 1955 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. 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 1857 SST 09268-45012 t. Reconnect the fuel inlet pipe to the delivery pipe with 2 new gaskets and the union bolt. Torque: 29 Nm (300 kg.cm, 22 ft.lb) u. Reconnect the negative (-) terminal cable to the battery. v. Check for fuel leakage. 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 2336 Page 3771 Page 1259 CHART 21 Page 1713 CHART 16 CHART 17 Page 4244 Audible Warning Device: Diagnostic Aids Voltage Check Voltage Check Voltage Check A. Establish conditions in which voltage is present at the check point. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (SW 2 OFF) B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Continuity and Resistance Check Continuity and Resistance Check Continuity And Resistance Check A. Disconnect the battery terminal or wire so there is no voltage between the check points. B. Contact the two leads of an ohmmeter to each of the check points. Page 3285 Diagrams Axle Shaft: Diagrams Part 1 Of 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 4315 Steps 1 - 2 INSPECTION PROCEDURE Front Wheel Fastener: Service and Repair Front REPLACEMENT 1. REMOVE FRONT WHEEL 2. REMOVE AXLE HUB WITH STEERING KNUCKLE 3. REMOVE HUB BOLT a. Place matchmarks on the disc and axle hub. b. Remove the 5 bolts and separate the disc and axle hub. c. Install the nut to the hub bolt. d. Using a brass bar and press, remove the hub bolt. 4. INSTALL HUB BOLT a. Using a brass bar and press, install a new hub bolt. b. Align the matchmarks and install the axle hub to the disc with the 5 bolts. Torque: 64 Nm (650 kgf-cm, 47 ft. lbs.) 5. INSTALL AXLE HUB WITH STEERING KNUCKLE 6. INSTALL FRONT WHEEL Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.) Page 3903 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 2660 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 1502 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 2092 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 367 Page 2280 9. INSTALL OIL STRAINER a. Install a new gasket to the oil strainer. b. Install the oil strainer to the valve body with the 5 bolts. Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.) 10. INSTALL OIL PIPES Using a plastic hammer, install the 2 pipes. NOTICE: Be careful not to bend or damage the pipe. 11. INSTALL OIL PAN a. Install the 2 magnets in the oil pan. NOTICE: Make sure that the magnets do not interfere with the oil pipes. b. Install a new gasket to the transmission case. HINT: Align the cut part of the gasket and case. c. Install the oil pan with the 14 bolts. Torque: 4.4 Nm (45 kgf-cm, 39 inch lbs.) NOTICE: Be careful not to damage the filler pipe. Page 799 * For vehicle capacity weight. ** For reduced loads (1 to 4 passengers). *** For trailer towing. Page 1304 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 1414 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 PCV HOSES 3. Except California Spec.: DISCONNECT HIGH-TENSION CORDS FROM SPARK PLUGS 4. California Spec.: REMOVE IGNITION COILS (WITH IGNITER) NOTICE: Pulling on or bending the cords may damage the conductor inside. 5. DISCONNECT ENGINE WIRE a) w/ A/C: Disconnect the A/C compressor connector. b) Disconnect the oil pressure sensor connector. c) Disconnect the ECT sender gauge connector. d) Except California Spec.: Disconnect the ignition coil connector. e) Disconnect the 4 engine wire clamps and engine wire. 6. REMOVE CYLINDER HEAD COVER Remove the 10 bolts, 10 seal washers, cylinder head cover and gasket. 7. SET NO.1 CYLINDER TO TDC/COMPRESSION a) Turn the crankshaft pulley clockwise and align its groove with the "0" mark on the timing chain cover. b) Check that the timing marks (1 and 2 dots) of the camshaft drive and driven gears are in straight line on the cylinder head surface as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) and align the marks as above. 8. INSPECT VALVE CLEARANCE Locations Page 1339 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 1567 CHART 8 CHART 9 Page 1917 Fuel Pressure: Specifications Volume Specification Information not supplied by the manufacturer. Page 4268 Junction Box / No. 1 Page 1360 b. Disconnect the connector from the integration relay and inspect the connectors on the wire harness side. Page 3798 Wire Harness Fuse Location Troubleshooting Procedure Page 2387 6. INSTALL INNER BEARING AND OIL SEAL a. Place inner bearing into the axle hub. b. Using SST and a hammer, install a new oil seal into the axle hub. SST 09527-17011, 09950-60020 (09951-00710), 09950-70010 (09951-07150) NOTICE: Be careful not to damage the ABS speed sensor rotor. c. Coat the oil seal lip with MP grease. 7. INSTALL AXLE HUB WITH DISC a. Place the axle hub on the spindle. b. Install a new outer bearing and claw washer. 8. ADJUST PRELOAD a. Install and torque the nut. Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.) b. Turn the hub several times to make the bearing more smoothly. c. Loosen the nut until it can be turned by hand. d. Using a spring tension gauge, measure and make a note down of the frictional force of the oil seal. HINT: Make sure to check preload in the direction of rotation. e. Tighten the nut until the preload is within the specified value. Preload (at starting): Frictional force plus 6-18 N (0.6-1.8 kgf, 1.3-4.0 lbs.) HINT: Make sure to check preload in the direction of rotation. Service and Repair Counter Gear: Service and Repair For further information regarding this component and the system that it is a part of please refer to Manual Transmission/Transaxle; Service and Repair. Page 1058 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 Specifications Shift Interlock Switch: Specifications Park/Neutral Position Switch ......................................................................................................................................... 5.4 Nm (55 kgf.cm, 48 inch lbs.) Park/Neutral Position Switch Adjusting Bolt ................................................................................................................. 3.9 Nm (40 kgf.cm, 35 inch lbs.) Page 2788 Battery: Technical Service Bulletins Electrical - Battery Maintenance and Testing PRODUCT GENERAL INFORMATION PG001-06 Title: BATTERY MAINTENANCE FOR IN-STOCK VEHICLES & PRE-DELIVERY Models: All Models & Model Years January 26, 2006 TSB REVISION NOTICE: ^ November 28, 2006: "Required SSTs" have been updated (SST P/N 00002-MCGR8 has been added). "Recommended Equipment" has been removed (superseded by SST P/N 00002-MCGR8). Screen prints and text have been updated in the "Battery Inspection Procedure". "Battery Service Procedure" has been renamed "Battery Inspection Results". Two sections have been added for SST P/N 00002-MCGR8: "Battery Charging Procedure" and "Battery Charging Results". PLEASE READ ENTIRE TSB. Previous versions of this TSB should be discarded. TSB UPDATE NOTICE: The information contained in this TSB supersedes TSB No. PG017-02. TSB No. PGO17-02 is now obsolete and should be discarded. Introduction A battery in a stored vehicle is subject to conditions that can reduce its performance and life. These conditions include storage period, temperature, parasitic drain, and battery load. Because of these factors, battery inspection and maintenance are required in order to ensure proper operation and optimal battery life. As a matter of policy, Toyota does not provide battery warranty coverage for discharged and/or failed batteries due to lack of maintenance. It is the dealer's responsibility to maintain the specified State of Charge (SOC) of the vehicle's battery while in stock and assure proper State of Charge (SOC) at delivery. To eliminate customer service concerns due to an undercharged battery during the first few weeks of ownership, all dealers should check battery State of Charge (SOC) and recharge, if necessary, within 48 hours of delivery to customers. Applicable Vehicles ^ All models and model years. Warranty Information Page 4413 Page 420 EGR Temperature Sensor: Testing and Inspection EGR Gas Temperature Sensor [Except Calif. Spec.] 1. REMOVE EGR VALVE 2. REMOVE EGR GAS TEMPERATURE SENSOR 3. INSPECT EGR GAS TEMPERATURE SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: at 50 °C (122 °F) 64 - 97 kohms at 100 °C (212 °F) 11 - 16 kohms at 150 °C (302 °F) 2 - 4 kohms If the resistance is not as specified, replace the sensor. 4. REINSTALL EGR GAS TEMPERATURE SENSOR 5. REINSTALL EGR VALVE Page 1042 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection 1. DRAIN ENGINE COOLANT 2. REMOVE ECT SENSOR a. Disconnect the engine wire protector from the 3 brackets. b. Disconnect the ECT sensor connector. c. Using a 19 mm deep socket wrench, remove the ECT sensor and gasket. Component Locations Clock: Component Locations Page 610 Spark Plug: Specifications Torque Specification Spark Plug x Cylinder Head ................................................................................................................ ......................................................................... 20 Nm Page 290 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. 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 660 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 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. Locations Page 3147 1. REMOVE 2 TURN PRESSURE TUBES a. Using SST, remove the tube. SST 09633-00020 b. Remove the 4 O-rings from the tube. 2. SECURE PS GEAR ASSEMBLY IN VISE Using SST, secure the gear assembly in a vise. SST 09612-00012 3. REMOVE RH AND LH TIE ROD ENDS AND LOCK NUTS Place matchmarks on the tie rod end and rack end. 4. 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. 5. REMOVE RH AND LH RACK ENDS AND CLAW WASHERS Page 2706 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 1472 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 3100 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. 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 the coil, closing the contacts of the EFI main relay (Marking: EFI) and supplying power to terminal +B of the ECM. WIRING DIAGRAM Specifications Valve Clearance: Specifications Valve Clearance Intake ................................................................................................................................................... ......................................................... 0.006 - 0.010 in Exhaust ................................................................................................................................................ ......................................................... 0.010 - 0.014 in Page 1003 Spark Plug: Application and ID Recommended Spark Plugs ND K16R-U NGK BKR5EYA 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 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 3117 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 2382 Page 1387 e. Install the injector to the delivery pipe and cylinder head as shown in the illustration. NOTE: Before installing the injector, must apply spindle oil or gasoline on the place where the delivery pipe or cylinder head touches an O-ring of the injector. f. Check that there are no fuel leaks after doing maintenance anywhere on the fuel system. 1. Connect the TOYOTA hand-held tester to the DLC3. 2. Turn ignition switch ON and push the TOYOTA hand-held tester main switch ON. NOTE: Do not start the engine. 3. Select the active test mode on the TOYOTA hand-held tester. 4. Please refer to the TOYOTA hand-held tester operator's manual for further details. 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 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. Page 2093 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 4289 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 3355 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. Page 1986 Throttle Body: Testing and Inspection Component 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 closed throttle position. 3. INSPECT THROTTLE POSITION SENSOR a. Apply vacuum to the throttle opener. b. Insert a thickness gauge between the throttle stop screw and stop lever. Locations Vehicle Speed Sensor NO.1 (A43D) 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 2846 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. Standard Spring Installed Load Standard spring installed load: Page 3617 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. 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. Capacity Specifications Fluid - Differential: Capacity Specifications Differential Fluid ................................................................................................................................... ....................................................................... 1.4 Qt Page 2314 Steps 3 - 4 INSPECTION PROCEDURE 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. Locations Page 2768 Steps 3 - 4 INSPECTION PROCEDURE Locations Page 4095 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 431 Mass Air Flow Meter: Service and Repair COMPONENTS REMOVAL 1. REMOVE AIR CLEANER CAP WITH MAF METER a. Disconnect the MAF meter connector and wire clamp. b. Loosen the air cleaner hose clamp. c. Disconnect the air hose from air cleaner cap. d. Loosen the 4 clips, and remove the air cleaner cap together with the MAF meter. 2. REMOVE MAF METER FROM AIR CLEANER CAP Page 2662 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. Service and Repair Throttle Valve Cable/Linkage: Service and Repair ON-VEHICLE REPAIR 1. DISCONNECT THROTTLE CABLE FROM ENGINE Disconnect the cable from the throttle linkage. 2. REMOVE PARK/NEUTRAL POSITION SWITCH 3. DISCONNECT THROTTLE CABLE FROM TRANSMISSION HOUSING Remove the bolt and disconnect the cable. 4. REMOVE DRAIN PLUG AND DRAIN ATF 5. REMOVE VALVE BODY 6. REMOVE THROTTLE CABLE FROM TRANSMISSION CASE a. Using a 10 mm socket driver, push the throttle cable end to remove it. b. Remove the O-ring. 7. INSTALL THROTTLE CABLE TO TRANSMISSION CASE If the throttle cable is new, perform the following operations a to c. a. Bend the cable so there is a radius of about 200 mm (7.87 inch). b. Pull the inner cable lightly until a slight resistance is felt, and hold it. c. Stake the stopper 0.8 - 1.5 mm (0.031 - 0.059 inch) from the end of outer cable. d. Coat a new O-ring with ATF and install it to the cable. e. Install the cable to the case. 8. INSTALL VALVE BODY 9. CONNECT THROTTLE CABLE TO TRANSMISSION HOUSING Connect the cable with the bolt. 10. INSTALL PARK/NEUTRAL POSITION SWITCH 11. CONNECT THROTTLE CABLE TO ENGINE 12. INSTALL DRAIN PLUG Torque: 20 Nm (205 kgf-cm, 15 ft. lbs.) 13. FILL ATF AND CHECK FLUID LEVEL 14. ADJUST THROTTLE CABLE 15. TEST DRIVE VEHICLE 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 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 3102 Pressure Specification Fuel Pressure: Specifications Fuel Pressure No Vacuum 38 to 44 psi Page 3669 Locations Relay Box: Locations Relay Box / No. 2 Page 1964 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. Check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. 3. REINSTALL CIRCUIT OPENING RELAY Front Wheel Fastener: Service and Repair Front REPLACEMENT 1. REMOVE FRONT WHEEL 2. REMOVE AXLE HUB WITH STEERING KNUCKLE 3. REMOVE HUB BOLT a. Place matchmarks on the disc and axle hub. b. Remove the 5 bolts and separate the disc and axle hub. c. Install the nut to the hub bolt. d. Using a brass bar and press, remove the hub bolt. 4. INSTALL HUB BOLT a. Using a brass bar and press, install a new hub bolt. b. Align the matchmarks and install the axle hub to the disc with the 5 bolts. Torque: 64 Nm (650 kgf-cm, 47 ft. lbs.) 5. INSTALL AXLE HUB WITH STEERING KNUCKLE 6. INSTALL FRONT WHEEL Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.) Page 88 Part 1 Of 2 (Except California Spec.) Locations Page 349 CHART 12 CHART 13 Page 1098 Part 2 Of 2 Part 2 of 2 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. Electrical Specifications Fuel Injector: Electrical Specifications Resistance Between Terminals 12 to 16 ohms at 68 deg F Removal and Installation Starter Motor: Service and Repair Removal and Installation Locations Relay Box: Locations Relay Box / No. 2 Page 3799 Page 3138 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 2177 Junction Box / No. 3 Page 1163 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 1373 SST 09268-45012 t. Reconnect the fuel inlet pipe to the delivery pipe with 2 new gaskets and the union bolt. Torque: 29 Nm (300 kg.cm, 22 ft.lb) u. Reconnect the negative (-) terminal cable to the battery. v. Check for fuel leakage. 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 50 Junction Box / No. 1 Details Page 916 Page 4239 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 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 2990 Engine Compartment Instrument Panel Locations 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 2441 Page 858 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 PCV HOSES 3. Except California Spec.: DISCONNECT HIGH-TENSION CORDS FROM SPARK PLUGS 4. California Spec.: REMOVE IGNITION COILS (WITH IGNITER) NOTICE: Pulling on or bending the cords may damage the conductor inside. 5. DISCONNECT ENGINE WIRE a) w/ A/C: Disconnect the A/C compressor connector. b) Disconnect the oil pressure sensor connector. c) Disconnect the ECT sender gauge connector. d) Except California Spec.: Disconnect the ignition coil connector. e) Disconnect the 4 engine wire clamps and engine wire. 6. REMOVE CYLINDER HEAD COVER Remove the 10 bolts, 10 seal washers, cylinder head cover and gasket. 7. SET NO.1 CYLINDER TO TDC/COMPRESSION a) Turn the crankshaft pulley clockwise and align its groove with the "0" mark on the timing chain cover. b) Check that the timing marks (1 and 2 dots) of the camshaft drive and driven gears are in straight line on the cylinder head surface as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) and align the marks as above. 8. INSPECT VALVE CLEARANCE Page 730 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. 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 939 Part 6 of 7 Page 1680 Knock Sensor: Testing and Inspection 1. REMOVE STARTER 2. REMOVE FUEL FILTER SET BOLTS 3. REMOVE KNOCK SENSOR a. Disconnect the knock sensor connector. b. Using SST, remove the knock sensor. SST 09816-30010 4. INSPECT KNOCK SENSOR Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor. 5. REINSTALL KNOCK SENSOR a. Using SST, install the knock sensor. SST 09816 - 30010 Torque: 44 Nm (450 kg.cm, 33 ft.lb) b. Connect the knock sensor connector. 6. REINSTALL FUEL FILTER SET BOLTS Torque: 20 Nm (200 kg.cm, 14 ft.lb) 7. REINSTALL STARTER Page 3014 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°05' (0.08°) Caster: 0°50' (0.83°) 3. Mark the alignment value measured when the vehicle was non-loaded on the adjustment chart. Example: Camber: 0°05' (0.08°) 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 shim thickness accordingly. Example: Page 1659 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 intake camshaft. 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. 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 2977 Engine Room R/B # 2 Engine Room R/B # 2 Page 3689 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 156 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 2348 Diagram Legend Page 500 Ignition Switch: Testing and Inspection 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 1015 4) Remove the adjusting shim with a small screwdriver and magnetic finger. b) Determine the replacement adjusting shim size by these Formula or Charts: 1) Using a micrometer, measure the thickness of the removed shim. 2) Calculate the thickness of a new shim so that the valve clearance comes within the specified value. T Thickness of removed shim A Measured valve clearance N Thickness of new shim Intake: N = T + (A - 0.20 mm (0.008 inch) Exhaust: N = T + (A - 0.30 mm (0.012 inch) Page 3290 6. INSTALL INNER BEARING AND OIL SEAL a. Place inner bearing into the axle hub. b. Using SST and a hammer, install a new oil seal into the axle hub. SST 09527-17011, 09950-60020 (09951-00710), 09950-70010 (09951-07150) NOTICE: Be careful not to damage the ABS speed sensor rotor. c. Coat the oil seal lip with MP grease. 7. INSTALL AXLE HUB WITH DISC a. Place the axle hub on the spindle. b. Install a new outer bearing and claw washer. 8. ADJUST PRELOAD a. Install and torque the nut. Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.) b. Turn the hub several times to make the bearing more smoothly. c. Loosen the nut until it can be turned by hand. d. Using a spring tension gauge, measure and make a note down of the frictional force of the oil seal. HINT: Make sure to check preload in the direction of rotation. e. Tighten the nut until the preload is within the specified value. Preload (at starting): Frictional force plus 6-18 N (0.6-1.8 kgf, 1.3-4.0 lbs.) HINT: Make sure to check preload in the direction of rotation. Page 4365 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 2118 Transmission Speed Sensor: Description and Operation Vehicle Speed Sensor NO.1 Vehicle Speed Sensor NO.1 Circuit Description The vehicle speed sensor outputs a 4-pulse signal for every revolution of the rotor shaft, which is rotated by the transmission output shaft via the driven gear. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. Vehicle Speed Sensor NO.2 Vehicle Speed Sensor NO.2 Circuit Description The No.2 vehicle speed sensor detects the rotation speed of the transmission output shaft and sends signals to the ECM. The ECM determines the vehicle speed based on these signals. Lower Control Arm: Service and Repair Lower REMOVAL 1. REMOVE FRONT WHEEL Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.) 2. REMOVE SHOCK ABSORBER Page 3204 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). Locations Vehicle Lifting: Locations Page 3660 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. 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. 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 radiator core) Page 3327 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. Page 1701 Page 2412 ^ 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. 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 Locations Camshaft Position Sensor: Locations Page 3370 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. Description and Operation Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor Crankshaft position sensor (NE signal) consists of and pickup coil. The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor generates 34 signals at every engine revolution. The ECM detects the standard crankshaft angle based on the G signal, and the actual crankshaft angle and the engine speed by the NE signal. Page 1688 A/F and 02 Sensor Identification Page 4373 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. 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. 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 2340 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 1724 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. Page 2918 Junction Box / No. 1 Details Page 243 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 555 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 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. Locations Page 3423 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 684 Fluid - A/T: Testing and Inspection FLUID INSPECTION 1. Check fluid level, as follows: NOTE: Drive the vehicle so that the engine and transaxle are at normal operating temperature. ATF temperature: 70 - 80°C (158 - 176°F). Only use the COOL range on the dipstick as a rough reference when the fluid is replaced or the engine does not run. a. Park the vehicle on a level surface and set the parking brake. b. With the engine idling and the brake pedal depressed, shift the shift lever into all positions from the Park (P) to Low (L) position and return to the P position. c. Pull out the oil level gauge and wipe it clean. d. Push it back fully into the pipe. e. Pull it out and check that the fluid level is in the HOT range. If the level is at the low side, add new Automatic Transmission Fluid. Fluid type: ATF D-II or DEXRON III (DEXRON II) NOTICE: Do not overfill. 2. Check fluid condition. If the fluid smells burnt or is black, replace fluid. Page 4409 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 2877 Connector Locations Page 78 Part 2 Of 2 (California Spec.) *1: Only for A/T *2: Only for 3RZ-FE *3: The ECM terminal voltage is fixed regardless of the output voltage from the sensor. Connectors (Except California Spec.) Page 593 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: 30 Nm (310 kg.cm, 22 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. Page 675 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 radiator reservoir until it is "FULL" line. 3. CHECK ENGINE COOLANT FOR LEAKS 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. Upper 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. Component Locations Auxiliary Power Outlet: Component Locations Page 3066 8. INSTALL WAVE WASHER Install the washer so that its protrusions fit into the slots in the side plate. 9. INSTALL REAR HOUSING a. Coat 2 new O-rings with power steering fluid and install them to the housing. b. Torque the 2 bolts. Torque: 24 Nm (240 kgf-cm, 17 ft. lbs.) 10. 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, 61 ft. lbs.) 11. 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.) 12. 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.) 13. MEASURE PS VANE PUMP ROTATING TORQUE Page 2748 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 2522 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 1238 ^ 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: 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 - 0.8 V is applied to terminal VTA of the ECM. The voltage applied to the terminals VTA of the ECM increases in proportion to the opening angle of the throttle valve and becomes approximately 3.2 - 4.9 V when the throttle valve is fully opened. The ECM judges the vehicle driving conditions from these signals input from terminal VTA, uses it as one of the conditions to decide the air-fuel ratio correction, power increase correction and fuel cut control etc. Page 2598 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 4182 Actuator Control Cable: Testing and Inspection FORD Made Step 1 INSPECTION PROCEDURE Page 2766 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 1497 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 1764 Page 4085 Page 2795 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 1878 Remove the 4 nuts, MAF meter and gasket. INSTALLATION 1. INSTALL MAF METER TO AIR CLEANER CAP a. Place a new gasket on the air cleaner cap. b. Install the MAF meter with the 4 nuts. Torque: 8.5 Nm (85 kg.cm, 74 in.lb) 2. INSTALL MAF METER WITH AIR CLEANER CAP Page 4425 Seat Belt Reminder Lamp: Fuse and Fusible Link Locations Relay Box / No. 2 Page 3202 Page 1768 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. Component Locations Shift Indicator: Component Locations Page 784 3. DISCONNECT BRAKE CALIPER a. Remove the 2 bolts and brake caliper. b. Support the brake caliper securely. 4. CHECK AXLE HUB BEARING BACKLASH a. Using a screwdriver, remove the grease cap. b. Using a dial indicator near the center of the axle hub and check the backlash in the bearing shaft direction. Maximum: 0.05 mm (0.0020 inch) If the backlash exceeds the maximum, replace the axle hub bearing. 5. REMOVE AXLE HUB WITH DISC a. Remove the cotter pin and lock cap. b. Using a 30 mm socket wrench, remove the nut. c. Remove the claw washer, outer bearing and axle hub with the disc from the steering knuckle. NOTICE: Be careful not to drop the outer bearing. 6. REMOVE OIL SEAL AND INNER BEARING a. Using a screwdriver, pry out the oil sea[. NOTICE: Be careful not to damage the ABS speed sensor rotor. b. Remove the inner bearing from the axle hub. 7. REMOVE DUST COVER Remove the 4 bolts and dust cover. 8. REMOVE STABILIZER BAR LINK Hold the bolt with a wrench, then remove the nut, 5 retainers, collar, 4 cushions and bolt. 9. REMOVE STEERING KNUCKLE a. Support the lower suspension arm with a jack. 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 1004 Spark Plug: Testing and Inspection INSPECT SPARK PLUGS a. Except California Spec.: Disconnect the high-tension cords from the spark plugs. b. California Spec.: Remove the ignition coils. c. Using a 16 mm plug wrench, remove the 4 spark plug. d. Using a spark plug cleaner or wire brush, clean the spark plug. e. Check the spark plug for electrode wear, threads damage and insulator damage. If abnormal, replace the plugs. Recommended spark plug: Except California Spec. DENSO made K16R-U NGK made BKR5EYA California Spec. DENSO made K16R-U11 NGK made BKR5EYA-U f. Adjust the electrode gap. Carefully bend the outer electrode to obtain the correct electrode gap. Correct electrode gap: Except California Spec. 1.1 mm (0.043 in.) California Spec. 0.8 mm (0.031 in.) Locations Vehicle Speed Sensor NO.1 (A43D) Page 3926 Page 3626 Front Seat Belt Extender Applications 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 2907 Engine Room Fuse Details Interior J/B # 1 Locations Intake Air Temperature Sensor: Locations The Intake Air Temperature (IAT) Sensor is installed in the Mass Air Flow (MAF) Meter. Page 1036 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. 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 4278 Splice Locations Page 3899 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. 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. Locations Page 4405 Page 2637 Brake Pad: Service and Repair REPLACEMENT 1. REMOVE FRONT WHEEL 2. INSPECT PAD LINING THICKNESS Check the pad thickness through the caliper inspection hole and replace pads if not within specification. Minimum thickness: 1.0 mm (0.039 inch) 3. LIFT UP CALIPER a. Remove the bottom side slide pin. b. Lift up the caliper and suspend it securely. HINT: Do not disconnect the flexible hose from the caliper. 4. REMOVE 2 BRAKE PADS WITH 4 ANTI-SQUEAL SHIMS 5. REMOVE PAD WEAR INDICATOR PLATE 6. REMOVE 4 PAD SUPPORT PLATES 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. REINSTALLER MAIN RELAY Page 110 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. 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 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 577 Fuel Pressure: Specifications Volume Specification Information not supplied by the manufacturer. 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. Collision / Non-Collision Inspections Airbag Sensor Assembly: Testing and Inspection Collision / Non-Collision Inspections VEHICLE NOT INVOLVED IN COLLISION Check a diagnostic system. VEHICLE INVOLVED IN COLLISION WITH AIRBAG NOT DEPLOYED Check a diagnostic system. * VEHICLE INVOLVED IN COLLISION WITH AIRBAG DEPLOYED Replace the airbag sensor assembly. * * Refer to SRS Warning Light Check, and How to Display and Read Diagnostic Trouble Codes. See: Air Bag Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Displaying & Reading Trouble Codes Page 450 Crankshaft Position Sensor: Service and Repair REPLACEMENT 1. REMOVE ENGINE UNDER COVER 2. REMOVE GENERATOR 3. REMOVE GENERATOR BRACKET Remove the 3 bolts and bracket. 4. REMOVE CRANKSHAFT POSITION SENSOR a. Disconnect the sensor connector. b. Disconnect the sensor connector from the connector bracket. c. Remove the 2 bolts and crankshaft position sensor. d. Remove the O-ring. 5. REINSTALL NEW CRANKSHAFT POSITION SENSOR a. Install a new O-ring to the sensor. b. Install the sensor with the 2 bolts. Torque: 8.5 Nm (85 kg.cm, 74 in.lb) c. Reinstall the sensor connector to the connector bracket. d. Reconnect the sensor connector. 6. REINSTALL GENERATOR BRACKET Install the bracket with the 3 bolts Torque: Bolt A: 74.5 Nm (760 kg.cm, 55 ft.lb) Bolt B: 18 Nm (180 kg.cm, 13 ft.lb) 7. REINSTALL GENERATOR 8. REINSTALL ENGINE UNDER COVER Page 2234 An AC voltage is generated in the No.2 vehicle speed sensor coil as the rotor mounted on the output shaft rotates, and this voltage is sent to the ECM. The gear shift point and lock-up timing are controlled by the ECM based on the signals from this vehicle speed sensor and the throttle position sensor signal. If the No.2 vehicle speed sensor malfunctions, the ECM uses input signals from the No.1 vehicle speed sensor as a back-up signal. ABS/TCS - Zero Point Calibration Information Steering Angle Sensor: Technical Service Bulletins ABS/TCS - Zero Point Calibration Information T-SB-0020-08 March 25, 2008 Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment Service Category Brake Section Brake Control/Dynamic Control System Market USA Applicability Introduction The purpose of this TSB is to provide information on when and how to perform the zero point calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting the battery is a necessary step for performing the zero point calibration. Warranty Information Required Tools & Equipment ^ Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE). ^ The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the service procedures listed in this bulletin. Preliminary Information Perform this procedure if any of these repairs have been performed on the vehicle: ^ Wheel alignment has been adjusted. ^ Any chassis components have been removed/installed or replaced. Locations Fusible Link: Locations Relay Box / No. 2 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 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 1265 CHART 25 Page 2454 Shift Indicator: Pinout Values and Diagnostic Parameters O 4 O/D MAIN SW 1-3 : Open with O/D main SW at ON position Closed with O/D main SW at OFF position Page 611 Spark Plug: Application and ID Recommended Spark Plugs ND K16R-U NGK BKR5EYA 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 1709 CHART 11 Page 1594 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) Removal and Installation Hydraulic Control Assembly - Antilock Brakes: Service and Repair Removal and Installation REMOVAL 1. REMOVE BRAKE LINE COVER Page 2800 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-fuse, M-fuses and fuses for continuity. Page 3929 Perform the procedure shown if there is any lamp malfunction. 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 685 Fluid - A/T: Service and Repair 1. Drain transaxle fluid, then install drain plug and new gasket. 2. With engine Off, add fluid through dipstick tube. Do not overfill. 3. Start engine, then move shift selector through all positions, ensuring smooth operation. 4. Allow to idle, then check at COOL level. 5. Allow to reach normal operating temperature, then recheck. Page 3652 Page 2051 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. Locations Page 58 Refer to Reset Procedure 1 for the vehicles with Electronically Controlled Automatic Transmissions: Locations Page 3151 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) 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 2 BEARINGS Page 3999 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 77 Engine Control Module: Connector Views Connectors (California Spec.) Part 1 Of 2 (California Spec.) Page 1696 ^ O2S TEST RESULTS A list of the available oxygen sensors will be displayed. 2. Select the desired oxygen sensor and press Enter. NOTE: The monitor result of the A/F sensor will not be displayed. If you select "Bank 1-Sensor 1" or Bank 2-Sensor 1" for a vehicle equipped with an A/F sensor, the Diagnostic Tester will display "No parameter to display." 3. Compare the test results with the values listed in the Failure Threshold Chart. * Although this procedure references the Toyota Diagnostic Tester, the O2S test results can be checked using a generic OBD II scantool. Refer to your OBD II scantool operator's manual for specific procedures. Comparing O2S Test Results to Failure Thresholds 1. Determine the correct O2S Failure Threshold Chart for your vehicle by looking in the "O2S Application Table," in this bulletin. 2. Select appropriate year, model, and engine for specified O2S Failure Threshold Chart. 3. Compare O2S test results with the specified O2S Failure Threshold Chart. It may be necessary to convert O2S test results to a specific measurement unit using the conversion factor that is supplied in the specified table. See example. Example: Capacity Specifications Fluid - M/T: Capacity Specifications Transmission Fluid Drain and refill ..................................................................................................................................... ........................................................................ 2.7 Qt Page 1245 CHART 1 Page 1473 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 4259 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 3671 Junction Box / No. 1 Locations Page 1237 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 4104 Removable Roof Page 4247 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. 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 87 Part 2 Of 2 (California Spec.) *1: Only for A/T *2: Only for 3RZ-FE *3: The ECM terminal voltage is fixed regardless of the output voltage from the sensor. Connectors (Except California Spec.) Specifications Accumulator: Specifications Accumulator Spring 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 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 Locations Relay Box: Locations Relay Box / No. 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. 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 Page 3063 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. 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 Page 3765 Page 1202 Camshaft Position Sensor: Testing and Inspection INSPECTION 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. 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 985 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: 30 Nm (310 kg.cm, 22 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. Page 165 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 3955 Page 2669 2. REMOVE PISTON SEAL FROM BRAKE CALIPER Using a screwdriver, remove the piston seal. 3. REMOVE SLIDING BUSHING AND BOOT Remove the sliding bushing and boot from the torque plate. HINT: At the time of installation, ensure that the sliding bushing and boot are secured firmly to the caliper grooves. INSPECTION 1. MEASURE PAD LINING THICKNESS Using a ruler, measure the pad lining thickness. Standard thickness: 12.0 mm (0.472 inch) Minimum thickness: 1.0 mm (0.039 inch) Replace the pad if the thickness is less than the minimum (the 1.0 mm slit is no longer visible), or if it shows signs of uneven wear. 2. MEASURE DISC THICKNESS Using a micrometer, measure the disc thickness. Standard thickness: 22.0 mm (0.866 inch) Minimum thickness: 20.0 mm (0.787 inch) If the disc is scored or worn, or if its thickness is less than the minimum, repair or replace the disc. 3. MEASURE DISC RUNOUT Using a dial indicator, measure the disc runout at a position 10 mm (0.39 inch) from the outside edge. 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 541 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 1074 7. Pump the radiator cap tester several times, and check the maximum pressure. Pumping speed: 1 pump/second HINT: Stop pumping when the valve opens and read the gauge. The gauge must be within the standard values listed below when the pressure valve opens. The cap is considered OK when the pressure holds steady or falls very slowly, but holds within the standard values listed below for one minute. Specification: If the maximum pressure is less than the minimum standard value, replace the radiator cap sub-assembly. Type: Plastic Cap, 108 kPa 1. Remove coolant and any foreign material on 0-ring "A." 2. Check that 0-ring "A" is not deformed, cracked, or swollen. 3. Apply engine coolant to 0-ring "A" and rubber point "B" before using the radiator cap tester. ^ Radiator Cap Tester: Snap-On/Sun P/N SVTS262A (or equivalent) 4. Before installing the radiator cap tester, use the applicable radiator cap adaptor provided in the following SST kits in conjunction with the radiator cap tester: ^ SST P/N 09230-00030-01 (09231-10080-01) or 09230-00020-01 (09231-10060-01) or 09230-00050-01(09231-10110-01 Page 1624 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 1025 Part 2 Of 2 INSPECTION 1. INSPECT WATER PUMP a) Visually check the air hole and drain hole for coolant leakage. If leakage is found, replace the water pump. 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 the fluid coupling for damage and silicon oil leakage. If necessary, replace the fluid coupling. c) Install the fan and fluid coupling with the 4 nuts. Torque: 5.5 Nm (55 kgf-cm, 49 inch lbs.) Page 1097 Water Pump: Diagrams WATER PUMP REPLACEMENT W/ RELATED COMPONENTS Part 1 Of 2 Part 1 of 2 Page 2366 Part 2 Of 2 REAR AXLE SHAFT REPLACEMENT AND OVERHAUL W/ RELATED COMPONENTS Page 4097 Paint: Application and ID Page 2940 Testing and Inspection Ignition Coil: Testing and Inspection Except California Spec.: INSPECT IGNITION COILS a. Disconnect the high-tension cords from the ignition coils. b. Disconnect the ignition coil connectors. c. Inspect the secondary coil resistance. Using an ohmmeter, measure the resistance between the high-tension terminals. Secondary coil resistance: Cold 9.7 - 16.7 kohms Hot 12.4 - 19.6 kohms If the resistance is not as specified, replace the ignition coil. d. Reconnect the ignition coil connectors. e. Reconnect the high-tension cords to the ignition coils. Page 3149 8. 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. 9. REMOVE RACK HOUSING CAP 10. REMOVE SELF-LOCKING NUT Using SST to stop the control valve shaft rotating, remove the nut. SST 09616-00010 11. REMOVE DUST COVER 12. 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. 13. REMOVE CONTROL VALVE ASSEMBLY a. To prevent oil seal lip damage, wind vinyl tape on the serrated part of the valve shaft. b. Press out the valve assembly with the oil seal. NOTICE: ^ Place a shop rag between the valve housing and the blocks. ^ Be careful not to drop the valve assembly. ^ Be careful not to damage the oil seal lip. 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 Page 1618 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 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 1792 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 3761 Page 4424 Junction Box / No. 3 Page 1442 REPLACEMENT 1. REMOVE THROTTLE BODY 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: 5.4 Nm (55 kg.cm, 48 in.lb) b. Connect the sensor connector. 4. REINSTALL THROTTLE BODY Page 4254 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. 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 1557 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 2883 Page 3870 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 1854 Fuel Pressure: Specifications Volume Specification Information not supplied by the manufacturer. Page 3504 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 3015 Front shim thickness: -1.7 mm (0.067 inch) Rear shim thickness: +11.6 mm (0.063 inch) d. Torque the upper suspension arm set bolts. Torque: 130 Nm (1,300 kgf-cm, 94 ft. lbs.) HINT: If the steering axis inclination is not as specified value after the camber and caster have been correctly adjusted, recheck the steering knuckle and front wheel for distortion or looseness. NOTICE: Adjust the shim thickness to 7 mm (4-11 mm), and adjust the difference between the front and rear of the upper suspension arm shaft to within 4 mm. Measuring Point Reference 5. INSPECT TOE-IN Toe-In: If the toe-in is not within the specified value, adjust the rack ends. 6. ADJUST TOE-IN 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: 54 Nm (550 kgf-cm, 40 ft. lbs.) f. Place the boots on the seats and install the clips. HINT: Make sure that the boots are not twisted. Page 2265 Valve Body: Diagrams VALVE BODY FRONT UPPER VALVE BODY REAR UPPER VALVE BODY Page 332 A/F and 02 Sensor Identification Page 2638 NOTICE: The pad support plates 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. 7. CHECK DISC THICKNESS AND RUNOUT 8. INSTALL 4 PAD SUPPORT PLATES 9. INSTALL NEW PADS NOTICE: When replacing worn pads, the anti-squeal shims and wear indicator plates must be replaced together with the pads. a. Install a pad wear indicator plate to the inner pad. b. Install the 2 anti-squeal shims to each pad. HINT: Apply disc brake grease to both sides of inner anti-squeal shims. c. Install the inner pad so that the wear indicator plate is facing downward, then install the outer pad NOTICE: Do not allow oil or grease to get on the rubbing face. 10. INSTALL CALIPER a. Draw out a small amount of brake fluid from the reservoir. b. Press in piston with a hammer handle or equivalent. HINT: If the piston is difficult to push in, loosen the bleeder plug and push in the piston while letting some brake fluid escape. c. Insert the brake caliper carefully so the boot is not wedged. d. Install and torque the slide pin. Torque: 88 Nm (900 kgf-cm, 65 ft. lbs.) 11. INSTALL FRONT WHEEL Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.) 12. DEPRESS BRAKE PEDAL SEVERAL TIMES 13. CHECK THAT FLUID LEVEL IS AT MAX LINE Locations Camshaft Position Sensor: Locations Page 1247 CHART 5 CHART 6 Page 4412 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. 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 51 Engine Compartment Instrument Panel Locations Page 4238 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 3942 Roof Headlining (Extra Cab) Page 510 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 4199 Steps 3 - 4 INSPECTION PROCEDURE Page 4166 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 Locations Ignition Switch and Key Unlock Warning Switch Page 2190 Shift Indicator: 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. Diagrams Radiator: Diagrams RADIATOR REPLACEMENT AND OVERHAUL W/ RELATED COMPONENTS Part 1 Of 2 Part 1 of 2 Page 3681 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 4157 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 3336 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 Manual Steering Gear Steering Gear: Diagrams Manual Steering Gear Part 1 Of 2 Service and Repair Reverse Idler Gear: Service and Repair For further information regarding this component and the system that it is a part of please refer to Manual Transmission/Transaxle; Service and Repair. Page 1906 2. DISCONNECT INJECTOR CONNECTOR Disconnect the 4 injection connectors. 