Page 1019
Ambient Light Sensor: Diagrams
Page 7830
Ambient Temperature Sensor / Switch HVAC: Locations Air Conditioning System (for Manual Air
Conditioning System)
AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Manual Air Conditioning System):
PARTS LOCATION
Page 464
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
4. REMOVE UPPER CONSOLE REAR PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
5. REMOVE REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
6. REMOVE CONSOLE BOX CARPET
7. REMOVE REAR CONSOLE BOX ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal
8. REMOVE FRONT CONSOLE BOX See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal
and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal
9. REMOVE CENTER AIRBAG SENSOR ASSEMBLY
(a) Disconnect the holder (with connectors).
(b) Remove the 3 bolts and airbag sensor.
Installation
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift
Type): INSTALLATION
1. INSTALL CENTER AIRBAG SENSOR ASSEMBLY
(a) Check that the ignition switch is OFF.
(b) Check that the cable is disconnected from the battery negative (-) terminal.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
(c) Install the airbag sensor with the 3 bolts.
Torque : 18 Nm (184 kgf-cm, 13 ft-lbf)
NOTICE: *
If the center airbag sensor has been dropped, or there are any cracks, dents or other defects in the
case, bracket or connector, replace it with a new one.
* When installing the center airbag sensor, be careful that the SRS wiring does not interfere with
other parts and that it is not pinched between other parts.
(d) Check that there is no looseness in the installation parts of the center airbag sensor.
Page 5191
(b) Remove the O-ring.
14. REMOVE REAR AXLE SHAFT OIL SEAL
(a) Using SST, tap out the oil seal.
SST : 09308-00010
NOTICE: Be careful not to damage the axle housing hole.
Installation
AXLE: REAR AXLE SHAFT: INSTALLATION
1. INSTALL REAR AXLE SHAFT OIL SEAL
(a) Using SST and a hammer, tap in a new oil seal.
SST : 09950-60020
09951-00770
SST : 09950-70010
09951-07150
(b) Apply MP grease to the lip of the oil seal.
NOTICE: Do not allow foreign matter, etc. to contact the axle shaft housing hole.
2. INSTALL REAR AXLE SHAFT
(a) Apply MP grease to a new O-ring.
Page 9371
shake is a normal and unavoidable condition in certain situations with this type of vehicle. Please
use the chart below to show customers the comparison to competitors. Also, show the vehicle
driver that reducing speed by as little as 5 mph has a considerable positive effect in reducing body
vibration.
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for
36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Parts Information
Repair Procedure
1. Test drive the vehicle and confirm the condition.
Repeat remaining steps for both No.3 cab mounts.
2. Loosen the No.2 cab mount nuts (at front of cab) down to the last thread on the long bolt. This is
necessary to allow the cab to be raised to remove
the No.3 mount.
Page 3151
Spark Plug: Service and Repair Installation
1UR-FE IGNITION: IGNITION COIL AND SPARK PLUG: INSTALLATION
1. INSTALL SPARK PLUG
(a) Using a 16 mm plug wrench, install the 8 spark plugs.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
2. INSTALL IGNITION COIL ASSEMBLY
(a) for Bank 1:
(1) Install the 4 ignition coils with the 4 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(2) Connect the 4 ignition coil connectors.
(3) Connect the 3 wire harness clamps.
(b) for Bank 2:
(1) Install the 4 ignition coils with the 4 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(2) Connect the 4 ignition coil connectors and 2 wire harness clamps.
(3) Connect the water by-pass pipe with the 2 bolts.
Torque : 18 Nm (184 kgf-cm, 13 ft-lbf)
Page 8760
Remote Switch: Locations Navigation System (w/ USB Audio System)
NAVIGATION: NAVIGATION SYSTEM (w/ USB Audio System): PARTS LOCATION
Page 5139
(b) for Rear Differential:
(1) Install a new gasket and the filler plug.
Torque : 49 Nm (500 kgf-cm, 36 ft-lbf)
(c) for Front Differential:
(1) Using a 10 mm hexagon wrench, install a new gasket and the filler plug.
Torque : 39 Nm (398 kgf-cm, 29 ft-lbf)
Page 4093
(c) Temporarily install the EGR valve assembly to the intake manifold with the 2 bolts and 4 nuts.
NOTICE: Be careful not to damage the intake manifold when installing the EGR valve assembly.
(d) Using several steps, uniformly tighten the 2 bolts and 4 nuts in the sequence shown in the
illustration.
for bolt - Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
for nut - Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
5. CONNECT NO. 13 WATER BY-PASS HOSE
(a) Connect the No. 13 water by-pass hose.
HINT The direction of the hose clamp is indicated in the illustration.
6. CONNECT NO. 12 WATER BY-PASS HOSE
(a) Connect the No. 12 water by-pass hose.
HINT The direction of the hose clamp is indicated in the illustration.
7. INSTALL AIR CLEANER HOSE ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Installation
8. ADD ENGINE COOLANT See: Engine, Cooling and Exhaust/Cooling System/Coolant/Service
and Repair
9. INSPECT FOR ENGINE COOLANT LEAK See: Engine, Cooling and Exhaust/Cooling
System/Testing and Inspection
10. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and
Exhaust/Engine/Service and Repair/Removal and
Replacement/Engine Assembly/Installation
Page 6362
If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness
or connector in that circuit in the past. Check the wire harness and connectors.
B -- SYSTEM NORMAL
A -- TROUBLESHOOTING OF EACH PROBLEM SYMPTOM
The problem is still occurring in a place other than the diagnostic circuit (the DTC displayed first is
either for a past problem or a secondary problem).
4. SYMPTOM SIMULATION
HINT The most difficult case in troubleshooting is when no problem symptoms occur. In such a
case, a thorough problem analysis must be carried out. A simulation of the same or similar
conditions and environment in which the problem occurred in the customer's vehicle should be
carried out. No matter how much skill or experience a technician has, troubleshooting without
confirming the problem symptoms will lead to important repairs being overlooked and mistakes or
delays.
For example:
With a problem that only occurs when the engine is cold or as a result of vibration caused by the
road during driving, the problem can never be determined if the symptoms are being checked on a
stationary vehicle or on a vehicle with a warmed-up engine. Vibration, heat or water penetration
(moisture) is difficult to reproduce. The symptom simulation tests below are effective substitutes for
the conditions and can be applied on a stationary vehicle.
Important points in the symptom simulation test:
In the symptom simulation test, the problem symptoms as well as the problem area or parts must
be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then,
connect the tester and carry out the symptom simulation test, judging whether the circuit being
tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the
problem symptoms table for each system to narrow down the possible causes.
To reproduce DTCs, it is necessary to satisfy the respective DTC detection conditions.
(a) VIBRATION METHOD:
When a malfunction seems to occur as a result of vibration.
(1) PART AND SENSOR
Apply slight vibration with a finger to the part of the sensor suspected to be the cause of the
problem, and check whether or not the malfunction occurs.
NOTICE: Applying strong vibration to relays may open them.
Page 840
(e) Attach the 3 clips (labeled F).
NOTICE: *
When installing the clips, do not twist the wire harness.
* When installing the clips, securely insert them as shown in the illustration.
(f) Connect the speed sensor connector (labeled G).
NOTICE: Securely connect the connector.
7. INSTALL FRONT WHEEL See: Steering and Suspension/Suspension/Suspension Strut / Shock
Absorber/Service and Repair/Removal and
Replacement/Front Shock Absorber/Installation
8. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
9. CHECK SPEED SENSOR SIGNAL
(a) Check the speed sensor signal See: Brakes and Traction Control/Antilock Brakes / Traction
Control Systems/Testing and Inspection/Scan
Tool Testing and Procedures/Test Mode Procedure.
Page 6718
Push the secondary locking device or terminal retainer in to the full lock position.
CONNECT CONNECTOR
Voltage Check
VOLTAGE CHECK
Page 2952
Manifold Pressure/Vacuum Sensor: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: MANIFOLD ABSOLUTE PRESSURE SENSOR:
INSTALLATION
1. INSTALL MANIFOLD ABSOLUTE PRESSURE SENSOR
(a) Install a new O-ring to the manifold absolute pressure sensor.
(b) Install the manifold absolute pressure sensor with the screw.
Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)
(c) Connect the manifold absolute pressure sensor connector.
2. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Installation
Page 5368
Standard voltage:
(3) If the voltage is not as specified, replace the 4WD control ECU See: Relays and Modules Transmission and Drivetrain/Relays and
Modules - Transfer Case/Control Module/Service and Repair/Removal. If the voltage is normal,
replace the 4WD control switch.
Components
Seat Heater Switch: Service and Repair Components
SEAT: SEAT HEATER SWITCH (w/ Seat Heater System or Climate Control Seat System):
COMPONENTS
Page 4749
4. Attach the Authorized Vehicle Modification Label.
Modifications to ECU calibrations MUST be recorded and properly displayed on the vehicle using
the Authorized Modification Label.
Techstream Preparation
Selecting the TIS Techstream VIM or the Mongoose MFC VIM.
Techstream software requires a VIM selection before you can use the Mongoose MFC VIM.
If using TIS Techstream no changes are needed.
Perform the following:
1. Select Setup from the Techstream Main Menu screen.
2. Select VIM Select from the Setup drop down menu.
3. Select the correct Interface Setup from the drop down list.
^ If using Techstream Lite select Mongoose MFC.
NOTE
Page 6022
(b) Using SST and a hammer, tap out the bearing.
SST : 09950-60010
09951-00250
SST : 09950-70010
09951-07100
Reassembly
1UR-FE CHARGING: GENERATOR: REASSEMBLY
1. REMOVE GENERATOR DRIVE END FRAME BEARING
(a) Using SST and a press, press in a new bearing.
SST : 09950-60010
09951-00470
SST : 09950-70010
09951-07100
(b) Install the retainer plate with the 4 screws.
Page 9040
Connectors Part 3
Locations
Throttle Position Sensor: Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 1014
Parking Brake Warning Switch: Service and Repair Reassembly
PARKING BRAKE: PARKING BRAKE PEDAL: REASSEMBLY
1. INSTALL PARKING BRAKE SWITCH ASSEMBLY
(a) Install the switch with the screw.
Torque : 0.9 Nm (9 kgf-cm, 8 in-lbf)
Page 2369
* Never reuse the O-ring.
* When placing a new O-ring on the injector, do not damage it.
* Coat a new O-ring with spindle oil or gasoline before installing it. Do not use engine oil, gear oil or
brake oil.
(c) Install the injector to the delivery pipe and intake manifold as shown in the illustration.
NOTICE: Before installing the injector, apply spindle oil or gasoline on the place where the delivery
pipe contacts the O-ring of the injector.
(d) Observe these precautions when disconnecting the fuel tube connector (for Quick Type).
(1) for Fuel Hose Connector Cover Type:
Detach the lock claw by lifting up the cover, as shown in the illustration.
(2) for Fuel Pipe Clamp Type:
Remove the fuel pipe clamp from the fuel tube connector.
Page 6601
when inserting and after full engagement.
NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal.
(d) REPAIR METHOD OF CONNECTOR TERMINAL
(1) If there is any foreign matter on the terminal, clean the contact point using an air gun or cloth.
Never rub the contact point using sandpaper
as the plating may come off.
(2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is
gold-plated (gold color), use a gold-plated female
terminal; if it is silver-plated (silver color), use a silver-plated female terminal.
(3) Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock
into the housing, the housing may have to be
replaced.
(e) HANDLING OF WIRE HARNESS
(1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be
restored in the same way.
(2) Never twist, pull or slacken the wire harness more than necessary.
(3) The wire harness should never come into contact with a high temperature part, or rotating,
moving, vibrating or sharp-edged parts. Avoid
contact with panel edges, screw tips and other sharp items.
(4) When installing parts, never pinch the wire harness.
(5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with
vinyl tape.
2. CHECK FOR OPEN CIRCUIT
Page 5063
Standard:
2. INSTALL FRONT DIFFERENTIAL SIDE GEAR SHAFT RH BEARING
(a) Using SST and a press, press in the bearing.
SST : 09223-00010
(b) Using a snap ring expander, install a new snap ring.
3. INSTALL DIFFERENTIAL SIDE GEAR SHAFT SUB-ASSEMBLY RH
(a) Install the side gear shaft into the differential tube.
Page 8776
Page 5366
Four Wheel Drive Selector Switch: Testing and Inspection
JF1A TRANSFER: 4WD CONTROL SWITCH: ON-VEHICLE INSPECTION
1. INSPECT 4WD CONTROL SWITCH
(a) Check the harness and connector (ECU - battery and body ground).
(1) Measure the voltage and resistance according to the value(s) in the table below.
Standard voltage:
(2) If there is a malfunction, inspect the harness or connector. If the harness is malfunctioning,
repair or replace harness or connector. If the
harness or connector is normal, replace the 4WD control ECU See: Relays and Modules Transmission and Drivetrain/Relays and Modules - Transfer Case/Control Module/Service and
Repair/Removal.
Standard resistance:
(3) If there is a malfunction, repair or replace the harness or connector.
(b) Check the harness and connector (switch - ECU).
(1) Disconnect the A25 ECU connector.
(2) Disconnect the L1 switch connector.
(3) Measure the resistance according to the value(s) in the table below.
Page 6737
Driver Side J/B - Cowl Side Left
Page 3438
OK -- REPLACE BUS BUFFER ECU
25. CHECK FOR SHORT IN CAN BUS WIRES (4WD CONTROL ECU)
(a) Disconnect the A25 4WD control ECU connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO 4WD CONTROL ECU
(CANH, CANL)
OK -- REPLACE 4WD CONTROL ECU
26. CHECK FOR SHORT IN CAN BUS WIRES (ECM)
(a) Disconnect the A24 ECM connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
Result
E -- REPAIR OR REPLACE CAN MAIN WIRE CONNECTED TO ECM (CANH, CANL)
D -- REPLACE ECM See: Engine Control Module/Service and Repair/Removal
C -- REPLACE ECM See: Engine Control Module/Service and Repair/Removal
Components
Engine Temperature Sensor: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: ENGINE COOLANT TEMPERATURE SENSOR:
COMPONENTS
Page 4839
NOTICE: The ATF temperature can be confirmed by using the Techstream.
(a) Turn the ignition switch off.
(b) Connect the Techstream to the DLC3.
(c) Turn the ignition switch to ON.
(d) Enter the following menus: Powertrain / ECT / Data List / A/T Oil Temperature 1.
(e) Check the ATF temperature.
NOTICE: If the ATF temperature is higher than 59°C (138°F), turn the ignition switch off and wait
until the fluid temperature drops to between 53 and 59°C (127 and 138°F).
5. FLUID LEVEL CHECK
NOTICE: *
It is necessary to change to temperature detection mode in order to idle the vehicle appropriately.
* The ATF temperature must be between 53 and 59°C (127 and 138°F) to accurately check the
fluid level.
(a) When using the Techstream:
Enter the following menus: Powertrain / ECT / Active Test / Connect the TC and TE1.
Standard condition:
Indicator lights in the combination meter blink.
(b) When not using the Techstream:
Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3.
SST : 09843-18040
Standard condition:
Indicator lights in the combination meter blink.
(c) Start the engine and idle it.
NOTICE: Check that electrical systems such as the air conditioning system, audio system and
lighting system are off.
(d) Slowly move the shift lever from P to S, and then change the gear from 1st to 5th. Then return
the shift lever to P.
HINT Slowly move the shift lever to circulate the fluid through each part of the transmission.
(e) Move the shift lever to D, and quickly move it back and forth between N and D (once within 1.5
seconds) for at least 6 seconds. This will
activate the fluid temperature detection mode.
Page 203
(2) CONNECTORS
Slightly shake the connector vertically and horizontally.
(3) WIRE HARNESS
Slightly shake the wire harness vertically and horizontally.
HINT The connector joint and fulcrum of the vibration are the major areas that should be checked
thoroughly.
(b) HEAT METHOD:
When a malfunction seems to occur when the area in question is heated.
(1) Heat the component that is the possible cause of the malfunction with a hair dryer or similar
device. Check if the malfunction occurs.
NOTICE: *
Do not heat to more than 60°C (140°F). Exceeding this temperature may damage components.
* Do not apply heat directly to the parts in the ECU.
(c) WATER SPRINKLING METHOD:
When a malfunction seems to occur on a rainy day or in high-humidity.
(1) Sprinkle water onto the vehicle and check if the malfunction occurs.
NOTICE: *
Never sprinkle water directly into the engine compartment. Indirectly change the temperature and
humidity by spraying water onto the front of the radiator.
* Never apply water directly onto the electronic components.
HINT If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU
or connections. Look for evidence of corrosion or short circuits. Proceed with caution during water
tests.
(d) HIGH ELECTRICAL LOAD METHOD:
When a malfunction seems to occur when the electrical load is excessive.
(1) Turn on the heater blower, headlights, rear window defogger and all other electrical loads.
Check if the malfunction reoccurs.
5. DIAGNOSTIC TROUBLE CODE CHART
Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate
section's Diagnostic Trouble Code Chart. Use the chart to determine the trouble area and the
proper inspection procedure. A description of each of the chart's columns is below.
Page 1458
Seat Position Sensor: Service and Repair Installation
SUPPLEMENTAL RESTRAINT SYSTEM: SEAT POSITION SENSOR: INSTALLATION
1. INSTALL SEAT POSITION SENSOR
(a) Check that the ignition switch is OFF.
(b) Check that the cable is disconnected from the battery negative (-) terminal.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
NOTICE: Some systems need to be initialized after the cable is reconnected See: Testing and
Inspection/Programming and Relearning
(c) Using a feeler gauge 1.0 mm (0.0393 in.), install the seat position sensor.
NOTICE: *
If the seat position sensor has been dropped, or there are any cracks, dents or other defects in the
case or connector, replace the seat position sensor with a new one.
* When installing the seat position sensor, be careful that the SRS wiring does not interfere with
other parts and that it is not pinched between other parts.
HINT Be sure that the clearance between the seat position sensor and the seat rail is within 0.6 to
1.4 mm (0.0236 to 0.0551 in.).
(d) Using a T30 "TORX" socket wrench, install the seat position sensor with the screw.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
(e) Make sure that the clearance between the seat position sensor and the seat rail is within 0.6 to
1.4 mm (0.0236 to 0.0551 in.).
(f) Check that there is no looseness in the installation parts of the seat position sensor.
(g) Connect the connector.
(h) Install the seat slide position sensor protector to the seat position sensor.
Locations
Alarm Horn Relay: Locations
THEFT DETERRENT: THEFT DETERRENT SYSTEM: PARTS LOCATION
Page 564
Power Window Relay: Locations Power Window Control System (w/o Jam Protection Function)
WINDSHIELD / WINDOWGLASS: POWER WINDOW CONTROL SYSTEM (w/o Jam Protection
Function): PARTS LOCATION
Page 3099
Page 7871
(1) Insert the pin into the plate groove.
(2) Attach the claw to install the main plate.
(3) Install the 2 screws.
(c) Set the damper servo so that the cutout part engages with the tooth of the gear, and attach the
claw to install the damper servo.
(d) Install the 4 screws and connect the 2 connectors.
9. INSTALL AIR DUCT
(a) Install the duct with the 2 screws.
10. INSTALL BLOWER WITH FAN MOTOR SUB-ASSEMBLY
Removal and Replacement
Oil Cooler: Removal and Replacement
Components
1UR-FE LUBRICATION: ENGINE OIL COOLER: COMPONENTS
Testing and Inspection
Positive Crankcase Ventilation Valve: Testing and Inspection
1UR-FE EMISSION CONTROL: PCV VALVE: INSPECTION
1. INSPECT PCV VALVE SUB-ASSEMBLY
(a) Install a clean hose to the PCV valve.
(b) Check the PCV valve operation.
(1) Blow air into the cylinder head side, and check that air passes through easily.
CAUTION: Do not suck air through the valve.
Petroleum substances inside the valve are hazardous to your health.
(2) Blow air into the intake manifold side, and check that air passes through with difficulty.
If the result is not as specified, replace the PCV valve sub-assembly.
(c) Remove the clean hose from the PCV valve.
Page 4818
Transfer Case Actuator: Locations JF1A Transfer Case
JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION
Page 3379
(a) For an open circuit in the wire harness in Fig. 1, check the resistance or voltage, as described
below.
(b) Check the resistance.
(1) Disconnect connectors A and C and measure the resistance between them.
Standard resistance (Fig. 2):
HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally.
If the results match the examples above, an open circuit exists between terminal 1 of connector A
and terminal 1 of connector C.
(2) Disconnect connector B and measure the resistance between the connectors.
Standard resistance (Fig. 3):
* If the results match the examples above, an open circuit exists between terminal 1 of connector
B2 and terminal 1 of connector C.
(c) Check the voltage.
Page 608
3. INSTALL NO. 2 ULTRASONIC SENSOR RETAINER
(a) Align the keyhole and protrusion as shown in the illustration.
(b) Install the sensor retainer to the rear bumper.
NOTICE: Do not damage the bumper with the protrusion when installing the retainer.
4. INSTALL NO. 2 ULTRASONIC SENSOR
(a) Attach the 2 claws to install the ultrasonic sensor.
5. INSTALL REAR BUMPER BAR (for Steel Type Bumper) See: Body and Frame/Bumper/Front
Bumper/Service and Repair/Removal and
Replacement/Front Bumper (for Steel Type Bumper)/Installation
6. INSTALL REAR BUMPER COVER (for Resin Type Bumper) See: Body and
Frame/Bumper/Rear Bumper/Service and Repair/Removal and
Page 6428
Power Distribution Relay: Testing and Inspection ACC Relay
1UR-FE STARTING: ACC RELAY: ON-VEHICLE INSPECTION
1. INSPECT MAIN BODY ECU (ACC RELAY)
(a) Measure the resistance of the ACC relay circuit.
(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(2) If the result is not as specified, replace the main body ECU.
Page 1294
Crankshaft Position Sensor: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: CRANKSHAFT POSITION SENSOR: REMOVAL
1. REMOVE CRANKSHAFT POSITION SENSOR PROTECTOR
(a) Remove the 2 bolts and sensor protector.
2. REMOVE CRANKSHAFT POSITION SENSOR
(a) Disconnect the sensor connector.
(b) Remove the bolt and sensor.
Locations
Parking Assist Distance Sensor: Locations
PARK ASSIST / MONITORING: INTUITIVE PARKING ASSIST SYSTEM: PARTS LOCATION
Page 7117
Tire Pressure Monitor Receiver / Transponder: Service and Repair Installation
TIRE AND WHEEL: TIRE PRESSURE WARNING RECEIVER: INSTALLATION
1. INSTALL TIRE PRESSURE WARNING ANTENNA AND RECEIVER
(a) Install the receiver with the bolt.
Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
(b) Connect the receiver connector.
2. INSTALL ROOF HEADLINING ASSEMBLY
(a) for Regular Cab:
Install the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Installation.
(b) for Double Cab:
Install the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Double Cab)/Installation.
(c) for CrewMax:
Install the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (for CrewMax)/Installation.
Page 7820
Remove the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Floor Shift Type)/Removal.
6. REMOVE LOWER INSTRUMENT PANEL
(a) for Column Shift Type:
Remove the lower instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Column Shift Type)/Removal.
(b) for Floor Shift Type:
Remove the lower instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Floor Shift Type)/Removal.
7. REMOVE LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY
(a) for Column Shift Type:
Remove the No. 2 instrument panel airbag assembly See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument
Panel Safety Pad (for Column Shift Type)/Removal.
(b) for Floor Shift Type:
Remove the No. 2 instrument panel airbag assembly See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument
Panel Safety Pad (for Floor Shift Type)/Removal.
8. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH
(a) for Column Shift Type:
Remove the instrument panel finish panel See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument
Panel Safety Pad (for Column Shift Type)/Removal.
(b) for Floor Shift Type:
Remove the instrument panel finish panel See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument
Panel Safety Pad (for Floor Shift Type)/Removal.
9. REMOVE NO. 2 AIR DUCT SUB-ASSEMBLY
(a) Remove the screw and duct.
10. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY
Components
Variable Valve Timing Actuator: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT OIL CONTROL VALVE: COMPONENTS
Page 4559
Camshaft Position Sensor: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT POSITION SENSOR: REMOVAL
1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Removal
2. REMOVE CAMSHAFT POSITION SENSOR
(a) Disconnect the sensor connector.
(b) Remove the bolt and sensor.
Diagrams
Ignition Coil: Diagrams
Page 4758
Then click Start.
I. Do NOT disturb the vehicle during flash reprogramming.
NOTE
^ ECU flash reprogramming may take anywhere from 3 - 30 minutes per calibration file.
^ Reprogramming time will vary depending on model and ECU communication protocol. Vehicles
using CAN communication protocol will reprogram much faster (2 - 7 minutes).
NOTE
^ If vehicle requires only ONE calibration update, then proceed to step N in this bulletin.
^ If vehicle requires a SECOND calibration update, then continue as follows:
^ For serial communication vehicles, go to step J.
^ For CAN communication vehicles, go to step L.
Diagram Information and Instructions
Ignition Switch: Diagram Information and Instructions
Wiring Color Codes
Abbreviations Used Within Diagrams
Abbreviations Used Within Diagrams
Page 72
Cab)/Installation
7. INSTALL LUGGAGE COMPARTMENT SIDE COVER SUB-ASSEMBLY RH See: Body and
Frame/Seats/Service and Repair/Removal and
Replacement/Rear Seat Assembly (for Double Cab)/Installation
8. INSTALL LUGGAGE COMPARTMENT SIDE COVER SUB-ASSEMBLY LH See: Body and
Frame/Seats/Service and Repair/Removal and
Replacement/Rear Seat Assembly (for Double Cab)/Installation
Page 7108
Tire Pressure Module: Service and Repair Installation
TIRE AND WHEEL: TIRE PRESSURE WARNING ECU: INSTALLATION
1. INSTALL TIRE PRESSURE WARNING ECU
(a) Install the ECU with the 2 nuts.
Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
(b) Connect the ECU connector.
2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Installation
3. INSTALL INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
4. INSTALL COWL SIDE TRIM BOARD RH
(a) Install the cowl side trim board RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Installation.
HINT Use the same procedures described for the LH side.
5. INSTALL FRONT DOOR SCUFF PLATE RH (for Double Cab, for CrewMax)
(a) Install the front door scuff plate RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Installation.
HINT Use the same procedures described for the LH side.
6. INSTALL FRONT DOOR SCUFF PLATE RH (for Regular Cab)
(a) Install the front door scuff plate RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Installation.
HINT Use the same procedures described for the LH side.
7. REGISTRATION OF TRANSMITTER ID
(a) Register the transmitter ID See: Wheels and Tires/Tire Monitoring System/Testing and
Inspection/Programming and Relearning/Registration
.
8. PERFORM INITIALIZATION
(a) Perform initialization See: Wheels and Tires/Tire Monitoring System/Testing and
Inspection/Programming and Relearning/Initialization.
NOTICE: Be sure to inflate all tires to the proper inflation pressure before initialization.
Page 7670
Torque : 18 Nm (184 kgf-cm, 13 ft-lbf)
NOTICE: Make sure that there is no foreign matter or oil on the compressor shaft, bolt, and clutch
hub.
2. INSTALL COOLER BRACKET
(a) Install the cooler bracket with the screw.
(b) Attach the clamp.
3. INSPECT MAGNET CLUTCH CLEARANCE
(a) Clamp the cooler compressor in a vise.
(b) Set the dial indicator to the magnet clutch hub.
(c) Connect the battery positive lead to terminal 3 of the magnet clutch connector and the negative
lead to the ground wire. Turn the magnet clutch
on and off and measure the clearance.
Standard clearance:
0.35 to 0.60 mm (0.014 to 0.024 in.)
(d) If the measured value is not within the standard clearance, remove the magnet clutch hub and
adjust the clearance using compressor washers to
obtain the standard clearance.
Page 2694
(a) Remove the 3 bolts and water inlet housing.
(b) Remove the gasket from the water pump.
10. REMOVE WATER PUMP PULLEY
(a) Using SST, hold the water pump pulley.
SST : 09960-10010
09962-01000
09963-01000
(b) Remove the 4 bolts and water pump pulley.
11. REMOVE WATER PUMP ASSEMBLY
(a) Remove the 8 bolts, water pump and gasket.
Page 191
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: ELECTRONIC
CIRCUIT INSPECTION PROCEDURE
1. BASIC INSPECTION
(a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS
(1) Unless otherwise stated, all resistance measurements should be made at an ambient
temperature of 20°C (68°F). Resistance measurements
may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been
running. Measurements should be made after the engine has cooled down.
(b) HANDLING CONNECTORS
(1) When disconnecting a connector, first squeeze the mating halves tightly together to release the
lock, and then press the lock claw and
separate the connector.
(2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly
and separate it.
(3) Before connecting a connector, check that there are no deformed, damaged, loose or missing
terminals.
(4) When connecting a connector, press firmly until it locks with a "click" sound.
(5) If checking a connector with a TOYOTA electrical tester, check the connector from the backside
(harness side) using a mini test lead.
NOTICE: *
As a waterproof connector cannot be checked from the backside, check it by connecting a
sub-harness.
* Do not damage the terminals by moving the inserted tester needle.
(c) CHECKING CONNECTORS
(1) Checking when a connector is connected: Squeeze the connectors together to confirm that they
are fully connected and locked.
(2) Checking when a connector is disconnected: Check by pulling the wire harness lightly from the
backside of the connector. Look for
unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for
corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or
deformed terminals.
(3) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a
female terminal, and check for ample tension
Page 3228
"Case2" Open the secondary locking device.
[B] For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray
Gray or White : Black
Page 2795
4. Attach the Authorized Vehicle Modification Label.
Modifications to ECU calibrations MUST be recorded and properly displayed on the vehicle using
the Authorized Modification Label.
Techstream Preparation
Selecting the TIS Techstream VIM or the Mongoose MFC VIM.
Techstream software requires a VIM selection before you can use the Mongoose MFC VIM.
If using TIS Techstream no changes are needed.
Perform the following:
1. Select Setup from the Techstream Main Menu screen.
2. Select VIM Select from the Setup drop down menu.
3. Select the correct Interface Setup from the drop down list.
^ If using Techstream Lite select Mongoose MFC.
NOTE
Page 5953
"Case2" Open the secondary locking device.
[B] For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray
Gray or White : Black
Page 6486
* In the DTC check, it is very important to determine whether the problem indicated by the DTC is
either: 1) still occurring; or 2) occurred in the past but has since returned to normal. In addition, the
DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs
should be checked before and after confirmation of symptoms (i.e., whether or not problem
symptoms exist) to determine current system conditions, as shown in the flowchart below.
* Never skip the DTC check. Failing to check DTCs may, depending on the case, result in
unnecessary troubleshooting for systems operating normally or lead to repairs not related to the
problem. Follow the procedures listed in the flowchart in the correct order.
* The following flowchart shows how to proceed with troubleshooting using the DTC check.
Directions from the flowchart will indicate how to proceed either to DTC troubleshooting or to the
troubleshooting of each problem symptom.
1. DTC CHECK
NEXT -- Continue to next step.
2. MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR MEMORY
NEXT -- Continue to next step.
3. SYMPTOM CONFIRMATION
B -- Go to step 5 A -- Continue to next step.
4. SIMULATION TEST USING SYMPTOM SIMULATION METHODS
NEXT -- Continue to next step.
5. DTC CHECK
B -- TROUBLESHOOTING OF PROBLEM INDICATED BY DTC A -- Continue to next step.
6. SYMPTOM CONFIRMATION
Page 2214
Tire Pressure Warning Reset Switch: Testing and Inspection
TIRE AND WHEEL: TIRE PRESSURE WARNING RESET SWITCH: INSPECTION
1. CHECK TIRE PRESSURE WARNING RESET SWITCH
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the switch.
Regular Cab
Fuel Pump Control Unit: Locations Regular Cab
Body
Page 7760
NOTICE: *
Do not use a screwdriver or similar tool to disconnect the tube.
* Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign
matter from entering them.
(d) Remove the 2 O-rings from the suction pipe sub-assembly and liquid tube.
6. DISCONNECT INLET HEATER WATER HOSE AND OUTLET HEATER WATER HOSE
(a) Using pliers, grip the claws of the clip and slide the clip.
(b) Disconnect the 2 heater water hoses.
7. REMOVE FRONT WIPER MOTOR AND BRACKET
(a) Remove the front wiper motor and bracket See: Wiper and Washer Systems/Wiper
Motor/Service and Repair/Removal.
8. REMOVE STEERING COLUMN ASSEMBLY
(a) Remove the steering column See: Steering and Suspension/Steering/Steering Column/Service
and Repair/Removal and
Replacement/Steering Column Assembly (for Manual Tilt)/Removal.
9. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY
(a) for Column Shift Type:
Remove the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Column Shift Type)/Removal.
(b) for Floor Shift Type:
Remove the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Floor Shift Type)/Removal.
10. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY
(a) Disconnect the clamps, connectors and wire harness.
(b) Remove the 8 bolts, 2 screws and 4 nuts.
Page 9063
Push the secondary locking device or terminal retainer in to the full lock position.
CONNECT CONNECTOR
Voltage Check
VOLTAGE CHECK
Components
Auxiliary Power Outlet Switch: Service and Repair Components
OTHER SYSTEM: INVERTER MAIN SWITCH (for CrewMax): COMPONENTS
Page 3471
HINT *
o: DTC is memorized.
* *1: Only during failure status.
Page 3694
J. When Cal 1 has completed the update process turn ignition OFF for a minimum of 10 seconds.
Then click Next.
K. Turn ignition to the ON position. Then click Start.
L. Do NOT disturb the vehicle during flash reprogramming.
Page 3319
(e) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR OK -- Continue to next step.