3. REMOVE DELIVERY PIPE AND INJECTORS a. Disconnect the vacuum sensing hose from the fuel pressure regulator. b. Disconnect the fuel return hose from the fuel pressure regulator. c. Remove the union bolt and 2 gaskets, and disconnect the fuel inlet pipe from the delivery pipe. CAUTION: Put a suitable container or shop rag under the delivery pipe. - Slowly loosen the union bolt. d. Remove the 2 bolts and delivery pipe together with the 4 injectors. NOTE: Be careful not to drop the injectors when removing the delivery pipe. e. Remove the 4 insulators from the 4 spacers. f. Pull out the 4 injectors from the delivery pipe. g. Remove the grommet (Except California Spec.) and O-ring from each injector. INSTALLATION 1. INSTALL INJECTORS TO DELIVERY PIPE a. Except California Spec.: Install a new grommet to each injector. b. Apply a light coat of gasoline to the new O-ring and install them to the injector. c. While turning the injector left and right, install it to the delivery pipe. Install the 4 injectors. d. Position the injector connector upward. Page 960 a) Install the A/C compressor bracket with the 4 bolts. Torque: 44 Nm (440 kgf-cm, 32 ft. lbs.) b) Install the A/C compressor with the 4 bolts. Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.) 18. INSTALL CYLINDER HEAD ASSEMBLY 19. INSTALL WATER PUMP PULLEY, FAN WITH FLUID COUPLING AND DRIVE BELT FOR GENERATOR 20. 4WD: INSTALL FRONT DIFFERENTIAL AND DRIVE SHAFTS ASSEMBLY 21. FILL WITH ENGINE OIL 22. START ENGINE AND CHECK FOR LEAKS 23. INSTALL ENGINE UNDER COVER 24. VEHICLE ROAD TEST Check for abnormal noise, shock slippage, correct shift points and smooth operation. 25. RECHECK ENGINE COOLANT AND ENGINE OIL LEVEL Page 2722 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. Page 1249 CHART 8 CHART 9 Page 3137 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 3443 - 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 3672 Junction Box / No. 3 Page 562 Alignment: Specifications NOTE: RZN140L: Regular Cab, Short Wheelbase with 2RZ-FE engine RZN150L: Extra Cab, Extra Long Wheelbase with 2RZ-FE engine VZN150L: Extra Cab, Extra Long Wheelbase with 5VZ-FE engine INSPECTION 1. MEASURE VEHICLE HEIGHT Vehicle Height: Measuring points: A: Ground clearance of spindle center. B: Ground clearance of lower suspension arm bolt center. C: Ground clearance of rear axle shaft center. D: Ground clearance of leaf spring front hanger pin bolt center. NOTICE: Before inspecting the wheel alignment, adjust the vehicle height to the specified value. If the vehicle height is not the specified value, try to adjust it by pushing down on or lifting the body. 2. INSTALL CAMBER-CASTER-KINGPIN GAUGE OR POSITION VEHICLE ON WHEEL ALIGNMENT TESTER Follow the specific instructions of the equipment manufacturer. 3. INSPECT CAMBER, CASTER AND STEERING AXIS INCLINATION Camber, caster and steering axis inclination: Page 2052 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 570 Front shim thickness: -1.7 mm (0.067 inch) Rear shim thickness: +11.6 mm (0.063 inch) d. Torque the upper suspension arm set bolts. Torque: 130 Nm (1,300 kgf-cm, 94 ft. lbs.) HINT: If the steering axis inclination is not as specified value after the camber and caster have been correctly adjusted, recheck the steering knuckle and front wheel for distortion or looseness. NOTICE: Adjust the shim thickness to 7 mm (4-11 mm), and adjust the difference between the front and rear of the upper suspension arm shaft to within 4 mm. Measuring Point Reference 5. INSPECT TOE-IN Toe-In: If the toe-in is not within the specified value, adjust the rack ends. 6. ADJUST TOE-IN 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: 54 Nm (550 kgf-cm, 40 ft. lbs.) f. Place the boots on the seats and install the clips. HINT: Make sure that the boots are not twisted. Page 1722 CHART 24 Page 403 Diagram Information and Instructions Shift Indicator: 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 300 Camshaft Position Sensor: Service and Repair COMPONENTS Page 4294 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 976 6. TROUBLESHOOTING If the CO/HC concentration does not comply with regulations, troubleshoot according in the order given. 1) Check heated oxygen sensor operation. 2) See the table for possible causes, then inspect and correct the applicable causes if necessary. Page 3499 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 3243 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 2647 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 1209 3. INSPECT ECT SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: Refer to the chart graph If the resistance is not as specified, replace the ECT sensor. 4. REINSTALL ECT SENSOR a. Install a new gasket to the ECT sensor. b. Using a 19 mm deep socket wrench, install the ECT sensor. Torque: 20 Nm (200 kg.cm, 14 ft.lb) c. Connect the ECT sensor connector. d. Install the engine wire protector to the 3 brackets. 5. REFILL WITH ENGINE COOLANT Page 1308 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 1830 EGR Temperature Sensor: Testing and Inspection EGR Gas Temperature Sensor [Except Calif. Spec.] 1. REMOVE EGR VALVE 2. REMOVE EGR GAS TEMPERATURE SENSOR 3. INSPECT EGR GAS TEMPERATURE SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: at 50 °C (122 °F) 64 - 97 kohms at 100 °C (212 °F) 11 - 16 kohms at 150 °C (302 °F) 2 - 4 kohms If the resistance is not as specified, replace the sensor. 4. REINSTALL EGR GAS TEMPERATURE SENSOR 5. REINSTALL EGR VALVE Locations Heater Control Assembly Page 4410 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 1559 Drivetrain - Drive/Axle Shaft Replacement Precautions Drive/Propeller Shaft: Technical Service Bulletins Drivetrain - Drive/Axle Shaft Replacement Precautions TRANSMISSION & CLUTCH TC003-07 Title: DRIVESHAFT ASSEMBLY REPLACEMENT Models: '90 - '07 Toyota Introduction The purpose of this bulletin is to provide information regarding anti-corrosion grease that is present on replacement driveshaft assemblies. It is important to remove this grease prior to installing the hub nut to prevent overtightening. This also applies when reusing an old driveshaft that may have come into contact with oil or foreign matter. Applicable Vehicles ^ 1990 - 2007 model year Toyota vehicles. Required Tools & Material Repair Procedure Clean the threaded area of the driveshaft with Toyota Brake Cleaner (or equivalent) to remove the anti-corrosion grease, oil, or foreign matter before installing the driveshaft into the vehicle. NOTE: A new axle hub nut may be required when installing the driveshaft. Check the Repair Manual procedure for more information. Warranty Information Page 3943 Headliner: Diagrams Roof Headlining (Regular Cab) 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. 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 1063 3. DISCONNECT AIR PIPE Remove the 2 bolts and disconnect the air pipe. 4. DISCONNECT UPPER RADIATOR HOSE 5. DISCONNECT RADIATOR RESERVOIR HOSE 6. DISCONNECT LOWER RADIATOR HOSE 7. REMOVE NO.2 FAN SHROUD 8. A/T: DISCONNECT OIL COOLER HOSES 9. REMOVE RADIATOR Remove the 4 bolts and radiator. Torque: 12.5 Nm (125 kgf-cm, 9 ft. lbs.) HINT: At the time of installation, please refer to the following items. Insert the tabs of the radiator support through the radiator service holes. DISASSEMBLY 1. REMOVE NO.1 FAN SHROUD Remove the 4 bolts and fan shroud. Page 3058 4. INSTALL DRIVE BELT a. Tightening the belt adjusting bolt and adjust drive belt tension. b. Torque the power steering idle pulley set nut. Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.) 5. BLEED POWER STEERING SYSTEM Page 2311 Step 4 INSPECTION PROCEDURE Page 2202 Shift Indicator: Pinout Values and Diagnostic Parameters O 4 O/D MAIN SW 1-3 : Open with O/D main SW at ON position Closed with O/D main SW at OFF position 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 781 Page 2893 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 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 2088 Page 2299 1. PULL OUT BOOT WITH PUSH ROD 2. REMOVE PISTON Using compressed air, remove the piston with the spring from the cylinder. REASSEMBLY 1. COAT PISTON WITH LITHIUM SOAP BASE GLYCOL GREASE, AS SHOWN 2. INSTALL PISTON WITH SPRING INTO CYLINDER 3. INSTALL BOOT WITH PUSH ROD TO CYLINDER INSTALLATION Installation is in the reverse order of removal. HINT: After installation, bleed clutch system. Page 3099 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 3589 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 3312 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 1022 Water Pump: Diagrams WATER PUMP REPLACEMENT W/ RELATED COMPONENTS Part 1 Of 2 Part 1 of 2 Page 3462 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 4323 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 2780 If there is no continuity, replace the relay. 3. REINSTALL STARTER RELAY Page 430 Mass Air Flow Meter: Testing and Inspection 1. INSPECT MAF METER RESISTANCE Using an ohmmeter, measure the resistance between terminals THA and E3. Temperature Resistance -20 °C (-4 °F) 10 - 20 Kohms 0 °C (32 °F) 4 - 7 Kohms 20 °C (68 °F) 2 - 3 Kohms 40 °C (104 °F) 0.9 - 1.3 Kohms 60 °C (140 °F) 0.4 - 0.7 Kohms 80 °C (176 °F) 0.2 - 0.4 Kohms If the resistance is not as specified, replace the MAF meter. 2. INSPECT MAF METER OPERATION a. Connect the negative (-) terminal cable to the battery. b. Turn the ignition switch ON. c. Connect the MAF meter connector. d. Using a voltmeter, connect the positive (+) tester probe to terminal VG, and negative (-) tester probe to terminal E3. e. Blow air into the MAF meter, and check that the voltage fluctuates. If operation is not as specified, replace the MAF meter. f. Turn the ignition switch OFF. g. Disconnect the negative (-) terminal cable from the battery. h. Disconnect the MAF meter connector. Page 1452 Step 1 Step 2 OBD II scan tool (excluding TOYOTA hand-held tester): 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 4307 Clock: Testing and Inspection #1 Page 4167 Steps 1 - 2 Page 1769 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 1456 Crankshaft Position Sensor: Testing and Inspection INSPECT CRANKSHAFT POSITION SENSOR a. Remove the sensor. b. Using an ohmmeter, measure the resistance between terminals NE and NE-. Resistance: Cold 1,630 - 2,740 kohms Hot 2,065 - 3,225 kohms If the resistance is not as specified, replace the sensor. c. Reinstall the sensor. Page 255 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 1024 Water Pump: Testing and Inspection Part 1 Of 2 Page 473 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 1555 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 1047 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 3605 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 206 Steps 2 - 3 INSPECTION PROCEDURE Page 3732 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. Component Locations Cigarette Lighter: Component Locations Page 3338 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 1150 Page 2490 Transmission Position Switch/Sensor: Service and Repair ON-VEHICLE REPAIR 1. REMOVE FRONT EXHAUST PIPE AND HEAT INSULATOR 2. DISCONNECT OIL COOLER PIPE a. Remove the 3 oil cooler pipe clamps. b. Disconnect the oil cooler pipe. 3. REMOVE ELBOW AND O-RING 4. REMOVE PARK/NEUTRAL POSITION SWITCH a. Disconnect the connector. b. Pry off the lock washer and remove the nut. c. Remove the bolt and park/neutral position switch. 5. INSTALL PARK/NEUTRAL POSITION SWITCH a. Install the park/neutral position switch and bolt. Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.) b. Install a new lock plate and the nut. Torque: 3.9 Nm (40 kgf-cm, 35 inch lbs.) c. Bend claws on the lock plate to fix the nut. d. Adjust the park/neutral position switch. e. Connect the connector. 6. INSTALL ELBOW AND NEW O-RING Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.) 7. CONNECT OIL COOLER PIPES a. Connect the oil cooler pipe. Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.) b. Install the 3 oil cooler pipe clamps. 8. INSTALL FRONT EXHAUST PIPE AND HEAT INSULATOR Specifications Planetary Gears: Specifications Planetary Sun Gear Maximum Inside Diameter .................................................................................................................................................... 21.58 mm (0.8496 inch) Front Planetary Gear Planetary Pinion Gear Thrust Clearance ......................................................................................................... 0.20 - 0.50 mm (0.0079 - 0.0197 inch) Rear Planetary Gear Planetary Pinion Gear Thrust Clearance ......................................................................................................... 0.20 - 0.50 mm (0.0079 - 0.0197 inch) Page 2078 Junction Box / No. 3 Page 1227 Applicable Vehicles Page 970 Fuel Pressure: Testing and Inspection 1. INSPECT FUEL PUMP OPERATION a. Connect the TOYOTA hand-held tester to the DLC3. b. Turn the ignition switch ON and push the 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. f. Check that there is pressure in the 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. 2. CHECK FUEL PRESSURE a. Check that the battery positive voltage is above 12V. b. Disconnect the negative (-) terminal cable from the battery. c. Remove the union bolt and 2 gaskets, and disconnect the fuel inlet pipe from the delivery pipe. CAUTION: Put a suitable container or shop rag under the delivery pipe. Page 337 Page 336 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 4421 Page 3639 Front Seat Belt Extender Applications Page 2176 Junction Box / No. 1 Page 1907 2. INSTALL INJECTORS AND DELIVERY PIPE a. Place the 4 new insulators and in position on the spacers. b. Place the 4 injectors together with the delivery pipe in position on the cylinder head. c. Temporarily install the 2 bolts holding the delivery pipe to the cylinder head. d. 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. e. Position the injector connector upward. f. Tighten the 2 bolts holding the delivery pipe to the cylinder head. Torque: 21 Nm (210 kg.cm, 15 ft.lb) g. Connect the fuel inlet pipe to the delivery pipe with 2 new gaskets and the union bolt. Torque: 29 Nm (300 kg.cm, 22 ft.lb) h. Connect the fuel return hose to the fuel pressure regulator. i. Connect the vacuum sensing hose to the fuel pressure regulator. 3. CONNECT INJECTOR CONNECTOR 4. INSTALL AIR CLEANER HOSE WITH RESONATOR AND INTAKE AIR CONNECTOR Page 84 Step 1 Step 2 Step 3 Step 4 Page 222 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. 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) Page 4314 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 2519 Page 1639 Step 5 Step 6 Step 7 INSPECTION PROCEDURE Page 2064 Spark Plug: Testing and Inspection INSPECT SPARK PLUGS a. Except California Spec.: Disconnect the high-tension cords from the spark plugs. b. California Spec.: Remove the ignition coils. c. Using a 16 mm plug wrench, remove the 4 spark plug. d. Using a spark plug cleaner or wire brush, clean the spark plug. e. Check the spark plug for electrode wear, threads damage and insulator damage. If abnormal, replace the plugs. Recommended spark plug: Except California Spec. DENSO made K16R-U NGK made BKR5EYA California Spec. DENSO made K16R-U11 NGK made BKR5EYA-U f. Adjust the electrode gap. Carefully bend the outer electrode to obtain the correct electrode gap. Correct electrode gap: Except California Spec. 1.1 mm (0.043 in.) California Spec. 0.8 mm (0.031 in.) Locations Page 1690 Applicable Vehicles Page 2390 2. REMOVE BEARING OUTER RACES Using SST, a brass bar and hammer, remove the inside and out side of the bearing outer races. SST 09527-17011 NOTICE: Be careful not to damage the ABS speed sensor rotor. REASSEMBLY INSTALL NEW BEARING OUTER RACES a. Using SST and a press, install a new inside of the bearing outer race. SST 09527-17011, 09950-60010 (09951-00640), 09950-70010 (09951-07150) b. Using SST and a press, install a new outside of the bearing race. SST 09527-17011, 09950-60010 (09951-00490), 09950-70010 (09951-07150) NOTICE: Be careful not to damage the ABS speed sensor rotor. Page 2980 Interior Fuse Box Interior Panel Fuse Details Page 569 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°05' (0.08°) Caster: 0°50' (0.83°) 3. Mark the alignment value measured when the vehicle was non-loaded on the adjustment chart. Example: Camber: 0°05' (0.08°) 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 shim thickness accordingly. Example: Page 2014 Crankshaft Position Sensor: Testing and Inspection INSPECT CRANKSHAFT POSITION SENSOR a. Remove the sensor. b. Using an ohmmeter, measure the resistance between terminals NE and NE-. Resistance: Cold 1,630 - 2,740 kohms Hot 2,065 - 3,225 kohms If the resistance is not as specified, replace the sensor. c. Reinstall the sensor. Page 3769 ^ 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 Specifications Engine Oil Drain Plug: Specifications Oil Drain Plug Torque .......................................................................................................................... .............................................................................................. 33 ft.lb Locations Timing Component Alignment Marks: Locations Timing Mark Locations Page 3800 Perform the procedure shown if there is any lamp malfunction. Page 1250 CHART 10 Page 3498 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 1717 CHART 21 Page 1727 CHART 27 Page 2872 Auxiliary Power Outlet: Fuse and Fusible Link Locations Relay Box / No. 2 Page 3410 Refrigerant Oil: Fluid Type Specifications Type ND-OIL 8 Page 2941 Specifications Crankshaft: Specifications Crankshaft Thrust Clearance Standard ............................................................................................... ...................................................................................................... 0.020 - 0.220 mm Maximum ......... .............................................................................................................................................................. ....................................... 0.30 mm Thrust Washer Thickness ............................................................. .............................................................................................................. 2.440 - 2.490 mm Bearing Inside Diameter (From Front Side) 2.7L (3RZ-FE) No.1 (RH) ............................................... ............................................................................................................................................... 38.025 38.045 mm No.2 (LH) .......................................................................................................................... .................................................................... 37.525 - 37.545 mm Main Journal Diameter (From Front Side) 2.7L (3RZ-FE) No.1 (RH) .................................................. ............................................................................................................................................ 37.969 38.985 mm No.2 (LH) .......................................................................................................................... .................................................................... 37.449 - 37.465 mm Maximum Circle Runout ...................................................................................................................... .................................................................... 0.03 mm Main Journal Diameter STD No.3 ........................................................................................................ ............................................................................................... 59.981 - 59.994 mm Others ................. .............................................................................................................................................................. ...................... 59.987 - 60.000 mm U/S 0.25 No.3 .............................................................................. ......................................................................................................................... 59.740 - 59.750 mm Others .................................................................................................................................................. ................................................... 59.745 - 59.755 mm Crank Pin Diameter STD ..................................................................................................................... ................................................................................... 52.987 - 53.000 mm U/S 0.25 ......................... .............................................................................................................................................................. .......... 52.745 - 52.755 mm Maximum Taper Out-Of-Round ........................................................................................................... .................................................................. 0.005 mm Specifications Compression Check: Specifications Compression Pressure ........................................................................................................................ ..................................................... 1,230 kPa or More Minimum Pressure .......................................... .......................................................................................................................................................... 880 kPa Difference Between Each Cylinder ........................................................................................ ........................................................................ 98 kPa or Less Capacity Specifications Engine Oil: Capacity Specifications Engine Oil Drain and refill With oil filter change .................................................................................................... ..................................................................................... 6.0 qt (5.7L) Without oil filter change ............. .............................................................................................................................................................. ......... 5.3 qt (5.0L) Dry fill .................................................................................................................... ............................................................................................ 6.3 qt (6.0L) Page 2854 a. Remove the 2 screws. Torque: 5.9 Nm (60 kg.cm, 52 in.lb) for 1.4 kW 9.3 Nm (93 kg.cm, 82 in.lb) for 2.0 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 and end cover from the field frame. Torque: 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 3449 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 . Testing and Inspection Igniter: Testing and Inspection ON-VEHICLE INSPECTION NOTE: "Cold" and "Hot" in these sentences express the temperature of the coils themselves. "Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F). INSPECT IGNITION COIL WITH IGNITOR AND SPARK TEST Check that the spark occurs. 1. Remove the ignition coils. 2. Remove the spark plugs. 3. Install the spark plugs to each ignition coil, and connect the ignition coil connector. 4. Ground the spark plug. 5. Check if spark occurs while engine is being cranked. NOTE: To prevent gasoline from being injected from injectors during this test, crank the engine for no more than 1 - 2 seconds at time. If the spark does not occur, do the test as per the flow chart. Page 2521 Shift Indicator: 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 2073 Page 4234 Junction Box / No. 1 Junction Box / No. 3 Page 568 RZN140L Model RZN150L Model VZN150L 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 upper suspension arm set bolts. b. Adjust the camber and caster by adding or removing shims (See adjustment chart). Shim Thickness: HINT: Try to adjust the camber and caster to the center of the specified values. Page 4033 Page 2954 Page 2950 Relay Box / No. 2 Ground Locations Page 203 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 623 4) Remove the adjusting shim with a small screwdriver and magnetic finger. b) Determine the replacement adjusting shim size by these Formula or Charts: 1) Using a micrometer, measure the thickness of the removed shim. 2) Calculate the thickness of a new shim so that the valve clearance comes within the specified value. T Thickness of removed shim A Measured valve clearance N Thickness of new shim Intake: N = T + (A - 0.20 mm (0.008 inch) Exhaust: N = T + (A - 0.30 mm (0.012 inch) Page 281 If continuity is not as specified, replace the switch. Page 937 Part 4 of 7 Page 1568 CHART 10 Page 3123 Steering Gear: Diagrams Power Steering Gear Part 1 Of 3 Page 1889 e. Install the injector to the delivery pipe and cylinder head as shown in the illustration. NOTE: Before installing the injector, must apply spindle oil or gasoline on the place where the delivery pipe or cylinder head touches an O-ring of the injector. f. Check that there are no fuel leaks after doing maintenance anywhere on the fuel system. 1. Connect the TOYOTA hand-held tester to the DLC3. 2. Turn ignition switch ON and push the TOYOTA hand-held tester main switch ON. NOTE: Do not start the engine. 3. Select the active test mode on the TOYOTA hand-held tester. 4. Please refer to the TOYOTA hand-held tester operator's manual for further details. 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 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. Page 3388 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 3166 Service Information Page 2279 a. Remove the 17 bolts. b. Disconnect the throttle cable from the cam and remove the valve body. 8. INSTALL VALVE BODY a. While holding the cam down with your hand, connect the throttle cable. b. Install the 17 bolts as shown in the illustration. Torque: 10 Nm (100 kgf-cm, 7 ft. lbs.) HINT: Each bolt length is indicated. Bolt length: A: 20 mm (0.79 inch) B: 25 mm (0.98 inch) C: 30 mm (1.18 inch) D: 35 mm (1.42 inch) E: 40 mm (1.57 inch) F: 47 mm (1.85 inch) G: 55 mm (2.17 inch) c. Align the groove of the manual valve to the pin of the lever. Page 625 3) Select a new shim with a thickness as close as possible to the calculated value. HINT: Shims are available in 17 sized in increments of 0.05 mm (0.0020 inch), from 2.50 mm (0.0984 inch) to 3.30 mm (0.1299 inch). Page 3904 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 1552 Engine Bank Identification Page 2945 Page 2214 Planetary Gears: Diagrams PLANETARY SUN GEAR FRONT PLANETARY GEAR REAR PLANETARY GEAR Page 1687 Engine Bank Identification Page 3210 a. Loosen the 2 lower ball joint set bolts. Torque: 160 Nm (1,600 kgf-cm, 116 ft. lbs.) HINT: Do not remove the bolts. b. Remove the cotter pin and nut. Torque: 72 Nm (730 kgf-cm, 53 ft. lbs.) HINT: At the time of installation, if the holes for the coffer pin are not aligned, tighten the nut further up to 60°. c. Using SST, disconnect the tie rod end. SST 09610-20012 4. REMOVE LOWER BALL JOINT a. Remove the coffer pin and loosen the nut. Torque: 110 Nm (1,100 kgf-cm, 80 ft. lbs.) HINT: At the time of installation, if the holes for the coffer pin are not aligned, tighten the nut further up to 60°. b. Using SST, disconnect the lower ball joint. SST 09628-62011 c. Remove the nut, 2 bolts and lower ball joint. INSPECTION INSPECT LOWER BALL JOINT FOR ROTATION CONDITION Page 958 a) Install 3 new gaskets to the cylinder block and water bypass pipe. b) Install the timing chain cover with the 9 bolts and 2 nuts. Torque: 20 Nm (200 kgf-cm, 14 ft. lbs.) for 12 mm head bolt A 24.5 Nm (250 kgf-cm, 18 ft. lbs.) for 12 mm head bolt B 44 Nm (440 kgf-cm, 32 ft. lbs.) for 14 mm head bolt 20 Nm (200 kgf-cm, 14 ft. lbs.) for nut c) Install the 2 timing chain cover bolts. Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.) d) Install the 2 water bypass pipe nuts. Torque: 20 Nm (200 kgf-cm, 14 ft. lbs.) e) Remove the cord from the chain. 10. INSTALL CRANKSHAFT PULLEY a) Align the pulley set key with the key groove of the pulley, and slide on the pulley. b) Using SST, install and torque the pulley bolt. SST 09213-54015, 09330-00021 Torque: 260 Nm (2,650 kgf-cm, 193 ft. lbs.) c) w/ A/C: Install the No.3 and No.2 crankshaft pulleys with the 4 bolts. Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.) 11. INSTALL OIL STRAINER Install a new gasket and the oil strainer with the bolt and 2 nuts. Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.) Locations Page 1495 Page 1704 CHART 2 CHART 3 CHART 4 Page 1419 c) Install a new adjusting shim. 1) Place a new adjusting shim on the valve lifter. 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. 10. REINSTALL CYLINDER HEAD COVER 11. RECONNECT ENGINE WIRE 12. Except California Spec.: REINSTALL HIGH-TENSION CORDS TO SPARK PLUGS 13. California Spec.: REINSTALL IGNITION COILS (WITH IGNITER) 14. REINSTALL PCV HOSES 15. REINSTALL INTAKE AIR CONNECTOR Page 2406 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. 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.) INSTALLATION Page 3369 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 Page 3872 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 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 1651 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. 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 ECM will be erased when the battery negative (-) terminal cable is removed from the battery. Therefore, if necessary, read the diagnostic trouble code(s) 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 a new gasket. 2. Tighten the union bolt by hand. 3. Tighten the union bolt to the specified torque. Torque: 29 Nm (300 kg.cm, 22 ft.lb) Page 861 Specifications Idle Speed: Specifications Idle Speed 700 +/- 50 rpm Page 1524 Idle Air Control Valve: Service and Repair COMPONENTS REMOVAL 1. REMOVE THROTTLE BODY Page 1140 Refer to Reset Procedure 1 for the vehicles with Electronically Controlled Automatic Transmissions: Page 442 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 intake camshaft. 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. 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 3697 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 2505 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. 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 800 Wheel Fastener: Specifications Hub Nut ............................................................................................................................................... ................................................... 110 Nm (83 ft. lbs.) Page 2370 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 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 4432 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 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. 2. Using an ohmmeter, check that there is continuity between terminals 3 and 5. 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. Testing and Inspection Headlamp Relay: Testing and Inspection INSPECT HEADLIGHT CONTROL RELAY CONTINUITY If continuity is not as specified, replace the relay. Page 2197 Shift Indicator: Electrical Diagrams Page 1985 2. INSPECT THROTTLE POSITION SENSOR a. Disconnect the sensor connector. b. Apply vacuum to the throttle opener. c. Using an ohmmeter, measure the resistance between each terminal. d. Reconnect the sensor connector. 3. INSPECT THROTTLE OPENER a. Allow the engine to warm up to normal operating temperature. b. Check the idle speed. Idle speed: 650 - 750 rpm 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: 1,200 - 1,500 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. h. Disconnect TOYOTA hand-held tester or OBDII scan tool. Page 2119 An AC voltage is generated in the No.2 vehicle speed sensor coil as the rotor mounted on the output shaft rotates, and this voltage is sent to the ECM. The gear shift point and lock-up timing are controlled by the ECM based on the signals from this vehicle speed sensor and the throttle position sensor signal. If the No.2 vehicle speed sensor malfunctions, the ECM uses input signals from the No.1 vehicle speed sensor as a back-up signal. Page 2039 Camshaft Position Sensor: Testing and Inspection INSPECTION 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 1945 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. 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 HINT: All vacuum hoses for EGR systems, etc. should be properly connected. f) SFI system wiring connectors fully plugged g) Ignition timing check 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 HINT: When doing the 2 mode (idle and 2,500 rpm) test, these measurement order prescribed by the applicable local regulations. Page 2593 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 957 a) Install the No.1 damper with the bolt and nut. Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.) b) Install the slipper with the bolt. Torque: 27 Nm (270 kgf-cm, 20 ft. lbs.) c) Check that the slipper moves smoothly. 7. INSTALL CRANKSHAFT TIMING SPROCKET HINT: If necessary, install the sprocket with SST. SST 09636-20010 8. INSTALL NO.1 TIMING CHAIN AND CAMSHAFT TIMING SPROCKET a) Align the timing mark between the mark link of the No.1 timing chain, and install the No.1 timing chain to the timing sprocket. b) Align the timing mark of the crankshaft timing sprocket with the mark link of the No.1 timing chain and install the No.1 timing chain. c) Tie the No.1 timing chain with a cord as shown in the illustration, and make sure it doesn't come loose. 9. INSTALL TIMING CHAIN COVER Page 4292 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 Shift Interlock Switch: Specifications Park/Neutral Position Switch ......................................................................................................................................... 5.4 Nm (55 kgf.cm, 48 inch lbs.) Park/Neutral Position Switch Adjusting Bolt ................................................................................................................. 3.9 Nm (40 kgf.cm, 35 inch lbs.) 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. 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 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 4288 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 85 Step 5 Step 6 Step 7 INSPECTION PROCEDURE Page 2975 Engine Compartment Instrument Panel Locations Page 1288 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 Locations Intake Air Temperature Sensor: Locations The Intake Air Temperature (IAT) Sensor is installed in the Mass Air Flow (MAF) Meter. Pressure Specification Fuel Pressure: Specifications Fuel Pressure No Vacuum 38 to 44 psi Page 3267 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 1584 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. Locations Ignition Switch and Key Unlock Warning Switch Page 3276 Page 3792 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.). 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. 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 1525 2. REMOVE IAC VALVE - Except California Spec.: Remove the 4 screws, IAC valve and gasket. - California Spec.: Remove the 3 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 2009 Camshaft Position Sensor: Service and Repair COMPONENTS Page 4019 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 1072 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 3966 Page 1203 Camshaft Position Sensor: Service and Repair COMPONENTS Page 3104 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 1404 Spark Plug: Application and ID Recommended Spark Plugs ND K16R-U NGK BKR5EYA 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 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. REINSTALLER MAIN RELAY Page 2836 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 644 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: 30 Nm (310 kg.cm, 22 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. 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 ........................................................................................................................ ..................................................... 1,230 kPa or More Minimum Pressure .......................................... .......................................................................................................................................................... 880 kPa Difference Between Each Cylinder ........................................................................................ ........................................................................ 98 kPa or Less 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 3192 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. Specifications Parking Pawl: Specifications Parking Lock Pawl Bracket ............................................................................................................................................ 7.4 Nm (75 kgf.cm, 65 inch lbs.) Page 1309 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 1694 Oxygen Sensor: Technical Service Bulletins Engine Controls - O2 Sensor Monitor Threshold Values SPECIAL SERVICE TOOLS SS002-03 December 17, 2003 Title O2S TEST RESULTS (MODE 05) Models All '96 - '03, '04 Corolla, ECHO, Matrix, Sienna & Scion xA & xB Introduction This Service Bulletin contains Oxygen Sensor (O2S) Monitor threshold values for all models from 1996 to 2003 and some 2004 models. Starting in 2004, the O2S Monitor threshold values can be found in the repair manual. These values are used when analyzing the O2S test results to determine the O2S condition. Applicable Vehicles ^ All 1996 - 2003 model year Toyota vehicles. ^ 2004 model year Corolla, ECHO, Matrix and Sienna vehicles. ^ 2004 model year Scion xA and xB vehicles. Function Description Checking O2S Test Results To view O2S test results, the O2S Monitor must be completed and the test results must be checked within the same key cycle. If the ignition key is cycled OFF, the O2S test results will be set to the minimum or maximum limits, and all test results will be erased. The O2S test results are stored in the ECU (SAE term: Powertrain Control Module/PCM) when the monitor is completed. The test results are static and will not change once the monitor is complete. The process for checking 02S test results is described in the following three basic steps: 1. Completing the O2S Readiness Monitor. 2. Accessing O2S Test Results. 3. Comparing O2S Test Results to Failure Thresholds. Required SSTs NOTE: Additional Diagnostic Tester Kits, Program Cards or other SSTs may be ordered by calling SPX-OTC at 1-800-933-8335. Warranty Information Completing O2S Readiness Monitor 1. Clear any stored Diagnostic Trouble Codes (DTCs) using the Toyota Diagnostic Tester. Page 126 If there is no continuity, replace the relay. 3. REINSTALL STARTER RELAY Page 4148 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 4086 Page 1856 - Slowly loosen the union bolt. d. Install the fuel inlet pipe and SST (pressure gauge) to the delivery pipe with the 3 gaskets and SST (union bolt). SST 09268-45012 Torque: 29 Nm (300 kg.cm, 22 ft.lb) e. Wipe off any splattered gasoline. f. Connect the TOYOTA hand-held tester to the DLC3. g. Turn the ignition switch ON and push the TOYOTA hand-held tester main switch ON. NOTE: Do not start the engine. h. Select the active test mode on the TOYOTA hand-held tester. i. Please refer to the TOYOTA hand-held tester operator's manual for further details. j. If you have no TOYOTA hand-held tester, connect the positive (+) and negative (-) leads from the battery to the fuel pump connector. k. Reconnect the negative (-) terminal cable to the battery. l. Turn the ignition switch ON. m. 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. n. Remove the TOYOTA hand-held tester. o. Start the engine. p. Measure the fuel pressure at idle. Fuel pressure: 206 - 255 kPa (2.1 - 2.6 kg/Sq.cm, 31 - 37 psi) If pressure is not as specified, check the vacuum sensing hose and fuel pressure regulator. q. Stop the engine. r. 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 injector. s. After checking fuel pressure, disconnect the negative (-) terminal cable from the battery and carefully remove the SST to prevent gasoline from splashing. Page 1154 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 3021 7. INSPECT WHEEL ANGLE Turn the steering wheel fully and measure the turning angle. Wheel Turning Angle: If the right and left inside wheel angles differ from the specified value, check the right and left rack end lengths. HINT: If the rack ends lengths are not equal, the wheel turning angle cannot be adjusted properly. Reinspect the toe-in after adjusting the rack ends lengths. Page 2984 Junction Box / No. 1 Details Page 4366 Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Finding A Short Circuit Finding A Short Circuit A. Remove the blown fuse and disconnect all loads of the fuse. Service Data Connecting Rod: Specifications Service Data Connecting Rod Thrust Clearance Standard ....................................................................................... .............................................................................................................. 0.160 - 0.312 mm Maximum . .............................................................................................................................................................. .................................................. 0.35 mm Connecting Rod Alignment Maximum Bend ........................................................................................ ........................................................................................... 0.05 mm per 100 mm Maximum Twist .... .............................................................................................................................................................. ................ 0.15 mm per 100 mm Connecting Rod Bolts Standard Outside Diameter ............................................................................. ............................................................................................... 7.80 - 7.90 mm Minimum Outside Diameter .............................................................................................................................................. ....................................... 7.60 mm Connecting Rod Cap Torque ............................................................................................................... .......................................................................................................... 45 Nm 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. REINSTALLER MAIN RELAY Page 986 e. Install the injector to the delivery pipe and cylinder head as shown in the illustration. NOTE: Before installing the injector, must apply spindle oil or gasoline on the place where the delivery pipe or cylinder head touches an O-ring of the injector. f. Check that there are no fuel leaks after doing maintenance anywhere on the fuel system. 1. Connect the TOYOTA hand-held tester to the DLC3. 2. Turn ignition switch ON and push the TOYOTA hand-held tester main switch ON. NOTE: Do not start the engine. 3. Select the active test mode on the TOYOTA hand-held tester. 4. Please refer to the TOYOTA hand-held tester operator's manual for further details. 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 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. Page 3194 e. Draw a new line on the masking tape of the steering wheel as shown in the illustration. f. Measure the distance between the 2 lines on the masking tape of the steering wheel. g. Convert the measured distance to steering angle. Measured distance 1 mm (0.04 inch) = Steering angle approximately 1°. HINT: Make a note of the steering angle. 2. ADJUST STEERING ANGLE a. Draw a line on the RH and LH tie rod and rack ends where it can easily be seen. b. Using a paper gauge, measure the distance from RH and LH tie rod ends to the rack end screws. HINT: ^ Measure the RH side and LH side. ^ Make a note of the measured values. c. Remove the RH and LH boot clips from the rack boots. d. Loosen the RH and LH lock nuts. e. Turn the RH and LH rack end by the same amount (but in different directions) according to the steering angle. 1 turn 360° of rack end (1.5 mm ( 1.5mm ( 0.059 in.) horizontal movement ) = 12° of steering angle f. Tighten the RH and LH lock nuts. Torque: 55 Nm (560 kgf-cm, 41 ft. lbs.) NOTICE: Make sure that the difference in length between RH and LH tie rod ends and rack end screws are within 1.5 mm (0.059 inch). g. Install the RH and LH boot clips. Page 4406 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 4438 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 2271 5. Remove bolts from lower valve body. Remove the three bolts. 6. Remove bolts from front and rear upper valve bodies, as follows: a. Turn over the valve body. b. Remove the five bolts from the front upper valve body, and remove the five bolts from the rear upper valve body. 7. Lift off front and rear upper valve bodies and plate as a single unit, as follows: a. Hold the valve body plate to the upper valve bodies and lift off the upper valve bodies. NOTE: Be careful that the check balls and retainers do not fall out. b. Remove the two gaskets and plate. Assembly NOTE: For removal and installation procedures refer to "Automatic Transmission/Transaxle, Service and Repair." ASSEMBLY 1. Position new No.2 gasket and plate on lower valve body, as follows: Page 346 CHART 8 CHART 9 Page 2549 Transmission Speed Sensor: Description and Operation Vehicle Speed Sensor NO.1 Vehicle Speed Sensor NO.1 Circuit Description The vehicle speed sensor outputs a 4-pulse signal for every revolution of the rotor shaft, which is rotated by the transmission output shaft via the driven gear. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. Vehicle Speed Sensor NO.2 Vehicle Speed Sensor NO.2 Circuit Description The No.2 vehicle speed sensor detects the rotation speed of the transmission output shaft and sends signals to the ECM. The ECM determines the vehicle speed based on these signals. Page 1157 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 1784 Transmission Position Switch/Sensor: Service and Repair ON-VEHICLE REPAIR 1. REMOVE FRONT EXHAUST PIPE AND HEAT INSULATOR 2. DISCONNECT OIL COOLER PIPE a. Remove the 3 oil cooler pipe clamps. b. Disconnect the oil cooler pipe. 3. REMOVE ELBOW AND O-RING 4. REMOVE PARK/NEUTRAL POSITION SWITCH a. Disconnect the connector. b. Pry off the lock washer and remove the nut. c. Remove the bolt and park/neutral position switch. 5. INSTALL PARK/NEUTRAL POSITION SWITCH a. Install the park/neutral position switch and bolt. Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.) b. Install a new lock plate and the nut. Torque: 3.9 Nm (40 kgf-cm, 35 inch lbs.) c. Bend claws on the lock plate to fix the nut. d. Adjust the park/neutral position switch. e. Connect the connector. 6. INSTALL ELBOW AND NEW O-RING Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.) 7. CONNECT OIL COOLER PIPES a. Connect the oil cooler pipe. Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.) b. Install the 3 oil cooler pipe clamps. 8. INSTALL FRONT EXHAUST PIPE AND HEAT INSULATOR Page 399 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 3130 Part 1 Of 2 Page 3133 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. Page 3920 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 4106 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 1746 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 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. 2. Using an ohmmeter, check that there is continuity between terminals 3 and 5. Page 1418 3) Select a new shim with a thickness as close as possible to the calculated value. HINT: Shims are available in 17 sized in increments of 0.05 mm (0.0020 inch), from 2.50 mm (0.0984 inch) to 3.30 mm (0.1299 inch). Page 2388 f. Using a dial indicator near the center of the axle hub and measure the backlash in the bearing shaft direction. Maximum: 0.05 mm (0.0020 inch) or less 9. INSTALL LOCK CAP, COTTER PIN AND GREASE CAP a. Install the lock cap and a new cotter pin. If the holes for the cotter pin are not aligned, tighten the nut further up to 60°. b. Install the grease cap. 10. INSTALL BRAKE CALIPER Install the brake caliper with the 2 bolts. Torque: 108 Nm (1,100 kgf-cm, 80 ft. lbs.) 11. w/ ABS: CONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP TO STEERING KNUCKLE Connect the ABS speed sensor and wire harness clamp with the 2 bolts. Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.) 12. INSTALL FRONT WHEEL Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.) 13. DEPRESS BRAKE PEDAL SEVERAL TIMES 14. CHECK FRONT WHEEL ALIGNMENT 15. w/ ABS: CHECK ABS SPEED SENSOR SIGNAL Page 3169 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. Locations Page 4270 Junction Box / No. 3 Page 4034 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. Page 2430 Junction Box / No. 3 Page 940 Part 7 of 7 Page 3571 Page 1626 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. Connector Locations Key Reminder Switch: Connector Locations Page 2084 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. 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. Page 1476 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 2166 d. Stake the lock plate. 9. INSTALL VEHICLE SPEED SENSOR DRIVE GEAR a. Using a snap ring expander, install the snap ring. b. Install the ball into the hole on the output shaft. c. Align the groove of the drive gear with the ball, and install the drive gear. d. Using a snap ring expander, install the snap ring. 10. INSTALL EXTENSION HOUSING a. Install the oil apply tube and a new gasket to the extension housing. b. Install the extension housing with a new gasket to the case. c. Apply sealant to the bolts. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent d. Tighten the 6 bolts. Torque: 36 Nm (370 kgf-cm, 27 ft. lbs.) HINT: The 2 lower bolts are shorter. 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 4177 Steps 3 - 4 INSPECTION PROCEDURE 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 204 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 4282 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. Specifications Thermostat: Specifications Valve Opening Temperature 80 - 84 deg C Valve Lift 8 mm at 95 deg C or More Page 3400 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 1711 CHART 14 Description and Operation Knock Sensor: Description and Operation Knock Sensor The knock sensor is fitted to 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. 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 588 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 HINT: All vacuum hoses for EGR system, etc. should be properly connected. f) SFI system wiring connectors fully plugged g) Ignition timing check correctly h) Transmission in neutral position 2. CONNECT TOYOTA HANDHELD TESTER OR OBDII SCAN TOOL 3. INSPECT IDLE SPEED a) Race the engine speed at 2,500 rpm for approx. 90 seconds. b) Check the idle speed. Idle speed: 650 - 750 rpm If the idle speed is not as specified, check the IAC valve, intake air leakage and SFI system. 4. DISCONNECT TOYOTA HAND-HELD TESTER OR OBDII SCAN TOOL Page 3772 Page 1589 CHART 28 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 764 Engine Compartment Instrument Panel Locations Page 4051 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 1712 CHART 15 Page 3452 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. 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 4191 Wiring Diagram Step 1 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 4304 Junction Box / No. 3 Page 3500 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. 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 3606 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 862 3) Select a new shim with a thickness as close as possible to the calculated value. HINT: Shims are available in 17 sized in increments of 0.05 mm (0.0020 inch), from 2.50 mm (0.0984 inch) to 3.30 mm (0.1299 inch). Page 4368 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 355 Page 359 CHART 23 Page 549 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. Description and Operation ABS Light: Description and Operation Testing and Inspection Page 1505 Part 1 Of 2 (Except California Spec.) Page 3548 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 1754 Transmission Position Switch/Sensor: Service and Repair ON-VEHICLE REPAIR 1. REMOVE FRONT EXHAUST PIPE AND HEAT INSULATOR 2. DISCONNECT OIL COOLER PIPE a. Remove the 3 oil cooler pipe clamps. b. Disconnect the oil cooler pipe. 3. REMOVE ELBOW AND O-RING 4. REMOVE PARK/NEUTRAL POSITION SWITCH a. Disconnect the connector. b. Pry off the lock washer and remove the nut. c. Remove the bolt and park/neutral position switch. 5. INSTALL PARK/NEUTRAL POSITION SWITCH a. Install the park/neutral position switch and bolt. Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.) b. Install a new lock plate and the nut. Torque: 3.9 Nm (40 kgf-cm, 35 inch lbs.) c. Bend claws on the lock plate to fix the nut. d. Adjust the park/neutral position switch. e. Connect the connector. 6. INSTALL ELBOW AND NEW O-RING Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.) 7. CONNECT OIL COOLER PIPES a. Connect the oil cooler pipe. Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.) b. Install the 3 oil cooler pipe clamps. 8. INSTALL FRONT EXHAUST PIPE AND HEAT INSULATOR Page 3142 Part 3 Of 3 REMOVAL 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. DISCONNECT RH AND LH TIE ROD ENDS 5. DISCONNECT INTERMEDIATE NO. 2 SHAFT Page 3146 Part 3 Of 3 DISASSEMBLY NOTICE: When using a vise, do not overtighten it. Capacity Specifications Fluid - Differential: Capacity Specifications Differential Fluid ................................................................................................................................... ....................................................................... 1.4 Qt Page 4415 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 1348 REPLACEMENT 1. REMOVE THROTTLE BODY 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: 5.4 Nm (55 kg.cm, 48 in.lb) b. Connect the sensor connector. 4. REINSTALL THROTTLE BODY Page 1918 Fuel Pressure: Testing and Inspection 1. INSPECT FUEL PUMP OPERATION a. Connect the TOYOTA hand-held tester to the DLC3. b. Turn the ignition switch ON and push the 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. f. Check that there is pressure in the 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. 2. CHECK FUEL PRESSURE a. Check that the battery positive voltage is above 12V. b. Disconnect the negative (-) terminal cable from the battery. c. Remove the union bolt and 2 gaskets, and disconnect the fuel inlet pipe from the delivery pipe. CAUTION: Put a suitable container or shop rag under the delivery pipe. Page 3703 - 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 1347 Camshaft Position Sensor: Service and Repair COMPONENTS Diagrams Page 2440 Page 3253 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.) Page 3161 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.) 20. INSTALL 2 TURN PRESSURE TUBES a. Coat 4 new O-rings with power steering fluid and install them to the tube. b. Using SST, install the tube. SST 09633-00020 Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.) HINT: ^ Use a torque wrench with a fulcrum length of 250 mm (9.84 inch). ^ This torque value is effective in case that SST is parallel to a torque wrench. Page 3910 3. ADJUST HOOD LOCK Adjust the lock by loosening the bolts. Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf) Page 454 Ignition Switch: Testing and Inspection 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 3725 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. 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 186 Steps 1 - 2 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 3056 Part 2 Of 2 REMOVAL Page 613 g. Using a 16 mm plug wrench, reinstall the 4 spark plug. Torque: 20 Nm (200 kg.cm, 14 ft.lb) h. Except California Spec.: Reconnect the high-tension cords to the spark plugs. i. California Spec.: Reinstall the ignition coil. Page 1619 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 3091 Junction Box / No. 3 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 4240 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 1196 Remove the 4 nuts, MAF meter and gasket. INSTALLATION 1. INSTALL MAF METER TO AIR CLEANER CAP a. Place a new gasket on the air cleaner cap. b. Install the MAF meter with the 4 nuts. Torque: 8.5 Nm (85 kg.cm, 74 in.lb) 2. INSTALL MAF METER WITH AIR CLEANER CAP 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 3846 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 2903 Junction Box / No. 1 Details Page 2276 c. Place a new No.3 and No.4 gaskets and plate on the lower valve body. NOTE: Since No.3 gasket and No.4 gasket look similar, use the illustrations to differentiate between them. d. Install the lower valve body cover. e. Install and tighten the eight bolts. NOTE: Each bolt length (mm, inch) is indicated in the illustration. Torque: 5.4 N.m (48 inch lbs.). Page 3709 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 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) Page 2773 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 1358 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 1861 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: 30 Nm (310 kg.cm, 22 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. On-Vehicle Inspection Throttle Body: Testing and Inspection On-Vehicle Inspection 1. INSPECT THROTTLE BODY a. Check that the throttle linkage moves smoothly. b. check the vacuum at each port. - Start the engine. - Check the vacuum with your finger. Specifications Axle Nut: Specifications - INSTALL AXLE HUB WITH DISC a. Place the axle hub on the spindle. b. Install a new outer bearing and claw washer. - ADJUST PRELOAD a. Install and torque the nut. Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.) b. Turn the hub several times to make the bearing more smoothly. c. Loosen the nut until it can be turned by hand. d. Using a spring tension gauge, measure and make a note down of the frictional force of the oil seal. HINT: Make sure to check preload in the direction of rotation. e. Tighten the nut until the preload is within the specified value. Preload (at starting): Frictional force plus 6 - 18 N (0.6 - 1.8 kgf, 1.3 - 4.0 ft. lbs.) HINT: Make sure to check preload in the direction of rotation. f. Using a dial indicator near the center of the axle hub and measure the backlash in the bearing shaft direction. Maximum: 0.05 mm (0.0020 inch) or less Page 445 REPLACEMENT 1. REMOVE THROTTLE BODY 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: 5.4 Nm (55 kg.cm, 48 in.lb) b. Connect the sensor connector. 4. REINSTALL THROTTLE BODY Page 187 Steps 3 - 4 INSPECTION PROCEDURE Page 3716 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 176 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection 1. DRAIN ENGINE COOLANT 2. REMOVE ECT SENSOR a. Disconnect the engine wire protector from the 3 brackets. b. Disconnect the ECT sensor connector. c. Using a 19 mm deep socket wrench, remove the ECT sensor and gasket. Page 4443 Specifications Brake Fluid: Specifications Fluid Type FMVSS 116 DOT 3 Brake Fluid Page 3187 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.) Description and Operation Knock Sensor: Description and Operation Knock Sensor The knock sensor is fitted to 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. Locations Page 4378 b. Disconnect the connector from the integration relay and inspect the connectors on the wire harness side. Page 3590 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 354 CHART 20 Page 1069 Required SSTs Radiator Cap Identification Procedure 1. Use the illustration below to identify the vehicle's radiator cap type and kPa rating. 2. Proceed to the required inspection procedure for the radiator cap and kPa rating. Radiator Cap Inspection Procedure Type: N-cap, 88 kPa 1. Remove coolant and any foreign material on rubber points "A," "B," and "C." 2. Check that points "A," "B," and "C" are not deformed, cracked, or swollen. 3. Check that points "C" and "D" are not stuck together. 4. Apply engine coolant to points "B" and "C" before using the radiator cap tester. ^ Radiator Cap Tester: Snap-On/Sun P/N SVTS262A (or equivalent) Page 3340 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.) Locations Page 3501 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 2705 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 516 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 4246 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 2558 Step 2 Step 3 INSPECTION PROCEDURE Troubleshooting in accordance with the chart for each trouble symptom. Page 3143 6. REMOVE PRESSURE FEED TUBE AND RETURN TUBE Using SST, disconnect the tube. SST 09631-22020 7. REMOVE PS GEAR ASSEMBLY Remove the 2 gear assembly set bolts, nuts and washers. INSTALLATION 1. INSTALL PS GEAR ASSEMBLY Torque the 2 gear assembly set bolts, nuts and washers. Torque: 201 Nm (2,050 kgf-cm, 148 ft. lbs.) 2. CONNECT PRESSURE FEED TUBE AND RETURN TUBE 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. 3. CONNECT INTERMEDIATE NO. 2 SHAFT 4. CONNECT RH AND LH TIE ROD ENDS 5. POSITION FRONT WHEELS FACING STRAIGHT AHEAD HINT: Do it with the front of the vehicle jacked up. 6. CENTER SPIRAL CABLE 7. 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. 8. BLEED POWER STEERING SYSTEM 9. CHECK STEERING WHEEL CENTER POINT 10. TORQUE STEERING WHEEL SET NUT Torque: 35 Nm (360 kgf-cm, 26 ft. lbs.) 11. INSTALL STEERING WHEEL PAD 12. CHECK FRONT WHEEL ALIGNMENT Disassembly and Reassembly Page 3641 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 Page 1667 3. INSPECT ECT SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: Refer to the chart graph If the resistance is not as specified, replace the ECT sensor. 4. REINSTALL ECT SENSOR a. Install a new gasket to the ECT sensor. b. Using a 19 mm deep socket wrench, install the ECT sensor. Torque: 20 Nm (200 kg.cm, 14 ft.lb) c. Connect the ECT sensor connector. d. Install the engine wire protector to the 3 brackets. 5. REFILL WITH ENGINE COOLANT 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 1092 Thermostat: Service and Repair REMOVAL 1. DRAIN ENGINE COOLANT 2. DISCONNECT LOWER RADIATOR HOSE 3. REMOVE THERMOSTAT a) Remove the 2 nuts, water inlet and thermostat with gasket from the water pump. b) Remove the gasket from the thermostat. INSPECTION INSPECT THERMOSTAT HINT: The thermostat is numbered with the valve opening temperature. a) Immerse the thermostat in water and gradually heat the water. b) Check the valve opening temperature. Valve opening temperature: 80 - 84°C (176 - 183°F) If the valve opening temperature is not as specified, replace the thermostat. Page 3182 - 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 3975 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 2976 Fuse: Application and ID Engine Room R/B # 2 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 1498 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. Specifications Governor: Specifications Governor Body Lock Plate ............................................................................................................................................. 3.9 Nm (40 kgf.cm, 35 inch lbs.) Page 2425 Page 1863 NOTE: Always pinch the hose. Avoid bending as it may cause to hose to crack. 7. Turn the ignition switch OFF. 8. Disconnect the TOYOTA hand-held tester from the DLC3. Page 1239 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). Removal and Installation Wheel Bearing: Service and Repair Removal and Installation REMOVAL 1. REMOVE FRONT WHEEL 2. w/ ABS: DISCONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP FROM STEERING KNUCKLE Remove the 2 bolts and disconnect the ABS speed sensor and wire harness clamp from the steering knuckle. Page 4422 Seat Belt Reminder Lamp: Connector Locations Page 4426 Seat Belt Reminder Lamp: Ground Locations Page 1507 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 1975 Remove the 4 nuts, MAF meter and gasket. INSTALLATION 1. INSTALL MAF METER TO AIR CLEANER CAP a. Place a new gasket on the air cleaner cap. b. Install the MAF meter with the 4 nuts. Torque: 8.5 Nm (85 kg.cm, 74 in.lb) 2. INSTALL MAF METER WITH AIR CLEANER CAP Locations Intake Air Temperature Sensor: Locations The Intake Air Temperature (IAT) Sensor is installed in the Mass Air Flow (MAF) Meter. Testing and Inspection Vacuum Control Valve: Testing and Inspection VSV For Exhaust Gas Recirculation (EGR) 1. REMOVE VSV a. Remove the bolt. b. Disconnect the connector and 2 vacuum hoses from the VSV. 2. INSPECT VSV a. Inspect the VSV for open circuit. Using an ohmmeter, check that there is continuity between terminals. Resistance: 33-39 ohms at 20 °C (68 °F) If there is no continuity, replace the VSV. b. Inspect the VSV for ground. Using an ohmmeter, check that there is no continuity between each terminal and the body. If there is continuity, replace the VSV. c. Inspect the VSV operation. Page 4076 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 1930 Fuel Return Line: Testing and Inspection CAUTION: - Always use new gaskets when replacing the fuel tank or component parts. - Apply the proper torque to all parts tightened. 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 - 0.8 V is applied to terminal VTA of the ECM. The voltage applied to the terminals VTA of the ECM increases in proportion to the opening angle of the throttle valve and becomes approximately 3.2 - 4.9 V when the throttle valve is fully opened. The ECM judges the vehicle driving conditions from these signals input from terminal VTA, uses it as one of the conditions to decide the air-fuel ratio correction, power increase correction and fuel cut control etc. 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 737 Air Bag(s) Arming and Disarming: Service and Repair Release Method of Airbag Activation Prevention Mechanism Page 4427 Seat Belt Reminder Lamp: Splice Locations Page 1501 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 3861 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 Output Shaft: Service and Repair For further information regarding this component and the system that it is a part of please refer to Manual Transmission/Transaxle; Service and Repair. Page 2090 Shift Indicator: 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 1936 Fuel Supply Line: Testing and Inspection CAUTION: - Always use new gaskets when replacing the fuel tank or component parts. - Apply the proper torque to all parts tightened. Page 4198 Steps 1 - 2 Removal and Installation Wheel Bearing: Service and Repair Removal and Installation REMOVAL 1. REMOVE FRONT WHEEL 2. w/ ABS: DISCONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP FROM STEERING KNUCKLE Remove the 2 bolts and disconnect the ABS speed sensor and wire harness clamp from the steering knuckle. Page 3094 Key Reminder Switch: Splice Locations Page 3654 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 3714 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 2272 a. Place a new No.2 gasket and plate on the lower valve body. NOTE: Since No.1 gasket and No.2 gasket look similar, use the illustrations to differentiate between them. b. Temporarily secure the plate with the 2 bolts. NOTE: Use the two bolts for the oil strainer. Page 3559 Air Bag(s) Arming and Disarming: Service and Repair Release Method of Airbag Activation Prevention Mechanism Page 712 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 1730 CHART 29 Page 3222 Control Arm: Service and Repair Upper REMOVAL 1. REMOVE FRONT WHEEL Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.) 2. w/ ABS: REMOVE ABS SPEED SENSOR AND WIRE HARNESS CLAMP a. Remove the bolt and ABS speed sensor from the steering knuckle. Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.) b. Remove the 3 bolts and ABS speed sensor wire harness clamps from the upper suspension arm and steering knuckle. Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.) 3. REMOVE STABILIZER BAR LINK Hold the bolt with a wrench, then remove the nut, 5 retainers, 4 cushions, collar and bolt. Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.) 4. DISCONNECT UPPER BALL JOINT a. Support the lower suspension arm with a jack. b. Remove the cotter pin and loosen the nut. Torque: 110 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°. Page 2193 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. 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 375 Heated Oxygen Sensor Page 758 Junction Box / No. 1 Details Page 1706 CHART 7 Page 3871 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 1317 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 1475 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 1103 6. w/PS: REMOVE DRIVE BELT FOR PS PUMP Loosen the lock bolt and adjusting bolt, and remove the drive belt. 7. REMOVE FAN SHROUDS a) Remove the 2 clips and No.2 fan shroud. b) Remove the 4 bolts and No.1 fan shroud. 8. REMOVE DRIVE BELT FOR A/C COMPRESSOR Loosen the idler pulley nut and adjusting bolt, and remove the drive belt. 9. REMOVE DRIVE BELT FOR GENERATOR, FAN WITH FLUID COUPLING AND WATER PUMP PULLEY a) Loosen the water pump pulley nuts. b) Loosen the lock bolt and pivot bolt of generator. c) Loosen the Adjusting bolt of generator, remove the drive belt. d) Remove the 4 water pump pulley nuts. Torque: 21 Nm (210 kgf-cm, 16 ft. lbs.) e) Pull out the fan together with the fluid coupling and water pump pulley. 10. REMOVE WATER PUMP Remove the 10 bolts, water pump and gasket. Torque: 24.5 Nm (250 kgf-cm, 18 ft. lbs.) for 14 mm head 8.9 Nm (90 kgf-cm, 78 inch lbs.) for 12 mm head HINT: At the time of installation, please refer to the following items. Use a new gasket. Page 3105 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 2041 REPLACEMENT 1. REMOVE THROTTLE BODY 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: 5.4 Nm (55 kg.cm, 48 in.lb) b. Connect the sensor connector. 4. REINSTALL THROTTLE BODY Page 1816 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 Page 3263 6. INSTALL INNER BEARING AND OIL SEAL a. Place inner bearing into the axle hub. b. Using SST and a hammer, install a new oil seal into the axle hub. SST 09527-17011, 09950-60020 (09951-00710), 09950-70010 (09951-07150) NOTICE: Be careful not to damage the ABS speed sensor rotor. c. Coat the oil seal lip with MP grease. 7. INSTALL AXLE HUB WITH DISC a. Place the axle hub on the spindle. b. Install a new outer bearing and claw washer. 8. ADJUST PRELOAD a. Install and torque the nut. Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.) b. Turn the hub several times to make the bearing more smoothly. c. Loosen the nut until it can be turned by hand. d. Using a spring tension gauge, measure and make a note down of the frictional force of the oil seal. HINT: Make sure to check preload in the direction of rotation. e. Tighten the nut until the preload is within the specified value. Preload (at starting): Frictional force plus 6-18 N (0.6-1.8 kgf, 1.3-4.0 lbs.) HINT: Make sure to check preload in the direction of rotation. Page 4369 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 2180 Shift Indicator: Splice Locations Diagrams Page 410 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 2978 Engine Room Fuse Details Interior J/B # 1 Specifications Water Pump: Specifications Water Pump and Gasket 14 mm Head 24.5 Nm (18 ft.lb) 12 mm Head 8.9 Nm (78 in.lb) Page 369 CHART 29 Page 4313 Steps 1 - 2 INSPECTION PROCEDURE Page 2378 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 2357 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 1168 Engine Control Module: Pinout Values and Diagnostic Parameters Connectors (California Spec.) Part 1 Of 2 (California Spec.) Specifications Fluid Pump: Specifications SERVICE SPECIFICATIONS Body Clearance STD ..................................................................................................................................................... ............ 0.07 - 0.15 mm (0.0028 - 0.0059 inch) Maximum ................................................................... .................................................................................................................. 0.3 mm (0.012 inch) Tip Clearance STD ..................................................................................................................................................... ............ 0.11 - 0.14 mm (0.0043 - 0.0055 inch) Maximum ................................................................... .................................................................................................................. 0.3 mm (0.012 inch) Side Clearance STD ..................................................................................................................................................... ............ 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 ............................................................................................................................................. ............................ 21.58 mm (0.8496 inch) TORQUE SPECIFICATIONS Stator shaft x Oil pump body .......................................................................................................................................... 7.4 Nm (75 kgf.cm, 65 inch lbs.) Page 2996 Engine Compartment Instrument Panel Locations Page 2843 4. DO NO-LOAD PERFORMANCE TEST a. Connect the battery and ammeter to the starter as shown. b. Check that the starter rotates smoothly and steadily with the pinion gear moving out. Check that the ammeter shows the specified current. Specified Current 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 2142 Extension Housing: Testing and Inspection EXTENSION HOUSING Extension Housing Inspection 1. INSPECT EXTENSION HOUSING BUSHING Using a cylinder gauge, measure the inside diameter of the extension housing bushing. Maximum inside diameter: 38.09 mm (1.4996 inch) If the inside diameter is greater than the maximum, replace the extension housing. Page 311 Crankshaft Position Sensor: Service and Repair REPLACEMENT 1. REMOVE ENGINE UNDER COVER 2. REMOVE GENERATOR 3. REMOVE GENERATOR BRACKET Remove the 3 bolts and bracket. 4. REMOVE CRANKSHAFT POSITION SENSOR a. Disconnect the sensor connector. b. Disconnect the sensor connector from the connector bracket. c. Remove the 2 bolts and crankshaft position sensor. d. Remove the O-ring. 5. REINSTALL NEW CRANKSHAFT POSITION SENSOR a. Install a new O-ring to the sensor. b. Install the sensor with the 2 bolts. Torque: 8.5 Nm (85 kg.cm, 74 in.lb) c. Reinstall the sensor connector to the connector bracket. d. Reconnect the sensor connector. 6. REINSTALL GENERATOR BRACKET Install the bracket with the 3 bolts Torque: Bolt A: 74.5 Nm (760 kg.cm, 55 ft.lb) Bolt B: 18 Nm (180 kg.cm, 13 ft.lb) 7. REINSTALL GENERATOR 8. REINSTALL ENGINE UNDER COVER 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. Page 1109 Catalytic Converter: Testing and Inspection ON-VEHICLE INSPECTION 1. INSPECT EXHAUST PIPE AND TWC a. Check the connections for looseness or damage. b. Check the clamps for weakness, cracks or damage. c. Check the TWC 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. 2. INSPECT HEAT INSULATOR a. Check the heat insulator for damage. b. Check for the adequate clearance between the TWC and heat insulator. Page 3361 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 1770 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. 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 Locations Page 1723 CHART 25 Page 3643 Seat Belt Extender Worksheet Page 1364 Knock Sensor: Testing and Inspection 1. REMOVE STARTER 2. REMOVE FUEL FILTER SET BOLTS 3. REMOVE KNOCK SENSOR a. Disconnect the knock sensor connector. b. Using SST, remove the knock sensor. SST 09816-30010 4. INSPECT KNOCK SENSOR Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor. 5. REINSTALL KNOCK SENSOR a. Using SST, install the knock sensor. SST 09816 - 30010 Torque: 44 Nm (450 kg.cm, 33 ft.lb) b. Connect the knock sensor connector. 6. REINSTALL FUEL FILTER SET BOLTS Torque: 20 Nm (200 kg.cm, 14 ft.lb) 7. REINSTALL STARTER Page 1318 Vehicle Speed Sensor: Service and Repair ON-VEHICLE REPAIR 1. DISCONNECT VEHICLE SPEED SENSOR CONNECTOR Vehicle Speed Sensor NO.1 (A43D) 2. REMOVE VEHICLE SPEED SENSOR ASSEMBLY a. Remove the bolt and the vehicle speed sensor assembly. b. Remove the clip and the driven gear from the vehicle speed sensor. c. Remove the O-ring from the vehicle speed sensor. 3. INSTALL VEHICLE SPEED SENSOR ASSEMBLY a. Coat a new O-ring with ATF and install it to the vehicle speed sensor. b. Install the driven gear and the clip to the vehicle speed sensor. c. Install the vehicle speed sensor assembly with the bolt. Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.) 4. CONNECT VEHICLE SPEED SENSOR CONNECTOR 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 Locations Vehicle Lifting: Locations Page 1484 Refer to Reset Procedure 1 for the vehicles with Electronically Controlled Automatic Transmissions: 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 900 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 2298 Clutch Slave Cylinder: Service and Repair REMOVAL 1. DISCONNECT CLUTCH LINE Using SST, disconnect the line. Use a container to catch the fluid. SST 09023-00100 Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.) 2. REMOVE 2 BOLTS AND PULL OUT RELEASE CYLINDER Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.) DISASSEMBLY Page 1564 CHART 2 CHART 3 CHART 4 Page 432 Remove the 4 nuts, MAF meter and gasket. INSTALLATION 1. INSTALL MAF METER TO AIR CLEANER CAP a. Place a new gasket on the air cleaner cap. b. Install the MAF meter with the 4 nuts. Torque: 8.5 Nm (85 kg.cm, 74 in.lb) 2. INSTALL MAF METER WITH AIR CLEANER CAP 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 3012 Alignment: Specifications NOTE: RZN140L: Regular Cab, Short Wheelbase with 2RZ-FE engine RZN150L: Extra Cab, Extra Long Wheelbase with 2RZ-FE engine VZN150L: Extra Cab, Extra Long Wheelbase with 5VZ-FE engine INSPECTION 1. MEASURE VEHICLE HEIGHT Vehicle Height: Measuring points: A: Ground clearance of spindle center. B: Ground clearance of lower suspension arm bolt center. C: Ground clearance of rear axle shaft center. D: Ground clearance of leaf spring front hanger pin bolt center. NOTICE: Before inspecting the wheel alignment, adjust the vehicle height to the specified value. If the vehicle height is not the specified value, try to adjust it by pushing down on or lifting the body. 2. INSTALL CAMBER-CASTER-KINGPIN GAUGE OR POSITION VEHICLE ON WHEEL ALIGNMENT TESTER Follow the specific instructions of the equipment manufacturer. 3. INSPECT CAMBER, CASTER AND STEERING AXIS INCLINATION Camber, caster and steering axis inclination: Page 1929 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 2135 Clutch: Diagrams OVERDRIVE DIRECT CLUTCH OVERDRIVE BRAKE FRONT CLUTCH 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. Locations Camshaft Position Sensor: Locations Page 4241 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 2970 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 4149 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 477 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 4233 Audible Warning Device: Connector Locations Page 1545 Applicable Vehicles 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. Page 4401 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 3715 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 3541 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 3484 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. 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 4147 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 942 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. Locations Page 1562 O2S Application Table O2S Failure Threshold Charts Page 1277 Oxygen Sensor: Locations Air-Fuel Ratio (A/F) Sensor Locations Camshaft Position Sensor: Locations Locations Page 4189 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 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. Page 3150 14. REMOVE OIL SEAL Remove the oil seal from the control valve assembly. 15. REMOVE CYLINDER END STOPPER a. Using SST, turn the stopper clockwise until the wire end is visible through the service hole. SST 09631-10021 b. Using SST, turn the stopper counterclockwise, and remove the wire. SST 09631-10021 16. REMOVE STEERING RACK AND OIL SEAL a. Using an extension bar and socket wrench (19 mm), press out the rack with the bushing. NOTICE: Take care not to drop the rack. b. Remove the bushing from the rack. c. Remove the O-ring from the bushing. 17. REMOVE OIL SEAL Using SST, press out the oil seal. SST 09950-60010 (09951-00280), 09950-70010 (09951-07360) INSPECTION NOTICE: When using a vise, do not overtighten it. 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 315 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 534 Transmission Speed Sensor: Service and Repair VEHICLE SPEED SENSOR ON-VEHICLE REPAIR Vehicle Speed Sensor NO.1(A43D) 1. DISCONNECT VEHICLE SPEED SENSOR CONNECTOR 2. REMOVE VEHICLE SPEED SENSOR ASSEMBLY (a) Remove the bolt and the vehicle speed sensor assembly. (b) Remove the clip and the driven gear from the vehicle speed sensor. (c) Remove the o-ring from the vehicle speed sensor. 3. INSTALL VEHICLE SPEED SENSOR ASSEMBLY (a) Coat a new o-ring with ATF and install it to the vehicle speed sensor. (b) Install the driven gear and the clip to the vehicle speed sensor. (c) Install the vehicle speed sensor assembly with the bolt. Torque: 16 Nm (160 kgf.cm, 12 ft.lbf) 4. CONNECT VEHICLE SPEED SENSOR CONNECTOR Page 325 Page 3186 2. Using 3 wire harness, wind the wire harness at least 2 times each around the bolts installed on the left and right sides of the steering wheel pad. CAUTION: Tightly wind the wire harness around the bolts so that there is no slack. - If there is slack in the wire harness, the steering wheel pad may come loose due to the shock when the airbag Is deployed. This is highly dangerous. 3. Face the upper surface of the steering wheel pad upward. Separately tie the left and right sides of the steering wheel pad to the disc wheel through the hub nut holes. Position the steering wheel pad connector so that it hangs downward through a hub hole in the disc wheel. CAUTION: Make sure that the wire harness is tight. It is very dangerous when looseness in the wire harness results in the steering wheel pad coming free through the shock from the airbag deploying. - Always tie down the steering wheel pad with the pad side facing upward. It is very dangerous if the steering wheel pad is tied down with the metal surface facing upward as the wire harness will be cut by the shock from the airbag deploying and the steering wheel pad will be thrown into the air. NOTE: The disc wheel will be marked by airbag deployment, so when disposing of the airbag use a redundant disc wheel. c. Check functioning of the SST. SST 09082-0700 Page 1716 Locations 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. Page 3512 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 1990 g. Disconnect the water bypass hoses from the throttle body, and remove the throttle body. h. Remove the throttle body gasket. 7. Except California Spec.: REMOVE AIR HOSE FROM IAC VALVE INSTALLATION Installation is in the reverse order of removal. Page 2273 2. Position new No.1 gasket on plate. 3. Place lower valve body with plate and gaskets on rear upper valve body. Hold the lower valve body, plate and gaskets securely so they do not separate. Align each bolt hole in the valve bodies with the gaskets and plate. 4. Install and finger tighten bolts in lower valve body to secure rear upper valve body, as follows: a. Install and finger tighten the bolt. NOTE: Bolt length (mm, in.) is indicated in the illustration. b. Hold the rear upper valve body and lower valve body, turn over the assembly. c. Install and finger tighten the five bolts. NOTE: Bolt length (mm, in.) is indicated in the illustration. Page 345 CHART 7 Page 1159 Engine Control Module: Connector Views Connectors (California Spec.) Part 1 Of 2 (California Spec.) Front Page 2633 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 2919 Engine Compartment Instrument Panel Locations Page 1772 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 444 Camshaft Position Sensor: Service and Repair COMPONENTS Page 3160 b. Using a spanner to hold the steering rack steady, and using SST, torque the rack end. SST 09922-10010 Torque: 60 Nm (615 kgf-cm, 45 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. 18. 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. Using SST, tighten the clamp as shown in the illustration. SST 09521-24010 19. INSTALL RH AND LH TIE ROD ENDS AND LOCK NUTS Page 3093 Key Reminder Switch: Ground Locations Page 2152 Fluid - A/T: Service and Repair 1. Drain transaxle fluid, then install drain plug and new gasket. 2. With engine Off, add fluid through dipstick tube. Do not overfill. 3. Start engine, then move shift selector through all positions, ensuring smooth operation. 4. Allow to idle, then check at COOL level. 5. Allow to reach normal operating temperature, then recheck. Page 1811 Catalytic Converter: Testing and Inspection ON-VEHICLE INSPECTION 1. INSPECT EXHAUST PIPE AND TWC a. Check the connections for looseness or damage. b. Check the clamps for weakness, cracks or damage. c. Check the TWC 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. 2. INSPECT HEAT INSULATOR a. Check the heat insulator for damage. b. Check for the adequate clearance between the TWC and heat insulator. Locations Page 2258 An AC voltage is generated in the No.2 vehicle speed sensor coil as the rotor mounted on the output shaft rotates, and this voltage is sent to the ECM. The gear shift point and lock-up timing are controlled by the ECM based on the signals from this vehicle speed sensor and the throttle position sensor signal. If the No.2 vehicle speed sensor malfunctions, the ECM uses input signals from the No.1 vehicle speed sensor as a back-up signal. Removal and Installation Brake Caliper: Service and Repair Removal and Installation REMOVAL 1. DISCONNECT FLEXIBLE HOSE a. Remove the union bolt and disconnect the flexible hose. Torque: 30 Nm (310 kgf-cm, 22 ft. lbs.) NOTICE: At the time of installation, for correct brake hose routing, ensure that the hose hangs down before installing hose to caliper. b. Use a container to catch the brake fluid. 2. REMOVE CALIPER FROM TORQUE PLATE Remove the 2 slide pins and caliper. Torque: 88 Nm (900 kgf-cm, 65 ft. lbs.) 3. REMOVE 2 BRAKE PADS WITH 4 ANTI-SQUEAL SHIMS AND PAD WEAR INDICATOR 4. REMOVE 4 PAD SUPPORT PLATES Page 1633 Part 1 Of 2 (Except California Spec.) Page 3675 Seat Belt Reminder Lamp: Splice Locations Page 3505 a. Spiral Cable b. Upper And Lower Column Covers c. Steering Wheel d. Steering Wheel Pad Page 2174 Locations Relay Box: Locations Relay Box / No. 2 Page 1141 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 3569 Page 2086 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 3106 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 1580 CHART 23 Page 880 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 1372 - Slowly loosen the union bolt. d. Install the fuel inlet pipe and SST (pressure gauge) to the delivery pipe with the 3 gaskets and SST (union bolt). SST 09268-45012 Torque: 29 Nm (300 kg.cm, 22 ft.lb) e. Wipe off any splattered gasoline. f. Connect the TOYOTA hand-held tester to the DLC3. g. Turn the ignition switch ON and push the TOYOTA hand-held tester main switch ON. NOTE: Do not start the engine. h. Select the active test mode on the TOYOTA hand-held tester. i. Please refer to the TOYOTA hand-held tester operator's manual for further details. j. If you have no TOYOTA hand-held tester, connect the positive (+) and negative (-) leads from the battery to the fuel pump connector. k. Reconnect the negative (-) terminal cable to the battery. l. Turn the ignition switch ON. m. 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. n. Remove the TOYOTA hand-held tester. o. Start the engine. p. Measure the fuel pressure at idle. Fuel pressure: 206 - 255 kPa (2.1 - 2.6 kg/Sq.cm, 31 - 37 psi) If pressure is not as specified, check the vacuum sensing hose and fuel pressure regulator. q. Stop the engine. r. 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 injector. s. After checking fuel pressure, disconnect the negative (-) terminal cable from the battery and carefully remove the SST to prevent gasoline from splashing. Capacity Specifications Coolant: Capacity Specifications Drain and Refill Drain and Refill Capacity (manual transmission) 8.5 qt (US) Capacity (automatic transmission) 8.2 qt (US) Page 2894 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. 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 580 SST 09268-45012 t. Reconnect the fuel inlet pipe to the delivery pipe with 2 new gaskets and the union bolt. Torque: 29 Nm (300 kg.cm, 22 ft.lb) u. Reconnect the negative (-) terminal cable to the battery. v. Check for fuel leakage. 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 2789 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. 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 818 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 INTAKE AIR CONNECTOR 3. Except California Spec.: DISCONNECT HIGH-TENSION CORDS FROM SPARK PLUGS NOTICE: Pulling on or bending the cords may damage the conductor inside. 4. California Spec.: REMOVE IGNITION COILS (WITH IGNITER) 5. REMOVE SPARK PLUGS 6. 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: 1,230 kPa (12.5 kgf/cm2, 178 psi) or more Minimum pressure: 880 kPa (9.0 kgf/cm2, 127 psi) Difference between each cylinder: 98 kPa (1.0 kgf/cm2, 14 psi) or less e) If the cylinder compression in one or more cylinders is low, pour 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, chances are that the piston rings and/or cylinder bore are worn or damage. - If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket. 7. REINSTALL SPARK PLUGS Torque: 19 Nm (200 kgf-cm, 14 ft. lbs.) 8. Except California Spec.: REINSTALL HIGH-TENSION CORDS TO SPARK PLUGS 9. California Spec.: REINSTALL IGNITION COILS (WITH IGNITER) 10. REINSTALL INTAKE AIR CONNECTOR 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 4296 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 196 Steps 3 - 4 INSPECTION PROCEDURE 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. Page 2259 Transmission Speed Sensor: Service and Repair VEHICLE SPEED SENSOR ON-VEHICLE REPAIR Vehicle Speed Sensor NO.1(A43D) 1. DISCONNECT VEHICLE SPEED SENSOR CONNECTOR 2. REMOVE VEHICLE SPEED SENSOR ASSEMBLY (a) Remove the bolt and the vehicle speed sensor assembly. (b) Remove the clip and the driven gear from the vehicle speed sensor. (c) Remove the o-ring from the vehicle speed sensor. 3. INSTALL VEHICLE SPEED SENSOR ASSEMBLY (a) Coat a new o-ring with ATF and install it to the vehicle speed sensor. (b) Install the driven gear and the clip to the vehicle speed sensor. (c) Install the vehicle speed sensor assembly with the bolt. Torque: 16 Nm (160 kgf.cm, 12 ft.lbf) 4. CONNECT VEHICLE SPEED SENSOR CONNECTOR Page 3898 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 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 4249 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 1403 Spark Plug: Specifications Torque Specification Spark Plug x Cylinder Head ................................................................................................................ ......................................................................... 