6. INSPECT IGNITION SWITCH See: Testing and Inspection/Diagnostic Trouble Code Tests and
Associated Procedures/P Code
Charts/P0617
NG -- REPLACE IGNITION SWITCH See: Ignition System/Sensors and Switches - Ignition
System/Ignition Switch/Service and Repair/Removal OK -- Continue to next step.
7. CHECK HARNESS AND CONNECTOR (INTEGRATION RELAY - ECM, BATTERY AND BODY
GROUND)
(a) Disconnect the ECM connector.
(b) Disconnect the cable from the battery positive terminal.
(c) Remove the integration relay from the engine room relay block.
(d) Disconnect the integration relay connectors.
Page 4194
Page 9007
Use a volt/ohmmeter with high impedance (10 kohms/V minimum) for troubleshooting of the
electrical circuit.
Disconnection of Male and Female Connectors
DISCONNECTION OF MALE AND FEMALE CONNECTORS
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Finding A Short Circuit
FINDING A SHORT CIRCUIT
Page 7956
Wire harness:
Stripped wire harness section 1.25 mm2 or more (0.00193 in.2 or more)
CAUTION: If the wire harness is too thin or an alternative object is used to tie down the steering
pad, it may be snapped by the shock when the airbag is deployed. Always use a wire harness for
vehicle use with an area of at least 1.25 mm2 (0.00193 in.2).
HINT To calculate the area of the stripped wire harness section:
Area = 3.14 x (Diameter)2 divided by 4
(1) Install the 2 bolts with washers into the 2 bolt holes on the steering pad.
Bolt:
L: 35.0 mm (1.38 in.)
M 6.0 mm (0.236 in.)
Pitch 1.0 mm (0.0394 in.)
NOTICE: *
Tighten the bolts by hand until they become difficult to turn.
* Do not tighten the bolts excessively.
(2) After connecting SST each other, connect them to the steering pad.
SST : 09082-00820
(3) Wind 3 wire harnesses at least 2 times each around the bolts installed on the left and right sides
of the steering pad.
Page 3072
DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector.
Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
Page 8461
Alarm Module: Service and Repair Removal
THEFT DETERRENT: THEFT WARNING ECU: REMOVAL
1. REMOVE FRONT DOOR SCUFF PLATE LH
(a) for Regular Cab:
Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular Cab)/Removal.
(b) for Double Cab:
Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Removal.
(c) for CrewMax:
Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for CrewMax)/Removal.
2. REMOVE COWL SIDE TRIM BOARD LH
(a) for Regular Cab:
Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular Cab)/Removal.
(b) for Double Cab:
Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Removal.
(c) for CrewMax:
Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for CrewMax)/Removal.
3. REMOVE INSTRUMENT SIDE PANEL LH
(a) for Column Shift Type:
Remove the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Column Shift Type)/Removal.
(b) for Floor Shift Type:
Remove the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Floor Shift Type)/Removal.
4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH
(a) for Column Shift Type:
Remove the instrument panel finish panel See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument
Panel Safety Pad (for Column Shift Type)/Removal.
(b) for Floor Shift Type:
Remove the instrument panel finish panel See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument
Panel Safety Pad (for Floor Shift Type)/Removal.
5. REMOVE GLASS BREAKAGE SENSOR ECU
Page 2317
(a) Align the No. 1 chain's orange mark plates with the camshaft timing gear's timing mark, and
attach the chain to the gear as shown in the
illustration.
(b) Align the No. 1 chain's orange mark plate with the crankshaft timing gear's timing mark, and
attach the chain to the gear as shown in the
illustration.
(c) Align the No. 2 chain's yellow mark plates with the timing marks of the camshaft timing gear and
camshaft timing exhaust gear, and attach the
No. 2 chain to the gears as shown in the illustration.
HINT The crankshaft timing gear and camshaft exhaust gear will be installed with the No. 1 and
No. 2 chains connected to the gears.
(d) Install the crankshaft timing sprocket to the crankshaft.
(e) Align and attach the knock pin of the No. 1 camshaft with the pin hole of the camshaft timing
gear.
(f) Using the hexagonal portion of the No. 2 camshaft, align and attach the knock pin of the No. 2
camshaft with the pin hole of the camshaft
timing exhaust gear.
(g) Remove the pin from the No. 2 chain tensioner.
5. INSTALL NO. 1 CHAIN VIBRATION DAMPER RH
(a) Install the vibration damper with the 2 bolts.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
6. INSTALL NO. 1 CHAIN TENSIONER SLIPPER RH
HINT If you cannot install the chain tensioner slipper due to the tension of the chain, use the
hexagonal portion of the camshaft to loosen the chain, and then install the chain tensioner slipper.
7. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY RH
Page 3722
Standard Voltage:
NG -- CHECK HARNESS AND CONNECTOR (RELAY BLOCK - ECM, IGNITION SWITCH,
BATTERY AND BODY GROUND)
OK -- REPLACE ECM See: Service and Repair/Removal
5. CHECK HARNESS AND CONNECTOR (RELAY BLOCK - ECM, IGNITION SWITCH, BATTERY
AND BODY GROUND)
(a) Disconnect the ECM connector.
(b) Disconnect the ignition switch connector.
(c) Disconnect the cable from the battery positive (+) terminal.
(d) Remove the AM2 fuse and integration relay.
Components
Ambient Light Sensor: Service and Repair Components
LIGHTING: AUTOMATIC LIGHT CONTROL SENSOR: COMPONENTS
Page 5785
Parking Brake Warning Switch: Locations From 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 6768
JJ1-JL1
Page 6417
Power Distribution Module: Diagrams Voltage Inverter
Locations
Gear Sensor/Switch: Locations
JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION
Page 9221
Front Door Panel: Service and Repair Front Door (for Regular Cab)
Components
ENGINE HOOD / DOOR: FRONT DOOR (for Regular Cab): COMPONENTS
Page 6172
Auxiliary Power Outlet: Electrical Diagrams
Power Outlet [120V]
Power Outlet [120V]
Page 2684
Page 6459
Locations
Hood Sensor/Switch (For Alarm): Locations
THEFT DETERRENT: THEFT DETERRENT SYSTEM: PARTS LOCATION
Components
Tire Pressure Warning Reset Switch: Service and Repair Components
TIRE AND WHEEL: TIRE PRESSURE WARNING RESET SWITCH: COMPONENTS
Page 4603
3. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE
HINT The diagnostic system in the TOYOTA TUNDRA has various functions.
* The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU
memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a
previous malfunction's DTC can be checked by a technician during troubleshooting.
* Another function is the Input Signal Check, which checks if the signals from various switches are
sent to the ECU correctly.
* By using these functions, the problem areas can be narrowed down and troubleshooting is more
effective. Diagnostic functions are incorporated in the following systems in the TOYOTA TUNDRA.
Page 6524
DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector.
Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
Page 8340
System.
(b) When the quarter panel of the vehicle or its area is damaged, check if there is any damage to
the rear airbag sensor. If there are any defects as
mentioned below, replace the side airbag sensor with a new one:
* Cracks, dents or chips on the sensor housing.
* Cracks or other damage to the connector.
* Peeling off of the label or damage to the serial number.
CAUTION: For removal and installation procedures of the side airbag sensor, be sure to follow the
correct procedure.
3. CHECK REAR AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS
DEPLOYED)
(a) Replace the side airbag sensor.
CAUTION: *
For removal and installation procedures of the side airbag sensor, be sure to follow the correct
procedure.
* If the airbags have deployed, replace the rear airbag sensor on the side in which the collision
occurred. Replace both if necessary.
Side Airbag Sensor (for Regular Cab)
SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Regular Cab):
ON-VEHICLE INSPECTION
1. CHECK SIDE AIRBAG SENSOR (VEHICLE NOT INVOLVED IN COLLISION)
(a) Perform a diagnostic system check See: Air Bag Systems/Testing and Inspection/Initial
Inspection and Diagnostic Overview/Diagnosis
System.
2. CHECK SIDE AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS
NOT DEPLOYED)
(a) Perform a diagnostic system check See: Air Bag Systems/Testing and Inspection/Initial
Inspection and Diagnostic Overview/Diagnosis
System.
(b) When the center pillar of the vehicle or its area is damaged, check if there is any damage to the
side airbag sensor. If there are any defects as
mentioned below, replace the side airbag sensor with a new one:
* Cracks, dents or chips on the sensor housing.
* Cracks or other damage to the connector.
* Peeling off of the label or damage to the serial number.
CAUTION: For removal and installation procedures of the side airbag sensor, be sure to follow the
correct procedure.
3. CHECK SIDE AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS
DEPLOYED)
(a) Replace the side airbag sensor.
CAUTION: *
For removal and installation procedures of the side airbag sensor, be sure to follow the correct
procedure.
* If the airbags have deployed, replace the side airbag sensor on the side in which the collision
occurred. Replace both if necessary.
Page 7652
NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do
not operate the ignition switch, any other switches, or the doors.
(a) If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the
harness and connector.
(b) Connect the cable of the Techstream to the DLC3, turn the ignition switch ON and attempt to
use the tester. If the display indicates that a
communication error has occurred, there is a problem either with the vehicle or with the tester.
HINT *
If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of
the original vehicle.
* If communication is still not possible when the tester is connected to another vehicle, the problem
may be in the tester itself. Consult the Service Department listed in the tester's instruction manual.
How To Proceed With Troubleshooting
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: HOW TO
PROCEED WITH TROUBLESHOOTING
1. OPERATION FLOW
HINT Perform troubleshooting in accordance with the procedures below. The following is an outline
of basic troubleshooting procedures. Confirm the troubleshooting procedures for the circuit you are
working on before beginning troubleshooting.
1. VEHICLE BROUGHT TO WORKSHOP
NEXT -- Continue to next step.
2. CUSTOMER PROBLEM ANALYSIS
(a) Ask the customer about the conditions and environment when the problem occurred.
NEXT -- Continue to next step.
3. INSPECT BATTERY VOLTAGE
Standard voltage:
11 to 14 V
If the voltage is below 11 V, recharge or replace the battery before proceeding.
NEXT -- Continue to next step.
Page 835
(d) Remove the 3 bolts (labeled E), 3 harness clamps (labeled F) and sensor wire.
4. REMOVE FRONT SPEED SENSOR LH
(a) Remove the hexagon socket head cap bolt (labeled A) and speed sensor (labeled B) from the
knuckle.
5. REMOVE FRONT SKID CONTROL SENSOR CLAMP LH
(a) Remove the bolt (labeled C) and skid control sensor clamp (labeled D) from the knuckle.
6. REMOVE FRONT SKID CONTROL SENSOR WIRE RH
(a) Disconnect the connector (labeled A) from the front speed sensor.
(b) Detach the 3 clips (labeled B) and remove the clamp bolt (labeled C).
Front Door Courtesy Switch
Door Switch: Service and Repair Front Door Courtesy Switch
Components
LIGHTING: FRONT DOOR COURTESY SWITCH: COMPONENTS
Recall 10V017000: Accelerator Pedal Sticking
Accelerator Pedal Position Sensor: All Technical Service Bulletins Recall 10V017000: Accelerator
Pedal Sticking
VEHICLE MAKE/MODEL: MODEL YEAR(S): Toyota/Avalon 2005-2010 Toyota/Camry 2007-2010
Toyota/Corolla 2009-2010 Toyota/Corolla Matrix 2009-2010 Toyota/Highlander 2010 Toyota/ RAV4
2009-2010 Toyota/Sequoia 2008-2010 Toyota/Tundra 2007-2010 MANUFACTURER: Toyota
Motor North America, Inc.
MFR'S REPORT DATE: January 21, 2010
NHTSA CAMPAIGN ID NUMBER: 10V017000
NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Accelerator Assembly:
Pedal/Linkage
POTENTIAL NUMBER OF UNITS AFFECTED: ?
SUMMARY: Toyota is recalling certain model year 2005-2010 Avalon, model year 2007-2010
Camry, model year 2009-2010 Corolla, Corolla Matrix, RAV4, model year 2010 Highlander, model
year 2008-2010 Sequoia, and model year 2007-2010 Tundra. due to the manner in which the
friction lever interacts with the sliding surface of the accelerator pedal inside the pedal sensor
assembly, the sliding surface of the lever may become smooth during vehicle operation. In this
condition, if condensation occurs on the surface, as may occur from heater operation (without A/C)
when the pedal assembly is cold, the friction when the accelerator pedal is operated may increase,
which may result in the accelerator pedal becoming harder to depress, slower to return, or, in the
worst case, mechanically stuck in a partially depressed position.
CONSEQUENCE: The accelerator pedal may become hard to depress, slow to return to idle, or, in
the worst case, mechanically stuck in a partially depressed position, increasing the risk of a crash.
REMEDY: Toyota has not yet provided a remedy plan or an owner notification schedule. Owners
may contact Toyota at 1-800-331-4331.
NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle
Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov.
Page 2464
(a) Place 2 new gaskets on the intake manifold.
(b) Place the intake manifold on the cylinder head.
(c) Install and uniformly tighten the 8 bolts and 2 nuts in several steps.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
(d) Connect the fuel tube to the fuel delivery pipe LH See: Powertrain Management/Fuel Delivery
and Air Induction/Service Precautions.
(e) Connect the fuel tube to the fuel delivery pipe RH See: Powertrain Management/Fuel Delivery
and Air Induction/Service Precautions.
(f) Attach the 4 clamps to the fuel tube as shown in the illustration.
(g) Attach the 3 wire harness clamps to the 3 wire harness brackets.
(h) Connect the wire harness to the wire harness bracket with the bolt.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
(i) Connect the vacuum hose.
Page 7532
Required Tools & Equipment
Repair Procedure Overview
^ Confirm noise is coming from the rear of the vehicle and changes with vehicle speed.
^ Install ChaSSiSEAR(TM) (or equivalent) and isolate the noise to the rear wheel bearing.
^ Remove the rear axle shaft assembly.
^ Install new rear wheel bearing brake caliper bracket and seals.
^ Reinstall rear axle shaft assembly and confirm the noise is no longer present.
Repair Procedure
1. Test drive the vehicle and confirm the customer complaint.
Does the noise increase and decrease with vehicle speed?
^ YES - Go to step 2.
^ NO - This TSB does NOT apply. Refer to the Repair Manual for further diagnosis.
Page 637
(a) Connect the connector.
(b) Attach the 4 clips to install the panel.
3. INSTALL CENTER LOWER INSTRUMENT PANEL FINISH PANEL See: Body and
Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
4. INSTALL REAR UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
5. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding
/ Trim/Dashboard / Instrument Panel/Service
and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
6. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation
7. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
8. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Floor Shift Type)/Installation
9. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation
10. INSTALL COWL SIDE TRIM BOARD LH
(a) for Regular Cab:
Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular Cab)/Installation.
(b) for Double Cab:
Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Installation.
(c) for CrewMax:
Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for CrewMax)/Installation.
Page 3497
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO POWER STEERING ECU
(CANH, CANL)
OK -- REPLACE POWER STEERING ECU See: Relays and Modules/Relays and Modules Steering and Suspension/Relays and Modules - Steering/Steering Control Module/Service and
Repair/Removal
18. CHECK FOR SHORT IN CAN BUS WIRES (CENTER AIRBAG SENSOR)
(a) Disconnect the J46 center airbag sensor connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO CENTER AIRBAG
SENSOR (CANH, CANL)
OK -- REPLACE CENTER AIRBAG SENSOR
19. CHECK FOR SHORT IN CAN BUS WIRES (NO. 2 JUNCTION CONNECTOR - AIR
CONDITIONING AMPLIFIER)
(a) Measure the resistance according to the value(s) in the table below.
Page 3071
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION: Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC
terminals are touched, the IC may be destroyed by static electricity.)
When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact with the terminals of leads from the IC, etc. of the
replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown on the left.
DISCONNECT CONNECTOR
Page 843
1. INSTALL SKID CONTROL SENSOR WIRE
(a) Install the sensor clamp with the nut (labeled A).
Torque : 13 Nm (127 kgf-cm, 9 ft-lbf)
NOTICE: Make sure the clamp's rotation stopper touches the installation position.
(b) Install the sensor clamp with the bolt (labeled B).
Torque : 13 Nm (127 kgf-cm, 9 ft-lbf)
NOTICE: When installing the clamp, do not twist the wire harness.
(c) Attach the 7 clips (labeled C).
NOTICE: *
When installing the clamps, do not twist the wire harness.
* When installing the clamps, securely insert them as shown in the illustration.
(d) Connect the sensor connector (labeled D).
NOTICE: Securely connect the connector.
2. INSTALL REAR SPEED SENSOR LH
(a) Install the speed sensor (labeled A) with the nut (labeled B).
Torque : 11 Nm (107 kgf-cm, 8 ft-lbf)
(b) Connect the speed sensor connector (labeled C).
NOTICE: Securely connect the connector.
3. INSTALL REAR SPEED SENSOR RH
(a) Install the speed sensor (labeled A) with the nut (labeled B).
Page 6320
PJ1-QK1
Front Speed Sensor
Wheel Speed Sensor: Service and Repair Front Speed Sensor
Components
BRAKE CONTROL: FRONT SPEED SENSOR: COMPONENTS
Removal
BRAKE CONTROL: FRONT SPEED SENSOR: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to disable the SRS system.