20 Nm Page 4353 Junction Box / No. 3 Page 1550 Applicable Vehicles Page 3961 Wireless Transmitter Identification Page 4411 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 4250 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. Airbag(s) Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Airbag(s) Arming and Disarming CAUTION: * Work must be started 90 seconds after the ignition switch is turned to the "LOCK" position and the negative (-) terminal cable is disconnected from the battery. (The SRS is equipped with a back-up power source so that if work is started within 90 seconds of disconnecting the negative (-) terminal cable of the battery, the SRS may be deployed.) * When the negative (-) terminal cable is disconnected from the battery, the memory of the clock and audio system will be canceled. So before starting work, make a record of the contents memorized in the audio memory system. When work is finished, reset the audio systems as before and adjust the clock. To avoid erasing the memory of each memory system, never use a backup power supply from outside the vehicle. * Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during repairs. * Do not expose the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor directly to hot air or flames. AIR BAG SYSTEM DISARMING The Air Bag/Supplemental Restraint System (SRS) incorporates a backup energy source that maintains sufficient deployment voltage for up to 90 seconds after the ignition is turned Off and the battery has been disconnected. Before disconnecting battery, note radio station settings, since all vehicle memory will be lost. Never use a backup power source from outside the vehicle. 1. Turn ignition to Lock, then disconnect battery ground cable. 2. Wait at least 90 seconds after disconnection before beginning service or diagnostic procedures. AIR BAG SYSTEM ARMING 1. Ensure ignition is in Lock position. 2. Connect battery ground cable. 3. Wait at least 10 seconds before turning ignition from Lock position. 4. Turn ignition to ACC or On position and ensure SRS lamp lights, then goes off after approximately six seconds. If lamp remains lit, an SRS condition is indicated. Refer to Restraint Systems, Air Bag Systems, Testing And Inspection. See: Air Bag Systems/Testing and Inspection Page 1043 3. INSPECT ECT SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: Refer to the chart graph If the resistance is not as specified, replace the ECT sensor. 4. REINSTALL ECT SENSOR a. Install a new gasket to the ECT sensor. b. Using a 19 mm deep socket wrench, install the ECT sensor. Torque: 20 Nm (200 kg.cm, 14 ft.lb) c. Connect the ECT sensor connector. d. Install the engine wire protector to the 3 brackets. 5. REFILL WITH ENGINE COOLANT Page 3141 Part 2 Of 3 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 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 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 2899 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 882 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. 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 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 1195 Mass Air Flow Meter: Service and Repair COMPONENTS REMOVAL 1. REMOVE AIR CLEANER CAP WITH MAF METER a. Disconnect the MAF meter connector and wire clamp. b. Loosen the air cleaner hose clamp. c. Disconnect the air hose from air cleaner cap. d. Loosen the 4 clips, and remove the air cleaner cap together with the MAF meter. 2. REMOVE MAF METER FROM AIR CLEANER CAP Page 4277 Relay Box / No. 2 Ground Locations Page 2293 Clutch Master Cylinder: Service and Repair REMOVAL 1. DRAW OUT FLUID WITH SYRINGE 2. DISCONNECT CLUTCH LINE Using SST disconnect the line. Use a container to catch the fluid. SST 09023-00100 Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.) 3. REMOVE CLIP AND CLEVIS PIN 4. REMOVE MOUNTING NUTS AND PULL OUT MASTER CYLINDER Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.) DISASSEMBLY 1. REMOVE RESERVOIR TANK a. Using a pin punch and hammer, drive out the slotted spring pin. b. Remove the reservoir tank and grommet. Diagrams 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 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 1285 c. Connect the sensor connector. 2. INSPECT OPERATION OF A/F SENSOR Page 3258 Page 3122 Part 2 Of 2 MANUAL STEERING GEAR REPLACEMENT AND OVERHAUL W/ RELATED COMPONENTS Page 1839 2. INSPECT HOSES, CONNECTIONS AND GASKETS Visually check for cracks, leaks or damage. Page 2342 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 4071 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 2886 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 327 A/F and 02 Sensor Identification Page 935 Part 2 of 7 Page 195 Steps 1 - 2 Page 3203 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 2651 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 1834 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 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 2403 Drive/Propeller Shaft: Service and Repair REMOVAL REMOVE PROPELLER SHAFT a. Place matchmarks on the propeller shaft and differential flanges. b. Remove the 4 nuts, bolts and washers. Page 4303 Junction Box / No. 3 Page 1496 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 3704 Seat Belt Tensioner: Testing and Inspection Replacement Requirements REPLACE REQUIREMENTS In the following cases, replace the seat belt pretensioner. - If the seat belt pretensioner has been activated. - If the seat belt pretensioner has been found to be faulty in troubleshooting. - If the front seat outer belt has been found to be faulty during checking item functioning of SST. - If the front seat outer belt has been dropped. CAUTION: Be sure to follow the correct procedure, for removal and installation of the seat belt pretensioner. Page 1386 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: 30 Nm (310 kg.cm, 22 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. 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 4343 Air Bag(s) Arming and Disarming: Service and Repair Release Method of Airbag Activation Prevention Mechanism Page 1503 Engine Control Module: Connector Views Connectors (California Spec.) Part 1 Of 2 (California Spec.) Page 2436 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 2871 Auxiliary Power Outlet: Connector Locations Junction Box / No. 3 Page 249 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 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 3097 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 754 Engine Compartment Instrument Panel 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 - 0.8 V is applied to terminal VTA of the ECM. The voltage applied to the terminals VTA of the ECM increases in proportion to the opening angle of the throttle valve and becomes approximately 3.2 - 4.9 V when the throttle valve is fully opened. The ECM judges the vehicle driving conditions from these signals input from terminal VTA, uses it as one of the conditions to decide the air-fuel ratio correction, power increase correction and fuel cut control etc. Page 2389 Wheel Bearing: Service and Repair Disassembly and Reassembly DISASSEMBLY 1. CHECK HUB BEARINGS Clean the bearings and outer races and inspect them for wear or damage. Page 3615 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. 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 Crankshaft Main Bearing: Specifications Main Bearing Cap Bolts Standard Outside Diameter .......................................................................... .............................................................................................. 10.76 - 10.97 mm Minimum Outside Diameter .............................................................................................................................................. ..................................... 10.40 mm Torque .......................................................................................... ............................................................................................................................... 39 Nm Page 1222 Knock Sensor: Testing and Inspection 1. REMOVE STARTER 2. REMOVE FUEL FILTER SET BOLTS 3. REMOVE KNOCK SENSOR a. Disconnect the knock sensor connector. b. Using SST, remove the knock sensor. SST 09816-30010 4. INSPECT KNOCK SENSOR Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor. 5. REINSTALL KNOCK SENSOR a. Using SST, install the knock sensor. SST 09816 - 30010 Torque: 44 Nm (450 kg.cm, 33 ft.lb) b. Connect the knock sensor connector. 6. REINSTALL FUEL FILTER SET BOLTS Torque: 20 Nm (200 kg.cm, 14 ft.lb) 7. REINSTALL STARTER Page 1269 CHART 27 Page 635 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. 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 2942 Auxiliary Power Outlet: Connector Locations Junction Box / No. 3 Page 3497 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 1263 Page 1848 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 the following conditions: 1. Apply vacuum (2.0 kpa, 15 mmHg, 0.59 in.Hg) to the vapor pressure sensor. Voltage: 1.3 - 2.1 V 2. Release the vacuum from the vapor pressure sensor. Voltage: 3.0 - 3.6 V 3. Apply pressure (1.5 kpa, 15 gf/Sq.cm, 0.22 psi) to the vapor pressure sensor. Voltage: 4.2 - 4.8 V d. Reconnect the vacuum hose to the vapor pressure sensor. Page 2446 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 3625 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 2087 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 3281 * For vehicle capacity weight. ** For reduced loads (1 to 4 passengers). *** For trailer towing. Page 2642 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. Testing and Inspection Power Window Relay: Testing and Inspection INSPECT POWER MAIN RELAY CONTINUITY If continuity is not as specified, replace the relay. Page 348 CHART 11 Page 1447 3. INSPECT ECT SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: Refer to the chart graph If the resistance is not as specified, replace the ECT sensor. 4. REINSTALL ECT SENSOR a. Install a new gasket to the ECT sensor. b. Using a 19 mm deep socket wrench, install the ECT sensor. Torque: 20 Nm (200 kg.cm, 14 ft.lb) c. Connect the ECT sensor connector. d. Install the engine wire protector to the 3 brackets. 5. REFILL WITH ENGINE COOLANT Page 238 Key Reminder Switch: Splice Locations Page 1721 Page 2524 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 2704 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 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. Locations Page 738 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. 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 2188 Page 3116 b. Disconnect the connector from the integration relay and inspect the connectors on the wire harness side. Page 429 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 406 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 1672 Crankshaft Position Sensor: Service and Repair REPLACEMENT 1. REMOVE ENGINE UNDER COVER 2. REMOVE GENERATOR 3. REMOVE GENERATOR BRACKET Remove the 3 bolts and bracket. 4. REMOVE CRANKSHAFT POSITION SENSOR a. Disconnect the sensor connector. b. Disconnect the sensor connector from the connector bracket. c. Remove the 2 bolts and crankshaft position sensor. d. Remove the O-ring. 5. REINSTALL NEW CRANKSHAFT POSITION SENSOR a. Install a new O-ring to the sensor. b. Install the sensor with the 2 bolts. Torque: 8.5 Nm (85 kg.cm, 74 in.lb) c. Reinstall the sensor connector to the connector bracket. d. Reconnect the sensor connector. 6. REINSTALL GENERATOR BRACKET Install the bracket with the 3 bolts Torque: Bolt A: 74.5 Nm (760 kg.cm, 55 ft.lb) Bolt B: 18 Nm (180 kg.cm, 13 ft.lb) 7. REINSTALL GENERATOR 8. REINSTALL ENGINE UNDER COVER Page 136 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 1523 Idle Air Control Valve: Testing and Inspection On-Vehicle Inspection INSPECT IAC VALVE OPERATION a. Initial conditions: - Engine at normal operating temperature - Idle speed check correctly - Transmission in neutral position b. Using SST, connect terminals TE1 and E1 of the DLC1. SST 09843-18020 c. After engine speed are kept at 1,000 - 1,500 rpm for 5 seconds, check that they return to idle speed. If the engine speed operation is not as specified, check the IAC valve, wiring and ECM. d. Remove the SST SST 09843-18020 Page 2201 Step 2 Step 3 INSPECTION PROCEDURE Page 1492 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 2887 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 Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid Dry fill ................................................................................................................................................... ....................................................................... 6.7 Qt Drain and refill ................................................... .......................................................................................................................................................... 2.5 Qt Description and Operation Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor Crankshaft position sensor (NE signal) consists of and pickup coil. The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor generates 34 signals at every engine revolution. The ECM detects the standard crankshaft angle based on the G signal, and the actual crankshaft angle and the engine speed by the NE signal. Page 1654 Remove the 4 nuts, MAF meter and gasket. INSTALLATION 1. INSTALL MAF METER TO AIR CLEANER CAP a. Place a new gasket on the air cleaner cap. b. Install the MAF meter with the 4 nuts. Torque: 8.5 Nm (85 kg.cm, 74 in.lb) 2. INSTALL MAF METER WITH AIR CLEANER CAP Page 306 3. INSPECT ECT SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: Refer to the chart graph If the resistance is not as specified, replace the ECT sensor. 4. REINSTALL ECT SENSOR a. Install a new gasket to the ECT sensor. b. Using a 19 mm deep socket wrench, install the ECT sensor. Torque: 20 Nm (200 kg.cm, 14 ft.lb) c. Connect the ECT sensor connector. d. Install the engine wire protector to the 3 brackets. 5. REFILL WITH ENGINE COOLANT Testing and Inspection Igniter: Testing and Inspection ON-VEHICLE INSPECTION NOTE: "Cold" and "Hot" in these sentences express the temperature of the coils themselves. "Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F). INSPECT IGNITION COIL WITH IGNITOR AND SPARK TEST Check that the spark occurs. 1. Remove the ignition coils. 2. Remove the spark plugs. 3. Install the spark plugs to each ignition coil, and connect the ignition coil connector. 4. Ground the spark plug. 5. Check if spark occurs while engine is being cranked. NOTE: To prevent gasoline from being injected from injectors during this test, crank the engine for no more than 1 - 2 seconds at time. If the spark does not occur, do the test as per the flow chart. 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 1625 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 1323 EGR Temperature Sensor: Testing and Inspection EGR Gas Temperature Sensor [Except Calif. Spec.] 1. REMOVE EGR VALVE 2. REMOVE EGR GAS TEMPERATURE SENSOR 3. INSPECT EGR GAS TEMPERATURE SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: at 50 °C (122 °F) 64 - 97 kohms at 100 °C (212 °F) 11 - 16 kohms at 150 °C (302 °F) 2 - 4 kohms If the resistance is not as specified, replace the sensor. 4. REINSTALL EGR GAS TEMPERATURE SENSOR 5. REINSTALL EGR VALVE Page 1451 Step 1 Step 2 TOYOTA hand-held tester: Page 193 Step 4 INSPECTION PROCEDURE Locations Vehicle Speed Sensor NO.1 (A43D) 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. 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 2890 Description and Operation Knock Sensor: Description and Operation Knock Sensor The knock sensor is fitted to 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. 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. 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 1740 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. 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 2948 Connector Locations Page 2080 Shift Indicator: Splice Locations Page 2167 11. INSTALL REAR MOUNTING INSULATOR TO EXTENSION HOUSING Install the rear mounting insulator to the extension housing with the 4 bolts. Torque: 25 Nm (260 kgf-cm, 19 ft. lbs.) 12. INSTALL ENGINE REAR MOUNTING BRACKET TO REAR SUPPORT MEMBER Install the rear mounting bracket to the rear support member with the 8 bolts. Torque: Rear mounting side: 18 Nm (185 kgf-cm, 13 ft. lbs.) Frame side: 58 Nm (590 kgf-cm, 42 ft. lbs.) 13. INSTALL VEHICLE SPEED SENSOR AND CONNECT SPEED SENSOR CONNECTOR 14. INSTALL PROPELLER SHAFT Page 1630 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 3001 Engine Compartment Instrument Panel Locations Page 3690 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 2904 Engine Compartment Instrument Panel Locations Page 3092 Key Reminder Switch: Fuse and Fusible Link Locations Relay Box / No. 2 Specifications Compression Check: Specifications Compression Pressure ........................................................................................................................ ..................................................... 1,230 kPa or More Minimum Pressure .......................................... .......................................................................................................................................................... 880 kPa Difference Between Each Cylinder ........................................................................................ ........................................................................ 98 kPa or Less Page 1603 c. Connect the sensor connector. 2. INSPECT OPERATION OF A/F SENSOR Page 400 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 2962 Page 1352 Crankshaft Position Sensor: Testing and Inspection INSPECT CRANKSHAFT POSITION SENSOR a. Remove the sensor. b. Using an ohmmeter, measure the resistance between terminals NE and NE-. Resistance: Cold 1,630 - 2,740 kohms Hot 2,065 - 3,225 kohms If the resistance is not as specified, replace the sensor. c. Reinstall the sensor. Page 2557 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 3894 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. 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 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 3061 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: 0.25 Nm (2.5 kgf-cm, 2.2 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 REAR HOUSING a. Remove the 2 bolts and rear housing. b. Remove the 2 O-rings from the housing. 6. REMOVE WAVE WASHER 7. REMOVE SIDE PLATE 8. 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. 9. REMOVE STRAIGHT PINS Remove the 2 pins from the front housing. 10. REMOVE GASKET 11. REMOVE VANE PUMP SHAFT WITH BEARING a. Using snap ring pliers, remove the snap ring from the front housing. b. Wind vinyl tape on the serrated part of the vane pump shaft. c. Press out the shaft with the bearing. NOTICE: Be careful not to damage the oil seal lip. Page 943 Page 1685 Applicable Vehicles Page 2827 Step 4 INSPECTION PROCEDURE Page 1127 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. Component Inspections Fuel Injector: Testing and Inspection Component Inspections INSPECTION 1. INSPECT INJECTOR INJECTION CAUTION: Keep injector clean of sparks during the test. a. Remove the fuel inlet pipe from the fuel filter outlet. b. Connect SST (union and hose) to the fuel filter outlet with the 2 gaskets and union bolt. SST 09268-41047 (90405-09015) Torque: 29 Nm (300 kg.cm, 22 ft.lb) c. Remove the fuel pressure regulator from the delivery pipe. d. Install the O-ring to the fuel inlet of pressure regulator. e. Connect SST (hose) to the fuel inlet of the pressure regulator with SST (union) and the 2 bolts. SST 09268-41047 (09268-41091) f. Connect the fuel return hose to the fuel outlet of the pressure regulator. Page 2772 Ignition Switch: Testing and Inspection 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 812 Page 3685 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. 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 1262 CHART 23 Page 3964 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 Component Locations Auxiliary Power Outlet: Component Locations 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 3339 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. 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 3570 Page 4221 Steps 2 - 3 INSPECTION PROCEDURE Page 1565 CHART 5 CHART 6 Page 251 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. 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 1388 NOTE: Always pinch the hose. Avoid bending as it may cause to hose to crack. 7. Turn the ignition switch OFF. 8. Disconnect the TOYOTA hand-held tester from the DLC3. Page 2876 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 - 0.8 V is applied to terminal VTA of the ECM. The voltage applied to the terminals VTA of the ECM increases in proportion to the opening angle of the throttle valve and becomes approximately 3.2 - 4.9 V when the throttle valve is fully opened. The ECM judges the vehicle driving conditions from these signals input from terminal VTA, uses it as one of the conditions to decide the air-fuel ratio correction, power increase correction and fuel cut control etc. 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 1596 Heated Oxygen Sensor Page 1286 Oxygen Sensor: Testing and Inspection Heated Oxygen Sensor Heated Oxygen Sensor Page 2694 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 2179 Shift Indicator: Ground Locations Page 2347 Specifications Valve Clearance: Specifications Valve Clearance Intake ................................................................................................................................................... ......................................................... 0.006 - 0.010 in Exhaust ................................................................................................................................................ ......................................................... 0.010 - 0.014 in Page 3520 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 3614 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 637 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 2924 Junction Box / No. 1 Details Page 3129 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 Page 674 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 972 SST 09268-45012 t. Reconnect the fuel inlet pipe to the delivery pipe with 2 new gaskets and the union bolt. Torque: 29 Nm (300 kg.cm, 22 ft.lb) u. Reconnect the negative (-) terminal cable to the battery. v. Check for fuel leakage. 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 Igniter: Testing and Inspection ON-VEHICLE INSPECTION NOTE: "Cold" and "Hot" in these sentences express the temperature of the coils themselves. "Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F). INSPECT IGNITION COIL WITH IGNITOR AND SPARK TEST Check that the spark occurs. 1. Remove the ignition coils. 2. Remove the spark plugs. 3. Install the spark plugs to each ignition coil, and connect the ignition coil connector. 4. Ground the spark plug. 5. Check if spark occurs while engine is being cranked. NOTE: To prevent gasoline from being injected from injectors during this test, crank the engine for no more than 1 - 2 seconds at time. If the spark does not occur, do the test as per the flow chart. Page 3495 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 Page 4164 Steps 1 - 2 Page 495 Steps 1 - 2 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 3158 12. INSTALL RACK HOUSING 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. Torque the cap. Torque: 59 Nm (600 kgf-cm, 43 ft. lbs.) c. Using a punch and hammer, stake the 2 parts of the cap. 13. 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. 14. 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. Using SST, torque the rack guide spring cap. SST 09631-10021 Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.) c. Using SST, return the cap 120. SST 09631-10021 d. Using SST, turn the control valve shaft right and left 1 or 2 times. SST 09616-00010 e. Using SST, loosen the cap until the rack guide spring is not functioning. SST 09631-10021 Page 1252 CHART 12 CHART 13 Locations Vehicle Lifting: Locations Locations Page 3362 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 3028 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 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 2764 Steps 1 - 3 Page 1763 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 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 4235 Audible Warning Device: Fuse and Fusible Link Locations Relay Box / No. 2 Page 1332 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 4285 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 2979 Interior J/B # 1 Page 2943 Auxiliary Power Outlet: Fuse and Fusible Link Locations Relay Box / No. 2 Page 1248 CHART 7 Page 2091 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 2367 Axle Shaft: Service and Repair REMOVAL Part 1 Of 2 Page 2914 Engine Compartment Instrument Panel Locations Specifications Output Shaft: Specifications Output Shaft End Play .............................................................................................................................................. .................... 0.3 - 0.9 mm (0.012 - 0.035 inch) Page 2120 Transmission Speed Sensor: Service and Repair VEHICLE SPEED SENSOR ON-VEHICLE REPAIR Vehicle Speed Sensor NO.1(A43D) 1. DISCONNECT VEHICLE SPEED SENSOR CONNECTOR 2. REMOVE VEHICLE SPEED SENSOR ASSEMBLY (a) Remove the bolt and the vehicle speed sensor assembly. (b) Remove the clip and the driven gear from the vehicle speed sensor. (c) Remove the o-ring from the vehicle speed sensor. 3. INSTALL VEHICLE SPEED SENSOR ASSEMBLY (a) Coat a new o-ring with ATF and install it to the vehicle speed sensor. (b) Install the driven gear and the clip to the vehicle speed sensor. (c) Install the vehicle speed sensor assembly with the bolt. Torque: 16 Nm (160 kgf.cm, 12 ft.lbf) 4. CONNECT VEHICLE SPEED SENSOR CONNECTOR Component Locations Shift Indicator: Component Locations Page 291 Mass Air Flow Meter: Testing and Inspection 1. INSPECT MAF METER RESISTANCE Using an ohmmeter, measure the resistance between terminals THA and E3. Temperature Resistance -20 °C (-4 °F) 10 - 20 Kohms 0 °C (32 °F) 4 - 7 Kohms 20 °C (68 °F) 2 - 3 Kohms 40 °C (104 °F) 0.9 - 1.3 Kohms 60 °C (140 °F) 0.4 - 0.7 Kohms 80 °C (176 °F) 0.2 - 0.4 Kohms If the resistance is not as specified, replace the MAF meter. 2. INSPECT MAF METER OPERATION a. Connect the negative (-) terminal cable to the battery. b. Turn the ignition switch ON. c. Connect the MAF meter connector. d. Using a voltmeter, connect the positive (+) tester probe to terminal VG, and negative (-) tester probe to terminal E3. e. Blow air into the MAF meter, and check that the voltage fluctuates. If operation is not as specified, replace the MAF meter. f. Turn the ignition switch OFF. g. Disconnect the negative (-) terminal cable from the battery. h. Disconnect the MAF meter connector. Page 4156 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 2274 d. Remove the temporarily installed bolts. 5. Place lower valve body and rear upper valve body on front upper valve body. Align each bolt hole in the valve bodies with the gaskets and plate. 6. Install and finger tighten bolts in lower valve body to secure front upper valve body, as follows: a. Install and finger tighten the two bolts. NOTE: Bolt length (mm, in.) is indicated in the illustration. b. Hold the front upper valve body and lower valve body, turn over the assembly. c. Install and finger tighten the five bolts. NOTE: Bolt length (mm, in.) is indicated in the illustration. 7. Tighten bolts of upper and lower valve bodies, as follows: a. Tighten the 10 bolts in the upper valve bodies. Torque: 5.4 N.m (48 inch lbs.). Page 3059 Power Steering Pump: Service and Repair Disassembly and Reassembly Part 1 Of 2 Page 3387 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 4271 Cigarette Lighter: Fuse and Fusible Link Locations Relay Box / No. 2 Page 1446 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection 1. DRAIN ENGINE COOLANT 2. REMOVE ECT SENSOR a. Disconnect the engine wire protector from the 3 brackets. b. Disconnect the ECT sensor connector. c. Using a 19 mm deep socket wrench, remove the ECT sensor and gasket. Page 2626 ^ 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 3422 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 1726 Page 137 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 1359 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 1994 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 4158 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 2345 Differential Lock: Electrical Diagrams Page 2807 Service and Repair Pilot Bearing: Service and Repair For further information regarding this component and the system that it is a part of please refer to Clutch, M/T; Service and Repair. Page 2448 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 4000 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. Specifications Crankshaft Gear/Sprocket: Specifications Crankshaft Pulley Bolt Torque Using SST ........................................................................................... ...................................................................................................................... 260 Nm No. 3 and No. 2 Crankshaft Pulley Bolts (4) Torque (W/ A/C) ............................................................. ............................................................................................................................................ 25 Nm Page 3445 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. Page 2816 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 (46 kg.cm, 40 in.lb) 4. 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. Mount SST (C) in a vise. e. Install the generator to SST (C). Page 402 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 2604 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 3680 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 3225 HINT: Pass the arm shaft through the bushing. 4. Check that the arm shaft turns easily, and check that there is no axial play in the arm shaft. d. Install the lock bolts. Position the arm shaft so that the frame installation surface is at 90° to the suspension arm as shown, and torque the lock bolts. Torque: 125 Nm (1,270 kgf-cm, 92 ft. lbs.) INSTALLATION Installation is in the reverse order of removal. HINT: After installation, check the front wheel alignment and ABS speed sensor signal 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 3895 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. Electrode Gap Specification Spark Plug: Specifications Electrode Gap Specification Electrode Gap Correct Gap ......................................................................................................................................... ........................................................................ 0.8 mm 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 3928 Page 554 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 2856 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, 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.) Specifications Idle Speed: Specifications Idle Speed 700 +/- 50 rpm Electrode Gap Specification Spark Plug: Specifications Electrode Gap Specification Electrode Gap Correct Gap ......................................................................................................................................... ........................................................................ 0.8 mm Page 1232 Applicable Vehicles Page 1160 Part 2 Of 2 (California Spec.) *1: Only for A/T *2: Only for 3RZ-FE *3: The ECM terminal voltage is fixed regardless of the output voltage from the sensor. Connectors (Except California Spec.) Page 1563 CHART 1 Page 242 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 1251 CHART 11 Page 2951 Page 4377 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. 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. Specifications Removable Roof Page 3183 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. 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. 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 1469 Page 2343 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 566 7. INSPECT WHEEL ANGLE Turn the steering wheel fully and measure the turning angle. Wheel Turning Angle: If the right and left inside wheel angles differ from the specified value, check the right and left rack end lengths. HINT: If the rack ends lengths are not equal, the wheel turning angle cannot be adjusted properly. Reinspect the toe-in after adjusting the rack ends lengths. Page 360 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. 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 Page 1760 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. 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 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 612 Spark Plug: Testing and Inspection INSPECT SPARK PLUGS a. Except California Spec.: Disconnect the high-tension cords from the spark plugs. b. California Spec.: Remove the ignition coils. c. Using a 16 mm plug wrench, remove the 4 spark plug. d. Using a spark plug cleaner or wire brush, clean the spark plug. e. Check the spark plug for electrode wear, threads damage and insulator damage. If abnormal, replace the plugs. Recommended spark plug: Except California Spec. DENSO made K16R-U NGK made BKR5EYA California Spec. DENSO made K16R-U11 NGK made BKR5EYA-U f. Adjust the electrode gap. Carefully bend the outer electrode to obtain the correct electrode gap. Correct electrode gap: Except California Spec. 1.1 mm (0.043 in.) California Spec. 0.8 mm (0.031 in.) Page 3013 RZN140L Model RZN150L Model VZN150L 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 upper suspension arm set bolts. b. Adjust the camber and caster by adding or removing shims (See adjustment chart). Shim Thickness: HINT: Try to adjust the camber and caster to the center of the specified values. Page 1353 Crankshaft Position Sensor: Service and Repair REPLACEMENT 1. REMOVE ENGINE UNDER COVER 2. REMOVE GENERATOR 3. REMOVE GENERATOR BRACKET Remove the 3 bolts and bracket. 4. REMOVE CRANKSHAFT POSITION SENSOR a. Disconnect the sensor connector. b. Disconnect the sensor connector from the connector bracket. c. Remove the 2 bolts and crankshaft position sensor. d. Remove the O-ring. 5. REINSTALL NEW CRANKSHAFT POSITION SENSOR a. Install a new O-ring to the sensor. b. Install the sensor with the 2 bolts. Torque: 8.5 Nm (85 kg.cm, 74 in.lb) c. Reinstall the sensor connector to the connector bracket. d. Reconnect the sensor connector. 6. REINSTALL GENERATOR BRACKET Install the bracket with the 3 bolts Torque: Bolt A: 74.5 Nm (760 kg.cm, 55 ft.lb) Bolt B: 18 Nm (180 kg.cm, 13 ft.lb) 7. REINSTALL GENERATOR 8. REINSTALL ENGINE UNDER COVER Page 4168 Steps 3 - 4 INSPECTION PROCEDURE 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 Pressure Specification Fuel Pressure: Specifications Fuel Pressure No Vacuum 38 to 44 psi Page 326 Engine Bank Identification Page 2696 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 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 1009 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 INTAKE AIR CONNECTOR 3. Except California Spec.: DISCONNECT HIGH-TENSION CORDS FROM SPARK PLUGS NOTICE: Pulling on or bending the cords may damage the conductor inside. 4. California Spec.: REMOVE IGNITION COILS (WITH IGNITER) 5. REMOVE SPARK PLUGS 6. 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: 1,230 kPa (12.5 kgf/cm2, 178 psi) or more Minimum pressure: 880 kPa (9.0 kgf/cm2, 127 psi) Difference between each cylinder: 98 kPa (1.0 kgf/cm2, 14 psi) or less e) If the cylinder compression in one or more cylinders is low, pour 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, chances are that the piston rings and/or cylinder bore are worn or damage. - If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket. 7. REINSTALL SPARK PLUGS Torque: 19 Nm (200 kgf-cm, 14 ft. lbs.) 8. Except California Spec.: REINSTALL HIGH-TENSION CORDS TO SPARK PLUGS 9. California Spec.: REINSTALL IGNITION COILS (WITH IGNITER) 10. REINSTALL INTAKE AIR CONNECTOR Page 2407 Installation is in the reverse order of removal. HINT: 3-joint type: Center bearing center line and the center bearing housing center line must be adjusted within 0 ± 1 mm (0 ± 0.039 inch) of each other in the vehicles front and rear direction when the vehicle is unloaded. - When adjusting the center bearing housing center line, it should be perpendicular to the axis of front propeller shaft. Page 2517 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 1640 Engine Control Module: Pinout Values and Diagnostic Parameters Connectors (California Spec.) Part 1 Of 2 (California Spec.) 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 116 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 2798 Battery: Specifications Parasitic Draw: Information not supplied by the manufacturer. 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 ECM will be erased when the battery negative (-) terminal cable is removed from the battery. Therefore, if necessary, read the diagnostic trouble code(s) 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 a new gasket. 2. Tighten the union bolt by hand. 3. Tighten the union bolt to the specified torque. Torque: 29 Nm (300 kg.cm, 22 ft.lb) Page 3405 Refrigerant: Fluid Type Specifications Type R-134a Page 183 Steps 1 - 2 Page 3048 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 2339 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 4099 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 1931 INSPECT FUEL TANK AND LINE a. Check the fuel lines for cracks or leakage, and all connections for deformation. b. Check the fuel tank vapor vent system hoses and connections for looseness, sharp bends or damage. c. Check the fuel tank for defamation, cracks, fuel leakage or tank band looseness. d. Check the filler neck for damage or fuel leakage. e. Hose and tube connections are as shown in the illustration. If a problem is found, repair or replace the part as necessary. Page 3396 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 117 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 3670 Seat Belt Reminder Lamp: Connector Locations Page 4045 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 1767 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 1491 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 3291 f. Using a dial indicator near the center of the axle hub and measure the backlash in the bearing shaft direction. Maximum: 0.05 mm (0.0020 inch) or less 9. INSTALL LOCK CAP, COTTER PIN AND GREASE CAP a. Install the lock cap and a new cotter pin. If the holes for the cotter pin are not aligned, tighten the nut further up to 60°. b. Install the grease cap. 10. INSTALL BRAKE CALIPER Install the brake caliper with the 2 bolts. Torque: 108 Nm (1,100 kgf-cm, 80 ft. lbs.) 11. w/ ABS: CONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP TO STEERING KNUCKLE Connect the ABS speed sensor and wire harness clamp with the 2 bolts. Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.) 12. INSTALL FRONT WHEEL Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.) 13. DEPRESS BRAKE PEDAL SEVERAL TIMES 14. CHECK FRONT WHEEL ALIGNMENT 15. w/ ABS: CHECK ABS SPEED SENSOR SIGNAL Page 4400 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. Locations Page 1949 Idle Air Control Valve: Testing and Inspection On-Vehicle Inspection INSPECT IAC VALVE OPERATION a. Initial conditions: - Engine at normal operating temperature - Idle speed check correctly - Transmission in neutral position b. Using SST, connect terminals TE1 and E1 of the DLC1. SST 09843-18020 c. After engine speed are kept at 1,000 - 1,500 rpm for 5 seconds, check that they return to idle speed. If the engine speed operation is not as specified, check the IAC valve, wiring and ECM. d. Remove the SST SST 09843-18020 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 2873 Auxiliary Power Outlet: Ground Locations Locations Page 659 Hose/Line HVAC: Tools and Equipment A/C Clamp Remover AST tool# TOY 200 Page 2046 Crankshaft Position Sensor: Service and Repair REPLACEMENT 1. REMOVE ENGINE UNDER COVER 2. REMOVE GENERATOR 3. REMOVE GENERATOR BRACKET Remove the 3 bolts and bracket. 4. REMOVE CRANKSHAFT POSITION SENSOR a. Disconnect the sensor connector. b. Disconnect the sensor connector from the connector bracket. c. Remove the 2 bolts and crankshaft position sensor. d. Remove the O-ring. 5. REINSTALL NEW CRANKSHAFT POSITION SENSOR a. Install a new O-ring to the sensor. b. Install the sensor with the 2 bolts. Torque: 8.5 Nm (85 kg.cm, 74 in.lb) c. Reinstall the sensor connector to the connector bracket. d. Reconnect the sensor connector. 6. REINSTALL GENERATOR BRACKET Install the bracket with the 3 bolts Torque: Bolt A: 74.5 Nm (760 kg.cm, 55 ft.lb) Bolt B: 18 Nm (180 kg.cm, 13 ft.lb) 7. REINSTALL GENERATOR 8. REINSTALL ENGINE UNDER COVER Page 4330 W/ Tachometer W/o Tachometer If resistance value is not as specified, replace the receiver gauge. Page 2870 Page 2791 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 297 Locations Page 3768 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 3224 NOTICE: Be careful not to damage the edge of arm tubes. 1. Using SST and a press, press down the suspension arm tube until it touches SST. SST 09710-30021 (09710-03031, 09710-03141) NOTICE: Do not press the tube excessively. 2. Temporarily install a bolt to the arm shaft on the other side. Bolt length: 45-50 mm (1.8-2.0 inch) 3. Using SST and a press, remove the bushing and arm shaft. SST 09710-30021 (09710-03141) 4. Using SST and a press, remove the other bushing. SST 09710-30021 (09710-03071, 09710-03141) c. Install new bushings. 1. Using SST and a press, install a new bushing. SST 09710-30021 (09710-03101) 2. Place the arm shaft on the bushing. 3. Using SST and a press, install another new bushing. SST 09710-30021 (09710-03101) Page 3599 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 241 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 2045 Crankshaft Position Sensor: Testing and Inspection INSPECT CRANKSHAFT POSITION SENSOR a. Remove the sensor. b. Using an ohmmeter, measure the resistance between terminals NE and NE-. Resistance: Cold 1,630 - 2,740 kohms Hot 2,065 - 3,225 kohms If the resistance is not as specified, replace the sensor. c. Reinstall the sensor. Page 3320 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 4175 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 Removal and Installation Power Steering Pump: Service and Repair Removal and Installation Part 1 Of 2 Page 1327 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 the following conditions: 1. Apply vacuum (2.0 kpa, 15 mmHg, 0.59 in.Hg) to the vapor pressure sensor. Voltage: 1.3 - 2.1 V 2. Release the vacuum from the vapor pressure sensor. Voltage: 3.0 - 3.6 V 3. Apply pressure (1.5 kpa, 15 gf/Sq.cm, 0.22 psi) to the vapor pressure sensor. Voltage: 4.2 - 4.8 V d. Reconnect the vacuum hose to the vapor pressure sensor. 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 ECM will be erased when the battery negative (-) terminal cable is removed from the battery. Therefore, if necessary, read the diagnostic trouble code(s) 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 a new gasket. 2. Tighten the union bolt by hand. 3. Tighten the union bolt to the specified torque. Torque: 29 Nm (300 kg.cm, 22 ft.lb) Specifications Case: Specifications SERVICE SPECIFICATIONS Transmission Case Bushing Maximum ............................................................................................................................................. .................................. 38.19 mm (1.5035 inch) TORQUE SPECIFICATIONS Center Support x Transmission case ................................................................................................................................. 25 Nm (260 kgf.cm, 19 ft. lbs.) Transmission Housing x Transmission Case 10 mm Bolt .......................................................................................................................................... ....................... 34 Nm (345 kgf.cm, 25 ft. lbs.) 12 mm Bolt ................................................................. ................................................................................................ 57 Nm (580 kgf.cm, 42 ft. lbs.) Oil Pump x Transmission Case ......................................................................................................................................... 21 Nm (215 kgf.cm, 16 ft. lbs.) Oil Pan x Transmission Case .......................................................................................................................................... 4.4 Nm (45 kgf.cm, 39 inch lbs.) Extension Housing x Transmission Case .......................................................................................................................... 34 Nm (345 kgf.cm, 25 ft. lbs.) Overdrive Solenoid x Transmission Case ........................................................................................................................... 13 Nm (130 kgf.cm, 9 ft. lbs.) Page 3205 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 2767 Steps 1 - 2 Page 564 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°05' (0.08°) Caster: 0°50' (0.83°) 3. Mark the alignment value measured when the vehicle was non-loaded on the adjustment chart. Example: Camber: 0°05' (0.08°) 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 shim thickness accordingly. Example: Page 803 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 1989 DISCONNECT THROTTLE CABLE FROM THROTTLE BODY 4. REMOVE AIR CLEANER HOSE WITH RESONATOR a. Disconnect the 2 wire clamps from the air cleaner hose. b. Loosen the air cleaner hose clamps, remove the air cleaner together with the resonator. 5. REMOVE INTAKE AIR CONNECTOR 6. REMOVE THROTTLE BODY a. Disconnect the PCV hose and EVAP hose. b. Except California Spec.for 2RZ-FE: Disconnect the 3 EGR hoses. c. w/PS: Disconnect the air hose for PS idle-up. d. Disconnect the throttle position sensor connector. e. Disconnect the IAC valve connector. f. Remove the 2 bolts and 2 nuts, and disconnect the throttle body from the air intake chamber. Torque: 20 Nm (200 kg.cm, 14 ft.lb) HINT: At the time of installation, please refer to the following items. Use a new gasket. Intake Manifold Assembly Intake Manifold: Specifications Intake Manifold Assembly Intake Manifold Maximum Warpage ............................................................................................................................. ..................................................................... 