2. REMOVE FRONT WHEEL
3. REMOVE FRONT SKID CONTROL SENSOR WIRE LH
(a) Disconnect the connector (labeled A) from the front speed sensor.
(b) Detach the 3 clips (labeled B) and remove the clamp bolt (labeled C).
(c) Disconnect the connector (labeled D).
Page 6910
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION: Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC
terminals are touched, the IC may be destroyed by static electricity.)
When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact with the terminals of leads from the IC, etc. of the
replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown on the left.
DISCONNECT CONNECTOR
Page 5057
(b) If the drive gear or ring gear is damaged, replace them as a set.
16. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING
(a) Using a brass bar and hammer, tap out the bearing (outer race) and washer.
17. REMOVE FRONT DRIVE PINION FRONT RADIAL BALL BEARING
(a) Using SST and hummer, tap out the bearing (outer race).
SST : 09950-70010
09951-07100
SST : 09950-60010
09951-00450
SST : 09950-60020
09951-00710
09952-06010
18. REMOVE FRONT DIFFERENTIAL CASE BEARING
HINT *
Measure the plate washer and note its thickness.
* Tag the bearing outer races to show the location for reassembly.
(a) Using SST and a press, press out the bearing (outer race) and plate washer from the bearing
retainer.
Service and Repair
Fuel Pressure Release: Service and Repair
1UR-FE FUEL: FUEL SYSTEM: PRECAUTION
CAUTION: *
Before working on the fuel system, disconnect the cable from the negative (-) battery terminal.
* Do not smoke or be near an open flame when working on the fuel system.
* Keep gasoline away from rubber and leather parts.
1. DISCHARGE FUEL SYSTEM PRESSURE
CAUTION: *
Do not disconnect any part of the fuel system until you have discharged the fuel system pressure.
* After discharging the fuel pressure, place a cloth or equivalent over fittings as you separate them
to reduce the risk of fuel spray on yourself or in the engine compartment.
(a) Disconnect the cable from the negative (-) battery terminal.
(b) Disconnect the 2 fuel pump ECU connectors.
(c) Connect the cable to the negative (-) battery terminal.
(d) Start the engine. After the engine has stopped on its own, turn the ignition switch OFF.
HINT DTC P0171/0174 (system too lean) may be set.
(e) Crank the engine again, then check that the engine does not start.
(f) Loosen the fuel tank cap, then discharge the pressure in the fuel tank completely.
(g) Connect the 2 fuel pump ECU connectors.
2. FUEL SYSTEM
(a) When disconnecting the high fuel pressure line, a large amount of gasoline will spill out. Follow
these procedures.
(1) Perform the "DISCHARGE FUEL SYSTEM PRESSURE" procedures above.
(2) Put a container under the connecting part of the pressure line.
(3) Slowly loosen the connection.
(4) Disconnect the connection.
(5) Plug the connection with a rubber plug.
(b) Observe these precautions when removing and installing the injectors:
Page 6530
Release the locking lug from terminal and pull the terminal out from rear.
INSTALL TERMINAL TO CONNECTOR
Insert the terminal.
HINT: Make sure the terminal is positioned correctly.
Insert the terminal until the locking lug locks firmly.
Insert the terminal with terminal retainer in the temporary lock position.
Page 2460
9. REMOVE V-BANK COVER BRACKET
(a) Remove the 2 bolts and bracket.
10. REMOVE V-BANK COVER PIN
(a) Remove the pin from the intake manifold.
11. REMOVE STUD BOLT
(a) Using an E5 "TORX" socket wrench, remove the 2 stud bolts.
12. REMOVE VACUUM SWITCHING VALVE ASSEMBLY (for ACIS)
(a) Disconnect the 2 vacuum hoses from the vacuum switching valve.
(b) Remove the bolt and vacuum switching valve.
13. REMOVE PURGE VSV
(a) Disconnect the purge line hose from the intake manifold.
(b) Remove the bolt and purge VSV.
Page 1498
6. PROBLEM SYMPTOMS TABLE
When a "Normal" code is output during a DTC check but the problem is still occurring, use the
Problem Symptoms Table. The suspected areas (circuits or parts) for each problem symptom are
in the table. The suspected areas are listed in order of probability. A description of each of the
chart's columns is below.
HINT In some cases, the problem is not detected by the diagnostic system even though a problem
symptom is present. It is possible that the problem is occurring outside the detection range of the
diagnostic system, or that the problem is occurring in a completely different system.
7. CIRCUIT INSPECTION
A description of the main areas of each circuit inspection is below.
Front Door (for CrewMax)
Front Door Panel: Service and Repair Front Door (for CrewMax)
Components
ENGINE HOOD / DOOR: FRONT DOOR (for CrewMax): COMPONENTS
Page 3514
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO AIR CONDITIONING
AMPLIFIER (CANH, CANL)
OK -- REPLACE AIR CONDITIONING AMPLIFIER ASSEMBLY
24. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (BUS BUFFER ECU)
(a) Disconnect the J59 bus buffer ECU connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO BUS BUFFER ECU (CAN+,
CAN-)
OK -- REPLACE BUS BUFFER ECU
25. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (4WD CONTROL ECU)
(a) Disconnect the A25 4WD control ECU connector.
Page 390
Page 1878
Oil Filter: Service and Repair Replacement
1UR-FE LUBRICATION: OIL AND OIL FILTER: REPLACEMENT
CAUTION: *
Prolonged and repeated contact with engine oil will result in the removal of natural oils from the
skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially
harmful contaminants which may cause skin cancer.
* Precautions should be taken when replacing engine oil to minimize the risk of your skin making
contact with used engine oil. Protective clothing and gloves that cannot be penetrated by oil should
be worn. The skin should be washed with soap and water, or use waterless hand cleaner, to
remove any used engine oil thoroughly. Do not use gasoline, thinners, or solvents.
* In order to protect the environment, used oil and used oil filters must be disposed of at designated
disposal sites.
1. DRAIN ENGINE OIL
(a) Remove the oil filler cap.
(b) Remove the oil pan drain plug and gasket, and drain the engine oil into a container.
(c) Install a new gasket and the oil pan drain plug.
Torque : 40 Nm (408 kgf-cm, 30 ft-lbf)
2. REMOVE NO. 1 ENGINE UNDER COVER
(a) Remove the 3 screws and 5 bolts.
(b) Unhook the engine under cover from the vehicle body as shown in the illustration.
3. REMOVE OIL FILTER ELEMENT
(a) Connect a hose with an inside diameter of 15 mm (0.591 in.) to the pipe.
Page 2347
Variable Valve Timing Actuator: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT OIL CONTROL VALVE: INSTALLATION
1. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side of Bank 1)
(a) Apply a light coat of engine oil to the O-ring.
(b) Install a new O-ring to the oil control valve.
(c) Install the oil control valve with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(d) Connect the oil control valve connector.
2. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side of Bank 1)
(a) Apply a light coat of engine oil to the O-ring.
(b) Install a new O-ring to the oil control valve.
(c) Install the oil control valve with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(d) Connect the oil control valve connector.
3. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side of Bank 2)
(a) Apply a light coat of engine oil to the O-ring.
(b) Install a new O-ring to the oil control valve.
(c) Install the oil control valve with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(d) Connect the oil control valve connector.
4. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side of Bank 2)
Locations
Seat Belt Buckle Switch: Locations
SUPPLEMENTAL RESTRAINT SYSTEM: OCCUPANT CLASSIFICATION SYSTEM: PARTS
LOCATION
Page 3403
B -- GO TO CAN MAIN WIRE FOR DISCONNECTION See: Symptom Related Diagnostic
Procedures/CAN Communication System/Open In CAN Main Wire
C -- GO TO CHECK CAN BUS LINES FOR SHORT CIRCUIT See: Symptom Related Diagnostic
Procedures/CAN Communication System/Short in CAN Bus Lines A -- Continue to next step.
6. CHECK V BUS CIRCUIT +B (CANH, CANL - BAT)
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- GO TO CHECK CAN BUS LINE FOR SHORT TO +B See: Symptom Related Diagnostic
Procedures/CAN Communication System/Short to B+ in CAN Bus Line OK -- Continue to next
step.
7. CHECK V BUS CIRCUIT GND (CANH, CANL - CG)
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- GO TO CHECK CAN BUS LINE FOR SHORT TO GND See: Symptom Related Diagnostic
Procedures/CAN Communication System/Short to GND in CAN Bus Line OK -- Continue to next
step.
8. CHECK ECUS CONNECTED TO CAN BUS (USING TECHSTREAM)*
(a) Select "CAN Bus Check" from the "System Select".
Page 6117
1UR-FE STARTING: STARTER (for 1.6 kW Type): REASSEMBLY
1. INSTALL STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY
(a) Apply high temperature grease to the areas of the starter pinion drive lever indicated in the
illustration.
(b) Install the starter pinion drive lever and rubber seal to the starter center bearing clutch.
(c) Install the starter center bearing clutch together with the starter pinion drive lever and rubber
seal into the starter drive housing.
2. INSTALL PLANETARY GEAR
(a) Apply high temperature grease to the planetary gears and pins of the starter center bearing
clutch.
(b) Install the 3 planetary gears.
3. INSTALL STARTER ARMATURE ASSEMBLY
(a) Install the starter armature to the starter yoke.
NOTICE: The magnet of the starter yoke may attract the starter armature when the starter
commutator end frame is installed causing the magnet to break.
4. INSTALL STARTER BRUSH HOLDER ASSEMBLY
(a) Push out the 4 brushes from the brush holder so that they are held in place by the springs, as
shown in the illustration.
(b) Install the brush holder to the starter armature and push in the 4 brushes.
(c) Insert grommet between the positive (+) side and negative side.
Page 25
(a) for Column Shift Type:
Remove the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Column Shift Type)/Installation.
(b) for Floor Shift Type:
Remove the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Floor Shift Type)/Installation.
4. INSTALL COWL SIDE TRIM BOARD LH
(a) for Regular Cab:
Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular Cab)/Installation.
(b) for Double Cab:
Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Installation.
(c) for CrewMax:
Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for CrewMax)/Installation.
5. INSTALL FRONT DOOR SCUFF PLATE LH
(a) for Regular Cab:
Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular Cab)/Installation.
(b) for Double Cab:
Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Installation.
(c) for CrewMax:
Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for CrewMax)/Installation.
Page 3426
NG -- REPAIR OR REPLACE CAN BRANCH WIRE OR CONNECTOR (AIR CONDITIONING
AMPLIFIER)
OK -- REPLACE AIR CONDITIONING AMPLIFIER ASSEMBLY
Problem Symptoms Table
CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: PROBLEM SYMPTOMS TABLE
HINT *
Use the table below to help determine the cause of problem symptoms. If multiple suspected areas
are listed, the potential causes of the symptoms are listed in order of probability in the "Suspected
Area" column of the table. Check each symptom by checking the suspected areas in the order they
are listed. Replace parts as necessary.
* Inspect the fuses and relays related to this system before inspecting the suspected areas below.
Page 196
General Information
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: GENERAL
INFORMATION
* A large number of ECU controlled systems are used in the TOYOTA TUNDRA. In general, ECU
controlled systems are considered to be very intricate, requiring a high level of technical knowledge
to troubleshoot. However, most problem checking procedures only involve inspecting the ECU
controlled system's circuits one by one. An adequate understanding of the system and a basic
knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and
necessary repairs.
1. TROUBLESHOOTING PROCEDURES
* The troubleshooting procedures consist of diagnosis procedures for when a DTC is stored and
diagnosis procedures for when no DTC is stored. The basic idea is explained in the following table.
* Vehicle systems are complex and use many ECUs that are difficult to inspect independently.
Therefore, a process of elimination is used, where components that can be inspected individually
are inspected, and if no problems are found in these components, the related ECU is identified as
the problem and replaced.
* It is extremely important to ask the customer about the environment and the conditions present
when the problem occurred (Customer Problem Analysis). This makes it possible to simulate the
conditions and confirm the symptom. If the symptom cannot be confirmed or the DTC does not
recur, the malfunctioning part may not be identified using the troubleshooting procedure, and the
ECU for the related system may be replaced even though it is not defective. If this happens, the
original problem will not be solved.
* In order to prevent endless expansion of troubleshooting procedures, the troubleshooting
procedures are written with the assumption that multiple malfunctions do not occur simultaneously
for a single problem symptom.
* To identify the malfunctioning part, troubleshooting procedures narrow down the target by
separating components, ECUs and wire harnesses during the inspection. If the wire harness is
identified as the cause of the problem, it is necessary to inspect not only the connections to
components and ECUs but also all of the wire harness connectors between the component and the
ECU.
DIAGNOSTIC TESTER
2. DESCRIPTION
System data and the Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector
3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the Techstream* to
check for a malfunction and perform repairs.
HINT *: Techstream is the name for the diagnostic tester in North America.
3. DATA LINK CONNECTOR 3 (DLC3)
(a) The vehicle's ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of
the DLC3 complies with SAE J1962 and
matches the ISO 15765-4 format.
Page 2859
Fuel Pump Control Unit: Service and Repair Installation
1UR-FE FUEL: FUEL PUMP ECU: INSTALLATION
1. INSTALL FUEL PUMP ECU
(a) Install the fuel pump ECU with the 2 bolts.
Torque : 20 Nm (199 kgf-cm, 14 ft-lbf)
NOTICE: Do not use the fuel pump ECU if it has been subjected to physical shocks such as being
dropped, etc.
(b) Connect the 2 fuel pump ECU connectors.
Page 3711
^ Figure 17 shows an example of the update procedure for a two-processor ECU.
G. Turn ignition OFF. Then click Next.
H. Confirm the following:
^ Ignition is ON and engine is OFF or "READY" OFF (hybrid vehicles).
^ Hood is open.
^ All accessories are OFF.
^ Battery voltage is above 11.4 volts.
NOTICE
Verify the vehicle is connected to a battery charger before continuing - If battery voltage falls below
11.4 volts, ECU damage may occur.
Page 6832
Page 6770
MJ1-NP1
Page 8239
Removal
SEAT BELT: FRONT SEAT OUTER BELT ASSEMBLY (for Center Seat): REMOVAL
1. REMOVE FRONT SEAT ASSEMBLY (for Manual Seat)
(a) Remove the front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Manual
Seat)/Removal.
2. REMOVE FRONT SEAT ASSEMBLY (for Power Seat)
(a) Remove the front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Power
Seat)/Removal.
Page 2841
Main Relay (Computer/Fuel System): Testing and Inspection
1UR-FE ENGINE CONTROL SYSTEM: CIRCUIT OPENING RELAY: ON-VEHICLE INSPECTION
1. REMOVE CIRCUIT OPENING RELAY (C/OPN)
(a) Remove the circuit opening relay from the engine room relay block.
2. INSPECT CIRCUIT OPENING RELAY
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) If the result is not as specified, replace the circuit opening relay.
3. INSTALL CIRCUIT OPENING RELAY
(a) Install the circuit opening relay to the engine room relay block.
Page 8815
4. REMOVE FRONT UPPER ARMREST BASE PANEL LH See: Body and Frame/Doors, Hood
and Trunk/Doors/Front Door/Service and
Repair/Front Door (for CrewMax)/Disassembly
5. REMOVE FRONT DOOR ARMREST COVER LH
6. REMOVE COURTESY LIGHT ASSEMBLY See: Body and Frame/Doors, Hood and
Trunk/Doors/Front Door/Service and Repair/Front Door
(for CrewMax)/Disassembly
7. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH See: Body and Frame/Doors,
Hood and Trunk/Doors/Front Door/Service and
Repair/Front Door (for CrewMax)/Disassembly
8. REMOVE FRONT NO. 1 SPEAKER ASSEMBLY
(a) Disconnect the speaker connector.
(b) Remove the 4 screws and speaker.
NOTICE: Do not touch the cone part of the speaker.
9. REMOVE FRONT NO. 3 SPEAKER ASSEMBLY (for 12 Speakers)
(a) Remove the 3 screws and speaker with bracket.
(b) Detach the 3 claws and remove the speaker from the bracket.
NOTICE: Do not touch the cone part of the speaker.
Installation
AUDIO / VISUAL: FRONT DOOR SPEAKER (for CrewMax): INSTALLATION
HINT *
Use the same procedures for the LH side and RH side.
Page 424
Fuel Pump Control Unit: Diagrams
Page 5932
Yaw Rate Sensor: Service and Repair Removal
BRAKE CONTROL: YAW RATE AND DECELERATION SENSOR: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to disable the SRS system.
2. REMOVE CENTER FRONT SEAT ASSEMBLY (for Center Seat) See: Body and
Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Center Seat)/Removal
3. REMOVE CONSOLE BOX ASSEMBLY (for Separate Seat Type)
(a) Remove the console box See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and
Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal.
4. REMOVE YAW RATE SENSOR
(a) Remove the 2 nuts (labeled A) and sensor.
(b) Disconnect the sensor connector (labeled B), and then detach the clamp (labeled C) from the
sensor bracket.
Page 4382
Fuel Pump Control Unit: Service and Repair Removal
1UR-FE FUEL: FUEL PUMP ECU: REMOVAL
1. REMOVE FUEL PUMP ECU
(a) Disconnect the 2 fuel pump ECU connectors.
(b) Remove the 2 bolts and fuel pump ECU.
NOTICE: Make sure the fuel pump ECU is not subjected to physical shocks such as being
dropped, etc.
Page 5144
2. REMOVE PROPELLER SHAFT ASSEMBLY
(a) Remove the propeller shaft for 2WD See: Drive/Propeller Shafts, Bearings and
Joints/Drive/Propeller Shaft/Service and Repair/Removal and
Replacement/Propeller Shaft Assembly/Removal.
(b) Remove the propeller shaft for 4WD See: Drive/Propeller Shafts, Bearings and
Joints/Drive/Propeller Shaft/Service and Repair/Removal and
Replacement/Propeller Shaft Assembly/Removal.
3. REMOVE REAR DRIVE PINION NUT
(a) Using SST and a hammer, loosen the staked part of the nut.
SST : 09930-00010
(b) Using SST to hold the companion flange, remove the nut.
SST : 09330-00021
09330-00030
4. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY
(a) Using SST, remove the companion flange.
SST : 09950-30012
09951-03010
09953-03010
09954-03010
09956-03050
SST : 09955-03050
Page 481
Seat Occupant Classification Module - Air Bag: Service and Repair Installation
SUPPLEMENTAL RESTRAINT SYSTEM: OCCUPANT CLASSIFICATION ECU: INSTALLATION
1. INSTALL OCCUPANT CLASSIFICATION ECU
(a) Check that the ignition switch is OFF.
(b) Check that the cable is disconnected from the battery negative (-) terminal.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
(c) Attach the claw and install the occupant classification ECU to the seat.
NOTICE: *
If the ECU has been dropped, or there are any cracks, dents or other defects in the case, bracket
or connector, replace it with a new one.
* When installing the ECU, be careful that the SRS wiring does not interfere with other parts and
that it is not pinched between other parts.
(d) Check that there is no looseness in the installation parts of the ECU.
2. INSTALL FRONT SEAT ASSEMBLY RH
(a) Install the front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Manual
Seat)/Installation.
Components
Ambient Temperature Sensor / Switch HVAC: Service and Repair Components
AIR CONDITIONING: AMBIENT TEMPERATURE SENSOR: COMPONENTS
Page 284
NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do
not operate the ignition switch, any other switches, or the doors.
(a) If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the
harness and connector.
(b) Connect the cable of the Techstream to the DLC3, turn the ignition switch ON and attempt to
use the tester. If the display indicates that a
communication error has occurred, there is a problem either with the vehicle or with the tester.
HINT *
If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of
the original vehicle.
* If communication is still not possible when the tester is connected to another vehicle, the problem
may be in the tester itself. Consult the Service Department listed in the tester's instruction manual.
How To Proceed With Troubleshooting
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: HOW TO
PROCEED WITH TROUBLESHOOTING
1. OPERATION FLOW
HINT Perform troubleshooting in accordance with the procedures below. The following is an outline
of basic troubleshooting procedures. Confirm the troubleshooting procedures for the circuit you are
working on before beginning troubleshooting.
1. VEHICLE BROUGHT TO WORKSHOP
NEXT -- Continue to next step.
2. CUSTOMER PROBLEM ANALYSIS
(a) Ask the customer about the conditions and environment when the problem occurred.
NEXT -- Continue to next step.
3. INSPECT BATTERY VOLTAGE
Standard voltage:
11 to 14 V
If the voltage is below 11 V, recharge or replace the battery before proceeding.
NEXT -- Continue to next step.
Page 3451
NOTICE: For vehicles without 4WD, go to "CHECK FOR SHORT TO B+ IN CAN BUS WIRE (NO.
2 JUNCTION CONNECTOR - ECM)".
(a) Measure the resistance according to the value(s) in the table below.
Page 1186
Manifold Pressure/Vacuum Sensor: Diagrams
Airbag Cut-OFF Switch
Air Bag Deactivation Switch: Testing and Inspection Airbag Cut-OFF Switch
SUPPLEMENTAL RESTRAINT SYSTEM: AIRBAG CUT-OFF SWITCH: INSPECTION
1. INSPECT AIRBAG CUT-OFF SWITCH
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
Page 7651
General Information
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: GENERAL
INFORMATION
* A large number of ECU controlled systems are used in the TOYOTA TUNDRA. In general, ECU
controlled systems are considered to be very intricate, requiring a high level of technical knowledge
to troubleshoot. However, most problem checking procedures only involve inspecting the ECU
controlled system's circuits one by one. An adequate understanding of the system and a basic
knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and
necessary repairs.
1. TROUBLESHOOTING PROCEDURES
* The troubleshooting procedures consist of diagnosis procedures for when a DTC is stored and
diagnosis procedures for when no DTC is stored. The basic idea is explained in the following table.
* Vehicle systems are complex and use many ECUs that are difficult to inspect independently.
Therefore, a process of elimination is used, where components that can be inspected individually
are inspected, and if no problems are found in these components, the related ECU is identified as
the problem and replaced.
* It is extremely important to ask the customer about the environment and the conditions present
when the problem occurred (Customer Problem Analysis). This makes it possible to simulate the
conditions and confirm the symptom. If the symptom cannot be confirmed or the DTC does not
recur, the malfunctioning part may not be identified using the troubleshooting procedure, and the
ECU for the related system may be replaced even though it is not defective. If this happens, the
original problem will not be solved.
* In order to prevent endless expansion of troubleshooting procedures, the troubleshooting
procedures are written with the assumption that multiple malfunctions do not occur simultaneously
for a single problem symptom.
* To identify the malfunctioning part, troubleshooting procedures narrow down the target by
separating components, ECUs and wire harnesses during the inspection. If the wire harness is
identified as the cause of the problem, it is necessary to inspect not only the connections to
components and ECUs but also all of the wire harness connectors between the component and the
ECU.
DIAGNOSTIC TESTER
2. DESCRIPTION
System data and the Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector
3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the Techstream* to
check for a malfunction and perform repairs.
HINT *: Techstream is the name for the diagnostic tester in North America.
3. DATA LINK CONNECTOR 3 (DLC3)
(a) The vehicle's ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of
the DLC3 complies with SAE J1962 and
matches the ISO 15765-4 format.
Page 6647
Removal
OTHER SYSTEM: POWER OUTLET SOCKET (for Column Shift Type): REMOVAL
1. REMOVE FRONT DOOR SCUFF PLATE LH (for Double Cab)
2. REMOVE FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Removal
3. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Removal
4. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal
Page 8224
(b) Check if SST is functioning properly.
SST : 09082-00700
SST : 09082-00770
CAUTION: When activating a seat belt pretensioner, always use the specified SST.
(c) Prepare SST for activation of the seat belt pretensioner.
(1) Connect SST (A) to SST (B). Then connect SST (B)'s connector to the seat belt pretensioner.
NOTICE: To avoid damaging SST connector and wire harness, do not lock the secondary lock of
the twin lock.
(2) Place the front seat outer belt on the ground and cover it with a tire (with wheel).
NOTICE: Set up the front seat outer belt as shown in the illustration.
(3) Move SST at least 10 m (32.8 ft.) away from the wheel.
NOTICE: Take care not to damage SST wire harness.
Page 6189
(a) Attach the 2 claws to install the power outlet socket cover.
2. INSTALL POWER OUTLET SOCKET ASSEMBLY
(a) Attach the claw to install the power outlet socket.
3. INSTALL LOWER INSTRUMENT CLUSTER FINISH PANEL See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column
Shift Type)/Installation
4. INSTALL FRONT ASH RECEPTACLE BOX SUB-ASSEMBLY
5. INSTALL CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service
and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
6. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Installation
7. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
8. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Installation
9. INSTALL FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Installation
10. INSTALL FRONT DOOR SCUFF PLATE LH (for Double Cab)
Page 3850
Oxygen Sensor: Service and Repair Heated Oxygen Sensor
Components
1UR-FE ENGINE CONTROL SYSTEM: HEATED OXYGEN SENSOR: COMPONENTS
Removal
1UR-FE ENGINE CONTROL SYSTEM: HEATED OXYGEN SENSOR: REMOVAL
CAUTION: *
The procedures should be performed by at least 2 people.
* Wear protective gloves when removing the exhaust pipe.
* The exhaust pipe is extremely hot immediately after the engine has stopped.
* Confirm that the exhaust pipe has cooled down before removing it.
1. REMOVE PROPELLER SHAFT HEAT INSULATOR (for 4WD) See: Transmission and
Drivetrain/Drive/Propeller Shafts, Bearings and
Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Front Propeller Shaft
Assembly/Removal
2. REMOVE HEATED OXYGEN SENSOR (for Bank 1 Sensor 2)
(a) Disconnect the sensor connector.
(b) Using SST, remove the sensor.
SST : 09224-00010
3. REMOVE HEATED OXYGEN SENSOR (for Bank 2 Sensor 2)
(a) Disconnect the heated oxygen sensor connector and 2 clamps.
Page 5594
Electronic Brake Control Module: Locations From 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 9375
10. Lower the cab back onto the No. 3 cab mount.
11. Install the new bolt through the No.3 cab mount and install the large washer and NEW nut and
torque to specifications.
Torque: 54 N*m (551 kgf*cm, 40 ft*lbf)
12. Torque the nuts to the specified torque range on the No.2 mounts.
Torque: 54 N*m (551 kgf*cm, 40 ft*lbf)
Page 5671
Yaw Rate Sensor: Service and Repair Removal
BRAKE CONTROL: YAW RATE AND DECELERATION SENSOR: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to disable the SRS system.
2. REMOVE CENTER FRONT SEAT ASSEMBLY (for Center Seat) See: Body and
Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Center Seat)/Removal
3. REMOVE CONSOLE BOX ASSEMBLY (for Separate Seat Type)
(a) Remove the console box See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and
Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal.
4. REMOVE YAW RATE SENSOR
(a) Remove the 2 nuts (labeled A) and sensor.
(b) Disconnect the sensor connector (labeled B), and then detach the clamp (labeled C) from the
sensor bracket.
Components
Lower Side Moulding / Trim: Service and Repair Components
EXTERIOR: SIDE MOULDING: COMPONENTS
Up to 11/2009
Parking Brake Warning Switch: Locations Up to 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Locations
Overdrive Switch: Locations
A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS
LOCATION
Engine Controls - Techstream(R) ECU Re-Flash
Procedure
Engine Control Module: All Technical Service Bulletins Engine Controls - Techstream(R) ECU
Re-Flash Procedure
T-SB-0064-10
February 4, 2010
Techstream ECU Flash Reprogramming Procedure
Service Category Engine/Hybrid System
Section Engine Control
Market USA
Applicability
TSB SUPERSESSION NOTICE
The information contained in this TSB supersedes TSB No. SS002-07.
^ Applicability has been updated to include 2009 - 2011 model year Toyota vehicles.
^ A new section, Techstream Preparation, has been added.
^ Techstream Lite has been added as an option in Required Tools & Materials.
^ Process Overview and Operation Procedure sections have been updated.
TSB No. SS002-07 is Obsolete and any printed versions should be discarded. Be sure to review
the entire content of this service bulletin before proceeding.
Introduction
Flash reprogramming allows the ECU software to be updated without replacing the ECU. Flash
calibration updates for specific vehicle models/ECUs are released as field-fix procedures described
in individual service bulletins. This bulletin details the Techstream ECU flash reprogramming
process and outlines use of the Technical Information System (TIS) and the Calibration Update
Wizard (CUW). Flash calibration updates can only be applied to the vehicle/ECU combination for
which they are intended. ECUs have internal security that will not allow them to be programmed
with another ECU's information.
ECU
Electronic Control Unit (ECU) is a Toyota term used to describe integrated computerized devices
responsible for managing the operation of a system or subsystem. For the purposes of this bulletin,
the term "ECU" is used as a generic label for the following SAE J1930 standard references:
^ Powertrain Control Module (PCM)
Page 6891
Power Distribution Relay: Diagrams
Page 1073
Hazard Warning Switch: Testing and Inspection
LIGHTING: HAZARD WARNING SWITCH: INSPECTION
1. INSPECT HAZARD WARNING SWITCH
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the warning switch.
(c) Connect the battery's positive (+) lead to terminal 3 and the negative (-) lead to terminal 2.
(d) Check that the light comes on.
OK:
Light comes on
(e) If the result is not as specified, replace the warning switch.
Locations
Relay Box: Locations
Engine Compartment
Page 6898
Instrument Panel (Floor Shift)
Instrument Panel (Column Shift)
Components
Front Steering Knuckle: Service and Repair Components
AXLE: STEERING KNUCKLE: COMPONENTS
Page 2974
Oxygen Sensor: Service and Repair Heated Oxygen Sensor
Components
1UR-FE ENGINE CONTROL SYSTEM: HEATED OXYGEN SENSOR: COMPONENTS
Removal
1UR-FE ENGINE CONTROL SYSTEM: HEATED OXYGEN SENSOR: REMOVAL
CAUTION: *
The procedures should be performed by at least 2 people.
* Wear protective gloves when removing the exhaust pipe.
* The exhaust pipe is extremely hot immediately after the engine has stopped.
* Confirm that the exhaust pipe has cooled down before removing it.
1. REMOVE PROPELLER SHAFT HEAT INSULATOR (for 4WD) See: Transmission and
Drivetrain/Drive/Propeller Shafts, Bearings and
Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Front Propeller Shaft
Assembly/Removal
2. REMOVE HEATED OXYGEN SENSOR (for Bank 1 Sensor 2)
(a) Disconnect the sensor connector.
(b) Using SST, remove the sensor.
SST : 09224-00010
3. REMOVE HEATED OXYGEN SENSOR (for Bank 2 Sensor 2)
(a) Disconnect the heated oxygen sensor connector and 2 clamps.
Page 3301
NOTE
On some models, DTCs may set as a result of reprogramming. If DTCs are present, clear codes
and run the Health Check again. Troubleshoot any remaining Current, Pending, or History codes.
Permanent codes will not be cleared using Techstream. Permanent codes do not illuminate the MIL
and do not require troubleshooting. They will clear during normal driving once the Universal Trip
Drive Pattern is performed.
4. Attach the Authorized Modifications Label.
A. Using a permanent marker or ball point pen complete the Authorized Modifications Label and
attach to the vehicle. The Authorized
Modifications Label is available through the MDC P/N 00451-00001-LBL.
B. Attach the label under the hood in the location determined by the specific TSB or Campaign.
NOTE
Wait 60 - 90 seconds for ink to set before handling.
Page 8435
Airbag Cutoff Switch
Air Bag Deactivation Switch: Diagrams Airbag Cutoff Switch
Page 6822
Page 2272
This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown.
Page 3440
INSPECTION PROCEDURE
HINT Operating the ignition switch, any switches or any doors triggers related ECU and sensor
communication with the CAN, which causes resistance variation.
PROCEDURE
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
(a) Disconnect the cable from the negative (-) battery terminal before measuring the resistances of
the main wire and the branch wire.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
NEXT -- Continue to next step.
2. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (DLC3 BRANCH WIRE)
(a) Disconnect the J86 No. 1 junction connector connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO DLC3 (CANH, CANL) OK -Continue to next step.
3. CONNECT CONNECTOR
Page 5187
(a) Inspect and adjust the front wheel alignment See: Maintenance/Alignment/Service and Repair.
Components
AXLE: REAR AXLE SHAFT: COMPONENTS
Page 4791
Then click Start.
I. Do NOT disturb the vehicle during flash reprogramming.
NOTE
^ ECU flash reprogramming may take anywhere from 3 - 30 minutes per calibration file.
^ Reprogramming time will vary depending on model and ECU communication protocol. Vehicles
using CAN communication protocol will reprogram much faster (2 - 7 minutes).
NOTE
^ If vehicle requires only ONE calibration update, then proceed to step N in this bulletin.
^ If vehicle requires a SECOND calibration update, then continue as follows:
^ For serial communication vehicles, go to step J.
^ For CAN communication vehicles, go to step L.
Page 9181
3. INSTALL SIDE STEP BRACKET LH
(a) Install the side step bracket with the 2 bolts.
Torque : 12 Nm (122 kgf-cm, 9 ft-lbf)
4. INSTALL STEP ARM SPACER LH
5. INSTALL STEP COVER PROTECTOR LH
6. INSTALL STEP PLATE COVER LH
(a) for Double Cab:
Install the step plate cover.
(1) Attach the 19 clips to install the step plate cover.
(b) for CrewMax:
Install the step plate cover.
(1) Attach the 23 clips to install the step plate cover.
Page 1313
"Case2" Open the secondary locking device.
[B] For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray
Gray or White : Black
Page 7718
Control Module HVAC: Service and Repair Removal
AIR CONDITIONING: AIR CONDITIONING AMPLIFIER: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE FRONT DOOR SCUFF PLATE RH
(a) for Regular Cab:
Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular Cab)/Removal.
(b) for Double Cab:
Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Removal.
(c) for CrewMax:
Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for CrewMax)/Removal.