0.20 mm Torque ............................................................ ............................................................................................................................................................. 29 Nm Page 4155 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 3566 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 407 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 4227 Step 2 Step 3 INSPECTION PROCEDURE Troubleshooting in accordance with the chart for each trouble symptom. Fuel System - Fuel Injector Cleaning Procedure Fuel Injector: Technical Service Bulletins Fuel System - Fuel Injector Cleaning Procedure PRODUCT GENERAL INFORMATION PG011-05 REVISED October 13, 2005 Title: FUEL INJECTOR CLEANING Models: '90 - '06 Toyota & Scion Models With Port Electronic Fuel Injection TSB REVISION NOTICE: ^ June 9, 2006: In the Required Tools & Material section, part numbers have been updated (TYG S-Line Device and Toyota Adaptor Pak), and the note with ordering information has been updated. Previous versions of this TSB should be discarded. Introduction Due to fuel quality concerns, some Toyota and Scion vehicles with Port Electronic Fuel Injection may experience clogged or blocked fuel injectors. The following procedure has been developed to clean the fuel injectors. Applicable Vehicles: ^ All 1990 - 2006 Toyota and Scion models equipped with Port Electronic Fuel Vehicles Injection (EFI). Required Tools & Material Warranty Information Repair Procedure 1. If the fuel injector nozzles are visibly blocked or if the injectors do NOT pass the fuel injector volume test, complete the fuel injector power flush using the following instructions: A. Before an injector cleaning is performed, it is recommended that the following items be cleaned with Toyota Throttle Plate Cleaner (P/N 00289-1TP00): ^ Idle air control device ^ Throttle plate (both sides if possible) ^ Throttle body B. Bring the engine to operating temperature. C. Disconnect the fuel pump electrical connector. Locations Page 3019 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°05' (0.08°) Caster: 0°50' (0.83°) 3. Mark the alignment value measured when the vehicle was non-loaded on the adjustment chart. Example: Camber: 0°05' (0.08°) 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 shim thickness accordingly. Example: Page 3567 Page 3518 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 2185 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 4176 Steps 1 - 2 Page 4187 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 1745 Heated Oxygen Sensor COMPONENTS 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. Page 244 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 3948 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. Description and Operation Knock Sensor: Description and Operation Knock Sensor The knock sensor is fitted to 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 2466 Fluid - M/T: Fluid Type Specifications Transmission Fluid Grade ................................................................................................................................................... ............................................................ GL-4 or GL-5 Viscosity ........................................................... ................................................................................................................................................ SAE 75W-90 Page 2880 Page 1590 CHART 29 Page 1381 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 HINT: All vacuum hoses for EGR system, etc. should be properly connected. f) SFI system wiring connectors fully plugged g) Ignition timing check correctly h) Transmission in neutral position 2. CONNECT TOYOTA HANDHELD TESTER OR OBDII SCAN TOOL 3. INSPECT IDLE SPEED a) Race the engine speed at 2,500 rpm for approx. 90 seconds. b) Check the idle speed. Idle speed: 650 - 750 rpm If the idle speed is not as specified, check the IAC valve, intake air leakage and SFI system. 4. DISCONNECT TOYOTA HAND-HELD TESTER OR OBDII SCAN TOOL Page 2627 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 1737 Heated Oxygen Sensor Page 3764 Application Chart Page 1844 EGR Temperature Sensor: Testing and Inspection EGR Gas Temperature Sensor [Except Calif. Spec.] 1. REMOVE EGR VALVE 2. REMOVE EGR GAS TEMPERATURE SENSOR 3. INSPECT EGR GAS TEMPERATURE SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: at 50 °C (122 °F) 64 - 97 kohms at 100 °C (212 °F) 11 - 16 kohms at 150 °C (302 °F) 2 - 4 kohms If the resistance is not as specified, replace the sensor. 4. REINSTALL EGR GAS TEMPERATURE SENSOR 5. REINSTALL EGR VALVE Page 2985 Engine Compartment Instrument Panel Locations Page 3451 - 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. * Page 1166 Step 1 Step 2 Step 3 Step 4 Page 621 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 PCV HOSES 3. Except California Spec.: DISCONNECT HIGH-TENSION CORDS FROM SPARK PLUGS 4. California Spec.: REMOVE IGNITION COILS (WITH IGNITER) NOTICE: Pulling on or bending the cords may damage the conductor inside. 5. DISCONNECT ENGINE WIRE a) w/ A/C: Disconnect the A/C compressor connector. b) Disconnect the oil pressure sensor connector. c) Disconnect the ECT sender gauge connector. d) Except California Spec.: Disconnect the ignition coil connector. e) Disconnect the 4 engine wire clamps and engine wire. 6. REMOVE CYLINDER HEAD COVER Remove the 10 bolts, 10 seal washers, cylinder head cover and gasket. 7. SET NO.1 CYLINDER TO TDC/COMPRESSION a) Turn the crankshaft pulley clockwise and align its groove with the "0" mark on the timing chain cover. b) Check that the timing marks (1 and 2 dots) of the camshaft drive and driven gears are in straight line on the cylinder head surface as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) and align the marks as above. 8. INSPECT VALVE CLEARANCE Page 246 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. Component Inspection Idle Air Control Valve: Testing and Inspection Component Inspection 1. Except California Spec.: 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). Using an ohmmeter, measure the resistance between terminal +B and other terminals (RSC, RSO). Resistance: Cold: 17.0 - 24.5 ohms Hot: 21.5 - 28.5 ohms If resistance is not as specified, replace the IAC valve. 2. Except California Spec.: 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. Page 3628 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 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 310 Crankshaft Position Sensor: Testing and Inspection INSPECT CRANKSHAFT POSITION SENSOR a. Remove the sensor. b. Using an ohmmeter, measure the resistance between terminals NE and NE-. Resistance: Cold 1,630 - 2,740 kohms Hot 2,065 - 3,225 kohms If the resistance is not as specified, replace the sensor. c. Reinstall the sensor. Page 1519 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 3937 Air Bag(s) Arming and Disarming: Service and Repair Release Method of Airbag Activation Prevention Mechanism Page 2757 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 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 3185 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 1002 Spark Plug: Specifications Torque Specification Spark Plug x Cylinder Head ................................................................................................................ ......................................................................... 20 Nm Page 2511 Shift Indicator: Splice 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 3393 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 1242 Page 2863 If there is no continuity, replace the relay. 3. REINSTALL STARTER RELAY Page 3592 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 2584 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 2178 Junction Box / No. 3 Page 1485 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 4267 Cigarette Lighter: Connector Locations Page 4344 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. Diagrams Page 1806 Vehicle Speed Sensor: Service and Repair ON-VEHICLE REPAIR 1. DISCONNECT VEHICLE SPEED SENSOR CONNECTOR Vehicle Speed Sensor NO.1 (A43D) 2. REMOVE VEHICLE SPEED SENSOR ASSEMBLY a. Remove the bolt and the vehicle speed sensor assembly. b. Remove the clip and the driven gear from the vehicle speed sensor. c. Remove the O-ring from the vehicle speed sensor. 3. INSTALL VEHICLE SPEED SENSOR ASSEMBLY a. Coat a new O-ring with ATF and install it to the vehicle speed sensor. b. Install the driven gear and the clip to the vehicle speed sensor. c. Install the vehicle speed sensor assembly with the bolt. Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.) 4. CONNECT VEHICLE SPEED SENSOR CONNECTOR Page 1014 a) Check only the valves indicated. 1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft. 2) Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim. Valve clearance (Cold): b) Turn the crankshaft pulley 1 revolution (360°) and align its groove with timing mark "O" of the timing chain cover. c) Check only the valves indicated as shown. Measure the valve clearance. (See procedure in step (a)) 9. ADJUST VALVE CLEARANCE a) Remove the adjusting shim. 1) Turn the crankshaft to position the cam lobe of the camshaft on the adjusting valve upward. 2) Position the notch of the valve lifter toward the spark plug side. 3) Using SST (A), press down the valve lifter and place SST (B) between the camshaft and valve lifter flange. Remove SST (A). SST 09248-55040 (09248-05410, 09248-05420) HINT: Apply SST (B) at slight angle on the side marked with "9", at the position shown in the illustration. Page 2196 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 1776 Vehicle Speed Sensor: Service and Repair ON-VEHICLE REPAIR 1. DISCONNECT VEHICLE SPEED SENSOR CONNECTOR Vehicle Speed Sensor NO.1 (A43D) 2. REMOVE VEHICLE SPEED SENSOR ASSEMBLY a. Remove the bolt and the vehicle speed sensor assembly. b. Remove the clip and the driven gear from the vehicle speed sensor. c. Remove the O-ring from the vehicle speed sensor. 3. INSTALL VEHICLE SPEED SENSOR ASSEMBLY a. Coat a new O-ring with ATF and install it to the vehicle speed sensor. b. Install the driven gear and the clip to the vehicle speed sensor. c. Install the vehicle speed sensor assembly with the bolt. Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.) 4. CONNECT VEHICLE SPEED SENSOR CONNECTOR Page 3319 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. Specifications Shift Interlock Switch: Specifications Park/Neutral Position Switch ......................................................................................................................................... 5.4 Nm (55 kgf.cm, 48 inch lbs.) Park/Neutral Position Switch Adjusting Bolt ................................................................................................................. 3.9 Nm (40 kgf.cm, 35 inch lbs.) Page 2855 1.5 Nm (15 kg.cm, 13 in.lb) for 1.4 kW 3.8 Nm (38 kg.cm, 34 in.lb) for 2.0 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 401 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 1729 CHART 28 Page 1951 2. REMOVE IAC VALVE - Except California Spec.: Remove the 4 screws, IAC valve and gasket. - California Spec.: Remove the 3 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 1200 Locations Fuse: Locations Relay Box / No. 2 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 2097 Shift Indicator: Electrical Diagrams Page 665 Brake Fluid: Testing and Inspection Check for fluid leakage from actuator or hydraulic lines. Page 479 - 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 952 17. REMOVE NO.1 TIMING CHAIN TENSIONER SLIPPER AND NO.1 VIBRATION DAMPER a) Remove the bolt and slipper. b) 2RZ-FE: Remove the 2 bolts and No.1 damper. c) 3RZ-FE: Remove the bolt, nut and No.1 damper. 18. 2RZ-FE: REMOVE CRANKSHAFT POSITION SENSOR ROTOR 19. 2RZ-FE: REMOVE TIMING CHAIN OIL JET Remove the bolt, oil jet and gasket. 20. 3RZ-FE: REMOVE NO.2, NO.3 VIBRATION DAMPERS AND NO.2 CHAIN TENSIONER a) Install a pin to the No.2 chain tensioner and lock the plunger. b) Remove the bolt and No.2 damper. c) Remove the 2 bolts and No.3 damper. d) Remove the nut and No.2 chain tensioner. 21. 3RZ-FE: REMOVE BALANCE SHAFT DRIVE GEAR, SHAFT, NO.2 TIMING CHAIN AND NO.2 CRANKSHAFT TIMING SPROCKET a) Remove the bolt from the balance shaft drive gear. Page 3175 a. Spiral Cable b. Upper And Lower Column Covers c. Steering Wheel d. Steering Wheel Pad Page 1574 CHART 18 CHART 19 Page 528 Transmission Position Switch/Sensor: Service and Repair ON-VEHICLE REPAIR 1. REMOVE FRONT EXHAUST PIPE AND HEAT INSULATOR 2. DISCONNECT OIL COOLER PIPE a. Remove the 3 oil cooler pipe clamps. b. Disconnect the oil cooler pipe. 3. REMOVE ELBOW AND O-RING 4. REMOVE PARK/NEUTRAL POSITION SWITCH a. Disconnect the connector. b. Pry off the lock washer and remove the nut. c. Remove the bolt and park/neutral position switch. 5. INSTALL PARK/NEUTRAL POSITION SWITCH a. Install the park/neutral position switch and bolt. Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.) b. Install a new lock plate and the nut. Torque: 3.9 Nm (40 kgf-cm, 35 inch lbs.) c. Bend claws on the lock plate to fix the nut. d. Adjust the park/neutral position switch. e. Connect the connector. 6. INSTALL ELBOW AND NEW O-RING Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.) 7. CONNECT OIL COOLER PIPES a. Connect the oil cooler pipe. Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.) b. Install the 3 oil cooler pipe clamps. 8. INSTALL FRONT EXHAUST PIPE AND HEAT INSULATOR Page 1171 Part 2 Of 2 (Except California Spec.) *:Only for A/T Page 3034 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.). 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 4098 Specifications Firing Order: Specifications Firing Order Firing Order Firing Order 1 - 3 - 4 - 2 Page 4257 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 1702 O2S Application Table O2S Failure Threshold Charts Page 3288 3. DISCONNECT BRAKE CALIPER a. Remove the 2 bolts and brake caliper. b. Support the brake caliper securely. 4. CHECK AXLE HUB BEARING BACKLASH a. Using a screwdriver, remove the grease cap. b. Using a dial indicator near the center of the axle hub and check the backlash in the bearing shaft direction. Maximum: 0.05 mm (0.0020 inch) If the backlash exceeds the maximum, replace the axle hub bearing. 5. REMOVE AXLE HUB WITH DISC a. Remove the cotter pin and lock cap. b. Using a 30 mm socket wrench, remove the nut. c. Remove the claw washer, outer bearing and axle hub with the disc from the steering knuckle. NOTICE: Be careful not to drop the outer bearing. 6. REMOVE OIL SEAL AND INNER BEARING a. Using a screwdriver, pry out the oil sea[. NOTICE: Be careful not to damage the ABS speed sensor rotor. b. Remove the inner bearing from the axle hub. 7. REMOVE DUST COVER Remove the 4 bolts and dust cover. 8. REMOVE STABILIZER BAR LINK Hold the bolt with a wrench, then remove the nut, 5 retainers, collar, 4 cushions and bolt. 9. REMOVE STEERING KNUCKLE a. Support the lower suspension arm with a jack. Page 2101 Step 2 Step 3 INSPECTION PROCEDURE Page 3047 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 860 4) Remove the adjusting shim with a small screwdriver and magnetic finger. b) Determine the replacement adjusting shim size by these Formula or Charts: 1) Using a micrometer, measure the thickness of the removed shim. 2) Calculate the thickness of a new shim so that the valve clearance comes within the specified value. T Thickness of removed shim A Measured valve clearance N Thickness of new shim Intake: N = T + (A - 0.20 mm (0.008 inch) Exhaust: N = T + (A - 0.30 mm (0.012 inch) Page 2599 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 1155 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 184 Steps 3 - 4 INSPECTION PROCEDURE 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 617 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 INTAKE AIR CONNECTOR 3. Except California Spec.: DISCONNECT HIGH-TENSION CORDS FROM SPARK PLUGS NOTICE: Pulling on or bending the cords may damage the conductor inside. 4. California Spec.: REMOVE IGNITION COILS (WITH IGNITER) 5. REMOVE SPARK PLUGS 6. 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: 1,230 kPa (12.5 kgf/cm2, 178 psi) or more Minimum pressure: 880 kPa (9.0 kgf/cm2, 127 psi) Difference between each cylinder: 98 kPa (1.0 kgf/cm2, 14 psi) or less e) If the cylinder compression in one or more cylinders is low, pour 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, chances are that the piston rings and/or cylinder bore are worn or damage. - If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket. 7. REINSTALL SPARK PLUGS Torque: 19 Nm (200 kgf-cm, 14 ft. lbs.) 8. Except California Spec.: REINSTALL HIGH-TENSION CORDS TO SPARK PLUGS 9. California Spec.: REINSTALL IGNITION COILS (WITH IGNITER) 10. REINSTALL INTAKE AIR CONNECTOR Page 3835 Front Bumper Cover / Fascia: Technical Service Bulletins Paint - Refinishing Bumper Cover PAINT PA003-02 REVISED June 4, 2002 Title REFINISHING REPLACEMENT BUMPER COVERS Models All '83 - '05 Models TSB REVISION NOTICE: ^ February 14, 2005: Applicable Vehicles now includes 2004 - 2005 model years. Previous versions of this TSB should be discarded. Introduction In cases where a bumper cover is being replaced a special preparation process is necessary to assure the refinish is customer acceptable. This bulletin provides the recommended refinishing procedure for new bumper covers. Applicable Vehicles ^ All 1983 - 2005 model year Toyota vehicles. Required Tools & Material Note:Please visit www.3m.comlautomotive to find the nearest store that sells 3M automotive products. Warranty Information Refinishing Procedure 1. Mix a solution of mild soap (car wash soap with no wax additives) and clean water. Note: Carefully follow mixing instructions on the soap container. Too much soap or too much water may cause surface contamination or rinsing difficulty. Page 2952 Splice Locations Page 1720 CHART 23 Page 4211 Steps 3 - 4 INSPECTION PROCEDURE 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 2187 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. Capacity Specifications Refrigerant Oil: Capacity Specifications When Replacing, Add: Receiver 20 cc Condenser 40 cc Evaporator 40 to 50 cc Page 3254 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 1487 Page 3176 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 1279 Heated Oxygen Sensor Page 3642 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 2808 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 Camshaft Position Sensor: Locations 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 3139 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.) Electrode Gap Specification Spark Plug: Specifications Electrode Gap Specification Electrode Gap Correct Gap ......................................................................................................................................... ........................................................................ 0.8 mm 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 759 Engine Compartment Instrument Panel Locations Locations 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 2096 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 1493 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. 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 3189 - 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 624 Page 215 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 2614 Brake Caliper: Service and Repair Disassembly and Assembly DISASSEMBLY 1. REMOVE PISTON AND CYLINDER BOOT a. Put a piece of cloth or an equivalent between the piston and caliper. b. Use compressed air to remove the piston and cylinder boot from the caliper. CAUTION: Do not place your fingers in front of the piston when using compressed air. Page 253 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 3632 Front Seat Belt Extender Applications Page 896 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 drain plug, and drain the oil into a container. 2. REPLACE OIL FILTER a) Using SST, remove the oil filter. SST 09228-07501 b) Check and clean the oil filter installation surface. c) Apply clean engine oil to the gasket of a new oil filter. d) Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat. e) Using SST, tighten it an additional 3/4 turn. SST 09228-07501 3. REFILL WITH ENGINE OIL a) Clean and install the oil drain plug with a new gasket. Torque: 37 Nm (375 kgf-cm, 27 ft. lbs.) b) Fill with new engine oil. Oil capacity: c) Reinstall the oil filler cap. 4. START ENGINE AND CHECK FOR LEAKS 5. RECHECK ENGINE OIL LEVEL Service and Repair Input Shaft: Service and Repair For further information regarding this component and the system that it is a part of please refer to Manual Transmission/Transaxle; Service and Repair. Page 2794 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. Specifications Shift Interlock Switch: Specifications Park/Neutral Position Switch ......................................................................................................................................... 5.4 Nm (55 kgf.cm, 48 inch lbs.) Park/Neutral Position Switch Adjusting Bolt ................................................................................................................. 3.9 Nm (40 kgf.cm, 35 inch lbs.) Testing and Inspection Power Mirror Switch: Testing and Inspection INSPECT MIRROR SWITCH CONTINUITY Left Side Left Side: Page 3134 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 301 REPLACEMENT 1. REMOVE THROTTLE BODY 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: 5.4 Nm (55 kg.cm, 48 in.lb) b. Connect the sensor connector. 4. REINSTALL THROTTLE BODY Page 3262 b. Loosen the 2 lower ball joint set bolts. c. Remove the cotter pin and loosen the nut. d. Using SST, disconnect the steering knuckle from the up per ball joint. SST 09628-62011 e. Remove the 2 lower ball joint set bolts. f. Remove the nut and steering knuckle. NOTICE: Do not remove the Jack. INSTALLATION 1. INSTALL STEERING KNUCKLE a. Support the lower suspension arm with a jack. b. Place the steering knuckle to the lower ball joint and temporarily install the 2 bolts. c. Push down the upper suspension arm and connect the upper ball joint to the steering knuckle and install the nut. Torque: 110 Nm (1,100 kgf-cm, 80 ft. lbs.) d. Install a new cotter pin. If the holes for the cotter pin are not aligned, tighten the nut further up to 60°. e. Torque the 2 lower ball joint bolts. Torque: 160 Nm (1,600 kgf-cm, 116 ft. lbs.) 2. INSTALL DUST COVER Install the dust cover with the 4 bolts. Torque: 8.3 Nm (85 kgf-cm, 74 inch lbs.) 3. INSTALL STABILIZER BAR LINK Install the bolt, 5 retainers, collar, 4 cushions and a new nut. 4. PACK BEARINGS WITH MP GREASE a. Place MP grease in the your palm. b. Pack grease into the bearing, continuing until the grease oozes out from the other side. c. Employ the same manner around the bearing circumference. 5. COAT INSIDE OF HUB AND CAP WITH MP GREASE Page 250 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 2007 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 intake camshaft. 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. 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 170 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 352 CHART 16 CHART 17 Page 1948 3. California Spec.: INSPECT IAC VALVE OPERATION a. Check that the IAC valve is halfly opened. b. Connect the IAC valve connector to the IAC valve. c. Disconnect the ECT sensor connector from the ECT sensor. d. Turn the ignition switch ON. e. Check that the IAC valve moves. HINT: Repeat connecting and disconnecting of IAC valve connector several times and check the operation of the valve. If operation is not as specified, replace the IAC valve. f. Turn the ignition switch OFF. g. Reconnect the ECT sensor connector to the ECT sensor. h. Disconnect the IAC valve connector from the IAC valve. Page 1614 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 3085 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 1053 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. Locations Page 424 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 the following conditions: 1. Apply vacuum (2.0 kpa, 15 mmHg, 0.59 in.Hg) to the vapor pressure sensor. Voltage: 1.3 - 2.1 V 2. Release the vacuum from the vapor pressure sensor. Voltage: 3.0 - 3.6 V 3. Apply pressure (1.5 kpa, 15 gf/Sq.cm, 0.22 psi) to the vapor pressure sensor. Voltage: 4.2 - 4.8 V d. Reconnect the vacuum hose to the vapor pressure sensor. Locations Ignition Switch and Key Unlock Warning Switch Page 1744 Oxygen Sensor: Testing and Inspection Heated Oxygen Sensor Heated Oxygen Sensor 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. 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. 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 3663 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 1708 CHART 10 Page 2969 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 1312 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 2701 BRAKE MASTER CYLINDER W/ RELATED COMPONENTS Page 2275 b. Tighten the three bolts in the lower valve body. Torque: 5.4 N.m (48 inch lbs.). 8. Install lower valve body plate. NOTE: Each bolt length (mm, inch) is indicated in the illustration. 9. Install lower valve body cover, as follows: a. Install the retainer and three pins. Retainer: Height: 8.5 mm (0.335 inch). Width: 5.0 mm (0.197 inch). Thickness: 3.2 mm (0.126 inch). b. Install the four check balls. Check ball: Rubber ball diameter: 5.5 mm (0.217 inch). Page 3944 Roof Headlining (Extra Cab) Page 1169 Part 2 Of 2 (California Spec.) *1: Only for A/T *2: Only for 3RZ-FE *3: The ECM terminal voltage is fixed regardless of the output voltage from the sensor. Connectors (Except California Spec.) Page 2368 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 Page 2964 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 1583 CHART 25 Page 1161 Part 1 Of 2 (Except California Spec.) Page 788 Wheel Bearing: Service and Repair Disassembly and Reassembly DISASSEMBLY 1. CHECK HUB BEARINGS Clean the bearings and outer races and inspect them for wear or damage. Page 409 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 3442 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 944 Locations Capacity Specifications Refrigerant: Capacity Specifications Charge Volume 600 +/- 50 g Page 3657 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 2908 Interior J/B # 1 Page 2358 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 Locations Vehicle Speed Sensor NO.1 (A43D) Page 1241 Specifications Pressure Plate: Specifications Clutch Cover Bolts 19 Nm (14 ft.lb) Capacity Specifications Coolant: Capacity Specifications Drain and Refill Drain and Refill Capacity (manual transmission) 8.5 qt (US) Capacity (automatic transmission) 8.2 qt (US) Removal and Installation Hydraulic Control Assembly - Antilock Brakes: Service and Repair Removal and Installation REMOVAL 1. REMOVE BRAKE LINE COVER Page 2443 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 1586 Locations Page 3873 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 3547 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 1081 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection 1. DRAIN ENGINE COOLANT 2. REMOVE ECT SENSOR a. Disconnect the engine wire protector from the 3 brackets. b. Disconnect the ECT sensor connector. c. Using a 19 mm deep socket wrench, remove the ECT sensor and gasket. Testing and Inspection Igniter: Testing and Inspection ON-VEHICLE INSPECTION NOTE: "Cold" and "Hot" in these sentences express the temperature of the coils themselves. "Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F). INSPECT IGNITION COIL WITH IGNITOR AND SPARK TEST Check that the spark occurs. 1. Remove the ignition coils. 2. Remove the spark plugs. 3. Install the spark plugs to each ignition coil, and connect the ignition coil connector. 4. Ground the spark plug. 5. Check if spark occurs while engine is being cranked. NOTE: To prevent gasoline from being injected from injectors during this test, crank the engine for no more than 1 - 2 seconds at time. If the spark does not occur, do the test as per the flow chart. Page 2895 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 4302 Junction Box / No. 1 Page 753 Junction Box / No. 1 Details Page 4276 Junction Box / No. 3 Fuse and Fusible Link Locations Page 3453 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 2426 Page 235 Junction Box / No. 3 Page 2882 Harness Locations 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 2506 Shift Indicator: Connector 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 2401 Page 3963 ^ 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 1415 a) Check only the valves indicated. 1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft. 2) Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim. Valve clearance (Cold): b) Turn the crankshaft pulley 1 revolution (360°) and align its groove with timing mark "O" of the timing chain cover. c) Check only the valves indicated as shown. Measure the valve clearance. (See procedure in step (a)) 9. ADJUST VALVE CLEARANCE a) Remove the adjusting shim. 1) Turn the crankshaft to position the cam lobe of the camshaft on the adjusting valve upward. 2) Position the notch of the valve lifter toward the spark plug side. 3) Using SST (A), press down the valve lifter and place SST (B) between the camshaft and valve lifter flange. Remove SST (A). SST 09248-55040 (09248-05410, 09248-05420) HINT: Apply SST (B) at slight angle on the side marked with "9", at the position shown in the illustration. Page 3193 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 2909 Interior Fuse Box Interior Panel Fuse Details Page 1662 REPLACEMENT 1. REMOVE THROTTLE BODY 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: 5.4 Nm (55 kg.cm, 48 in.lb) b. Connect the sensor connector. 4. REINSTALL THROTTLE BODY Page 1273 CHART 30 Page 3242 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 731 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. 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 Page 1728 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 1799 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 3294 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 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 2588 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. Specifications Compressor Clutch: Specifications Clearance 0.5 +/- 0.15 mm 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 1548 A/F and 02 Sensor Identification Page 2510 Shift Indicator: Ground Locations Page 1805 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 3266 2. REMOVE BEARING OUTER RACES Using SST, a brass bar and hammer, remove the inside and out side of the bearing outer races. SST 09527-17011 NOTICE: Be careful not to damage the ABS speed sensor rotor. REASSEMBLY INSTALL NEW BEARING OUTER RACES a. Using SST and a press, install a new inside of the bearing outer race. SST 09527-17011, 09950-60010 (09951-00640), 09950-70010 (09951-07150) b. Using SST and a press, install a new outside of the bearing race. SST 09527-17011, 09950-60010 (09951-00490), 09950-70010 (09951-07150) NOTICE: Be careful not to damage the ABS speed sensor rotor. Page 3414 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 2195 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 1305 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 3767 Wireless Transmitter Identification 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 the coil, closing the contacts of the EFI main relay (Marking: EFI) and supplying power to terminal +B of the ECM. WIRING DIAGRAM Specifications Drive Belt: Specifications Alternator Belt New Belt ...................................................................................................................... ...................................................................................... 116 - 169 lbf Used Belt ................................. .............................................................................................................................................................. ................ 66 - 88 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 2432 Shift Indicator: Splice Locations Page 3289 b. Loosen the 2 lower ball joint set bolts. c. Remove the cotter pin and loosen the nut. d. Using SST, disconnect the steering knuckle from the up per ball joint. SST 09628-62011 e. Remove the 2 lower ball joint set bolts. f. Remove the nut and steering knuckle. NOTICE: Do not remove the Jack. INSTALLATION 1. INSTALL STEERING KNUCKLE a. Support the lower suspension arm with a jack. b. Place the steering knuckle to the lower ball joint and temporarily install the 2 bolts. c. Push down the upper suspension arm and connect the upper ball joint to the steering knuckle and install the nut. Torque: 110 Nm (1,100 kgf-cm, 80 ft. lbs.) d. Install a new cotter pin. If the holes for the cotter pin are not aligned, tighten the nut further up to 60°. e. Torque the 2 lower ball joint bolts. Torque: 160 Nm (1,600 kgf-cm, 116 ft. lbs.) 2. INSTALL DUST COVER Install the dust cover with the 4 bolts. Torque: 8.3 Nm (85 kgf-cm, 74 inch lbs.) 3. INSTALL STABILIZER BAR LINK Install the bolt, 5 retainers, collar, 4 cushions and a new nut. 4. PACK BEARINGS WITH MP GREASE a. Place MP grease in the your palm. b. Pack grease into the bearing, continuing until the grease oozes out from the other side. c. Employ the same manner around the bearing circumference. 5. COAT INSIDE OF HUB AND CAP WITH MP GREASE Page 3062 INSPECTION NOTICE: When using a vise, do not overtighten it. 1. CHECK OIL CLEARANCE BETWEEN VANE PUMP SHAFT AND BUSHING Using a micrometer and caliper gauge, measure the oil clearance. Standard clearance: 0.03-0.05 mm (0.0012-0.0020 inch) Maximum clearance: 0.07 mm (0.0028 inch) If it is more than the maximum, replace the front housing and vane pump shaft. 2. INSPECT VANE PUMP ROTOR AND VANE PLATES a. Using a micrometer, measure the height, thickness and length of the 10 plates. Minimum height: 8.6 mm (0.339 inch) Minimum thickness: 1.397 mm (0.0550 inch) Minimum length: 14.991 mm (0.5902 inch) b. Using a feeler gauge, measure the clearance between the rotor groove and plate. Maximum clearance: 0.035 mm (0.0014 inch) 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 Page 1494 Page 2341 Non-Waterproof Type Connector "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Pressure Specification Fuel Pressure: Specifications Fuel Pressure No Vacuum 38 to 44 psi Page 1213 Crankshaft Position Sensor: Testing and Inspection INSPECT CRANKSHAFT POSITION SENSOR a. Remove the sensor. b. Using an ohmmeter, measure the resistance between terminals NE and NE-. Resistance: Cold 1,630 - 2,740 kohms Hot 2,065 - 3,225 kohms If the resistance is not as specified, replace the sensor. c. Reinstall the sensor. Page 4430 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 656 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. Specifications Shift Interlock Switch: Specifications Park/Neutral Position Switch ......................................................................................................................................... 5.4 Nm (55 kgf.cm, 48 inch lbs.) Park/Neutral Position Switch Adjusting Bolt ................................................................................................................. 3.9 Nm (40 kgf.cm, 35 inch lbs.) Page 4402 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 2695 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. 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 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 1254 CHART 15 Page 356 CHART 21 Page 1867 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 HINT: All vacuum hoses for EGR system, etc. should be properly connected. f) SFI system wiring connectors fully plugged g) Ignition timing check correctly h) Transmission in neutral position 2. CONNECT TOYOTA HANDHELD TESTER OR OBDII SCAN TOOL 3. INSPECT IDLE SPEED a) Race the engine speed at 2,500 rpm for approx. 90 seconds. b) Check the idle speed. Idle speed: 650 - 750 rpm If the idle speed is not as specified, check the IAC valve, intake air leakage and SFI system. 4. DISCONNECT TOYOTA HAND-HELD TESTER OR OBDII SCAN TOOL Page 3673 Seat Belt Reminder Lamp: Fuse and Fusible Link Locations Relay Box / No. 2 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 3503 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. Locations Vehicle Speed Sensor NO.1 (A43D) Page 1623 Description and Operation Knock Sensor: Description and Operation Knock Sensor The knock sensor is fitted to 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 1529 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 4433 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. 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 3581 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 3607 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 3167 Page 4044 Page 4442 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 4066 be used during this type of repair due to the higher potential of damaging the paint surface. Remember no broken paint. Page 1344 Page 2215 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 1099 Water Pump: Testing and Inspection Part 1 Of 2 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 - 0.8 V is applied to terminal VTA of the ECM. The voltage applied to the terminals VTA of the ECM increases in proportion to the opening angle of the throttle valve and becomes approximately 3.2 - 4.9 V when the throttle valve is fully opened. The ECM judges the vehicle driving conditions from these signals input from terminal VTA, uses it as one of the conditions to decide the air-fuel ratio correction, power increase correction and fuel cut control etc. Page 3114 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 3762 Page 4436 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 2683 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 Locations Cooling / Heating Units Diagrams Brake Master Cylinder: Diagrams Component Inspection Idle Air Control Valve: Testing and Inspection Component Inspection 1. Except California Spec.: 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). Using an ohmmeter, measure the resistance between terminal +B and other terminals (RSC, RSO). Resistance: Cold: 17.0 - 24.5 ohms Hot: 21.5 - 28.5 ohms If resistance is not as specified, replace the IAC valve. 2. Except California Spec.: 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. Page 2229 Transmission Position Switch/Sensor: Service and Repair ON-VEHICLE REPAIR 1. REMOVE FRONT EXHAUST PIPE AND HEAT INSULATOR 2. DISCONNECT OIL COOLER PIPE a. Remove the 3 oil cooler pipe clamps. b. Disconnect the oil cooler pipe. 3. REMOVE ELBOW AND O-RING 4. REMOVE PARK/NEUTRAL POSITION SWITCH a. Disconnect the connector. b. Pry off the lock washer and remove the nut. c. Remove the bolt and park/neutral position switch. 5. INSTALL PARK/NEUTRAL POSITION SWITCH a. Install the park/neutral position switch and bolt. Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.) b. Install a new lock plate and the nut. Torque: 3.9 Nm (40 kgf-cm, 35 inch lbs.) c. Bend claws on the lock plate to fix the nut. d. Adjust the park/neutral position switch. e. Connect the connector. 6. INSTALL ELBOW AND NEW O-RING Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.) 7. CONNECT OIL COOLER PIPES a. Connect the oil cooler pipe. Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.) b. Install the 3 oil cooler pipe clamps. 8. INSTALL FRONT EXHAUST PIPE AND HEAT INSULATOR Page 4200 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 Testing and Inspection Blower Motor Resistor: Testing and Inspection INSPECT BLOWER RESISTOR RESISTANCE If resistance is not as specified, replace the blower resistor. Page 1018 c) Install a new adjusting shim. 1) Place a new adjusting shim on the valve lifter. 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. 10. REINSTALL CYLINDER HEAD COVER 11. RECONNECT ENGINE WIRE 12. Except California Spec.: REINSTALL HIGH-TENSION CORDS TO SPARK PLUGS 13. California Spec.: REINSTALL IGNITION COILS (WITH IGNITER) 14. REINSTALL PCV HOSES 15. REINSTALL INTAKE AIR CONNECTOR Page 1691 Locations Vehicle Speed Sensor NO.1 (A43D) Page 3900 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. Page 2095 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 1048 4. REMOVE WATER VALVE Remove the bolt and water valve. INSTALLATION Installation is in the reverse order of removal. 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 673 Coolant: Fluid Type Specifications Coolant Type "Toyota Long Life Coolant" or Equivelant Coolant Do Not use alcohol type antifreezs or plain water alone. Page 1515 Part 2 Of 2 (Except California Spec.) *:Only for A/T Page 1180 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. Check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. 3. REINSTALL CIRCUIT OPENING RELAY Page 97 Fuel Pump Relay: Testing and Inspection COMPONENTS 1. REMOVE CIRCUIT OPENING RELAY 2. INSPECT CIRCUIT OPENING RELAY a. Inspect the relay continuity. 1. Using and 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 3 and 5. If there is no continuity, replace the relay. Page 364 CHART 26 Page 956 3. 3RZ-FE: INSTALL NO.2, NO.3 VIBRATION DAMPERS AND NO.2 CHAIN TENSIONER NOTICE: Assemble the chain tensioner with the pin installed, then remove the pin after assembly. - When doing this, avoid pushing the No.2 vibration damper against the chain. a) Install the No.2 chain tensioner with the nut. Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.) b) Install No.3 damper with the 2 bolts. Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.) c) Install No.2 damper with the bolt. Torque: 27 Nm (270 kgf-cm, 20 ft. lbs.) d) Remove a pin from the No.2 chain tensioner and free the plunger. 4. 2RZ-FE: INSTALL OIL JET Install a new gasket and the oil jet with the bolt. Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.) 5. 2RZ-FE: INSTALL CRANKSHAFT POSITION SENSOR ROTOR Install the rotor to the crankshaft with the front mark (cavity) of the rotor facing forward. 6. INSTALL NO.1 TIMING CHAIN TENSIONER SLIPPER AND NO.1 VIBRATION DAMPER Page 4272 Cigarette Lighter: Ground Locations Page 1167 Step 5 Step 6 Step 7 INSPECTION PROCEDURE Page 2787 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 384 Heated Oxygen Sensor COMPONENTS 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. Page 1296 Transmission Position Switch/Sensor: Service and Repair ON-VEHICLE REPAIR 1. REMOVE FRONT EXHAUST PIPE AND HEAT INSULATOR 2. DISCONNECT OIL COOLER PIPE a. Remove the 3 oil cooler pipe clamps. b. Disconnect the oil cooler pipe. 3. REMOVE ELBOW AND O-RING 4. REMOVE PARK/NEUTRAL POSITION SWITCH a. Disconnect the connector. b. Pry off the lock washer and remove the nut. c. Remove the bolt and park/neutral position switch. 5. INSTALL PARK/NEUTRAL POSITION SWITCH a. Install the park/neutral position switch and bolt. Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.) b. Install a new lock plate and the nut. Torque: 3.9 Nm (40 kgf-cm, 35 inch lbs.) c. Bend claws on the lock plate to fix the nut. d. Adjust the park/neutral position switch. e. Connect the connector. 6. INSTALL ELBOW AND NEW O-RING Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.) 7. CONNECT OIL COOLER PIPES a. Connect the oil cooler pipe. Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.) b. Install the 3 oil cooler pipe clamps. 8. INSTALL FRONT EXHAUST PIPE AND HEAT INSULATOR 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) Page 3694 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 2959 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 3947 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 1233 Page 3220 d. Loosen the lower suspension arm set bolt and remove the nut. Torque: 200 Nm (2,050 kgf-cm, 148 ft. lbs.) HINT: At the time of installation, after stabilizing the suspension, torque the bolt. e. Loosen the strut bar front set bolt and remove the nut. Torque: 300 Nm (3,050 kgf-cm, 221 ft. lbs.) HINT: At the time of installation, after stabilizing the suspension, torque the bolt. f. Pull out the 2 bolts and remove the lower suspension arm with the strut bar. 6. REMOVE SST AND COIL SPRING HINT: At the time of installation, place the end of the coil spring and lower suspension arm seat in contact. 7. REMOVE STRUT BAR AND SPRING BUMPER a. Remove 2 nuts and strut bar from the lower suspension arm. Torque: 150 Nm (1,530 kgf-cm, 111 ft. lbs.) b. Remove the nut and spring bumper. Torque: 43 Nm (440 kgf-cm, 32 ft. lbs.) 8. REMOVE LOWER SUSPENSION ARM NO. 3 Remove the 2 nuts and lower suspension arm No. 3. Torque: 150 Nm (1,530 kgf-cm, 111 ft. lbs.) REPLACEMENT 1. REMOVE BUSHING a. Cut off the shaded portion shown in the illustration to expose the edge of the tube. NOTICE: Be careful not to damage the edge of the arm tube. b. Face the cut side downward and using SST and a press, remove the bushing. SST 09710-30021 (09710-03071, 09710-03141) Page 1243 Page 3179 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. Locations Vehicle Speed Sensor NO.1 (A43D) 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. 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 955 1) Check that the plunger moves smoothly when the ratchet pawl is raised with your finger. 2) Release the ratchet pawl and check that the plunger is locked in place by the ratchet pawl and does not move when pushed with your finger. b) Inspect the oil jet (No.2 chain tensioner). Check the oil jet for damage or clogging. If necessary, replace the oil jet (No.2 chain tensioner). INSTALLATION NOTICE: Check that No.1 cylinder is at TDC and that the weights of the No.1 and No.2 balance shafts are at the bottom side. 1. INSTALL NO.4 VIBRATION DAMPER Install the No.4 damper with the 2 bolts. 