3. REMOVE COWL SIDE TRIM BOARD RH
(a) for Regular Cab:
Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular Cab)/Removal.
(b) for Double Cab:
Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Removal.
(c) for CrewMax:
Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for CrewMax)/Removal.
4. REMOVE NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY
(a) for Column Shift Type:
Remove the No. 2 instrument panel under cover sub-assembly See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and
Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal.
(b) for Floor Shift Type:
Remove the No. 2 instrument panel under cover sub-assembly See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and
Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal.
5. REMOVE INSTRUMENT SIDE PANEL RH
(a) for Column Shift Type:
Remove the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Column Shift Type)/Removal.
(b) for Floor Shift Type:
Page 7723
Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular Cab)/Installation.
(b) for Double Cab:
Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Installation.
(c) for CrewMax:
Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for CrewMax)/Installation.
10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
11. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Reading and Clearing Diagnostic Trouble
Codes/Check Mode Procedure.
Page 2541
This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown.
Page 4998
(a) Install the shift solenoid valve.
(b) Install the 2 straight pins and lock plate with the bolt.
Torque : 6.4 Nm (65 kgf-cm, 57 in-lbf)
Page 5824
Electronic Brake Control Module: Locations From 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Components
Steering Control Module: Service and Repair Components
POWER STEERING: POWER STEERING ECU (for 1UR-FE): COMPONENTS
Page 903
Ambient Temperature Sensor / Switch HVAC: Diagrams
Locations
Switch: Locations
JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION
Page 6795
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: ELECTRONIC
CIRCUIT INSPECTION PROCEDURE
1. BASIC INSPECTION
(a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS
(1) Unless otherwise stated, all resistance measurements should be made at an ambient
temperature of 20°C (68°F). Resistance measurements
may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been
running. Measurements should be made after the engine has cooled down.
(b) HANDLING CONNECTORS
(1) When disconnecting a connector, first squeeze the mating halves tightly together to release the
lock, and then press the lock claw and
separate the connector.
(2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly
and separate it.
(3) Before connecting a connector, check that there are no deformed, damaged, loose or missing
terminals.
(4) When connecting a connector, press firmly until it locks with a "click" sound.
(5) If checking a connector with a TOYOTA electrical tester, check the connector from the backside
(harness side) using a mini test lead.
NOTICE: *
As a waterproof connector cannot be checked from the backside, check it by connecting a
sub-harness.
* Do not damage the terminals by moving the inserted tester needle.
(c) CHECKING CONNECTORS
(1) Checking when a connector is connected: Squeeze the connectors together to confirm that they
are fully connected and locked.
(2) Checking when a connector is disconnected: Check by pulling the wire harness lightly from the
backside of the connector. Look for
unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for
corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or
deformed terminals.
(3) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a
female terminal, and check for ample tension
Page 3479
Connect the Techstream to the vehicle, and turn a courtesy switch on and off at 1.5 second
intervals until communication between the tester and vehicle begins.
PROCEDURE
1. CHECK HARNESS AND CONNECTOR (AIR CONDITIONING AMPLIFIER - INTEGRATION
CONTROL AND PANEL)
(a) Disconnect the J37 integration control and panel assembly connector.
(b) Disconnect the J19 air conditioning amplifier assembly connector.
(c) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR OK -- Continue to next step.
2. CHECK HARNESS AND CONNECTOR (INTEGRATION CONTROL AND PANEL - BATTERY
AND BODY GROUND)
(a) Disconnect the J37 integration control and panel assembly connector.
(b) Measure the resistance and voltage according to the value(s) in the table below.
Standard Resistance:
Standard Voltage:
Page 5007
(a) Coat a new O-ring with ATF, and install it to the oil strainer.
(b) Install the oil strainer with the 4 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
4. INSTALL AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY
NOTICE: Be careful not to spill oil on the contacting surfaces of the transmission case and oil pan.
(a) Install a new gasket and the oil pan with the 20 bolts.
Torque : 7.0 Nm (71 kgf-cm, 62 in-lbf)
5. ADD AUTOMATIC TRANSMISSION FLUID
(a) Add automatic transmission fluid See: Service and Repair/Procedures.
Page 2835
(b) Spray gasket remover or equivalent on the remaining tape of the gasket.
NOTICE: When using gasket remover or equivalent, cover the ECM connector with a cloth.
(c) Remove the tape of the gasket without using bladed objects.
Page 120
Traction Control Relay: Locations From 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 942
7. INSTALL DAMPER SERVO SUB-ASSEMBLY
(a) Install the damper servo with the 3 screws.
(b) Connect the connector.
8. INSTALL DAMPER SERVO SUB-ASSEMBLY
(a) Install the servo motor.
(1) Set the plate so that the cutout part engages with the tooth of the gear, and attach the claw to
install the main plate.
(2) Install the 2 screws.
(b) Install the servo motor.
Page 6048
Push the terminal retainer down to the temporary lock position.
Page 2014
when inserting and after full engagement.
NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal.
(d) REPAIR METHOD OF CONNECTOR TERMINAL
(1) If there is any foreign matter on the terminal, clean the contact point using an air gun or cloth.
Never rub the contact point using sandpaper
as the plating may come off.
(2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is
gold-plated (gold color), use a gold-plated female
terminal; if it is silver-plated (silver color), use a silver-plated female terminal.
(3) Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock
into the housing, the housing may have to be
replaced.
(e) HANDLING OF WIRE HARNESS
(1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be
restored in the same way.
(2) Never twist, pull or slacken the wire harness more than necessary.
(3) The wire harness should never come into contact with a high temperature part, or rotating,
moving, vibrating or sharp-edged parts. Avoid
contact with panel edges, screw tips and other sharp items.
(4) When installing parts, never pinch the wire harness.
(5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with
vinyl tape.
2. CHECK FOR OPEN CIRCUIT
Page 6769
JQ1-LJ1
Page 4969
Transmission Position Switch/Sensor: Diagrams
Page 929
Evaporator Temperature Sensor / Switch: Locations Air Conditioning System (for Manual Air
Conditioning System)
AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Manual Air Conditioning System):
PARTS LOCATION
Page 435
Fuel Pump Relay: Testing and Inspection Fuel Pump Relay
1UR-FE ENGINE CONTROL SYSTEM: FUEL PUMP RELAY: ON-VEHICLE INSPECTION
1. REMOVE FUEL PUMP RELAY (F/PMP)
(a) Remove the fuel pump relay from the engine room relay block.
2. INSPECT FUEL PUMP RELAY
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) If the result is not as specified, replace the fuel pump relay.
3. INSTALL FUEL PUMP RELAY
(a) Install the fuel pump relay to the engine room relay block.
Page 6260
Page 8624
Removal
AUDIO / VISUAL: STEREO JACK ADAPTER ASSEMBLY (for Column Shift Type): REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE FRONT DOOR SCUFF PLATE LH
(a) for Double Cab:
Remove the front door scuff plate LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal.
(b) for Regular Cab:
Page 4484
Throttle Position Sensor: Diagrams
Page 4775
2. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in
Figure 1. Confirm if the ECM (PCM) calibration has
been updated. If the calibration ID listed is NOT the latest ECM (PCM) calibration - go to step 3.
3. Flash reprogram the ECM (PCM).
NOTE
^ The GR8 Battery Diagnostic Station MUST be used in Power Supply Mode to maintain battery
voltage at 13.5 volts while flash reprogramming the vehicle.
^ For details on how to use the GR8 Battery Diagnostic Station, refer to the located on the
Technical Information System (TIS), Diagnostics - Battery
Follow the procedures outlined in TSB No. T-SB-0064-10, "Techstream ECU Flash
Reprogramming Procedure1⁄4 and flash the ECM (PCM) with the NEW calibration file update.
4. Install the Authorized Modifications Label.
A. Using a permanent marker enter the following information on the label:
^ ECM part number [Refer to the Parts Information section for the CURRENT PART NUMBER]
^ Calibration ID(s) [Refer to the Calibration Identification Chart for the NEW CALIBRATION ID]
^ Dealer Code
^ Repair Date
^ Change Authority [This TSB number]
B. Affix the Authorized Modifications Label to the vehicle at the location shown in Figure 1. The
Authorized Modifications Label is available
through the MDC P/N 00451-00001-LBL.
5. Test drive the vehicle to confirm proper vehicle operation.
Page 3916
Variable Valve Timing Actuator: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT OIL CONTROL VALVE: INSTALLATION
1. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side of Bank 1)
(a) Apply a light coat of engine oil to the O-ring.
(b) Install a new O-ring to the oil control valve.
(c) Install the oil control valve with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(d) Connect the oil control valve connector.
2. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side of Bank 1)
(a) Apply a light coat of engine oil to the O-ring.
(b) Install a new O-ring to the oil control valve.
(c) Install the oil control valve with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(d) Connect the oil control valve connector.
3. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side of Bank 2)
(a) Apply a light coat of engine oil to the O-ring.
(b) Install a new O-ring to the oil control valve.
(c) Install the oil control valve with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(d) Connect the oil control valve connector.
4. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side of Bank 2)
Page 3244
Page 1221
Power Steering Pressure Switch: Testing and Inspection
1UR-FE ENGINE CONTROL SYSTEM: POWER STEERING OIL PRESSURE SWITCH:
ON-VEHICLE INSPECTION
1. INSPECT POWER STEERING OIL PRESSURE SWITCH
(a) Check the oil pressure switch.
(1) Connect the Techstream to the DLC3.
(2) Turn the ignition switch to ON.
(3) Turn the Techstream main switch on.
(4) Enter the following menus: Powertrain / Engine and ECT / Data List / All Data / Power Steering
pressure.
(5) Start the engine.
(6) Operate the steering wheel while idling, and read the value on the Techstream.
Standard:
(7) If not as specified, check for DTCs See: Powertrain Management/Computers and Control
Systems/Testing and Inspection/Reading and
Clearing Diagnostic Trouble Codes/DTC Check / Clear. If the power steering system inspection
results are normal and a DTC is not output, replace the power steering oil pressure switch.
Inspect the power steering system See: Steering and Suspension/Steering/Testing and
Inspection/Component Tests and General Diagnostics/Power Steering System/On-Vehicle
Inspection. If the power steering system inspection results are normal and a DTC is not output,
replace the power steering oil pressure switch.
Page 6280
(2) Disconnect connector B and measure the resistance.
Standard resistance (Fig. 7):
* If the results match the examples above, a short circuit exists between terminal 1 of connector B2
and terminal 1 of connector C.
4. CHECK AND REPLACE ECU
NOTICE: *
The connector should not be disconnected from the ECU. Perform the inspection from the backside
of the connector on the wire harness side.
* When no measuring condition is specified, perform the inspection with the engine stopped and
the ignition switch ON.
* Check that the connectors are fully seated. Check for loose, corroded or broken wires.
(a) First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be
faulty. Temporarily replace the ECU with a
normally functioning one and check if the symptoms occur. If the trouble symptoms disappear,
replace the original ECU.
(1) Measure the resistance between the ECU ground terminal and body ground.
Standard resistance:
Below 1 Ohms
(2) Disconnect the ECU connector. Check the ground terminal on the ECU side and wire harness
side for bending, corrosion or foreign matter.
Lastly, check the contact pressure of the female terminals.
Page 5026
Page 8842
Removal
AUDIO / VISUAL: INSTRUMENT PANEL SPEAKER (for Regular Cab): REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE FRONT PILLAR GARNISH LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Removal
3. REMOVE FRONT PILLAR GARNISH RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Removal
4. REMOVE NO. 1 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY
Components
Integrated Accessory Switch Assembly: Service and Repair Components
METER: DRIVE MONITOR SWITCH: COMPONENTS
Up to 11/2009
Parking Brake Warning Switch: Locations Up to 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 8437
(a) Remove the antenna ornament as shown in the illustration.
3. REMOVE FENDER APRON MUDGUARD SEAL RH See: Body and Frame/Fender/Front
Fender/Front Fender Liner/Service and
Repair/Removal
4. REMOVE FENDER ANTENNA ASSEMBLY
(a) Disconnect the connector.
(b) Remove the bolt and detach the 5 clamps.
(c) Remove the bolt and antenna.
Installation
AUDIO / VISUAL: RADIO ANTENNA: INSTALLATION
Page 4281
Then click Start.
I. Do NOT disturb the vehicle during flash reprogramming.
NOTE
^ ECU flash reprogramming may take anywhere from 3 - 30 minutes per calibration file.
^ Reprogramming time will vary depending on model and ECU communication protocol. Vehicles
using CAN communication protocol will reprogram much faster (2 - 7 minutes).
NOTE
^ If vehicle requires only ONE calibration update, then proceed to step N in this bulletin.
^ If vehicle requires a SECOND calibration update, then continue as follows:
^ For serial communication vehicles, go to step J.
^ For CAN communication vehicles, go to step L.
Page 5146
(b) Using SST and the companion flange, install the bearing (inner race). Then remove the
companion flange.
SST : 09950-30012
09951-03010
09953-03010
09954-03010
09956-03050
SST : 09955-03050
11. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
12. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL
(a) Using SST and a plastic-faced hammer, tap in a new oil seal until its surface is flush with the
differential carrier end.
SST : 09316-12010
SST : 09649-17010
Standard oil seal depth:
0.05 to 0.95 mm (0.0197 to 0.0374 in.)
HINT Connect 2 SST with vinyl tape.
(b) Coat the lip of the oil seal with MP grease.
13. INSTALL REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY
(a) Place the companion flange on the drive pinion.
Page 6373
Page 5708
2. Loosen the bleeder plug.
3. Using the Techstream, operate the brake actuator, completely depress the brake pedal and hold
it there.
HINT The operation stops automatically after 4 seconds. When performing this procedure
continuously, set an interval of at least 20 seconds.
NOTICE: *
During this procedure, the pedal will feel heavy, but completely depress it so that the brake fluid
comes out of the bleeder plug.
* Depress and hold the brake pedal. Do not depress and release the pedal repeatedly.
(10)4. Tighten the bleeder plug, and then release the brake pedal.
5. Repeat the 3 previous steps until all air in the fluid is completely bled out.
6. Tighten the bleeder plug.
Torque : 11 Nm (110 kgf-cm, 8 ft-lbf)
(11)7. Repeat all of the above procedures for the other wheels to bleed the air out of the pressure
reduction line.
(12)Clear the DTCs See: Antilock Brakes / Traction Control Systems/Testing and
Inspection/Reading and Clearing Diagnostic Trouble
Codes.
(13)Inspect for brake fluid leak.
(14)Check and adjust brake fluid level in reservoir See: Brake Fluid/Testing and Inspection.
(15)If any DTC is set, perform the troubleshooting for the DTC
(16)Check the DTC See: Antilock Brakes / Traction Control Systems/Testing and
Inspection/Reading and Clearing Diagnostic Trouble
Codes.
Components
Neutral Safety Switch: Service and Repair Components
A760F AUTOMATIC TRANSMISSION: PARK / NEUTRAL POSITION SWITCH: COMPONENTS
Page 607
HINT The type of claw on the top and bottom of the sensor are different. Observe the claws
carefully before removing the sensor.
14. REMOVE NO. 2 ULTRASONIC SENSOR RETAINER
(a) Detach the 2 claws and remove the sensor retainer from the rear bumper.
Installation
PARK ASSIST / MONITORING: ULTRASONIC SENSOR (for Rear Side): INSTALLATION
1. INSTALL NO. 1 ULTRASONIC SENSOR RETAINER
(a) Align the keyhole and protrusion as shown in the illustration.
(b) Install the sensor retainer to the rear bumper.
NOTICE: Do not damage the bumper with the protrusion when installing the retainer.
2. INSTALL NO. 1 ULTRASONIC SENSOR
(a) Attach the 2 claws to install the ultrasonic sensor.
Page 7185
(b) Inspect the vane pump plate.
(1) Using a micrometer, measure the thickness of the vane pump plates.
Standard thickness:
1.405 to 1.411 mm (0.05531 to 0.05555 in.)
(2) If the thickness is not within the specified range, replace the vane pump plates.
3. INSPECT TOTAL PRELOAD
(a) Check that the pump rotates smoothly without abnormal noise.
(b) Temporarily install the service bolt.
Recommended service bolt:
(c) Using a torque wrench, measure the pumps rotating torque.
Standard rotating torque:
0.3 N*m (3 kgf*cm, 2 in.*lbf) or less
(d) If the rotating torque is not as specified, check the vane pump housing oil seal.
Page 6102
(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(2) If the result is not as specified, replace the magnet starter switch assembly.
3. INSPECT STARTER ARMATURE ASSEMBLY
(a) Check the appearance.
If the surface is dirty or burnt, restore the surface with sandpaper (No. 400) or on a lathe.
(b) Measure the resistance.
(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(2) If the result is not as specified, replace the starter armature assembly.
(3) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(4) If the result is not as specified, replace the starter armature assembly.
(c) Check the commutator circle runout.
(1) Place the armature shaft on V-blocks.
Locations
Tire Pressure Sensor: Locations
TIRE AND WHEEL: TIRE PRESSURE WARNING SYSTEM: PARTS LOCATION
Page 839
Torque : 11 Nm (107 kgf-cm, 8 ft-lbf)
NOTICE: *
Make sure there are no pieces of iron or other foreign matter attached to the sensor tip part.
* While inserting the speed sensor into the knuckle hole, do not strike or damage the sensor tip
part.
* After installing the speed sensor, make sure there is no clearance or foreign matter between the
sensor stay part and the knuckle.
* Make sure there is no foreign matter attached to the magnetic rotor.
6. INSTALL FRONT SKID CONTROL SENSOR WIRE RH
(a) Install the skid control sensor clamp (labeled A) with the bolt (labeled B).
for Bolt B - Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)
(b) Install the connector (labeled C) with connect the connector (labeled C).
(c) Install the 2 harness clamps (labeled D) with the 2 bolts (labeled E).
for Bolt E - Torque : 13 Nm (127 kgf-cm, 9 ft-lbf)
NOTICE: *
When installing the clamps, do not twist the wire harness.
* For clamps with rotation stoppers, make sure the rotation stopper touches the installation
position.
(d) Install the harness clamp with the bolt (labeled E).
Torque : 13 Nm (127 kgf-cm, 9 ft-lbf)
NOTICE: *
When installing the clamp, do not twist the wire harness.
* Make sure the clamp's rotation stopper touches the installation position.
Page 6327
PJ1-TJ1
Page 2550
2. Install ChaSSiSEAR(TM) on the vehicle and attempt to isolate the source of the noise. Is the
noise loudest near the rear wheel bearing assembly?
^ YES - Go to step 3.
^ NO - This TSB does NOT apply. Continue diagnosis to isolate the source of the noise.
3. Replace the rear wheel bearing caliper bracket and related parts.
Refer to the Technical Information System (TIS) applicable model year Repair Manual:
4. Test drive the vehicle and confirm the noise is eliminated.
5. Re-check rear differential oil level and confirm NO leaks are present.
Power Mirror Control System (w/ Memory)
Power Mirror Switch: Locations Power Mirror Control System (w/ Memory)
MIRROR: POWER MIRROR CONTROL SYSTEM (w/ Memory): PARTS LOCATION
Page 2457
Page 4894
Shifter A/T: Component Tests and General Diagnostics
SHIFT LEVER ASSEMBLY (for Column Shift Type)
A760F AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY (for Column Shift Type):
INSPECTION
1. INSPECT COLUMN SHIFT SHIFT LEVER SUB-ASSEMBLY
(a) Disconnect the transmission control switch connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(c) If the result is not as specified, replace the column shift shift lever sub-assembly.
SHIFT LEVER ASSEMBLY (for Floor Shift Type)
A760F AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY (for Floor Shift Type):
INSPECTION
1. INSPECT TRANSMISSION CONTROL SWITCH
(a) Disconnect the transmission control switch connector.
(b) Measure the resistance according to the value(s) in the table below.
Page 2393
Engine Oil: Fluid Type Specifications
Grade ...................................................................................................................................................
..................................... ILSAC multigrade engine oil
4.6L V8 ................................................................................................................................................
............................................................... SAE 0W-20
5.7L V8 ................................................................................................................................................
.............................................. SAE 5W-20 or 0W-20
Page 4107
SST : 09268-31012
90467-13001
95336-08070
09268-41500
09268-41120
SST : 09268-45014
09268-41200
09268-41220
(g) Wipe off any gasoline.
(h) Reconnect the cable to the negative (-) battery terminal.
(i) Operate the fuel pump.
(1) Connect the Techstream to the DLC3.
(2) Turn the ignition switch to ON.
NOTICE: Do not start the engine.
(3) Turn the Techstream main switch ON.
(4) Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump /
Speed.
(j) Measure the fuel pressure.
Standard fuel pressure:
281 to 287 kPa (2.87 to 2.93 kgf/cm2, 41 to 42 psi)
(k) If the pressure is higher than the specification, replace the fuel pressure regulator.
If the pressure is lower than the specification, check the fuel hoses and connections, fuel pump,
fuel filter and fuel pressure regulator assembly.
(l) Start the engine.
Page 6549
Engine Room R/B, J/B - Engine Compartment Left
Page 2905
Air Flow Meter/Sensor: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: INSTALLATION
1. INSTALL MASS AIR FLOW METER
(a) Install the MAF meter with the 2 screws.
Torque : 1.7 Nm (17 kgf-cm, 15 in-lbf)
(b) Connect the MAF connector.
Page 837
2. INSTALL FRONT SPEED SENSOR LH
(a) Install the speed sensor (labeled D) with the hexagon socket head cap bolt (labeled E).
Torque : 11 Nm (107 kgf-cm, 8 ft-lbf)
NOTICE: *
Make sure there are no pieces of iron or other foreign matter attached to the sensor tip part.
* While inserting the speed sensor into the knuckle hole, do not strike or damage the sensor tip
part.
* After installing the speed sensor, make sure there is no clearance or foreign matter between the
sensor stay part and the knuckle.
* Make sure there is no foreign matter attached to the magnetic rotor.
3. INSTALL FRONT SKID CONTROL SENSOR WIRE LH
(a) Connect the connector (labeled A).
(b) Install the 3 harness clamps (labeled B) with the 3 bolts (labeled C).
Torque : 13 Nm (127 kgf-cm, 9 ft-lbf)
NOTICE: *
When installing the clamps, do not twist the wire harness.
* For clamps with rotation stoppers, make sure the rotation stopper touches the installation
position.
(c) Install the harness clamp with the bolt (labeled D).
Page 6187
Auxiliary Power Outlet: Service and Repair Power Outlet Socket (for Column Shift Type)
Components
OTHER SYSTEM: POWER OUTLET SOCKET (for Column Shift Type): COMPONENTS
Removal
OTHER SYSTEM: POWER OUTLET SOCKET (for Column Shift Type): REMOVAL
1. REMOVE FRONT DOOR SCUFF PLATE LH (for Double Cab)
Page 5065
SST : 09950-60010
09951-00420
Standard bearing depth:
1.2 to 1.8 mm (0.0472 to 0.0709 in.)
7. INSTALL FRONT DIFFERENTIAL CASE
(a) Install the 2 side gear thrust washers onto the 2 side gears.
HINT Using the table below, select the thrust washer which will ensure that the backlash is within
the specifications.
Washer thickness:
(b) Install the 2 side gears, 2 side gear thrust washers, 2 pinion gears, 2 pinion gear thrust washers
and pinion shaft into the differential case
assembly.
HINT *
Align the holes of the differential case assembly and pinion shaft.
* Apply hypoid gear oil to each sliding surface and rotating part.
(c) Measure the side gear backlash.
(1) Using a dial indicator, measure the side gear backlash while holding one pinion gear toward the
differential case assembly.
Page 8181
Page 6358
4. SYMPTOM CONFIRMATION AND DTC (INCLUDING FREEZE FRAME DATA) CHECK
(a) Visually check the wire harnesses, connectors and fuses for open and short circuits.
(b) Warm up the engine to the normal operating temperature.
(c) Confirm the problem symptoms and conditions, and check for DTCs.
B -- Go to step 6 A -- Continue to next step.
5. DTC CHART
(a) Check the results obtained in the DTC check. Then find the output DTC in the DTC chart. Look
at the "Trouble Area" column for a list of
potentially malfunctioning circuits and / or parts.
NEXT -- Go to step 7
6. PROBLEM SYMPTOMS TABLE
(a) Check the results obtained in the symptom confirmation. Then find the problem symptoms in
the problem symptoms table. Look at the
"Suspected Area" column for a list of potentially malfunctioning circuits and / or parts.
NEXT -- Continue to next step.
7. CIRCUIT INSPECTION OR PARTS INSPECTION
(a) Confirm the malfunctioning circuit or part.
NEXT -- Continue to next step.
8. ADJUST, REPAIR OR REPLACE
(a) Adjust, repair or replace the malfunctioning circuit or parts.
NEXT -- Continue to next step.
9. CONFIRMATION TEST
(a) After the adjustment, repairs or replacement, confirm that the malfunction no longer exists. If the
malfunction does not reoccur, perform a
confirmation test under the same conditions and in the same environment as when the malfunction
occurred the first time.
NEXT -- END
2. CUSTOMER PROBLEM ANALYSIS
HINT *
In troubleshooting, confirm that the problem symptoms have been accurately identified.
Preconceptions should be discarded in order to make an accurate judgment. To clearly understand
what the problem symptoms are, it is extremely important to ask the customer about the problem
and the conditions at the time the malfunction occurred.
* Gather as much information as possible for reference. Past problems that seem unrelated may
also help in some cases.
* The following 5 questions are important points in the problem analysis:
Page 7026
for Double Cab of Long Deck
Page 3490
INSPECTION PROCEDURE
HINT Operating the ignition switch, any switches or any doors triggers related ECU and sensor
communication with the CAN, which causes resistance variation.
PROCEDURE
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
(a) Disconnect the cable from the negative (-) battery terminal before measuring the resistances of
the main wire and the branch wire.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
NEXT -- Continue to next step.
2. CHECK FOR SHORT IN CAN BUS WIRES (DLC3 BRANCH WIRE)
(a) Disconnect the J86 No. 1 junction connector connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO DLC3 (CANH, CANL) OK -Continue to next step.
3. CONNECT CONNECTOR
Page 1774
Drive Belt: Service and Repair Installation
1UR-FE ENGINE MECHANICAL: DRIVE BELT: INSTALLATION
1. INSTALL FAN AND GENERATOR V BELT
(a) Set the V belt onto every part.
(b) While turning the belt tensioner counterclockwise, remove the pin.
NOTICE: Make sure that the V belt is properly set to each pulley.
(c) After installing the belt, check that it fits properly in the ribbed grooves.
HINT Make sure to check by hand that the belt has not slipped out of the grooves on the bottom of
the pulley.
2. INSTALL NO. 1 ENGINE UNDER COVER See: Fluids/Engine Oil/Service and
Repair/Replacement
3. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Installation
Engine Controls - Techstream(R) ECU Re-Flash
Procedure
Engine Control Module: All Technical Service Bulletins Engine Controls - Techstream(R) ECU
Re-Flash Procedure
T-SB-0064-10
February 4, 2010
Techstream ECU Flash Reprogramming Procedure
Service Category Engine/Hybrid System
Section Engine Control
Market USA
Applicability
TSB SUPERSESSION NOTICE
The information contained in this TSB supersedes TSB No. SS002-07.
^ Applicability has been updated to include 2009 - 2011 model year Toyota vehicles.
^ A new section, Techstream Preparation, has been added.
^ Techstream Lite has been added as an option in Required Tools & Materials.
^ Process Overview and Operation Procedure sections have been updated.
TSB No. SS002-07 is Obsolete and any printed versions should be discarded. Be sure to review
the entire content of this service bulletin before proceeding.
Introduction
Flash reprogramming allows the ECU software to be updated without replacing the ECU. Flash
calibration updates for specific vehicle models/ECUs are released as field-fix procedures described
in individual service bulletins. This bulletin details the Techstream ECU flash reprogramming
process and outlines use of the Technical Information System (TIS) and the Calibration Update
Wizard (CUW). Flash calibration updates can only be applied to the vehicle/ECU combination for
which they are intended. ECUs have internal security that will not allow them to be programmed
with another ECU's information.
ECU
Electronic Control Unit (ECU) is a Toyota term used to describe integrated computerized devices
responsible for managing the operation of a system or subsystem. For the purposes of this bulletin,
the term "ECU" is used as a generic label for the following SAE J1930 standard references:
^ Powertrain Control Module (PCM)
Page 8615
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for
36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Required Tools & Equipment
Parts Information
Repair Procedure
Page 2092
J/B No.5 - Instrument Panel Center
Locations
Main Relay (Computer/Fuel System): Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 2184
Tire Pressure Module: Locations
TIRE AND WHEEL: TIRE PRESSURE WARNING SYSTEM: PARTS LOCATION
Locations
Garage Door Opener Transmitter: Locations
GARAGE DOOR OPENER: GARAGE DOOR OPENER SYSTEM: PARTS LOCATION
Page 916
Cabin Temperature Sensor / Switch: Service and Repair Removal
AIR CONDITIONING: ROOM TEMPERATURE SENSOR (for Automatic Air Conditioning System):
REMOVAL
1. REMOVE FRONT DOOR SCUFF PLATE LH
(a) for Regular Cab:
Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular Cab)/Removal.
(b) for Double Cab:
Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Removal.
(c) for CrewMax:
Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for CrewMax)/Removal.
2. REMOVE COWL SIDE TRIM BOARD LH
(a) for Regular Cab:
Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular Cab)/Removal.
(b) for Double Cab:
Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Removal.
(c) for CrewMax:
Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for CrewMax)/Removal.
3. REMOVE INSTRUMENT SIDE PANEL LH
(a) for Column Shift Type:
Remove the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Column Shift Type)/Removal.
(b) for Floor Shift Type:
Remove the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Floor Shift Type)/Removal.
4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH
(a) for Column Shift Type:
Remove the instrument panel finish panel See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument
Panel Safety Pad (for Column Shift Type)/Removal.
(b) for Floor Shift Type:
Remove the instrument panel finish panel See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument
Panel Safety Pad (for Floor Shift Type)/Removal.
5. REMOVE ROOM TEMPERATURE SENSOR
Specifications
Intake Manifold: Specifications
INTAKE MANIFOLD
Install and uniformly tighten the 8 bolts and 2 nuts in several steps.
Torque..................................................................................................................................................
.....................................21 Nm (214 kgf-cm, 15 ft-lbf)
Page 1469
Page 871
Cruise Control Switch: Diagrams
Page 4525
Ignition Coil: Service and Repair Removal
1UR-FE IGNITION: IGNITION COIL AND SPARK PLUG: REMOVAL
1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Removal
2. REMOVE AIR CLEANER ASSEMBLY
(a) Disconnect the MAF meter connector and clamp.
(b) Disconnect the ventilation hose and vacuum hose.
(c) Loosen the hose clamp.
(d) Remove the 2 bolts and air cleaner.
3. REMOVE IGNITION COIL ASSEMBLY
(a) for Bank 1:
(1) Disconnect the 3 wire harness clamps.
(2) Disconnect the 4 ignition coil connectors.
(3) Remove the 4 bolts and 4 ignition coils.
(b) for Bank 2:
(1) Disconnect the 2 wire harness clamps.
(2) Disconnect the 4 ignition coil connectors.
(3) Disconnect the engine wire harness clamp.
Page 3236
when inserting and after full engagement.
NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal.
(d) REPAIR METHOD OF CONNECTOR TERMINAL
(1) If there is any foreign matter on the terminal, clean the contact point using an air gun or cloth.
Never rub the contact point using sandpaper
as the plating may come off.
(2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is
gold-plated (gold color), use a gold-plated female
terminal; if it is silver-plated (silver color), use a silver-plated female terminal.
(3) Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock
into the housing, the housing may have to be
replaced.
(e) HANDLING OF WIRE HARNESS
(1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be
restored in the same way.
(2) Never twist, pull or slacken the wire harness more than necessary.
(3) The wire harness should never come into contact with a high temperature part, or rotating,
moving, vibrating or sharp-edged parts. Avoid
contact with panel edges, screw tips and other sharp items.
(4) When installing parts, never pinch the wire harness.
(5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with
vinyl tape.
2. CHECK FOR OPEN CIRCUIT
Page 8034
Air Bag Deactivation Switch: Service and Repair Curtain Shield Airbag Cutoff Switch
Components
SUPPLEMENTAL RESTRAINT SYSTEM: CURTAIN SHIELD AIRBAG CUTOFF SWITCH:
COMPONENTS
Removal
SUPPLEMENTAL RESTRAINT SYSTEM: CURTAIN SHIELD AIRBAG CUTOFF SWITCH:
REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Removal
3. REMOVE FRONT DOOR SCUFF PLATE LH (for Double Cab, CrewMax) See: Body and
Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Removal
4. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Removal
5. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal
6. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Removal
7. REMOVE CURTAIN SHIELD AIRBAG CUTOFF SWITCH
(a) Disconnect the connector.
Heated Oxygen Sensor
Oxygen Sensor: Testing and Inspection Heated Oxygen Sensor
1UR-FE ENGINE CONTROL SYSTEM: HEATED OXYGEN SENSOR: ON-VEHICLE
INSPECTION
1. CHECK HEATED OXYGEN SENSOR
(a) Disconnect the heated oxygen sensor connector.
(b) Measure the heater resistance according to the value(s) in the table below.
Standard Resistance:
(c) If the result is not as specified, replace the heated oxygen sensor.
(d) Connect the heated oxygen sensor connector.
Page 4177
Page 3051
Crankshaft Position Sensor: Locations Ignition System
1UR-FE IGNITION: IGNITION SYSTEM: PARTS LOCATION
Page 1344
Knock Sensor: Diagrams
Page 9373
5. Pull the carpet back in the rear of the cab and remove the body plugs to expose the cab mount
bolts.
6. Remove the cab mount bolts by pulling them through the hole and discard. New bolts will be
used in their place.