2. 3RZ-FE: INSTALL NO.2 TIMING CHAIN, NO.2 CRANKSHAFT TIMING SPROCKET, BALANCE SHAFT DRIVE GEAR AND SHAFT a) Install the No.2 timing chain by matching its mark links with the timing marks on the No.2 crankshaft timing sprocket and balance shaft timing sprocket. b) Fit the other mark link of No.2 timing chain onto the sprocket behind the large timing mark of the balance shaft drive gear. c) Insert the balance shaft drive gear shaft through the balance shaft drive gear so that it fits into the thrust plate hole. Then align the small timing mark of the balance shaft drive gear with the timing mark of the balance shaft timing gear. d) Install the bolt to the balance shaft drive gear and tighten it. Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.) e) Check that each timing mark is matched with the corresponding mark link. Page 1425 Mass Air Flow Meter: Testing and Inspection 1. INSPECT MAF METER RESISTANCE Using an ohmmeter, measure the resistance between terminals THA and E3. Temperature Resistance -20 °C (-4 °F) 10 - 20 Kohms 0 °C (32 °F) 4 - 7 Kohms 20 °C (68 °F) 2 - 3 Kohms 40 °C (104 °F) 0.9 - 1.3 Kohms 60 °C (140 °F) 0.4 - 0.7 Kohms 80 °C (176 °F) 0.2 - 0.4 Kohms If the resistance is not as specified, replace the MAF meter. 2. INSPECT MAF METER OPERATION a. Connect the negative (-) terminal cable to the battery. b. Turn the ignition switch ON. c. Connect the MAF meter connector. d. Using a voltmeter, connect the positive (+) tester probe to terminal VG, and negative (-) tester probe to terminal E3. e. Blow air into the MAF meter, and check that the voltage fluctuates. If operation is not as specified, replace the MAF meter. f. Turn the ignition switch OFF. g. Disconnect the negative (-) terminal cable from the battery. h. Disconnect the MAF meter connector. Page 1260 CHART 22 Page 2253 Transmission Position Switch/Sensor: Service and Repair ON-VEHICLE REPAIR 1. REMOVE FRONT EXHAUST PIPE AND HEAT INSULATOR 2. DISCONNECT OIL COOLER PIPE a. Remove the 3 oil cooler pipe clamps. b. Disconnect the oil cooler pipe. 3. REMOVE ELBOW AND O-RING 4. REMOVE PARK/NEUTRAL POSITION SWITCH a. Disconnect the connector. b. Pry off the lock washer and remove the nut. c. Remove the bolt and park/neutral position switch. 5. INSTALL PARK/NEUTRAL POSITION SWITCH a. Install the park/neutral position switch and bolt. Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.) b. Install a new lock plate and the nut. Torque: 3.9 Nm (40 kgf-cm, 35 inch lbs.) c. Bend claws on the lock plate to fix the nut. d. Adjust the park/neutral position switch. e. Connect the connector. 6. INSTALL ELBOW AND NEW O-RING Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.) 7. CONNECT OIL COOLER PIPES a. Connect the oil cooler pipe. Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.) b. Install the 3 oil cooler pipe clamps. 8. INSTALL FRONT EXHAUST PIPE AND HEAT INSULATOR Page 404 Page 4407 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 636 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 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). Page 1513 Part 2 Of 2 (California Spec.) *1: Only for A/T *2: Only for 3RZ-FE *3: The ECM terminal voltage is fixed regardless of the output voltage from the sensor. Connectors (Except California Spec.) Page 3887 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 1820 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 the following conditions: 1. Apply vacuum (2.0 kpa, 15 mmHg, 0.59 in.Hg) to the vapor pressure sensor. Voltage: 1.3 - 2.1 V 2. Release the vacuum from the vapor pressure sensor. Voltage: 3.0 - 3.6 V 3. Apply pressure (1.5 kpa, 15 gf/Sq.cm, 0.22 psi) to the vapor pressure sensor. Voltage: 4.2 - 4.8 V d. Reconnect the vacuum hose to the vapor pressure sensor. Page 2790 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 1703 CHART 1 Specifications Firing Order: Specifications Firing Order Firing Order Firing Order 1 - 3 - 4 - 2 Page 4435 Page 2851 COMPONENTS Page 1311 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 1762 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source How to Read Power Source Locations Camshaft Position Sensor: Locations Locations Page 3392 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 2925 Engine Compartment Instrument Panel Locations Page 1244 O2S Application Table O2S Failure Threshold Charts Page 1345 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 intake camshaft. 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. 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 2063 Spark Plug: Application and ID Recommended Spark Plugs ND K16R-U NGK BKR5EYA Page 1235 A/F and 02 Sensor Identification Page 1474 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 749 Interior Fuse Box Interior Panel Fuse Details Page 1903 2. INSPECT LEAKAGE a. In the condition above, disconnect the test probes of SST (wire) from the battery and check the fuel leakage from the injector. SST 09842-30070 Fuel drop: Except California Spec. 1 drop or less per 3 minutes California Spec. 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. f. Reinstall the fuel pressure regulator and fuel inlet pipe. Locations Page 1218 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. Removal and Installation Generator: Service and Repair Removal and Installation COMPONENTS REMOVAL 1. DISCONNECT GENERATOR CONNECTOR AND WIRE a. Disconnect the generator connector. b. Remove the nut, and disconnect the generator wire. Torque: 9.8 Nm (100 kg.cm, 7.2 ft.lb) c. Disconnect the wire harness with the clip. 2. REMOVE GENERATOR DRIVE BELT a. Loosen the adjusting lock bolt and pivot bolt. b. Loosen the adjusting bolt, and remove the drive belt. 3. REMOVE GENERATOR a. Remove the pivot bolt and adjusting lock bolt. Torque: 59 Nm (600 kg.cm, 43 ft.lb) for pivot bolt 29 Nm (300 kg.cm, 21 ft.lb) for adjusting lock bolt b. Remove the generator. INSTALLATION Installation is in the reverse order of removal. Page 711 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. 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 3098 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 2006 Page 3057 1. REMOVE DRIVE BELT a. Loosen the power steering idle pulley set bolt. b. Loosen the belt adjusting bolt. 2. DISCONNECT PRESSURE FEED TUBE Using a spanner (24 mm) to hold the pressure port union, remove the union bolt and 2 gaskets. 3. DISCONNECT RETURN HOSE NOTICE: Take care not to spill fluid on the drive belt. 4. REMOVE PS VANE PUMP ASSEMBLY Remove the 2 pump assembly set bolts. INSTALLATION 1. INSTALL PS VANE PUMP ASSEMBLY Torque the 2 pump assembly set bolts. Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.) 2. CONNECT RETURN HOSE 3. CONNECT PRESSURE FEED TUBE 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. Page 2879 Relay Box / No. 2 Ground Locations 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 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. Page 2333 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 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 3177 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 2966 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 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. REINSTALLER MAIN RELAY Page 2815 5. REMOVE RECTIFIER END FRAME a. Remove the 4 nuts. b. Using SST, remove the rectifier end frame. SST 09286-46011 6. REMOVE ROTOR FROM DRIVE END FRAME REASSEMBLY 1. PLACE DRIVE END FRAME ON PULLEY 2. INSTALL ROTOR TO DRIVE END FRAME 3. INSTALL RECTIFIER END FRAME a. Place the generator washer on the rotor. Page 503 b. Disconnect the connector from the integration relay and inspect the connectors on the wire harness side. Page 4116 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 3612 Seat Belt Page 2010 REPLACEMENT 1. REMOVE THROTTLE BODY 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: 5.4 Nm (55 kg.cm, 48 in.lb) b. Connect the sensor connector. 4. REINSTALL THROTTLE BODY 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 3734 - 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 3650 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 1462 Page 1920 SST 09268-45012 t. Reconnect the fuel inlet pipe to the delivery pipe with 2 new gaskets and the union bolt. Torque: 29 Nm (300 kg.cm, 22 ft.lb) u. Reconnect the negative (-) terminal cable to the battery. v. Check for fuel leakage. 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 3181 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. 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. 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 745 Fuse: Application and ID Engine Room R/B # 2 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 329 Applicable Vehicles 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 1017 3) Select a new shim with a thickness as close as possible to the calculated value. HINT: Shims are available in 17 sized in increments of 0.05 mm (0.0020 inch), from 2.50 mm (0.0984 inch) to 3.30 mm (0.1299 inch). Page 1793 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 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 4121 Right Side Right Side: If continuity is not as specified, replace the switch. Page 358 Testing and Inspection Ignition Cable: Testing and Inspection ON-VEHICLE INSPECTION Except California Spec.: INSPECT HIGH-TENSION CORDS a. Remove the air cleaner cap and MAF meter assembly. b. Remove the intake air connector. c. 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. d. Using an ohmmeter, measure the high-tension cord resistance. Maximum resistance: 25 kohms per cord If the resistance is greater than the maximum, check the terminals. If necessary, replace the high-tension cord. e. Reinstall the high-tension cords. Secure the high-tension cords with the clamps as shown in the illustration. f. Reinstall the intake air connector. g. Reinstall the air cleaner cap and MAF meter assembly. Page 1642 Part 1 Of 2 (Except California Spec.) Page 3662 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 4035 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 1371 Fuel Pressure: Testing and Inspection 1. INSPECT FUEL PUMP OPERATION a. Connect the TOYOTA hand-held tester to the DLC3. b. Turn the ignition switch ON and push the 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. f. Check that there is pressure in the 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. 2. CHECK FUEL PRESSURE a. Check that the battery positive voltage is above 12V. b. Disconnect the negative (-) terminal cable from the battery. c. Remove the union bolt and 2 gaskets, and disconnect the fuel inlet pipe from the delivery pipe. CAUTION: Put a suitable container or shop rag under the delivery pipe. Page 4096 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 3345 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. Locations Ignition Switch and Key Unlock Warning Switch Page 4403 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 3351 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 3077 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.). 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. 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. Description and Operation Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor Crankshaft position sensor (NE signal) consists of and pickup coil. The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor generates 34 signals at every engine revolution. The ECM detects the standard crankshaft angle based on the G signal, and the actual crankshaft angle and the engine speed by the NE signal. Page 501 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 2786 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 1553 A/F and 02 Sensor Identification Page 1660 Camshaft Position Sensor: Testing and Inspection INSPECTION 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 1005 g. Using a 16 mm plug wrench, reinstall the 4 spark plug. Torque: 20 Nm (200 kg.cm, 14 ft.lb) h. Except California Spec.: Reconnect the high-tension cords to the spark plugs. i. California Spec.: Reinstall the ignition coil. Page 3103 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 2842 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. Page 2431 Shift Indicator: Ground Locations Page 1100 Part 2 Of 2 INSPECTION 1. INSPECT WATER PUMP a) Visually check the air hole and drain hole for coolant leakage. If leakage is found, replace the water pump. 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 the fluid coupling for damage and silicon oil leakage. If necessary, replace the fluid coupling. c) Install the fan and fluid coupling with the 4 nuts. Torque: 5.5 Nm (55 kgf-cm, 49 inch lbs.) Page 2844 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. Page 4174 Step 4 INSPECTION PROCEDURE 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 - 490 kPa (2.5 - 5.0 kgf/cm2, 36 - 71 psi) 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 86 Engine Control Module: Pinout Values and Diagnostic Parameters Connectors (California Spec.) Part 1 Of 2 (California Spec.) Page 373 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 3544 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. Locations Page 2164 Governor: Service and Repair ON-VEHICLE REPAIR 1. REMOVE PROPELLER SHAFT 2. DISCONNECT VEHICLE SPEED SENSOR CONNECTOR AND REMOVE VEHICLE SPEED SENSOR 3. REMOVE REAR MOUNTING BRACKET FROM REAR SUPPORT MEMBER Remove the 8 bolts and rear mounting bracket from the rear support member. 4. REMOVE REAR MOUNTING INSULATOR FROM EXTENSION HOUSING Remove the 4 bolts and rear mounting insulator from the extension housing. 5. REMOVE EXTENSION HOUSING a. Remove the 6 bolts, housing and gasket. If necessary, tap the extension housing with a plastic hammer or block of wood to loosen it. b. Remove the gasket and oil apply pipe from the extension housing. 6. REMOVE VEHICLE SPEED SENSOR DRIVE GEAR a. Using snap ring pliers, remove the snap ring. b. Slide off the vehicle speed sensor drive gear. Page 3304 Wheel Fastener: Specifications Hub Nut ............................................................................................................................................... ................................................... 110 Nm (83 ft. lbs.) Page 3316 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 1899 Page 339 Page 4165 Steps 3 - 4 INSPECTION PROCEDURE Page 938 Part 5 of 7 Page 3124 Part 2 Of 3 Page 3191 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. Service and Repair Mainshaft: Service and Repair For further information regarding this component and the system that it is a part of please refer to Manual Transmission/Transaxle; Service and Repair. 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 1257 CHART 20 Service and Repair Clutch Pedal Assembly: Service and Repair INSPECTION 1. CHECK THAT PEDAL HEIGHT IS CORRECT Pedal height from floor panel: 170.0 - 180.0 mm (6.692 - 7.086 inch) Pedal height from asphalt sheet: 167.0 - 177.0 mm (6.574 - 6.968 inch) 2. IF NECESSARY, ADJUST PEDAL HEIGHT Loosen the lock nut and turn the stopper bolt until the height is correct. Tighten the lock nut. 3. CHECK THAT PEDAL FREEPLAY AND PUSH ROD PLAY ARE CORRECT a. Depress the pedal until the clutch resistance begins to be felt. Pedal freeplay: 5.0 - 15.0 mm (0.197 - 0.591 inch) b. Gently depress the pedal until the resistance begins to in crease a little. Push rod play at pedal top: 1.0 - 5.0 mm (0.039 - 0.197 inch) 4. IF NECESSARY, ADJUST PEDAL FREEPLAY AND PUSH ROD PLAY a. Loosen the lock nut and turn the push rod until the freeplay and push rod play are correct. b. Tighten the lock nut. c. After adjusting the pedal freeplay, check the pedal height. d. Connect the air duct and install the lower finish panel. 5. CHECK CLUTCH RELEASE POINT a. Pull the parking brake lever and install wheel stopper. Page 3200 Page 1615 Page 883 Assenmacher Specialty Tools 1-800-525-2943 Page 201 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. 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 2690 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 1638 Step 1 Step 2 Step 3 Step 4 Page 594 e. Install the injector to the delivery pipe and cylinder head as shown in the illustration. NOTE: Before installing the injector, must apply spindle oil or gasoline on the place where the delivery pipe or cylinder head touches an O-ring of the injector. f. Check that there are no fuel leaks after doing maintenance anywhere on the fuel system. 1. Connect the TOYOTA hand-held tester to the DLC3. 2. Turn ignition switch ON and push the TOYOTA hand-held tester main switch ON. NOTE: Do not start the engine. 3. Select the active test mode on the TOYOTA hand-held tester. 4. Please refer to the TOYOTA hand-held tester operator's manual for further details. 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 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. 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 2585 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 2600 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 2878 Junction Box / No. 3 Fuse and Fusible Link Locations Page 1780 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 4210 Steps 1 - 2 Page 4190 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 3480 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 2810 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 1208 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection 1. DRAIN ENGINE COOLANT 2. REMOVE ECT SENSOR a. Disconnect the engine wire protector from the 3 brackets. b. Disconnect the ECT sensor connector. c. Using a 19 mm deep socket wrench, remove the ECT sensor and gasket. Page 368 CHART 28 Page 4269 Junction Box / No. 3 Page 2494 Transmission Speed Sensor: Description and Operation Vehicle Speed Sensor NO.1 Vehicle Speed Sensor NO.1 Circuit Description The vehicle speed sensor outputs a 4-pulse signal for every revolution of the rotor shaft, which is rotated by the transmission output shaft via the driven gear. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. Vehicle Speed Sensor NO.2 Vehicle Speed Sensor NO.2 Circuit Description The No.2 vehicle speed sensor detects the rotation speed of the transmission output shaft and sends signals to the ECM. The ECM determines the vehicle speed based on these signals. 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 2360 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 2613 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 Specifications Idle Speed: Specifications Idle Speed 700 +/- 50 rpm Page 3148 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 HOUSING NO.2 BRACKET AND GROMMET a. Place matchmarks on the bracket and rack housing. b. Remove the bolt. 7. 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. Page 2512 Shift Indicator: Harness Locations 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. Testing and Inspection Tail Lamp Relay: Testing and Inspection INSPECT TAILLIGHT CONTROL RELAY CONTINUITY If continuity is not as specified, replace the relay. 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 68 Page 2752 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 3461 Air Bag(s) Arming and Disarming: Service and Repair Release Method of Airbag Activation Prevention Mechanism 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 Component Locations Shift Indicator: Component Locations Page 1714 CHART 18 CHART 19 Page 1883 Fuel: Specifications Fuel Type Unleaded Gasoline Octane Rating 87 Octane or Higher Page 350 CHART 14 Page 2527 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 1761 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 785 b. Loosen the 2 lower ball joint set bolts. c. Remove the cotter pin and loosen the nut. d. Using SST, disconnect the steering knuckle from the up per ball joint. SST 09628-62011 e. Remove the 2 lower ball joint set bolts. f. Remove the nut and steering knuckle. NOTICE: Do not remove the Jack. INSTALLATION 1. INSTALL STEERING KNUCKLE a. Support the lower suspension arm with a jack. b. Place the steering knuckle to the lower ball joint and temporarily install the 2 bolts. c. Push down the upper suspension arm and connect the upper ball joint to the steering knuckle and install the nut. Torque: 110 Nm (1,100 kgf-cm, 80 ft. lbs.) d. Install a new cotter pin. If the holes for the cotter pin are not aligned, tighten the nut further up to 60°. e. Torque the 2 lower ball joint bolts. Torque: 160 Nm (1,600 kgf-cm, 116 ft. lbs.) 2. INSTALL DUST COVER Install the dust cover with the 4 bolts. Torque: 8.3 Nm (85 kgf-cm, 74 inch lbs.) 3. INSTALL STABILIZER BAR LINK Install the bolt, 5 retainers, collar, 4 cushions and a new nut. 4. PACK BEARINGS WITH MP GREASE a. Place MP grease in the your palm. b. Pack grease into the bearing, continuing until the grease oozes out from the other side. c. Employ the same manner around the bearing circumference. 5. COAT INSIDE OF HUB AND CAP WITH MP GREASE Page 3648 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 1142 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 2094 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 366 CHART 27 Page 4404 Page 3201 Page 1028 6. w/PS: REMOVE DRIVE BELT FOR PS PUMP Loosen the lock bolt and adjusting bolt, and remove the drive belt. 7. REMOVE FAN SHROUDS a) Remove the 2 clips and No.2 fan shroud. b) Remove the 4 bolts and No.1 fan shroud. 8. REMOVE DRIVE BELT FOR A/C COMPRESSOR Loosen the idler pulley nut and adjusting bolt, and remove the drive belt. 9. REMOVE DRIVE BELT FOR GENERATOR, FAN WITH FLUID COUPLING AND WATER PUMP PULLEY a) Loosen the water pump pulley nuts. b) Loosen the lock bolt and pivot bolt of generator. c) Loosen the Adjusting bolt of generator, remove the drive belt. d) Remove the 4 water pump pulley nuts. Torque: 21 Nm (210 kgf-cm, 16 ft. lbs.) e) Pull out the fan together with the fluid coupling and water pump pulley. 10. REMOVE WATER PUMP Remove the 10 bolts, water pump and gasket. Torque: 24.5 Nm (250 kgf-cm, 18 ft. lbs.) for 14 mm head 8.9 Nm (90 kgf-cm, 78 inch lbs.) for 12 mm head HINT: At the time of installation, please refer to the following items. Use a new gasket. Page 259 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. Diagrams Page 3711 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. 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 4360 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 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 357 CHART 22 Page 3682 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 478 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. Specifications Water Pump: Specifications Water Pump and Gasket 14 mm Head 24.5 Nm (18 ft.lb) 12 mm Head 8.9 Nm (78 in.lb) Page 3661 Page 1575 CHART 20 Page 4146 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 328 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 2995 Junction Box / No. 1 Details Page 1162 Part 2 Of 2 (Except California Spec.) *:Only for A/T 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 2749 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 2774 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. Locations Page 2515 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 2944 Auxiliary Power Outlet: Ground Locations Page 3938 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 2057 Knock Sensor: Testing and Inspection 1. REMOVE STARTER 2. REMOVE FUEL FILTER SET BOLTS 3. REMOVE KNOCK SENSOR a. Disconnect the knock sensor connector. b. Using SST, remove the knock sensor. SST 09816-30010 4. INSPECT KNOCK SENSOR Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor. 5. REINSTALL KNOCK SENSOR a. Using SST, install the knock sensor. SST 09816 - 30010 Torque: 44 Nm (450 kg.cm, 33 ft.lb) b. Connect the knock sensor connector. 6. REINSTALL FUEL FILTER SET BOLTS Torque: 20 Nm (200 kg.cm, 14 ft.lb) 7. REINSTALL STARTER Page 2834 Ignition Switch: Testing and Inspection 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 3515 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. 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 3046 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 1556 ^ 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 2008 Camshaft Position Sensor: Testing and Inspection INSPECTION 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 1431 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 1310 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 3713 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. Testing and Inspection Wiper Switch: Testing and Inspection INSPECT FRONT WIPER AND WASHER SWITCH CONTINUITY W/ Mist w/ MIST: Page 1924 Fuel Pump Relay: Testing and Inspection COMPONENTS 1. REMOVE CIRCUIT OPENING RELAY 2. INSPECT CIRCUIT OPENING RELAY a. Inspect the relay continuity. 1. Using and 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 3 and 5. If there is no continuity, replace the relay. Specifications Firing Order: Specifications Firing Order Firing Order Firing Order 1 - 3 - 4 - 2 Page 2136 REAR CLUTCH NO.1 BRAKE Page 1253 CHART 14 Page 772 Page 1512 Engine Control Module: Pinout Values and Diagnostic Parameters Connectors (California Spec.) Part 1 Of 2 (California Spec.) Page 1560 Page 936 Part 3 of 7 Page 4362 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. 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. Capacity Specifications Power Steering Fluid: Capacity Specifications Power Steering Fluid: Total ..................................................................................................................................................... .......................................... 0.8 liters (0.9 US Qts.) Page 3337 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 4367 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 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. Specifications Compression Check: Specifications Compression Pressure ........................................................................................................................ ..................................................... 1,230 kPa or More Minimum Pressure .......................................... .......................................................................................................................................................... 880 kPa Difference Between Each Cylinder ........................................................................................ ........................................................................ 98 kPa or Less Page 2775 b. Disconnect the connector from the integration relay and inspect the connectors on the wire harness side. Page 2267 Page 413 An AC voltage is generated in the No.2 vehicle speed sensor coil as the rotor mounted on the output shaft rotates, and this voltage is sent to the ECM. The gear shift point and lock-up timing are controlled by the ECM based on the signals from this vehicle speed sensor and the throttle position sensor signal. If the No.2 vehicle speed sensor malfunctions, the ECM uses input signals from the No.1 vehicle speed sensor as a back-up signal. Page 1121 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 2797 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) Connector Locations Key Reminder Switch: Connector Locations Page 4273 Cigarette Lighter: Locations Component Locations Connector Locations Page 746 Engine Room R/B # 2 Engine Room R/B # 2 Page 2532 Step 2 Step 3 INSPECTION PROCEDURE 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) 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. Page 2391 Wheel Bearing: Tools and Equipment Wheel Bearing Nut Socket AST tool# TOY 185 For R and R of wheel bearing nut located on inboard side of wheel hub. Applicable: Newer Toyota trucks and SUV's (2wd only). - Made in USA Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Locations Vehicle Speed Sensor NO.1 (A43D) Service and Repair Seals and Gaskets: Service and Repair ON-VEHICLE REPAIR 1. REMOVE PROPELLER SHAFT 2. REMOVE REAR OIL SEAL Using SST, remove the oil seal. SST 09308-10010 NOTICE: Clean the extension housing before removing the oil seal. 3. INSTALL NEW OIL SEAL Coat the lip of a new oil seal with MP grease and using SST and a hammer, carefully drive the oil seal in as far as it will go. SST 09325-20010 4. INSTALL PROPELLER SHAFT 5. CHECK FLUID LEVEL Page 1988 Throttle Body: Service and Repair COMPONENTS REMOVAL 1. DRAIN ENGINE COOLANT 2. DISCONNECT ACCELERATOR CABLE FROM THROTTLE BODY 3. A/T: Page 1697 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). 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 4293 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 2847 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 2248 Torque Converter: Testing and Inspection INSPECTION 1. INSPECT ONE-WAY CLUTCH a. Install SST in the inner race of the one-way clutch. SST 09350-20015 (09397-22020) b. Install SST so that it fits in the notch of the converter hub and outer race of the one-way clutch. SST 09350-20015 (09397-22020) c. With the torque converter clutch held upright, the clutch should lock when turned counterclockwise, and rotate 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 and measure the drive plate runout. Maximum runout: 0.20 mm (0.0079 inch) If runout is not within the specification or if the ring gear is damaged, replace the drive plate. If installing a new drive plate, note the orientation of spacers and tighten the bolts. Torque: 74 Nm (750 kgf-cm, 54 ft. lbs.) 3. MEASURE TORQUE CONVERTER CLUTCH SLEEVE RUNOUT Temporarily mount the torque converter clutch to the drive plate. Set up a dial indicator and measure the torque converter clutch sleeve runout. Maximum runout: 0.30 mm (0.0118 inch) If runout is not within the specification, try to correct by reorienting the installation of the converter. Page 2837 b. Disconnect the connector from the integration relay and inspect the connectors on the wire harness side. 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 1270 Page 3959 Page 2385 3. DISCONNECT BRAKE CALIPER a. Remove the 2 bolts and brake caliper. b. Support the brake caliper securely. 4. CHECK AXLE HUB BEARING BACKLASH a. Using a screwdriver, remove the grease cap. b. Using a dial indicator near the center of the axle hub and check the backlash in the bearing shaft direction. Maximum: 0.05 mm (0.0020 inch) If the backlash exceeds the maximum, replace the axle hub bearing. 5. REMOVE AXLE HUB WITH DISC a. Remove the cotter pin and lock cap. b. Using a 30 mm socket wrench, remove the nut. c. Remove the claw washer, outer bearing and axle hub with the disc from the steering knuckle. NOTICE: Be careful not to drop the outer bearing. 6. REMOVE OIL SEAL AND INNER BEARING a. Using a screwdriver, pry out the oil sea[. NOTICE: Be careful not to damage the ABS speed sensor rotor. b. Remove the inner bearing from the axle hub. 7. REMOVE DUST COVER Remove the 4 bolts and dust cover. 8. REMOVE STABILIZER BAR LINK Hold the bolt with a wrench, then remove the nut, 5 retainers, collar, 4 cushions and bolt. 9. REMOVE STEERING KNUCKLE a. Support the lower suspension arm with a jack. Page 3679 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 2186 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 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 540 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 2437 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 2906 Engine Room R/B # 2 Engine Room R/B # 2 Page 194 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 3863 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 646 NOTE: Always pinch the hose. Avoid bending as it may cause to hose to crack. 7. Turn the ignition switch OFF. 8. Disconnect the TOYOTA hand-held tester from the DLC3. Page 987 NOTE: Always pinch the hose. Avoid bending as it may cause to hose to crack. 7. Turn the ignition switch OFF. 8. Disconnect the TOYOTA hand-held tester from the DLC3. Locations Page 3241 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 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. 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 Page 2835 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 4356 Key Reminder Switch: Splice Locations Page 3178 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. Locations Page 1876 Mass Air Flow Meter: Testing and Inspection 1. INSPECT MAF METER RESISTANCE Using an ohmmeter, measure the resistance between terminals THA and E3. Temperature Resistance -20 °C (-4 °F) 10 - 20 Kohms 0 °C (32 °F) 4 - 7 Kohms 20 °C (68 °F) 2 - 3 Kohms 40 °C (104 °F) 0.9 - 1.3 Kohms 60 °C (140 °F) 0.4 - 0.7 Kohms 80 °C (176 °F) 0.2 - 0.4 Kohms If the resistance is not as specified, replace the MAF meter. 2. INSPECT MAF METER OPERATION a. Connect the negative (-) terminal cable to the battery. b. Turn the ignition switch ON. c. Connect the MAF meter connector. d. Using a voltmeter, connect the positive (+) tester probe to terminal VG, and negative (-) tester probe to terminal E3. e. Blow air into the MAF meter, and check that the voltage fluctuates. If operation is not as specified, replace the MAF meter. f. Turn the ignition switch OFF. g. Disconnect the negative (-) terminal cable from the battery. h. Disconnect the MAF meter connector. Page 704 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 Body - Bumper Component Repair Rear Bumper Reinforcement: Technical Service Bulletins Body - Bumper Component Repair COLLISION REPAIR INFORMATION FOR THE COLLISION REPAIR PROFESSIONAL TITLE: BUMPER COMPONENT REPAIR SECTION: EXTERIOR BULLETIN # 172 MODELS: ALL TOYOTA LEXUS and SCION DATE: MARCH 2009 While it may seem cost effective to repair damaged bumper components specifically impact energy absorbers and reinforcements there is no way to certify that a repaired part will function as originally intended under all future operating conditions and subsequent collisions. Original Equipment bumper components comply with Federal Motor Vehicle Safety Standards established under the National Highway Traffic Safety Administration Title 49 Part 581. Therefore it is recommended to replace damaged bumper impact energy absorbers and reinforcements with genuine new original equipment replacement parts only. For more information on collision damage repair topics please refer to Collision Repair Information Bulletin # 161 Collision Damage Repair Precautions and plan to attend Toyota Collision Repair & Refinish Training. Visit www.crrtraining.com for training information. Page 2303 b. Start the engine and idle the engine. c. Without depressing the clutch pedal, slowly shift the shift lever into reverse position until the gears contact. d. Gradually depress the clutch pedal and measure the stroke distance from the point that the gear noise stops (release point) up to the full stroke end position. Standard distance: 25 mm (0.98 inch) or more (From pedal stroke end position to release point) If the distance is not as specified, perform the following operation. Check pedal height. - Check push rod play and pedal freeplay. - Bleed the clutch line. - Check the clutch cover and disc. 6. CHECK CLUTCH START SYSTEM a. Check that the engine does not start when the clutch pedal is released. b. Check that the engine starts when the clutch pedal is fully depressed. If necessary, replace the clutch start switch. 7. CHECK CONTINUITY OF CLUTCH START SWITCH Check the continuity between terminals when the switch is ON and OFF. If continuity is not as specified, replace the switch. 8. CHECK CONTINUITY OF CLUTCH START CANCEL SWITCH Diagram Information and Instructions Shift Indicator: 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 461 Knock Sensor: Testing and Inspection 1. REMOVE STARTER 2. REMOVE FUEL FILTER SET BOLTS 3. REMOVE KNOCK SENSOR a. Disconnect the knock sensor connector. b. Using SST, remove the knock sensor. SST 09816-30010 4. INSPECT KNOCK SENSOR Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor. 5. REINSTALL KNOCK SENSOR a. Using SST, install the knock sensor. SST 09816 - 30010 Torque: 44 Nm (450 kg.cm, 33 ft.lb) b. Connect the knock sensor connector. 6. REINSTALL FUEL FILTER SET BOLTS Torque: 20 Nm (200 kg.cm, 14 ft.lb) 7. REINSTALL STARTER Page 2445 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 2371 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 1621 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. 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 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 1316 An AC voltage is generated in the No.2 vehicle speed sensor coil as the rotor mounted on the output shaft rotates, and this voltage is sent to the ECM. The gear shift point and lock-up timing are controlled by the ECM based on the signals from this vehicle speed sensor and the throttle position sensor signal. If the No.2 vehicle speed sensor malfunctions, the ECM uses input signals from the No.1 vehicle speed sensor as a back-up signal. Page 3773 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 1871 6. TROUBLESHOOTING If the CO/HC concentration does not comply with regulations, troubleshoot according in the order given. 1) Check heated oxygen sensor operation. 2) See the table for possible causes, then inspect and correct the applicable causes if necessary. Page 1622 Page 1292 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 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. REINSTALLER MAIN RELAY Page 953 b) Remove the balance shaft drive gear with the shaft. c) Remove the No.2 timing chain with the No.2 crankshaft timing sprocket. 22. 3RZ-FE: REMOVE NO.4 VIBRATION DAMPER Remove the 2 bolts and No.4 damper. INSPECTION 1. INSPECT TIMING CHAINS AND SPROCKETS a) Measure the length of the 16 links with the chain fully stretched. Maximum chain elongation: If the elongation is greater than maximum, replace the chain. HINT: Make the same measurements pulling at 3 or more places selected at random. b) Wrap the chain around the timing sprocket. c) Using vernier calipers, measure the sprocket diameter with the chain. Page 361 CHART 24 Page 2616 Maximum disc runout: 0.07 mm (0.0028 inch) If the runout is greater than the maximum, replace the disc or grind it on a "On-Car" brake lathe. HINT: Before measuring the runout, confirm that the front hub bearing play is within the specification. 4. IF NECESSARY, REPLACE DISC a. Remove the torque plate from the knuckle. b. Remove the axle hub. c. Remove the disc from the axle hub. d. Install a new disc and torque the bolts. Torque: 64 Nm (650 kgf-cm, 47 ft. lbs.) e. Install the axle hub and adjust the front bearing preload. f. Install the torque plate onto the knuckle. Torque: 108 Nm (1,100 kgf-cm, 80 ft. lbs.) REASSEMBLY Reassembly is in the reverse order of disassembly. NOTICE: Apply lithium soap base glycol grease to the parts indicated by the arrows. Page 4217 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 383 Oxygen Sensor: Testing and Inspection Heated Oxygen Sensor Heated Oxygen Sensor 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 1467 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 4226 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 1715 CHART 20 Page 2151 Fluid - A/T: Testing and Inspection FLUID INSPECTION 1. Check fluid level, as follows: NOTE: Drive the vehicle so that the engine and transaxle are at normal operating temperature. ATF temperature: 70 - 80°C (158 - 176°F). Only use the COOL range on the dipstick as a rough reference when the fluid is replaced or the engine does not run. a. Park the vehicle on a level surface and set the parking brake. b. With the engine idling and the brake pedal depressed, shift the shift lever into all positions from the Park (P) to Low (L) position and return to the P position. c. Pull out the oil level gauge and wipe it clean. d. Push it back fully into the pipe. e. Pull it out and check that the fluid level is in the HOT range. If the level is at the low side, add new Automatic Transmission Fluid. Fluid type: ATF D-II or DEXRON III (DEXRON II) NOTICE: Do not overfill. 2. Check fluid condition. If the fluid smells burnt or is black, replace fluid. 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. Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid Dry fill ................................................................................................................................................... ....................................................................... 6.7 Qt Drain and refill ................................................... .......................................................................................................................................................... 2.5 Qt 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 1606 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 539 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 1750 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. Component Locations Seat Belt Reminder Lamp: Component Locations 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 1438 Page 1179 Fuel Pump Relay: Testing and Inspection COMPONENTS 1. REMOVE CIRCUIT OPENING RELAY 2. INSPECT CIRCUIT OPENING RELAY a. Inspect the relay continuity. 1. Using and 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 3 and 5. If there is no continuity, replace the relay. Page 414 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 3053 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 2869 Page 4251 Specifications Fluid Pan: Specifications Oil Pan Bolts 4.4 Nm (39 in.lb) Drain Plug 20 Nm (15 ft.lb) Specifications Wheel Bearing: Specifications On models with serviceable wheel bearings, use a Lithium Multipurpose Grease. Page 4301 Clock: Connector Locations Page 3244 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 2689 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 3496 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. Front Shock Absorber Suspension Strut / Shock Absorber: Service and Repair Front Shock Absorber REMOVAL 1. REMOVE FRONT WHEEL Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.) 2. REMOVE SHOCK ABSORBER Page 1693 A/F and 02 Sensor Identification Component Locations Shift Indicator: Component Locations Page 2257 Transmission Speed Sensor: Description and Operation Vehicle Speed Sensor NO.1 Vehicle Speed Sensor NO.1 Circuit Description The vehicle speed sensor outputs a 4-pulse signal for every revolution of the rotor shaft, which is rotated by the transmission output shaft via the driven gear. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. Vehicle Speed Sensor NO.2 Vehicle Speed Sensor NO.2 Circuit Description The No.2 vehicle speed sensor detects the rotation speed of the transmission output shaft and sends signals to the ECM. The ECM determines the vehicle speed based on these signals. 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 3261 3. DISCONNECT BRAKE CALIPER a. Remove the 2 bolts and brake caliper. b. Support the brake caliper securely. 4. CHECK AXLE HUB BEARING BACKLASH a. Using a screwdriver, remove the grease cap. b. Using a dial indicator near the center of the axle hub and check the backlash in the bearing shaft direction. Maximum: 0.05 mm (0.0020 inch) If the backlash exceeds the maximum, replace the axle hub bearing. 5. REMOVE AXLE HUB WITH DISC a. Remove the cotter pin and lock cap. b. Using a 30 mm socket wrench, remove the nut. c. Remove the claw washer, outer bearing and axle hub with the disc from the steering knuckle. NOTICE: Be careful not to drop the outer bearing. 6. REMOVE OIL SEAL AND INNER BEARING a. Using a screwdriver, pry out the oil sea[. NOTICE: Be careful not to damage the ABS speed sensor rotor. b. Remove the inner bearing from the axle hub. 7. REMOVE DUST COVER Remove the 4 bolts and dust cover. 8. REMOVE STABILIZER BAR LINK Hold the bolt with a wrench, then remove the nut, 5 retainers, collar, 4 cushions and bolt. 9. REMOVE STEERING KNUCKLE a. Support the lower suspension arm with a jack. Page 1307 Page 3862 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 2353 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 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 1334 Mass Air Flow Meter: Service and Repair COMPONENTS REMOVAL 1. REMOVE AIR CLEANER CAP WITH MAF METER a. Disconnect the MAF meter connector and wire clamp. b. Loosen the air cleaner hose clamp. c. Disconnect the air hose from air cleaner cap. d. Loosen the 4 clips, and remove the air cleaner cap together with the MAF meter. 2. REMOVE MAF METER FROM AIR CLEANER CAP Page 254 Page 835 Connecting Rod: Specifications Torque Specifications INSTALL CONNECTING ROD CAP NUTS HINT: The connecting rod cap nuts are tightened in 2 progressive steps (steps (b) and (d)). - If any connecting rod bolt is broken or deformed, replace it. a. Apply a light coat of engine oil on the threads and under the nuts of the connecting rod cap. b. Install and alternately tighten the nuts of the connecting rod cap in several passes. Torque: 45 Nm (460 kgf-cm, 33 ft. lbs.) If any one of the connecting rod cap nuts does not meet the torque specification, replace the connecting rod bolt and cap nut as a set. c. Mark the front of the connecting rod cap nut and bolt with paint. d. Retighten the connecting rod cap nuts 90°. e. Check that the painted mark on the nut is at a 90° angle in relation to the mark on the bolt. f. Check that the crankshaft turns smoothly. g. Check the connecting rod thrust clearance. Page 2344 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 3016 7. INSPECT WHEEL ANGLE Turn the steering wheel fully and measure the turning angle. Wheel Turning Angle: If the right and left inside wheel angles differ from the specified value, check the right and left rack end lengths. HINT: If the rack ends lengths are not equal, the wheel turning angle cannot be adjusted properly. Reinspect the toe-in after adjusting the rack ends lengths. Page 1692 Engine Bank 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 1064 2. REMOVE RADIATOR SUPPORTS Remove the 4 screws and 2 radiator supports. HINT: At the time of assembly, please refer to the following items. Insert the tabs the radiator upper tank through the radiator support holes. Torque: 5.5 Nm (55 kgf-cm, 49 inch lbs.) REASSEMBLY Reassembly is in the reverse order of disassembly. INSTALLATION Installation is in the reverse order of removal. Removal and Installation Wheel Bearing: Service and Repair Removal and Installation REMOVAL 1. REMOVE FRONT WHEEL 2. w/ ABS: DISCONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP FROM STEERING KNUCKLE Remove the 2 bolts and disconnect the ABS speed sensor and wire harness clamp from the steering knuckle. Page 4092 Locations Fuse Block: Locations Relay Box / No. 2 Page 2858 7. Wave washer 8. Terminal nut 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 Page 1511 Step 5 Step 6 Step 7 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 2075 Shift Indicator: Connector 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 - 0.8 V is applied to terminal VTA of the ECM. The voltage applied to the terminals VTA of the ECM increases in proportion to the opening angle of the throttle valve and becomes approximately 3.2 - 4.9 V when the throttle valve is fully opened. The ECM judges the vehicle driving conditions from these signals input from terminal VTA, uses it as one of the conditions to decide the air-fuel ratio correction, power increase correction and fuel cut control etc. Page 2015 Crankshaft Position Sensor: Service and Repair REPLACEMENT 1. REMOVE ENGINE UNDER COVER 2. REMOVE GENERATOR 3. REMOVE GENERATOR BRACKET Remove the 3 bolts and bracket. 4. REMOVE CRANKSHAFT POSITION SENSOR a. Disconnect the sensor connector. b. Disconnect the sensor connector from the connector bracket. c. Remove the 2 bolts and crankshaft position sensor. d. Remove the O-ring. 5. REINSTALL NEW CRANKSHAFT POSITION SENSOR a. Install a new O-ring to the sensor. b. Install the sensor with the 2 bolts. Torque: 8.5 Nm (85 kg.cm, 74 in.lb) c. Reinstall the sensor connector to the connector bracket. d. Reconnect the sensor connector. 6. REINSTALL GENERATOR BRACKET Install the bracket with the 3 bolts Torque: Bolt A: 74.5 Nm (760 kg.cm, 55 ft.lb) Bolt B: 18 Nm (180 kg.cm, 13 ft.lb) 7. REINSTALL GENERATOR 8. REINSTALL ENGINE UNDER COVER Unit Repair Valve Body: Service and Repair Unit Repair Disassembly NOTE: For removal and installation procedures refer to "Automatic Transmission/Transaxle, Service and Repair." DISASSEMBLY 1. Remove detent spring. 2. Remove manual valve. 3. Remove lower valve body cover, as follows: Page 1591 CHART 30 Page 3479 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 1499 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. With Manual Steering Steering Gear: Service and Repair With Manual Steering Removal and Installation Part 1 Of 2 Page 3885 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 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. 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 2449 Shift Indicator: Electrical Diagrams Page 1070 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 1987 c. Using an ohmmeter, measure the resistance between each terminal. Page 1731 CHART 30 Page 2896 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. 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. 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 344 CHART 5 CHART 6 Page 3901 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. Locations Fuse: Locations Relay Box / No. 2 Page 3755 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. Locations Fuse Block: Locations Relay Box / No. 2 Page 1911 Fuel Pressure Regulator: Service and Repair COMPONENTS REMOVAL 1. DISCONNECT VACUUM SENSING HOSE FROM FUEL PRESSURE REGULATOR 2. DISCONNECT FUEL RETURN HOSE FROM FUEL PRESSURE REGULATOR CAUTION: Put a suitable container or shop towel under the pressure regulator. 3. REMOVE FUEL PRESSURE REGULATOR a. Remove the 2 bolts and fuel pressure regulator. Torque: 8.8 Nm (90 kg.cm, 78 in.lb) b. Remove the O-ring. HINT: At the time of installation, please refer to the following items. Use a new O-ring. INSTALLATION Installation is in the reverse order of removal. Page 710 Power Steering Fluid: Fluid Type Specifications Lubricant Lubricant Type Automatic Transmission Fluid Dexron II or Dexron III Specifications Headliner: Specifications Roof Headlining (Regular Cab) 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. Description and Operation Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor Crankshaft position sensor (NE signal) consists of and pickup coil. The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor generates 34 signals at every engine revolution. The ECM detects the standard crankshaft angle based on the G signal, and the actual crankshaft angle and the engine speed by the NE signal. Page 1148 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 2312 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 2334 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 3209 Ball Joint: Service and Repair REMOVAL 1. REMOVE FRONT WHEEL Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.) 2. SUPPORT LOWER SUSPENSION ARM WITH JACK 3. DISCONNECT TIE ROD END Page 3848 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 342 CHART 1 Page 2404 Torque: 74 Nm (750 kgf-cm, 54 ft. lbs.) c. 3-joint type: Remove the center support bearing 2 set bolts from the frame crossmember. Torque: 36 Nm (370 kgf-cm, 27 ft. lbs.) d. Pull the sleeve yoke from the transmission and remove the propeller shaft. e. Insert SST in the transmission to prevent oil leakage. SST 09325-20010 (2-joint type), 09325-40010 (3-joint type) DISASSEMBLY NOTICE: Be careful not to grip the propeller shaft tube too tightly in a vise as this will cause deformation. 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) Page 763 Junction Box / No. 1 Details Page 3072 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 2859 - If the contact plate is not pressed down with the specified pressure, the contact plate may tilt due to coil deformation or the tightening of the nut. 2. Using SST, tighten the nuts to the specified torque. SST 09810-38140 Torque: 17 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 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 2.0 kW Page 4087 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. Specifications Idle Speed: Specifications Idle Speed 700 +/- 50 rpm Page 2081 Shift Indicator: Harness Locations Page 1676 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 1268 Page 1634 Part 2 Of 2 (Except California Spec.) *:Only for A/T Page 2184 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 3957 Page 4209 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 1424 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 1766 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 3249 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. 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 1595 Oxygen Sensor: Locations Air-Fuel Ratio (A/F) Sensor Page 365 Page 3610 Seat Belt 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 1267 CHART 26 Page 1465 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 1571 CHART 14 Page 4207 Steps 1 - 3 Page 2545 Transmission Position Switch/Sensor: Service and Repair ON-VEHICLE REPAIR 1. REMOVE FRONT EXHAUST PIPE AND HEAT INSULATOR 2. DISCONNECT OIL COOLER PIPE a. Remove the 3 oil cooler pipe clamps. b. Disconnect the oil cooler pipe. 3. REMOVE ELBOW AND O-RING 4. REMOVE PARK/NEUTRAL POSITION SWITCH a. Disconnect the connector. b. Pry off the lock washer and remove the nut. c. Remove the bolt and park/neutral position switch. 5. INSTALL PARK/NEUTRAL POSITION SWITCH a. Install the park/neutral position switch and bolt. Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.) b. Install a new lock plate and the nut. Torque: 3.9 Nm (40 kgf-cm, 35 inch lbs.) c. Bend claws on the lock plate to fix the nut. d. Adjust the park/neutral position switch. e. Connect the connector. 6. INSTALL ELBOW AND NEW O-RING Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.) 7. CONNECT OIL COOLER PIPES a. Connect the oil cooler pipe. Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.) b. Install the 3 oil cooler pipe clamps. 8. INSTALL FRONT EXHAUST PIPE AND HEAT INSULATOR Page 863 c) Install a new adjusting shim. 1) Place a new adjusting shim on the valve lifter. 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. 10. REINSTALL CYLINDER HEAD COVER 11. RECONNECT ENGINE WIRE 12. Except California Spec.: REINSTALL HIGH-TENSION CORDS TO SPARK PLUGS 13. California Spec.: REINSTALL IGNITION COILS (WITH IGNITER) 14. REINSTALL PCV HOSES 15. REINSTALL INTAKE AIR CONNECTOR Page 3469 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 1504 Part 2 Of 2 (California Spec.) *1: Only for A/T *2: Only for 3RZ-FE *3: The ECM terminal voltage is fixed regardless of the output voltage from the sensor. Connectors (Except California Spec.) 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 Capacity Specifications Refrigerant: Capacity Specifications Charge Volume 600 +/- 50 g Page 1671 Crankshaft Position Sensor: Testing and Inspection INSPECT CRANKSHAFT POSITION SENSOR a. Remove the sensor. b. Using an ohmmeter, measure the resistance between terminals NE and NE-. Resistance: Cold 1,630 - 2,740 kohms Hot 2,065 - 3,225 kohms If the resistance is not as specified, replace the sensor. c. Reinstall the sensor. Page 4354 Key Reminder Switch: Fuse and Fusible Link Locations Relay Box / No. 2 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 747 Engine Room Fuse Details Interior J/B # 1 Diagrams Page 1441 Camshaft Position Sensor: Service and Repair COMPONENTS Page 3357 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 2913 Junction Box / No. 1 Details Page 1888 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: 30 Nm (310 kg.cm, 22 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. 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 1333 Mass Air Flow Meter: Testing and Inspection 1. INSPECT MAF METER RESISTANCE Using an ohmmeter, measure the resistance between terminals THA and E3. Temperature Resistance -20 °C (-4 °F) 10 - 20 Kohms 0 °C (32 °F) 4 - 7 Kohms 20 °C (68 °F) 2 - 3 Kohms 40 °C (104 °F) 0.9 - 1.3 Kohms 60 °C (140 °F) 0.4 - 0.7 Kohms 80 °C (176 °F) 0.2 - 0.4 Kohms If the resistance is not as specified, replace the MAF meter. 2. INSPECT MAF METER OPERATION a. Connect the negative (-) terminal cable to the battery. b. Turn the ignition switch ON. c. Connect the MAF meter connector. d. Using a voltmeter, connect the positive (+) tester probe to terminal VG, and negative (-) tester probe to terminal E3. e. Blow air into the MAF meter, and check that the voltage fluctuates. If operation is not as specified, replace the MAF meter. f. Turn the ignition switch OFF. g. Disconnect the negative (-) terminal cable from the battery. h. Disconnect the MAF meter connector. 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 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 868 e. Install the injector to the delivery pipe and cylinder head as shown in the illustration. NOTE: Before installing the injector, must apply spindle oil or gasoline on the place where the delivery pipe or cylinder head touches an O-ring of the injector. f. Check that there are no fuel leaks after doing maintenance anywhere on the fuel system. 1. Connect the TOYOTA hand-held tester to the DLC3. 2. Turn ignition switch ON and push the TOYOTA hand-held tester main switch ON. NOTE: Do not start the engine. 3. Select the active test mode on the TOYOTA hand-held tester. 4. Please refer to the TOYOTA hand-held tester operator's manual for further details. 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 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. Page 3454 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. 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 3783 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. Specifications Clutch: Specifications Front Clutch Piston Stroke ......................................................................................................................................................... 1.32 - 2.66 mm (0.0520 - 0.1047 inch) Flange Thickness (selectable part) .............................................................................................................................................................. ....................................... 1.8 mm (0.071 inch) ..................................................................................... ................................................................................................................ 2.0 mm (0.079 inch) Overdrive Direct Clutch Clutch Drum Bushing Inside Diameter Maximum ............................................................................................................................................. .................................. 23.14 mm (0.9110 inch) Overdrive Direct Clutch Piston Stroke .................................................................................................................. 1.77 - 2.58 mm (0.0697 0.1016 inch) Overdrive Planetary Gear Bushing Maximum ............................................................................................................................................. .................................. 11.27 mm (0.4437 inch) Planetary Pinion Gear Thrust Clearance Standard .......................................................................................................................................................... 0.20 - 0.50 mm (0.0079 - 0.0197 inch) Rear Clutch Piston Stroke ......................................................................................................................................................... 0.91 - 1.99 mm (0.0358 - 0.0783 inch) No. 1 Brake Piston Stroke .............................................................................................................................................................. 0.78-1.50 mm (0.0307-0.0591 inch) Center Support Bushing Inside Diameter: Maximum ............................................................................................................................................. ................................... 36.46 mm (1.4354 inch) No. 2 Brake Piston Stroke .............................................................................................................................................................. 1.01-2.25 mm (0.0398-0.0886 inch) No. 3 Brake Pack Clearance ........................................................................................................................................................... 0.61-2.64 mm (0.0240-0.1039 inch) Page 3216 Locations Locations Starter Motor: Locations Page 4363 Page 4275 Junction Box / No. 1 Junction Box / No. 3 Page 1101 Water Pump: Service and Repair Part 1 Of 2 Page 3344 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 2533 Shift Indicator: Pinout Values and Diagnostic Parameters O 4 O/D MAIN SW 1-3 : Open with O/D main SW at ON position Closed with O/D main SW at OFF position Testing and Inspection Ignition Cable: Testing and Inspection ON-VEHICLE INSPECTION Except California Spec.: INSPECT HIGH-TENSION CORDS a. Remove the air cleaner cap and MAF meter assembly. b. Remove the intake air connector. c. 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. d. Using an ohmmeter, measure the high-tension cord resistance. Maximum resistance: 25 kohms per cord If the resistance is greater than the maximum, check the terminals. If necessary, replace the high-tension cord. e. Reinstall the high-tension cords. Secure the high-tension cords with the clamps as shown in the illustration. f. Reinstall the intake air connector. g. Reinstall the air cleaner cap and MAF meter assembly. Page 1890 NOTE: Always pinch the hose. Avoid bending as it may cause to hose to crack. 7. Turn the ignition switch OFF. 8. Disconnect the TOYOTA hand-held tester from the DLC3. Page 3766 Page 3190 - 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. 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 98 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. Check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. 3. REINSTALL CIRCUIT OPENING RELAY Page 1798 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 Timing Component Alignment Marks: Locations Timing Mark Locations Page 3488 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 1686 Locations 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 941 Timing Chain: Service and Repair Page 945 Page 1228 Service and Repair Clutch Disc: Service and Repair For further information regarding this component and the system that it is a part of please refer to Clutch, M/T; Service and Repair. Page 3560 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. Specifications Valve Clearance: Specifications Valve Clearance Intake ................................................................................................................................................... ......................................................... 0.006 - 0.010 in Exhaust ................................................................................................................................................ ......................................................... 0.010 - 0.014 in Page 1773 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor NO.1 Vehicle Speed Sensor NO.1 Circuit Description The vehicle speed sensor outputs a 4-pulse signal for every revolution of the rotor shaft, which is rotated by the transmission output shaft via the driven gear. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. Vehicle Speed Sensor NO.2 Vehicle Speed Sensor NO.2 Circuit Description The No.2 vehicle speed sensor detects the rotation speed of the transmission output shaft and sends signals to the ECM. The ECM determines the vehicle speed based on these signals. Locations Page 411 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 1572 CHART 15 Page 2137 NO.2 BRAKE NO.3 BRAKE Page 1090 Page 4232 Page 4093 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 Audible Warning Device: Component Locations Page 1652 Mass Air Flow Meter: Testing and Inspection 1. INSPECT MAF METER RESISTANCE Using an ohmmeter, measure the resistance between terminals THA and E3. Temperature Resistance -20 °C (-4 °F) 10 - 20 Kohms 0 °C (32 °F) 4 - 7 Kohms 20 °C (68 °F) 2 - 3 Kohms 40 °C (104 °F) 0.9 - 1.3 Kohms 60 °C (140 °F) 0.4 - 0.7 Kohms 80 °C (176 °F) 0.2 - 0.4 Kohms If the resistance is not as specified, replace the MAF meter. 2. INSPECT MAF METER OPERATION a. Connect the negative (-) terminal cable to the battery. b. Turn the ignition switch ON. c. Connect the MAF meter connector. d. Using a voltmeter, connect the positive (+) tester probe to terminal VG, and negative (-) tester probe to terminal E3. e. Blow air into the MAF meter, and check that the voltage fluctuates. If operation is not as specified, replace the MAF meter. f. Turn the ignition switch OFF. g. Disconnect the negative (-) terminal cable from the battery. h. Disconnect the MAF meter connector. Page 4283 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 3000 Junction Box / No. 1 Details Page 3468 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 2433 Shift Indicator: Harness Locations Locations Intake Air Temperature Sensor: Locations The Intake Air Temperature (IAT) Sensor is installed in the Mass Air Flow (MAF) Meter. 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 Specifications Exhaust Manifold: Specifications Exhaust Manifold Fasteners 49 Nm (36 ft.lb) Page 4305 Clock: Fuse and Fusible Link Locations Relay Box / No. 2 Page 443 Camshaft Position Sensor: Testing and Inspection INSPECTION 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 496 Steps 3 - 4 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 1950 Idle Air Control Valve: Service and Repair COMPONENTS REMOVAL 1. REMOVE THROTTLE BODY Specifications Piston Ring: Specifications Ring Groove Clearance No.1 .............................................................................................................. ............................................................................................. 0.020 - 0.070 mm No.2 .......................... .............................................................................................................................................................. ................... 0.030 - 0.070 mm Ring End Gap No.1 ............................................................................................................................. .............................................................................. 0.300 - 0.400 mm No.2 ......................................... .............................................................................................................................................................. .... 0.400 - 0.500 mm Page 2528 Shift Indicator: Electrical Diagrams Page 2159 Page 3683 Page 2829 Steps 1 - 2 Page 1561 Locations 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 456 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 1236 Oxygen Sensor: Technical Service Bulletins Engine Controls - O2 Sensor Monitor Threshold Values SPECIAL SERVICE TOOLS SS002-03 December 17, 2003 Title O2S TEST RESULTS (MODE 05) Models All '96 - '03, '04 Corolla, ECHO, Matrix, Sienna & Scion xA & xB Introduction This Service Bulletin contains Oxygen Sensor (O2S) Monitor threshold values for all models from 1996 to 2003 and some 2004 models. Starting in 2004, the O2S Monitor threshold values can be found in the repair manual. These values are used when analyzing the O2S test results to determine the O2S condition. Applicable Vehicles ^ All 1996 - 2003 model year Toyota vehicles. ^ 2004 model year Corolla, ECHO, Matrix and Sienna vehicles. ^ 2004 model year Scion xA and xB vehicles. Function Description Checking O2S Test Results To view O2S test results, the O2S Monitor must be completed and the test results must be checked within the same key cycle. If the ignition key is cycled OFF, the O2S test results will be set to the minimum or maximum limits, and all test results will be erased. The O2S test results are stored in the ECU (SAE term: Powertrain Control Module/PCM) when the monitor is completed. The test results are static and will not change once the monitor is complete. The process for checking 02S test results is described in the following three basic steps: 1. Completing the O2S Readiness Monitor. 2. Accessing O2S Test Results. 3. Comparing O2S Test Results to Failure Thresholds. Required SSTs NOTE: Additional Diagnostic Tester Kits, Program Cards or other SSTs may be ordered by calling SPX-OTC at 1-800-933-8335. Warranty Information Completing O2S Readiness Monitor 1. Clear any stored Diagnostic Trouble Codes (DTCs) using the Toyota Diagnostic Tester. Page 3221 2. INSTALL NEW BUSHING Using SST and a press, install a new bushing. SST 09710-30021 (0971G-03101, 09710-03141) NOTICE: Press in the bushing from the rear side. INSTALLATION Installation is in the reverse order of removal. HINT: After installation, check the front wheel alignment. Page 2189 Page 3967 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 4173 Steps 1 - 3 Page 1695 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 1790 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 2946 Auxiliary Power Outlet: Locations Component Locations Specifications Extension Housing: Specifications Extension Housing Bushing Maximum ............................................................................................................................................. ............................ 38.09 mm (1.4996 inch) Description and Operation Knock Sensor: Description and Operation Knock Sensor The knock sensor is fitted to 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 370 CHART 30 Page 2504 Page 2414 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. Capacity Specifications Engine Oil: Capacity Specifications Engine Oil Drain and refill With oil filter change .................................................................................................... ..................................................................................... 6.0 qt (5.7L) Without oil filter change ............. .............................................................................................................................................................. ......... 5.3 qt (5.0L) Dry fill .................................................................................................................... ............................................................................................ 6.3 qt (6.0L) Page 1427 Remove the 4 nuts, MAF meter and gasket. INSTALLATION 1. INSTALL MAF METER TO AIR CLEANER CAP a. Place a new gasket on the air cleaner cap. b. Install the MAF meter with the 4 nuts. Torque: 8.5 Nm (85 kg.cm, 74 in.lb) 2. INSTALL MAF METER WITH AIR CLEANER CAP Diagrams Timing Chain: Diagrams TIMING CHAIN REPLACEMENT W/ RELATED COMPONENTS Part 1 of 7 Page 3131 Part 2 Of 2 DISASSEMBLY NOTICE: When using a vise, do not overtighten it. Specifications Axle Nut: Specifications - INSTALL AXLE HUB WITH DISC a. Place the axle hub on the spindle. b. Install a new outer bearing and claw washer. - ADJUST PRELOAD a. Install and torque the nut. Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.) b. Turn the hub several times to make the bearing more smoothly. c. Loosen the nut until it can be turned by hand. d. Using a spring tension gauge, measure and make a note down of the frictional force of the oil seal. HINT: Make sure to check preload in the direction of rotation. e. Tighten the nut until the preload is within the specified value. Preload (at starting): Frictional force plus 6 - 18 N (0.6 - 1.8 kgf, 1.3 - 4.0 ft. lbs.) HINT: Make sure to check preload in the direction of rotation. f. Using a dial indicator near the center of the axle hub and measure the backlash in the bearing shaft direction. Maximum: 0.05 mm (0.0020 inch) or less Page 3659 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 2634 ^ 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 1605 Heated Oxygen Sensor COMPONENTS 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. Page 389 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 2507 Junction Box / No. 1 Page 470 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 645 e. Install the injector to the delivery pipe and cylinder head as shown in the illustration. NOTE: Before installing the injector, must apply spindle oil or gasoline on the place where the delivery pipe or cylinder head touches an O-ring of the injector. f. Check that there are no fuel leaks after doing maintenance anywhere on the fuel system. 1. Connect the TOYOTA hand-held tester to the DLC3. 2. Turn ignition switch ON and push the TOYOTA hand-held tester main switch ON. NOTE: Do not start the engine. 3. Select the active test mode on the TOYOTA hand-held tester. 4. Please refer to the TOYOTA hand-held tester operator's manual for further details. 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 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. Description and Operation Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor Crankshaft position sensor (NE signal) consists of and pickup coil. The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor generates 34 signals at every engine revolution. The ECM detects the standard crankshaft angle based on the G signal, and the actual crankshaft angle and the engine speed by the NE signal. Page 3045 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 2085 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 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 3864 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. 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 1705 CHART 5 CHART 6 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 79 Part 1 Of 2 (Except California Spec.) Page 1718 CHART 22 Page 1925 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. Check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. 3. REINSTALL CIRCUIT OPENING RELAY Page 2074 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 Power Mirror Switch: Testing and Inspection INSPECT MIRROR SWITCH CONTINUITY Left Side Left Side: Page 1919 - Slowly loosen the union bolt. d. Install the fuel inlet pipe and SST (pressure gauge) to the delivery pipe with the 3 gaskets and SST (union bolt). SST 09268-45012 Torque: 29 Nm (300 kg.cm, 22 ft.lb) e. Wipe off any splattered gasoline. f. Connect the TOYOTA hand-held tester to the DLC3. g. Turn the ignition switch ON and push the TOYOTA hand-held tester main switch ON. NOTE: Do not start the engine. h. Select the active test mode on the TOYOTA hand-held tester. i. Please refer to the TOYOTA hand-held tester operator's manual for further details. j. If you have no TOYOTA hand-held tester, connect the positive (+) and negative (-) leads from the battery to the fuel pump connector. k. Reconnect the negative (-) terminal cable to the battery. l. Turn the ignition switch ON. m. 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. n. Remove the TOYOTA hand-held tester. o. Start the engine. p. Measure the fuel pressure at idle. Fuel pressure: 206 - 255 kPa (2.1 - 2.6 kg/Sq.cm, 31 - 37 psi) If pressure is not as specified, check the vacuum sensing hose and fuel pressure regulator. q. Stop the engine. r. 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 injector. s. After checking fuel pressure, disconnect the negative (-) terminal cable from the battery and carefully remove the SST to prevent gasoline from splashing. Page 1546 Page 3630 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 1313 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. 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. 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 1734 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 2077 Junction Box / No. 3 Page 2785 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 2636 Brake Pad: Specifications Thickness: Standard 0.472 in Minimum 0.039 in Page 185 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 1490 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 4414 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 2853 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 (93 kg.cm, 82 in.lb) for 2.0 kW c. Pull out the field frame with the armature from the magnetic switch assembly. HINT: At the time of reassembly, please refer to the following items. Align the protrusion of the field frame with the cutout of the magnetic switch. d. Remove the O-ring. HINT: At the time of reassembly, please refer to the following items. Use a new O-ring. 2. REMOVE STARTER HOUSING, CLUTCH ASSEMBLY AND GEAR Page 1091 Thermostat: Testing and Inspection INSPECTION INSPECT THERMOSTAT HINT: The thermostat is numbered with the valve opening temperature. a) Immerse the thermostat in water and gradually heat the water. b) Check the valve opening temperature. Valve opening temperature: 80 - 84°C (176 - 183°F) If the valve opening temperature is not as specified, replace the thermostat. c) Check the valve opening lift. Valve lift: 8 mm (0.31 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. Page 786 6. INSTALL INNER BEARING AND OIL SEAL a. Place inner bearing into the axle hub. b. Using SST and a hammer, install a new oil seal into the axle hub. SST 09527-17011, 09950-60020 (09951-00710), 09950-70010 (09951-07150) NOTICE: Be careful not to damage the ABS speed sensor rotor. c. Coat the oil seal lip with MP grease. 7. INSTALL AXLE HUB WITH DISC a. Place the axle hub on the spindle. b. Install a new outer bearing and claw washer. 8. ADJUST PRELOAD a. Install and torque the nut. Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.) b. Turn the hub several times to make the bearing more smoothly. c. Loosen the nut until it can be turned by hand. d. Using a spring tension gauge, measure and make a note down of the frictional force of the oil seal. HINT: Make sure to check preload in the direction of rotation. e. Tighten the nut until the preload is within the specified value. Preload (at starting): Frictional force plus 6-18 N (0.6-1.8 kgf, 1.3-4.0 lbs.) HINT: Make sure to check preload in the direction of rotation. Page 3044 Power Steering Fluid: Fluid Type Specifications Lubricant Lubricant Type Automatic Transmission Fluid Dexron II or Dexron III Page 4291 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 2693 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 2065 g. Using a 16 mm plug wrench, reinstall the 4 spark plug. Torque: 20 Nm (200 kg.cm, 14 ft.lb) h. Except California Spec.: Reconnect the high-tension cords to the spark plugs. i. California Spec.: Reinstall the ignition coil. Page 1612 Refer to Reset Procedure 1 for the vehicles with Electronically Controlled Automatic Transmissions: Page 260 b. Disconnect the connector from the integration relay and inspect the connectors on the wire harness side. Page 2953 Harness Locations Locations Page 2826 Steps 1 - 3 Page 959 12. INSTALL OIL PAN a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surface of the oil pan. - Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves. - Thoroughly clean all components to remove all the loose material. - Using a non-residue solvent, clean both sealing surfaces. NOTICE: Do not use a solvent which will affect the painted surfaces. b) Apply seal packing to the oil pan as shown in the illustration. Seal packing: Part No. 08826 00080 or equivalent Install a nozzle that has been cut to a 2 - 3 mm (0.08 - 0.12 inch) opening or 3 - 4 mm (0.012 0.016 inch) opening. HINT: Avoid applying an excessive amount to the surface. - 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 oil pan with the 16 bolts and 2 nuts. Torque: 12.5 Nm (130 kgf-cm, 9 ft. lbs.) 13. INSTALL FLYWHEEL HOUSING UNDER COVER AND DUST SEAL 14. 2WD: INSTALL STIFFENER PLATES Torque: 37 Nm (380 kgf-cm, 27 ft. lbs.) 15. INSTALL CRANKSHAFT POSITION SENSOR Install a new O-ring. Torque: 8.5 Nm (85 kgf-cm, 74 inch lbs.) 16. INSTALL GENERATOR, ADJUSTING BAR AND BRACKET a) Install the bracket with the 3 bolts. Torque: 74.5 Nm (760 kgf-cm, 55 ft. lbs.) for bolt A 18 Nm (185 kgf-cm, 13 ft. lbs.) for bolt B b) Install the adjusting bar with the bolt. Torque: 63.5 Nm (650 kgf-cm, 47 ft. lbs.) c) Install the generator with the pivot bolt and lock bolt. 17. INSTALL A/C COMPRESSOR AND BRACKET 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 1576 Page 4322 Air Bag(s) Arming and Disarming: Service and Repair Release Method of Airbag Activation Prevention Mechanism Specifications Wheel Bearing: Specifications On models with serviceable wheel bearings, use a Lithium Multipurpose Grease. Page 1963 Fuel Pump Relay: Testing and Inspection COMPONENTS 1. REMOVE CIRCUIT OPENING RELAY 2. INSPECT CIRCUIT OPENING RELAY a. Inspect the relay continuity. 1. Using and 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 3 and 5. If there is no continuity, replace the relay. 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 3108 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 4370 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 3797 Page 567 Alignment: Service and Repair NOTICE: For Zero Point Calibration information, please refer to: TSB T-SB-0020-8 (3/25/08). NOTE: RZN140L: Regular Cab, Short Wheelbase with 2RZ-FE engine RZN150L: Extra Cab, Extra Long Wheelbase with 2RZ-FE engine VZN150L: Extra Cab, Extra Long Wheelbase with 5VZ-FE engine INSPECTION 1. MEASURE VEHICLE HEIGHT Vehicle Height: Measuring points: A: Ground clearance of spindle center. B: Ground clearance of lower suspension arm bolt center. C: Ground clearance of rear axle shaft center. D: Ground clearance of leaf spring front hanger pin bolt center. NOTICE: Before inspecting the wheel alignment, adjust the vehicle height to the specified value. If the vehicle height is not the specified value, try to adjust it by pushing down on or lifting the body. 2. INSTALL CAMBER-CASTER-KINGPIN GAUGE OR POSITION VEHICLE ON WHEEL ALIGNMENT TESTER Follow the specific instructions of the equipment manufacturer. 3. INSPECT CAMBER, CASTER AND STEERING AXIS INCLINATION Camber, caster and steering axis inclination: Page 2210 7. CHECK PARKING LOCK PAWL OPERATION Shift the manual valve lever to the P position, and check the planetary ring gear is correctly locked up by the lock pawl. 8. INSTALL VALVE BODY 9. INSTALL DRAIN PLUG Torque: 20 Nm (205 kgf-cm, 15 ft. lbs.) 10. FILL ATF AND CHECK FLUID LEVEL 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 - 0.8 V is applied to terminal VTA of the ECM. The voltage applied to the terminals VTA of the ECM increases in proportion to the opening angle of the throttle valve and becomes approximately 3.2 - 4.9 V when the throttle valve is fully opened. The ECM judges the vehicle driving conditions from these signals input from terminal VTA, uses it as one of the conditions to decide the air-fuel ratio correction, power increase correction and fuel cut control etc. Page 2828 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 2881 Splice Locations Page 4245 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. 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 3627 Rear Seat Belt Extender Applications Page 3109 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. Description and Operation Knock Sensor: Description and Operation Knock Sensor The knock sensor is fitted to 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 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. If operation is not as specified, replace the PCV valve. d. Remove the clean hose from the PCV valve. e. Reinstall the PCV valve. Page 2520 Page 3132 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 4446 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 2963 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 4371 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 4052 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 2573 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 1862 e. Install the injector to the delivery pipe and cylinder head as shown in the illustration. NOTE: Before installing the injector, must apply spindle oil or gasoline on the place where the delivery pipe or cylinder head touches an O-ring of the injector. f. Check that there are no fuel leaks after doing maintenance anywhere on the fuel system. 1. Connect the TOYOTA hand-held tester to the DLC3. 2. Turn ignition switch ON and push the TOYOTA hand-held tester main switch ON. NOTE: Do not start the engine. 3. Select the active test mode on the TOYOTA hand-held tester. 4. Please refer to the TOYOTA hand-held tester operator's manual for further details. 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 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. Page 2496 Transmission Speed Sensor: Service and Repair VEHICLE SPEED SENSOR ON-VEHICLE REPAIR Vehicle Speed Sensor NO.1(A43D) 1. DISCONNECT VEHICLE SPEED SENSOR CONNECTOR 2. REMOVE VEHICLE SPEED SENSOR ASSEMBLY (a) Remove the bolt and the vehicle speed sensor assembly. (b) Remove the clip and the driven gear from the vehicle speed sensor. (c) Remove the o-ring from the vehicle speed sensor. 3. INSTALL VEHICLE SPEED SENSOR ASSEMBLY (a) Coat a new o-ring with ATF and install it to the vehicle speed sensor. (b) Install the driven gear and the clip to the vehicle speed sensor. (c) Install the vehicle speed sensor assembly with the bolt. Torque: 16 Nm (160 kgf.cm, 12 ft.lbf) 4. CONNECT VEHICLE SPEED SENSOR CONNECTOR Page 949 7. REMOVE GENERATOR, ADJUSTING BAR AND BRACKET a) Disconnect the generator connector. b) Remove the nut, and disconnect the generator wire and wire clip. c) Remove the lock bolt, pivot bolt and generator. d) Remove the bolt and adjusting bar. e) Remove the 3 bolts and generator bracket. 8. REMOVE CRANKSHAFT POSITION SENSOR a) Remove the 2 bolts and crankshaft position sensor. b) Remove the O-ring from the crankshaft position sensor. 9. 2WD: REMOVE STIFFENER PLATES Remove the 8 bolts and stiffener plates. 10. REMOVE FLYWHEEL HOUSING UNDER COVER AND DUST SEAL Page 1597 Heated Oxygen Sensor Page 2848 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 1666 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection 1. DRAIN ENGINE COOLANT 2. REMOVE ECT SENSOR a. Disconnect the engine wire protector from the 3 brackets. b. Disconnect the ECT sensor connector. c. Using a 19 mm deep socket wrench, remove the ECT sensor and gasket. 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 376 Heated Oxygen Sensor 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 2965 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 3211 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: 0.5-3.5 Nm (5-35 kgf-cm, 4-30 inch lbs.) INSTALLATION Installation is in the reverse order of removal. Page 1824 Leak Detection Solenoid: Testing and Inspection VSV FOR VAPOR PRESSURE SENSOR 1. REMOVE VSV a. Disconnect the connector and 3 EVAP hoses from the VSV. 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. If there is continuity, replace the VSV. 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 4053 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 3380 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 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. Testing and Inspection Turn Signal Switch: Testing and Inspection INSPECT TURN SIGNAL SWITCH CONTINUITY If continuity is not as specified, replace the switch. Locations Ignition Switch and Key Unlock Warning Switch Specifications Piston: Specifications Piston Diameter STD ..................................................................................................................................................... ................................................... 94.923 - 94.933 mm O/S 0.50 .............................................................................................................................................. ................................................... 95.423 - 95.433 mm Page 3712 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. Page 1549 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 3265 Wheel Bearing: Service and Repair Disassembly and Reassembly DISASSEMBLY 1. CHECK HUB BEARINGS Clean the bearings and outer races and inspect them for wear or damage. Page 4352 Junction Box / No. 1 Page 969 Fuel Pressure: Specifications Volume Specification Information not supplied by the manufacturer. Connector Locations Key Reminder Switch: Connector Locations Testing and Inspection Brake Hose/Line: Testing and Inspection Check for fluid leakage from actuator or hydraulic lines. 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 1071 1. Remove coolant and any foreign material on rubber points "A," "B," and "C." 2. Check that points "A," "B " and "C" are not deformed, cracked, or swollen. 3. Check that points "C" and "D" are not stuck together. 4. Apply engine coolant to points "B" and "C" before using the radiator cap tester. ^ Radiator Cap Tester: Snap-On/Sun P/N SVTS262A (or equivalent) 5. Before installing the radiator cap tester, use the applicable radiator cap adaptor provided in the following SST kits in conjunction with the radiator cap tester: ^ SST P/N 09230-00030-01 (09231-10080-01) or 09230-00020-01 (09231-10060-01) or 09230-00050-01(09231-10110-01 6. When using the radiator cap tester, tilt it more than 30 degrees. 7. Pump the radiator cap tester several times, and check the maximum pressure. Pumping speed: 1 pump/second HINT: Stop pumping when the valve opens and read the gauge. The gauge must be within the standard values listed below when the pressure valve opens. The cap is considered OK when the pressure holds steady or falls very slowly, but holds within the standard values listed below for one minute. Specification: If the maximum pressure is less than the minimum standard value, replace the radiator cap sub-assembly. Type: Compact Cap, 88 kPa Page 3649 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 466 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. 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. Description and Operation ABS Light: Description and Operation Testing and Inspection Page 247 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 947 Page 3128 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 2277 10. Install manual valve. 11. Install detent spring. NOTE: Bolt length (mm, inch) is indicated in the illustration. Torque: 5.4 N.m (48 inch lbs.). 12. Make sure manual valve moves smoothly. Page 252 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 Mirror Switch: Testing and Inspection INSPECT MIRROR SWITCH CONTINUITY Left Side Left Side: Page 3188 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. Tightening Specifications Valve Body: Specifications Tightening Specifications Throttle Cam X Front Upper Valve Body ...................................................................................................................... 7.4 Nm (75 kgf.cm, 65 inch lbs.) Valve Body Cover x Front Upper Valve Body .............................................................................................................. 5.4 Nm (55 kgf.cm, 48 inch lbs.) Valve Body Cover x Rear Upper Valve Body ............................................................................................................... 5.4 Nm (55 kgf.cm, 48 inch lbs.) Valve Body Cover x Lower Valve Body ........................................................................................................................ 5.4 Nm (55 kgf.cm, 48 inch lbs.) Upper Valve Body x Lower Valve Body ....................................................................................................................... 5.4 Nm (55 kgf.cm, 48 inch lbs.) Lower Valve Body Cover x Lower Valve Body ............................................................................................................ 5.4 Nm (55 kgf.cm, 48 inch lbs.) Detent Spring x Valve Body ........................................................................................................................................... 5.4 Nm (55 kgf.cm, 48 inch lbs.) Valve body x Transmission case ......................................................................................................................................... 10 Nm (100 kgf.cm, 7 ft. lbs.) Oil strainer x Valve body ............................................................................................................................................... 5.4 Nm (55 kgf.cm, 48 inch lbs.) Page 2508 Junction Box / No. 3 Page 2661 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 1765 Page 1477 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 1973 Mass Air Flow Meter: Testing and Inspection 1. INSPECT MAF METER RESISTANCE Using an ohmmeter, measure the resistance between terminals THA and E3. Temperature Resistance -20 °C (-4 °F) 10 - 20 Kohms 0 °C (32 °F) 4 - 7 Kohms 20 °C (68 °F) 2 - 3 Kohms 40 °C (104 °F) 0.9 - 1.3 Kohms 60 °C (140 °F) 0.4 - 0.7 Kohms 80 °C (176 °F) 0.2 - 0.4 Kohms If the resistance is not as specified, replace the MAF meter. 2. INSPECT MAF METER OPERATION a. Connect the negative (-) terminal cable to the battery. b. Turn the ignition switch ON. c. Connect the MAF meter connector. d. Using a voltmeter, connect the positive (+) tester probe to terminal VG, and negative (-) tester probe to terminal E3. e. Blow air into the MAF meter, and check that the voltage fluctuates. If operation is not as specified, replace the MAF meter. f. Turn the ignition switch OFF. g. Disconnect the negative (-) terminal cable from the battery. h. Disconnect the MAF meter connector. Page 1643 Part 2 Of 2 (Except California Spec.) *:Only for A/T Page 3984 Right Side Right Side: If continuity is not as specified, replace the switch. Locations Page 3444 (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 1707 CHART 8 CHART 9 Page 3905 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 2799 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: It under the lower level, add distilled water. 2. Except Maintenance-Free Battery: CHECK BATTERY SPECIFIC GRAVITY Check the specific gravity of each cell. Standard specific gravity: 1.25 - 1.29 at 20°C (68°F) If the specific gravity is less than specification, charge the battery. 3. Maintenance-Free Battery: CHECK BATTERY VOLTAGE a. After having driven the vehicle and in the case that 20 minutes have not passed after having stopped the engine, turn the ignition switch ON and turn on the electrical system (headlight, blower motor, rear defogger etc.) for 60 seconds to remove the surface charge. b. Turn the ignition switch OFF and turn off the electrical systems. c. Measure the battery voltage between the negative (-) and positive (+) terminals of the battery. Standard voltage: 12.5 - 12.9 V at 20°C (68°F) If the voltage is less than specification, charge the battery. Page 4439 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 3897 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. Locations Fusible Link: Locations Relay Box / No. 2 Page 550 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 2281 12. INSTALL DRAIN PLUG Torque: 20 Nm (205 kgf-cm, 15 ft. lbs.) 13. FILL ATF AND CHECK FLUID LEVEL Page 4440 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. 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 657 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 705 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 drain plug, and drain the oil into a container. 2. REPLACE OIL FILTER a) Using SST, remove the oil filter. SST 09228-07501 b) Check and clean the oil filter installation surface. c) Apply clean engine oil to the gasket of a new oil filter. d) Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat. e) Using SST, tighten it an additional 3/4 turn. SST 09228-07501 3. REFILL WITH ENGINE OIL a) Clean and install the oil drain plug with a new gasket. Torque: 37 Nm (375 kgf-cm, 27 ft. lbs.) b) Fill with new engine oil. Oil capacity: c) Reinstall the oil filler cap. 4. START ENGINE AND CHECK FOR LEAKS 5. RECHECK ENGINE OIL LEVEL 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 1620 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 4117 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. Specifications Valve Clearance: Specifications Valve Clearance Intake ................................................................................................................................................... ......................................................... 0.006 - 0.010 in Exhaust ................................................................................................................................................ ......................................................... 0.010 - 0.014 in Page 1426 Mass Air Flow Meter: Service and Repair COMPONENTS REMOVAL 1. REMOVE AIR CLEANER CAP WITH MAF METER a. Disconnect the MAF meter connector and wire clamp. b. Loosen the air cleaner hose clamp. c. Disconnect the air hose from air cleaner cap. d. Loosen the 4 clips, and remove the air cleaner cap together with the MAF meter. 2. REMOVE MAF METER FROM AIR CLEANER CAP Page 449 Crankshaft Position Sensor: Testing and Inspection INSPECT CRANKSHAFT POSITION SENSOR a. Remove the sensor. b. Using an ohmmeter, measure the resistance between terminals NE and NE-. Resistance: Cold 1,630 - 2,740 kohms Hot 2,065 - 3,225 kohms If the resistance is not as specified, replace the sensor. c. Reinstall the sensor. Page 1486 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 192 Steps 1 - 3 Page 2875 Auxiliary Power Outlet: Locations Component Locations Page 3597 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: 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 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 4408 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 2889 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 4274 Page 4437 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 2053 b. Disconnect the connector from the integration relay and inspect the connectors on the wire harness side. 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 the coil, closing the contacts of the EFI main relay (Marking: EFI) and supplying power to terminal +B of the ECM. WIRING DIAGRAM Description and Operation Knock Sensor: Description and Operation Knock Sensor The knock sensor is fitted to 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 1581 Page 335 ^ 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 2845 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. 2.0 kW: INSPECT SHUNT COIL FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between terminal (A) and (B). Standard resistance: 1.5 - 1.9 Ohm at 20°C (68°F) If the resistance is not as specified, repair or replace the field frame. 5. INSPECT BRUSHES Page 1278 Heated Oxygen Sensor Page 3656 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 476 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. 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. 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 4279 Harness Locations Locations Page 1026 Water Pump: Service and Repair Part 1 Of 2 Page 3634 Owner Instructions Failure to follow the recommendations indicated below could result in reduced effectiveness of the seat belt restraint system in case of vehicle collision, causing personal injury. The Seat Belt Extender must not be used: a. By anyone other than for whom it was provided (name recorded on seat belt extender). b. In any vehicle and/or seat position other than the one for which it was provided. c. When the Seat Belt Extender is provided for rear seat positions (with automatic locking retractor), make sure the retractor is locked when in use. If your seat belt cannot be fastened securely because it is not long enough, a personalized Seat Belt Extender is available from your Toyota dealer free of charge. Please contact your local Toyota dealer so that the dealer can order the proper required length for the extender. Bring the heaviest coat you expect to wear for proper measurement and selection of length. Additional ordering information is available at your Toyota dealer. CAUTION: When using the Seat Belt Extender, observe the following. Failure to follow these instructions could result in reduced effectiveness of the seat belt restraint system in case of vehicle accident, increasing the chance of personal injury. ^ Never use the Seat Belt Extender if you can COMFORTABLY fasten the seat belt without it. ^ The Seat Belt Extender must never be used with any child safety seats. ^ Remember that the extender provided for you may not be safe when used on a; different vehicle, or for another person or at a different seating position than the one originally intended for. To connect the extender to the seat belt, insert the tab into the seat belt buckle so that the "PRESS" signs on the buckle-release buttons of the extender Page 658 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 3293 2. REMOVE BEARING OUTER RACES Using SST, a brass bar and hammer, remove the inside and out side of the bearing outer races. SST 09527-17011 NOTICE: Be careful not to damage the ABS speed sensor rotor. REASSEMBLY INSTALL NEW BEARING OUTER RACES a. Using SST and a press, install a new inside of the bearing outer race. SST 09527-17011, 09950-60010 (09951-00640), 09950-70010 (09951-07150) b. Using SST and a press, install a new outside of the bearing race. SST 09527-17011, 09950-60010 (09951-00490), 09950-70010 (09951-07150) NOTICE: Be careful not to damage the ABS speed sensor rotor. 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. 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 ECM will be erased when the battery negative (-) terminal cable is removed from the battery. Therefore, if necessary, read the diagnostic trouble code(s) 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 a new gasket. 2. Tighten the union bolt by hand. 3. Tighten the union bolt to the specified torque. Torque: 29 Nm (300 kg.cm, 22 ft.lb) Specifications Shift Interlock Switch: Specifications Park/Neutral Position Switch ......................................................................................................................................... 5.4 Nm (55 kgf.cm, 48 inch lbs.) Park/Neutral Position Switch Adjusting Bolt ................................................................................................................. 3.9 Nm (40 kgf.cm, 35 inch lbs.) Page 2989 Junction Box / No. 1 Details Page 1230 A/F and 02 Sensor Identification Page 4220 Wiring Diagram Step 1 Page 1904 Fuel Injector: Testing and Inspection On-Vehicle Inspection 1. INSPECT INJECTOR OPERATION Check operation sound from each injector. 1. With the engine running or cranking, use a sound scope to check that there is normal operating noise in proportion to engine speed. 2. If you have no sound scope, you can check the injector transmission operation with your finger. If no sound or unusual sound is heard, check the wiring connector, injector or injection signal from the ECM. 2. INSPECT INJECTOR RESISTANCE a. Remove the throttle body. b. Disconnect the injector connectors. c. Using an ohmmeter, measure the resistance between the terminals. Resistance: 12 - 16 ohms at 20 °C (68 °F) If the resistance is not as specified, replace the injector. d. Reconnect the injector connectors. e. Reinstall the throttle body. Page 3168 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 699 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 1736 Heated Oxygen Sensor Page 1335 Remove the 4 nuts, MAF meter and gasket. INSTALLATION 1. INSTALL MAF METER TO AIR CLEANER CAP a. Place a new gasket on the air cleaner cap. b. Install the MAF meter with the 4 nuts. Torque: 8.5 Nm (85 kg.cm, 74 in.lb) 2. INSTALL MAF METER WITH AIR CLEANER CAP Page 4218 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 2429 Junction Box / No. 3 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 2181 Shift Indicator: Harness Locations Page 1510 Step 1 Step 2 Step 3 Step 4 Component Locations Page 4216 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 1635 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 4423 Junction Box / No. 1 Page 2278 Valve Body: Service and Repair Without SR5 ON-VEHICLE REPAIR 1. CLEAN TRANSMISSION EXTERIOR To prevent contamination, clean the exterior of the transmission. 2. REMOVE DRAIN PLUG AND DRAIN ATF 3. REMOVE OIL PAN NOTICE: Some fluid will remain in the oil pan. - Be careful not to damage the filler pipe. a. Remove the 14 bolts, and carefully remove the oil pan. b. Remove the gasket. 4. EXAMINE PARTICLES IN PAN Remove the magnets and use them to collect any steel chips. Look carefully at the magnetic and non-magnetic chips to anticipate what type of wear you will find in the transmission. Steel (magnetic) ........................................................................................................................................................ bearing, gear and plate wear - Brass (non-magnetic) ........................................................................................................................ ................................................ bushing wear 5. REMOVE OIL PIPES Pry up both pipe ends with a large screwdriver and remove the 2 pipes. NOTICE: Be careful not to bend or damage the pipes. 6. REMOVE OIL STRAINER Remove the 5 bolts, oil strainer and the gasket. NOTICE: Be careful as some oil will come out with the strainer. 7. REMOVE VALVE BODY Page 2806 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 1234 Engine Bank Identification Capacity Specifications Fluid - M/T: Capacity Specifications Transmission Fluid Drain and refill ..................................................................................................................................... ........................................................................ 2.7 Qt Page 234 Junction Box / No. 1 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 901 TOY 730 - 73mm Toyota Oil Filter Wrench M 0219 - 74mm Oil Filter Wrench Page 4295 Page 408 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 2198 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 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 3637 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 Page 2905 Fuse: Application and ID Engine Room R/B # 2 Page 36 INSPECT DAYTIME RUNNING LIGHT NO.4 RELAY CONTINUITY If continuity is not as specified, replace the relay. Page 2723 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 2402 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 869 NOTE: Always pinch the hose. Avoid bending as it may cause to hose to crack. 7. Turn the ignition switch OFF. 8. Disconnect the TOYOTA hand-held tester from the DLC3. Page 2743 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 2667 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 2574 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 2264 Valve Body: Specifications Valve Body Springs and Keys Valve Body Spring Valve Body Key Page 3583 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 867 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: 30 Nm (310 kg.cm, 22 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. Page 1797 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 1898 Fuel Injector: Pressure, Vacuum and Temperature Specifications Pressure Drop Pressure Drop California 1 Drop per 12 Minutes Pressure Drop Pressure Drop Pressure Drop 1 Drop per 3 Minutes Page 2098 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. Service and Repair Extension Housing: Service and Repair For further information regarding this component and the system that it is a part of please refer to Manual Transmission/Transaxle; Service and Repair. Page 1585 CHART 26 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 790 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 3965 Page 298 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 intake camshaft. 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. 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 324 Applicable Vehicles Page 1272 CHART 29 Testing and Inspection Windshield Washer Switch: Testing and Inspection INSPECT FRONT WIPER AND WASHER SWITCH CONTINUITY W/ Mist w/ MIST: Page 2792 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. 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. Testing and Inspection Ignition Cable: Testing and Inspection ON-VEHICLE INSPECTION Except California Spec.: INSPECT HIGH-TENSION CORDS a. Remove the air cleaner cap and MAF meter assembly. b. Remove the intake air connector. c. 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. d. Using an ohmmeter, measure the high-tension cord resistance. Maximum resistance: 25 kohms per cord If the resistance is greater than the maximum, check the terminals. If necessary, replace the high-tension cord. e. Reinstall the high-tension cords. Secure the high-tension cords with the clamps as shown in the illustration. f. Reinstall the intake air connector. g. Reinstall the air cleaner cap and MAF meter assembly. Page 2310 Steps 1 - 3 Page 2635 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 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. Page 3655 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 3958 Application Chart Page 2852 REMOVAL REMOVE STARTER a. Disconnect the starter connector. b. Remove the nut, and disconnect the starter wire. Torque: 8.8 Nm (90 kg.cm, 78 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. Removal and Installation Brake Caliper: Service and Repair Removal and Installation REMOVAL 1. DISCONNECT FLEXIBLE HOSE a. Remove the union bolt and disconnect the flexible hose. Torque: 30 Nm (310 kgf-cm, 22 ft. lbs.) NOTICE: At the time of installation, for correct brake hose routing, ensure that the hose hangs down before installing hose to caliper. b. Use a container to catch the brake fluid. 2. REMOVE CALIPER FROM TORQUE PLATE Remove the 2 slide pins and caliper. Torque: 88 Nm (900 kgf-cm, 65 ft. lbs.) 3. REMOVE 2 BRAKE PADS WITH 4 ANTI-SQUEAL SHIMS AND PAD WEAR INDICATOR 4. REMOVE 4 PAD SUPPORT PLATES Diagrams Specifications Clutch Fluid: Specifications Fluid Type FMVSS 116 DOT 3 Brake Fluid Page 1802 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 2439 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 4258 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 3633 Rear Seat Belt Extender Applications Page 532 Transmission Speed Sensor: Description and Operation Vehicle Speed Sensor NO.1 Vehicle Speed Sensor NO.1 Circuit Description The vehicle speed sensor outputs a 4-pulse signal for every revolution of the rotor shaft, which is rotated by the transmission output shaft via the driven gear. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. Vehicle Speed Sensor NO.2 Vehicle Speed Sensor NO.2 Circuit Description The No.2 vehicle speed sensor detects the rotation speed of the transmission output shaft and sends signals to the ECM. The ECM determines the vehicle speed based on these signals. Specifications Wheel Bearing: Specifications On models with serviceable wheel bearings, use a Lithium Multipurpose Grease. Page 3888 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 1261 Page 2163 Page 895 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 2114 Transmission Position Switch/Sensor: Service and Repair ON-VEHICLE REPAIR 1. REMOVE FRONT EXHAUST PIPE AND HEAT INSULATOR 2. DISCONNECT OIL COOLER PIPE a. Remove the 3 oil cooler pipe clamps. b. Disconnect the oil cooler pipe. 3. REMOVE ELBOW AND O-RING 4. REMOVE PARK/NEUTRAL POSITION SWITCH a. Disconnect the connector. b. Pry off the lock washer and remove the nut. c. Remove the bolt and park/neutral position switch. 5. INSTALL PARK/NEUTRAL POSITION SWITCH a. Install the park/neutral position switch and bolt. Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.) b. Install a new lock plate and the nut. Torque: 3.9 Nm (40 kgf-cm, 35 inch lbs.) c. Bend claws on the lock plate to fix the nut. d. Adjust the park/neutral position switch. e. Connect the connector. 6. INSTALL ELBOW AND NEW O-RING Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.) 7. CONNECT OIL COOLER PIPES a. Connect the oil cooler pipe. Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.) b. Install the 3 oil cooler pipe clamps. 8. INSTALL FRONT EXHAUST PIPE AND HEAT INSULATOR Page 2929 Junction Box / No. 1 Details Page 3017 Alignment: Service and Repair NOTICE: For Zero Point Calibration information, please refer to: TSB T-SB-0020-8 (3/25/08). NOTE: RZN140L: Regular Cab, Short Wheelbase with 2RZ-FE engine RZN150L: Extra Cab, Extra Long Wheelbase with 2RZ-FE engine VZN150L: Extra Cab, Extra Long Wheelbase with 5VZ-FE engine INSPECTION 1. MEASURE VEHICLE HEIGHT Vehicle Height: Measuring points: A: Ground clearance of spindle center. B: Ground clearance of lower suspension arm bolt center. C: Ground clearance of rear axle shaft center. D: Ground clearance of leaf spring front hanger pin bolt center. NOTICE: Before inspecting the wheel alignment, adjust the vehicle height to the specified value. If the vehicle height is not the specified value, try to adjust it by pushing down on or lifting the body. 2. INSTALL CAMBER-CASTER-KINGPIN GAUGE OR POSITION VEHICLE ON WHEEL ALIGNMENT TESTER Follow the specific instructions of the equipment manufacturer. 3. INSPECT CAMBER, CASTER AND STEERING AXIS INCLINATION Camber, caster and steering axis inclination: Specifications Drive Belt: Specifications Alternator Belt New Belt ...................................................................................................................... ...................................................................................... 116 - 169 lbf Used Belt ................................. .............................................................................................................................................................. ................ 66 - 88 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 2550 An AC voltage is generated in the No.2 vehicle speed sensor coil as the rotor mounted on the output shaft rotates, and this voltage is sent to the ECM. The gear shift point and lock-up timing are controlled by the ECM based on the signals from this vehicle speed sensor and the throttle position sensor signal. If the No.2 vehicle speed sensor malfunctions, the ECM uses input signals from the No.1 vehicle speed sensor as a back-up signal. Page 3688 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 2369 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 261 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 Specifications Flywheel: Specifications Flywheel Bolts 2.4L (2RZ-FE) Engine 88 Nm Note: Use new bolts 2.7L (3RZ-FE) Engine Step 1 26.5 Nm Step 2 Additional 90 degrees 3.4L (5VZ-FE) Engine 85 Nm Flywheel Runout Maximum Runout 0.1 mm Sequence Sequence Page 2191 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 2625 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 1658 Page 3264 f. Using a dial indicator near the center of the axle hub and measure the backlash in the bearing shaft direction. Maximum: 0.05 mm (0.0020 inch) or less 9. INSTALL LOCK CAP, COTTER PIN AND GREASE CAP a. Install the lock cap and a new cotter pin. If the holes for the cotter pin are not aligned, tighten the nut further up to 60°. b. Install the grease cap. 10. INSTALL BRAKE CALIPER Install the brake caliper with the 2 bolts. Torque: 108 Nm (1,100 kgf-cm, 80 ft. lbs.) 11. w/ ABS: CONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP TO STEERING KNUCKLE Connect the ABS speed sensor and wire harness clamp with the 2 bolts. Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.) 12. INSTALL FRONT WHEEL Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.) 13. DEPRESS BRAKE PEDAL SEVERAL TIMES 14. CHECK FRONT WHEEL ALIGNMENT 15. w/ ABS: CHECK ABS SPEED SENSOR SIGNAL Page 3836 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 1264 CHART 24 Page 2173 Locations Camshaft Position Sensor: Locations Page 1774 An AC voltage is generated in the No.2 vehicle speed sensor coil as the rotor mounted on the output shaft rotates, and this voltage is sent to the ECM. The gear shift point and lock-up timing are controlled by the ECM based on the signals from this vehicle speed sensor and the throttle position sensor signal. If the No.2 vehicle speed sensor malfunctions, the ECM uses input signals from the No.1 vehicle speed sensor as a back-up signal. 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 HINT: All vacuum hoses for EGR systems, etc. should be properly connected. f) SFI system wiring connectors fully plugged g) Ignition timing check 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 HINT: When doing the 2 mode (idle and 2,500 rpm) test, these measurement order prescribed by the applicable local regulations. Page 1315 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor NO.1 Vehicle Speed Sensor NO.1 Circuit Description The vehicle speed sensor outputs a 4-pulse signal for every revolution of the rotor shaft, which is rotated by the transmission output shaft via the driven gear. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. Vehicle Speed Sensor NO.2 Vehicle Speed Sensor NO.2 Circuit Description The No.2 vehicle speed sensor detects the rotation speed of the transmission output shaft and sends signals to the ECM. The ECM determines the vehicle speed based on these signals. Page 3395 Hose/Line HVAC: Tools and Equipment A/C Clamp Remover AST tool# TOY 200 Page 3084 Air Bag(s) Arming and Disarming: Service and Repair Release Method of Airbag Activation Prevention Mechanism Page 3906 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. 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 3927 Wire Harness Fuse Location Troubleshooting Procedure 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. Specifications Axle Nut: Specifications - INSTALL AXLE HUB WITH DISC a. Place the axle hub on the spindle. b. Install a new outer bearing and claw washer. - ADJUST PRELOAD a. Install and torque the nut. Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.) b. Turn the hub several times to make the bearing more smoothly. c. Loosen the nut until it can be turned by hand. d. Using a spring tension gauge, measure and make a note down of the frictional force of the oil seal. HINT: Make sure to check preload in the direction of rotation. e. Tighten the nut until the preload is within the specified value. Preload (at starting): Frictional force plus 6 - 18 N (0.6 - 1.8 kgf, 1.3 - 4.0 ft. lbs.) HINT: Make sure to check preload in the direction of rotation. f. Using a dial indicator near the center of the axle hub and measure the backlash in the bearing shaft direction. Maximum: 0.05 mm (0.0020 inch) or less Page 2495 An AC voltage is generated in the No.2 vehicle speed sensor coil as the rotor mounted on the output shaft rotates, and this voltage is sent to the ECM. The gear shift point and lock-up timing are controlled by the ECM based on the signals from this vehicle speed sensor and the throttle position sensor signal. If the No.2 vehicle speed sensor malfunctions, the ECM uses input signals from the No.1 vehicle speed sensor as a back-up signal. Page 3613 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 2337 Page 714 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 1735 Oxygen Sensor: Locations Air-Fuel Ratio (A/F) Sensor Page 1346 Camshaft Position Sensor: Testing and Inspection INSPECTION 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 4202 Steps 3 - 4 INSPECTION PROCEDURE Component Locations Seat Belt Reminder Lamp: Component Locations Page 2830 Steps 3 - 4 INSPECTION PROCEDURE Page 3064 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 SST, tap out the oil seal from the front housing. SST 09631-10030 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 a socket wrench (24 mm), press in the oil seal. NOTICE: Make sure to install the oil seal facing the correct direction. 6. IF NECESSARY, REPLACE BEARING a. Press out the bearing from the vane pump shaft. b. Using snap ring expander, replace the snap ring with new one. NOTICE: Be careful not to damage the shaft. c. Coat a new bearing with power steering fluid. d. Press in the bearing to the shaft. 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 971 - Slowly loosen the union bolt. d. Install the fuel inlet pipe and SST (pressure gauge) to the delivery pipe with the 3 gaskets and SST (union bolt). SST 09268-45012 Torque: 29 Nm (300 kg.cm, 22 ft.lb) e. Wipe off any splattered gasoline. f. Connect the TOYOTA hand-held tester to the DLC3. g. Turn the ignition switch ON and push the TOYOTA hand-held tester main switch ON. NOTE: Do not start the engine. h. Select the active test mode on the TOYOTA hand-held tester. i. Please refer to the TOYOTA hand-held tester operator's manual for further details. j. If you have no TOYOTA hand-held tester, connect the positive (+) and negative (-) leads from the battery to the fuel pump connector. k. Reconnect the negative (-) terminal cable to the battery. l. Turn the ignition switch ON. m. 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. n. Remove the TOYOTA hand-held tester. o. Start the engine. p. Measure the fuel pressure at idle. Fuel pressure: 206 - 255 kPa (2.1 - 2.6 kg/Sq.cm, 31 - 37 psi) If pressure is not as specified, check the vacuum sensing hose and fuel pressure regulator. q. Stop the engine. r. 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 injector. s. After checking fuel pressure, disconnect the negative (-) terminal cable from the battery and carefully remove the SST to prevent gasoline from splashing. Page 441 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 1547 Engine Bank Identification 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 3896 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 331 Engine Bank Identification Page 2525 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 1587 CHART 27 Page 2765 Step 4 INSPECTION PROCEDURE Page 729 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 1506 Part 2 Of 2 (Except California Spec.) *:Only for A/T 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 565 Front shim thickness: -1.7 mm (0.067 inch) Rear shim thickness: +11.6 mm (0.063 inch) d. Torque the upper suspension arm set bolts. Torque: 130 Nm (1,300 kgf-cm, 94 ft. lbs.) HINT: If the steering axis inclination is not as specified value after the camber and caster have been correctly adjusted, recheck the steering knuckle and front wheel for distortion or looseness. NOTICE: Adjust the shim thickness to 7 mm (4-11 mm), and adjust the difference between the front and rear of the upper suspension arm shaft to within 4 mm. Measuring Point Reference 5. INSPECT TOE-IN Toe-In: If the toe-in is not within the specified value, adjust the rack ends. 6. ADJUST TOE-IN 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: 54 Nm (550 kgf-cm, 40 ft. lbs.) f. Place the boots on the seats and install the clips. HINT: Make sure that the boots are not twisted. Page 3018 RZN140L Model RZN150L Model VZN150L 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 upper suspension arm set bolts. b. Adjust the camber and caster by adding or removing shims (See adjustment chart). Shim Thickness: HINT: Try to adjust the camber and caster to the center of the specified values. Page 4201 Steps 1 - 2 Locations Page 748 Interior J/B # 1 Page 2897 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 1719 Page 1471 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 1628 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 3491 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 330 Page 2050 Ignition Switch: Testing and Inspection 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 2818 c. Install the 5 screws until there is a clearance of approx. 1 mm (0.04 in.) between the brush holder and connector. Torque: 1.96 Nm (20 kg.cm, 17.4 in.lb) 7. INSTALL REAR END COVER a. Install the end cover with the 3 nuts. Torque: 4.5 Nm (46 kg.cm, 40 in.lb) b. Install the terminal insulator with the nut. Torque: 4.1 Nm (42 kg.cm, 36 in.lb) 8. 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. Page 2526 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 Connecting Rod Bearing: Specifications Connecting Rod Bearing Standard oil clearance Maximum oil clearance: 0.10 mm (0.0039 inch) If the oil clearance is greater than maximum, replace the bearings. If necessary, grind or replace the crankshaft. HINT: If using a standard bearing, replace with one having the same number as marked on the bearing cap. There are 3 sizes of standard bearings, marked "4", "5" and "6" accordingly. Reference - Standard Sized Bearing Center Wall Thickness Page 3065 REASSEMBLY NOTICE: When using a vise, do not overtighten it. 1. COAT WITH POWER STEERING FLUID 2. INSTALL VANE PUMP SHAFT WITH BEARING a. Wind vinyl tape on the serrated part of the vane pump shaft. b. Using SST, press in the shaft with the bearing. SST 09608-04031 NOTICE: Be careful not to damage the oil seal. c. Using snap ring pliers, install a new snap ring to the front housing. 3. INSTALL STRAIGHT PINS Using a plastic hammer, tap in 2 new pins to the front housing. NOTICE: Be careful not to damage the pins. 4. INSTALL CAM RING Install the 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 AND GASKET a. Install the 10 plates with the round end facing outward. b. Install a new gasket on the front housing. NOTICE: Be careful the direction of the gasket. 7. INSTALL SIDE PLATE Align the holes of the plate and 2 straight pins. Page 584 6. TROUBLESHOOTING If the CO/HC concentration does not comply with regulations, troubleshoot according in the order given. 1) Check heated oxygen sensor operation. 2) See the table for possible causes, then inspect and correct the applicable causes if necessary. Page 61 Page 1246 CHART 2 CHART 3 CHART 4 Page 3763 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 ECM will be erased when the battery negative (-) terminal cable is removed from the battery. Therefore, if necessary, read the diagnostic trouble code(s) 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 a new gasket. 2. Tighten the union bolt by hand. 3. Tighten the union bolt to the specified torque. Torque: 29 Nm (300 kg.cm, 22 ft.lb) Page 4014 be used during this type of repair due to the higher potential of damaging the paint surface. Remember no broken paint. Page 1152 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 3252 a. Remove the 2 bolts and disconnect the shock absorber from the lower suspension arm. Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.) b. Hold the shock absorber rod, then remove the nut, retainer, cushion and shock absorber. Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.) c. Remove the cushion and retainer from the 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 disposing 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. INSTALLATION Installation is in the reverse order of removal. Page 2040 Camshaft Position Sensor: Service and Repair COMPONENTS Page 2305 d. Check that there is no continuity between terminals 1 and 2 when disconnecting the battery lead. If continuity is not as specified, replace the clutch start cancel switch. Page 2089 Page 2874 Page 1804 An AC voltage is generated in the No.2 vehicle speed sensor coil as the rotor mounted on the output shaft rotates, and this voltage is sent to the ECM. The gear shift point and lock-up timing are controlled by the ECM based on the signals from this vehicle speed sensor and the throttle position sensor signal. If the No.2 vehicle speed sensor malfunctions, the ECM uses input signals from the No.1 vehicle speed sensor as a back-up signal. Page 4242 Page 3640 Rear Seat Belt Extender Applications Part Number Information Page 3962 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 2076 Junction Box / No. 1 Page 1600 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 1229 Engine Bank Identification Page 3847 Rear Bumper Cover / Fascia: Technical Service Bulletins Paint - Refinishing Bumper Cover PAINT PA003-02 REVISED June 4, 2002 Title REFINISHING REPLACEMENT BUMPER COVERS Models All '83 - '05 Models TSB REVISION NOTICE: ^ February 14, 2005: Applicable Vehicles now includes 2004 - 2005 model years. Previous versions of this TSB should be discarded. Introduction In cases where a bumper cover is being replaced a special preparation process is necessary to assure the refinish is customer acceptable. This bulletin provides the recommended refinishing procedure for new bumper covers. Applicable Vehicles ^ All 1983 - 2005 model year Toyota vehicles. Required Tools & Material Note:Please visit www.3m.comlautomotive to find the nearest store that sells 3M automotive products. Warranty Information Refinishing Procedure 1. Mix a solution of mild soap (car wash soap with no wax additives) and clean water. Note: Carefully follow mixing instructions on the soap container. Too much soap or too much water may cause surface contamination or rinsing difficulty. Page 3674 Seat Belt Reminder Lamp: Ground Locations Page 3354 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 3207 Page 1522 3. California Spec.: INSPECT IAC VALVE OPERATION a. Check that the IAC valve is halfly opened. b. Connect the IAC valve connector to the IAC valve. c. Disconnect the ECT sensor connector from the ECT sensor. d. Turn the ignition switch ON. e. Check that the IAC valve moves. HINT: Repeat connecting and disconnecting of IAC valve connector several times and check the operation of the valve. If operation is not as specified, replace the IAC valve. f. Turn the ignition switch OFF. g. Reconnect the ECT sensor connector to the ECT sensor. h. Disconnect the IAC valve connector from the IAC valve. Page 1631 Engine Control Module: Connector Views Connectors (California Spec.) Part 1 Of 2 (California Spec.) Page 694 Fluid - M/T: Fluid Type Specifications Transmission Fluid Grade ................................................................................................................................................... ............................................................ GL-4 or GL-5 Viscosity ........................................................... ................................................................................................................................................ SAE 75W-90 Page 2523 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 1974 Mass Air Flow Meter: Service and Repair COMPONENTS REMOVAL 1. REMOVE AIR CLEANER CAP WITH MAF METER a. Disconnect the MAF meter connector and wire clamp. b. Loosen the air cleaner hose clamp. c. Disconnect the air hose from air cleaner cap. d. Loosen the 4 clips, and remove the air cleaner cap together with the MAF meter. 2. REMOVE MAF METER FROM AIR CLEANER CAP Page 1500 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 2338 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 2192 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 305 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection 1. DRAIN ENGINE COOLANT 2. REMOVE ECT SENSOR a. Disconnect the engine wire protector from the 3 brackets. b. Disconnect the ECT sensor connector. c. Using a 19 mm deep socket wrench, remove the ECT sensor and gasket. 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 2102 Shift Indicator: Pinout Values and Diagnostic Parameters O 4 O/D MAIN SW 1-3 : Open with O/D main SW at ON position Closed with O/D main SW at OFF position Page 1627 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. 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 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 719 Refrigerant: Fluid Type Specifications Type R-134a Front Page 393 Transmission Position Switch/Sensor: Service and Repair ON-VEHICLE REPAIR 1. REMOVE FRONT EXHAUST PIPE AND HEAT INSULATOR 2. DISCONNECT OIL COOLER PIPE a. Remove the 3 oil cooler pipe clamps. b. Disconnect the oil cooler pipe. 3. REMOVE ELBOW AND O-RING 4. REMOVE PARK/NEUTRAL POSITION SWITCH a. Disconnect the connector. b. Pry off the lock washer and remove the nut. c. Remove the bolt and park/neutral position switch. 5. INSTALL PARK/NEUTRAL POSITION SWITCH a. Install the park/neutral position switch and bolt. Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.) b. Install a new lock plate and the nut. Torque: 3.9 Nm (40 kgf-cm, 35 inch lbs.) c. Bend claws on the lock plate to fix the nut. d. Adjust the park/neutral position switch. e. Connect the connector. 6. INSTALL ELBOW AND NEW O-RING Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.) 7. CONNECT OIL COOLER PIPES a. Connect the oil cooler pipe. Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.) b. Install the 3 oil cooler pipe clamps. 8. INSTALL FRONT EXHAUST PIPE AND HEAT INSULATOR Locations Fuse Block: Locations Relay Box / No. 2 Page 571 7. INSPECT WHEEL ANGLE Turn the steering wheel fully and measure the turning angle. Wheel Turning Angle: If the right and left inside wheel angles differ from the specified value, check the right and left rack end lengths. HINT: If the rack ends lengths are not equal, the wheel turning angle cannot be adjusted properly. Reinspect the toe-in after adjusting the rack ends lengths. Page 1147 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 353 CHART 18 CHART 19 Page 2551 Transmission Speed Sensor: Service and Repair VEHICLE SPEED SENSOR ON-VEHICLE REPAIR Vehicle Speed Sensor NO.1(A43D) 1. DISCONNECT VEHICLE SPEED SENSOR CONNECTOR 2. REMOVE VEHICLE SPEED SENSOR ASSEMBLY (a) Remove the bolt and the vehicle speed sensor assembly. (b) Remove the clip and the driven gear from the vehicle speed sensor. (c) Remove the o-ring from the vehicle speed sensor. 3. INSTALL VEHICLE SPEED SENSOR ASSEMBLY (a) Coat a new o-ring with ATF and install it to the vehicle speed sensor. (b) Install the driven gear and the clip to the vehicle speed sensor. (c) Install the vehicle speed sensor assembly with the bolt. Torque: 16 Nm (160 kgf.cm, 12 ft.lbf) 4. CONNECT VEHICLE SPEED SENSOR CONNECTOR Locations Relay Box: Locations Relay Box / No. 2 Page 1093 c) Check the valve opening lift. Valve lift: 8 mm (0.31 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) Align the jiggle valve of the thermostat with the protrusion of the water inlet housing, and insert the thermostat in the water inlet housing. HINT: The jiggle valve may be set within 15° of either side of the prescribed position. c) Install the water inlet with the 2 nuts. HINT: Facing the top mark (protrusion) upward. Torque: 20 Nm (200 kgf-cm, 15 ft. lbs.) 2. CONNECT LOWER RADIATOR HOSE 3. FILL WITH ENGINE COOLANT 4. START ENGINE AND CHECK FOR LEAKS 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 2372 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 351 CHART 15 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. REINSTALLER MAIN RELAY Page 1201 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 intake camshaft. 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. 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 1661 Camshaft Position Sensor: Service and Repair COMPONENTS Page 3111 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. Capacity Specifications Power Steering Fluid: Capacity Specifications Power Steering Fluid: Total ..................................................................................................................................................... .......................................... 0.8 liters (0.9 US Qts.) Page 4219 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. 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 2149 Fluid - A/T: Fluid Type Specifications Transmission Fluid .............................................................................................................................. ................................................. ATF Dexron II or III Page 341 O2S Application Table O2S Failure Threshold Charts 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. Diagrams Power Steering Pump: Diagrams Part 1 Of 2 Page 3159 f. Using SST and a torque wrench, tighten the cap until the preload is within specification. SST 09616-00010, 09631-10021 Preload (turning): 0.9-1.5 Nm (9-15 kgf-cm, 7.8-13.0 inch lbs.) 15. 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 hold the rack guide spring cap, 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): 0.9-1.5 Nm (9-15 kgf-cm, 7.8-13.0 inch lbs.) d. Remove the RH and LH rack ends. 16. 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.) 17. 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 3052 Part 2 Of 2 POWER STEERING VANE PUMP REPLACEMENT AND OVERHAUL W/ RELATED COMPONENTS Page 808 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 1725 CHART 26 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 4372 Page 3902 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. Page 3303 * For vehicle capacity weight. ** For reduced loads (1 to 4 passengers). *** For trailer towing. Page 1775 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 1479 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 the 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. 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 2947 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 2321 Pressure Plate: Service and Repair For further information regarding this component and the system that it is a part of please refer to Clutch, M/T; Service and Repair. Page 626 c) Install a new adjusting shim. 1) Place a new adjusting shim on the valve lifter. 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. 10. REINSTALL CYLINDER HEAD COVER 11. RECONNECT ENGINE WIRE 12. Except California Spec.: REINSTALL HIGH-TENSION CORDS TO SPARK PLUGS 13. California Spec.: REINSTALL IGNITION COILS (WITH IGNITER) 14. REINSTALL PCV HOSES 15. REINSTALL INTAKE AIR CONNECTOR Page 3653 Page 2615 2. REMOVE PISTON SEAL FROM BRAKE CALIPER Using a screwdriver, remove the piston seal. 3. REMOVE SLIDING BUSHING AND BOOT Remove the sliding bushing and boot from the torque plate. HINT: At the time of installation, ensure that the sliding bushing and boot are secured firmly to the caliper grooves. INSPECTION 1. MEASURE PAD LINING THICKNESS Using a ruler, measure the pad lining thickness. Standard thickness: 12.0 mm (0.472 inch) Minimum thickness: 1.0 mm (0.039 inch) Replace the pad if the thickness is less than the minimum (the 1.0 mm slit is no longer visible), or if it shows signs of uneven wear. 2. MEASURE DISC THICKNESS Using a micrometer, measure the disc thickness. Standard thickness: 22.0 mm (0.866 inch) Minimum thickness: 20.0 mm (0.787 inch) If the disc is scored or worn, or if its thickness is less than the minimum, repair or replace the disc. 3. MEASURE DISC RUNOUT Using a dial indicator, measure the disc runout at a position 10 mm (0.39 inch) from the outside edge. Page 3629 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.