Page 2098
Driver Side J/B Inner Circuit
Page 2921
Crankshaft Position Sensor: Diagrams
Page 4974
Transmission Speed Sensor: Testing and Inspection
A760F AUTOMATIC TRANSMISSION: SPEED SENSOR: INSPECTION
1. INSPECT SPEED SENSOR NT
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) If the result is not as specified, replace the sensor.
2. INSPECT SPEED SENSOR SP2
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) If the result is not as specified, replace the sensor.
Page 8443
(d) Detach the 2 claws and remove the satellite radio antenna.
Installation
AUDIO / VISUAL: SATELLITE RADIO ANTENNA: INSTALLATION
1. INSTALL SATELLITE RADIO ANTENNA ASSEMBLY
(a) Attach the 2 claws to install the satellite radio antenna.
(b) Install the nut.
Torque : 4.5 Nm (45 kgf-cm, 39 in-lbf)
(c) Attach the 3 clamps.
(d) Connect the connector.
2. INSTALL ROOF HEADLINING ASSEMBLY
(a) for Double Cab:
Install the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Double Cab)/Installation.
(b) for CrewMax:
Install the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (for CrewMax)/Installation.
Page 8497
Keyless Entry Module: Service and Repair Door Control Receiver (for Regular Cab)
Components
DOOR LOCK: DOOR CONTROL RECEIVER (for Regular Cab): COMPONENTS
Page 3702
^ Engine Control Module (ECM)
^ Transmission Control Module (TCM)
^ Or any other Toyota specific control unit
Warranty Information
Parts Information
Required Tools & Equipment
NOTE
Additional SSTs may be ordered by calling 1-800-933-8335.
Process Overview
Techstream ECU flash reprogramming is a 4-step process:
1. Verify the vehicle's applicability for recalibration and locate desired calibration file by performing
the Techstream Health Check function.
NOTE
Techstream will automatically search TIS for the appropriate service bulletin using the current
Calibration ID from the vehicle. Calibration file links can be found embedded in the corresponding
service bulletin.
2. Connect the GR8 Battery Diagnostic Station using "Power Supply Mode" only.
The GR8 Battery Diagnostic Station includes a Power Supply Mode to help maintain battery
voltage at 13.5 volts during ECU reprogramming.
ECU damage may occur if the correct battery charger mode setting is NOT used.
3. Locate appropriate calibration ID and reprogram the vehicle ECU with Techstream.
Techstream uses the Calibration Update Wizard (CUW) application to open calibration files and
facilitate the ECU flash reprogramming process.
Page 6261
Page 9061
Push the terminal retainer down to the temporary lock position.
Page 5967
4. SYMPTOM CONFIRMATION AND DTC (INCLUDING FREEZE FRAME DATA) CHECK
(a) Visually check the wire harnesses, connectors and fuses for open and short circuits.
(b) Warm up the engine to the normal operating temperature.
(c) Confirm the problem symptoms and conditions, and check for DTCs.
B -- Go to step 6 A -- Continue to next step.
5. DTC CHART
(a) Check the results obtained in the DTC check. Then find the output DTC in the DTC chart. Look
at the "Trouble Area" column for a list of
potentially malfunctioning circuits and / or parts.
NEXT -- Go to step 7
6. PROBLEM SYMPTOMS TABLE
(a) Check the results obtained in the symptom confirmation. Then find the problem symptoms in
the problem symptoms table. Look at the
"Suspected Area" column for a list of potentially malfunctioning circuits and / or parts.
NEXT -- Continue to next step.
7. CIRCUIT INSPECTION OR PARTS INSPECTION
(a) Confirm the malfunctioning circuit or part.
NEXT -- Continue to next step.
8. ADJUST, REPAIR OR REPLACE
(a) Adjust, repair or replace the malfunctioning circuit or parts.
NEXT -- Continue to next step.
9. CONFIRMATION TEST
(a) After the adjustment, repairs or replacement, confirm that the malfunction no longer exists. If the
malfunction does not reoccur, perform a
confirmation test under the same conditions and in the same environment as when the malfunction
occurred the first time.
NEXT -- END
2. CUSTOMER PROBLEM ANALYSIS
HINT *
In troubleshooting, confirm that the problem symptoms have been accurately identified.
Preconceptions should be discarded in order to make an accurate judgment. To clearly understand
what the problem symptoms are, it is extremely important to ask the customer about the problem
and the conditions at the time the malfunction occurred.
* Gather as much information as possible for reference. Past problems that seem unrelated may
also help in some cases.
* The following 5 questions are important points in the problem analysis:
Page 8302
Rear Seat Belt Extender Applications
Part Number Information
Owners Instructions
Failure to follow the recommendations indicated below could result in reduced effectiveness of the
seat belt restraint system in case of vehicle collision causing personal injury.
If your seat belt cannot be fastened securely because it is not long enough a personalized Seat
Belt Extender is available from your Toyota dealer free of charge.
Please visit your local Toyota dealer so that the dealer can order the proper required length
extender.
Bring the heaviest coat you expect to wear for proper measurement and selection of length.
Additional ordering information is available at your Toyota dealer.
Page 6400
Page 2311
Camshaft: Service and Repair Camshaft (for Bank 2)
Components
1UR-FE ENGINE MECHANICAL: CAMSHAFT (for Bank 2): COMPONENTS
Removal
Page 2780
Parts Information
Calibration Information
Required Tools & Equipment
Repair Procedure
Locations
Dome Lamp Switch: Locations
LIGHTING: LIGHTING SYSTEM: PARTS LOCATION
Locations
Cabin Temperature Sensor / Switch: Locations
AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Automatic Air Conditioning System):
PARTS LOCATION
Up to 11/2009
Traction Control Switch: Locations Up to 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 6122
(b) Install the starter brush holder.
(c) Connect the 4 brushes to the starter brush holder.
(1) Using a screwdriver, hold back the spring.
(2) Connect the brush to the brush holder.
(d) Align the rubber part on the starter yoke with the groove of the starter commutator end frame.
(e) Install the starter commutator end frame with the 2 screws.
Torque : 3.8 Nm (39 kgf-cm, 33 in-lbf)
5. INSTALL STARTER DRIVE HOUSING ASSEMBLY
(a) Apply high temperature grease to the starter pinion drive lever as shown in the illustration.
(b) Install the starter pinion drive lever to the starter center bearing clutch.
(c) Align the protrusions of the starter center bearing clutch with the notches inside the starter drive
housing.
Testing and Inspection
Radiator: Testing and Inspection
1UR-FE COOLING: RADIATOR: ON-VEHICLE INSPECTION
1. INSPECT RADIATOR CAP SUB-ASSEMBLY
CAUTION: To avoid the danger of being burned, do not remove the radiator cap while the engine
and radiator are still hot, as fluid and steam can be blown out under pressure.
(a) Measure the valve opening pressure.
(1) If there are water stains or foreign matter on rubber packing 1, 2 or 3, clean it by using water
and finger scouring.
(2) Check that rubber packing 1, 2 and 3 are not deformed, cracked or swollen.
(3) Check that rubber packing 3 and 4 are not stuck together.
(4) Apply engine coolant to rubber packing 2 and 3.
(5) Prepare a radiator cap tester, and tilt it more than 30°.
(6) Pump the cap tester several times, and check the maximum pressure*.
Pumping speed:
1 pump per second
HINT *: Even if the cap cannot maintain the maximum pressure, it is not a defect.
Standard Judgment Criterion:
(7) If the maximum pressure is less than the minimum standard value, replace the radiator cap
sub-assembly.
2. INSPECT FINS FOR BLOCKAGE
(a) Check that the radiator and condenser are not blocked with leaves, dirt, or insects. Clean the
hose connections.
Up to 11/2009
Hydraulic Control Assembly - Antilock Brakes: Locations Up to 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Components
Oil Filter: Service and Repair Components
1UR-FE LUBRICATION: OIL AND OIL FILTER: COMPONENTS
Page 9170
1. Wrap a pry bar with a soft shop towel then gently pull the step pad in an upward motion from
front to back using the pry bar to assist.
Be careful NOT to damage the chrome/painted surface.
2. If the plastic posts break off when the step pad is removed and stay in the tube use a punch and
hammer to punch the plastic bits into the tube. Use an
air gun to blow the posts out through the end of the tube.
3. Discard the step pad.
4. Using a pair of pliers pull out the old stainless post retainers (12 pieces) and discard.
5. Install the new post retainers into the holes in the tube.
6. Line up the replacement step posts with the holes in the post retainers.
7. Using the palm of your hand push firmly down in all post locations.
Then using a rubber mallet strike the pad along its entire length to ensure it is seated properly.
Page 4915
7. DISCONNECT NO. 1 SHIFT LOCK PLATE SUB-ASSEMBLY
(a) Using a pin-punch and hammer, tap out the spring pin and disconnect the shift lock plate from
the shift lock solenoid.
8. REMOVE TRANSMISSION CONTROL SWITCH (S POSITION)
(a) Remove the 2 screws and switch from the column shift control shift lever retainer.
(b) Insert a thin-bladed screwdriver, release the locking lug of terminal 6 (IG) and 13 (S), and pull
the terminals out from the rear.
Diagrams
Steering Angle Sensor: Diagrams
Up to 11/2009
Acceleration/Deceleration Sensor: Locations Up to 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 7947
CAUTION: Make sure that the wire harnesses are tight. Looseness in the wire harnesses results in
the tires coming free due to the shock when the airbag is deployed.
(f) Connect SST connector.
SST : 09082-00700
NOTICE: To avoid damaging SST connector and wire harness, do not lock the secondary lock of
the twin lock. Also, secure some slack for SST wire harness inside the tires.
(g) Deploy the airbag.
(1) Connect the red clip of SST to the positive (+) battery terminal and the black clip of SST to the
negative (-) battery terminal.
(2) Check that no one is within a 10 m (32.8 ft.) radius of the tire which the lower No. 1 instrument
panel airbag is tied to.
(3) Press SST activation switch to deploy the airbag.
CAUTION: When deploying the airbag, make sure that no one is near the tires.
HINT The airbag is deployed as the LED of SST activation switch comes on.
(h) Dispose of the lower No. 1 instrument panel airbag.
CAUTION: *
The lower No. 1 instrument panel airbag becomes extremely hot when the airbag is deployed, so
do not touch it for at least 30 minutes after deployment.
* Use gloves and safety glasses when handling a lower No. 1 instrument panel airbag with a
deployed airbag.
* Do not apply water to a lower No. 1 instrument panel airbag with a deployed airbag.
* Always wash your hands with water after completing the operation.
(1) Remove the lower No. 1 instrument panel airbag from the tire.
(2) Place the lower No. 1 instrument panel airbag in a plastic bag, tie it tightly and dispose of it in
the same way as other general parts.
Front Passenger Airbag Assembly
SUPPLEMENTAL RESTRAINT SYSTEM: FRONT PASSENGER AIRBAG ASSEMBLY:
DISPOSAL
Page 2827
HINT The wavelength becomes shorter as the vehicle speed increases.
(k) WAVEFORM 10:
HINT The duty ratio varies depending on the throttle actuator operation.
(l) WAVEFORM 11:
HINT The duty ratio varies depending on the throttle actuator operation.
(m)WAVEFORM 12:
Page 5986
Neutral Safety Switch: Component Tests and General Diagnostics
A760F AUTOMATIC TRANSMISSION: PARK / NEUTRAL POSITION SWITCH: INSPECTION
1. INSPECT PARK/NEUTRAL POSITION SWITCH ASSEMBLY
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) If the result is not as specified, replace the switch assembly.
Components
Tire Pressure Sensor: Service and Repair Components
TIRE AND WHEEL: TIRE PRESSURE WARNING VALVE AND TRANSMITTER: COMPONENTS
Locations
Tire Pressure Monitor Receiver / Transponder: Locations
TIRE AND WHEEL: TIRE PRESSURE WARNING SYSTEM: PARTS LOCATION
Page 6914
"Case1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (/\ Mark) and pull the terminal retainer
up to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Page 4271
^ Engine Control Module (ECM)
^ Transmission Control Module (TCM)
^ Or any other Toyota specific control unit
Warranty Information
Parts Information
Required Tools & Equipment
NOTE
Additional SSTs may be ordered by calling 1-800-933-8335.
Process Overview
Techstream ECU flash reprogramming is a 4-step process:
1. Verify the vehicle's applicability for recalibration and locate desired calibration file by performing
the Techstream Health Check function.
NOTE
Techstream will automatically search TIS for the appropriate service bulletin using the current
Calibration ID from the vehicle. Calibration file links can be found embedded in the corresponding
service bulletin.
2. Connect the GR8 Battery Diagnostic Station using "Power Supply Mode" only.
The GR8 Battery Diagnostic Station includes a Power Supply Mode to help maintain battery
voltage at 13.5 volts during ECU reprogramming.
ECU damage may occur if the correct battery charger mode setting is NOT used.
3. Locate appropriate calibration ID and reprogram the vehicle ECU with Techstream.
Techstream uses the Calibration Update Wizard (CUW) application to open calibration files and
facilitate the ECU flash reprogramming process.
Page 7264
(a) Attach the claw to install the upper steering column cover.
(b) Attach the 4 clips to install the upper steering cover onto the instrument panel cluster finish
panel.
(c) Install the 2 screws.
Torque : 2.0 Nm (20 kgf-cm, 18 in-lbf)
HINT Turn the steering wheel to the right and left as necessary to install the 2 screws.
8. INSPECT SRS WARNING LIGHT
(a) Inspect the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
9. CONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
Page 8765
Remote Switch: Service and Repair Installation
AUDIO / VISUAL: STEERING PAD SWITCH: INSTALLATION
1. INSTALL STEERING PAD SWITCH ASSEMBLY
(a) Attach the 4 pins to install the switch with the 2 screws.
(b) Connect the connector.
2. INSTALL LOWER NO. 3 STEERING WHEEL COVER See: Restraint Systems/Air Bag
Systems/Air Bag/Service and Repair/Removal and
Replacement/Steering Pad/Installation
3. INSTALL LOWER NO. 2 STEERING WHEEL COVER See: Restraint Systems/Air Bag
Systems/Air Bag/Service and Repair/Removal and
Replacement/Steering Pad/Installation
4. INSTALL STEERING PAD See: Restraint Systems/Air Bag Systems/Air Bag/Service and
Repair/Removal and Replacement/Steering
Pad/Installation
5. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
6. INSPECT STEERING PAD See: Restraint Systems/Air Bag Systems/Air Bag/Service and
Repair/Removal and Replacement/Steering
Pad/Installation
7. CHECK SRS WARNING LIGHT See: Restraint Systems/Air Bag Systems/Air Bag/Service and
Repair/Removal and Replacement/Steering
Pad/Installation
Page 8509
If the customer has experienced a RES malfunction above -22 F (-30 C) proceed with diagnosis
referencing the applicable troubleshooting guide in the Technical Information System (TIS)
Accessory tab Accessory Diagnostic Guide:
For 2007 Camry, Camry HV; Tundra, and 2006 - 2007 RAV4:
Refer also to TSB T-SB-0070-08, "Remote Engine Starter (RES) Cold Temperature Operation".
Page 3056
Crankshaft Position Sensor: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: CRANKSHAFT POSITION SENSOR: INSTALLATION
1. INSTALL CRANKSHAFT POSITION SENSOR
(a) Install the sensor with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(b) Connect the sensor connector.
2. INSTALL CRANKSHAFT POSITION SENSOR PROTECTOR
(a) Install the sensor protector with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
Page 4379
Fuel Pump Control Unit: Diagrams
Page 136
Control Module HVAC: Locations Air Conditioning System (for Manual Air Conditioning System)
AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Manual Air Conditioning System):
PARTS LOCATION
Locations
Sunroof / Moonroof Switch: Locations
SLIDING ROOF: SLIDING ROOF SYSTEM: PARTS LOCATION
Page 5761
26. REMOVE NO. 2 CABLE RETAINER
(a) Remove the bolt and cable retainer.
27. REMOVE NO. 3 PARKING BRAKE CABLE ASSEMBLY
(a) Remove the 5 bolts and disconnect the No. 3 parking brake cable from the intermediate lever.
NOTICE: Do not bend and twist the parking brake cable.
(b) Remove the bolt and No. 3 parking brake cable from the rear axle carrier.
Page 3334
Engine Control Module: Programming and Relearning
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: REGISTRATION
NOTICE: The Vehicle Identification Number (VIN) must be input into the replacement ECM.
HINT The VIN is in the form of a 17-digit alphanumeric vehicle identification number. The
Techstream is required to register the VIN.
1. DESCRIPTION
NOTICE: The Vehicle Identification Number (VIN) must be input into the replacement ECM.
HINT This registration section consists of two parts: Read VIN and Write VIN.
(a) Read VIN: Explains the VIN reading process in a flowchart. This process allows the VIN stored
in the ECM to be read in order to confirm that
the two VINs, the one provided with the vehicle and the one stored in the vehicle's ECM, are the
same.
(b) Write VIN: Explains the VIN writing process in a flowchart. This process allows the VIN to be
input into the ECM. If the ECM is changed, or
the ECM VIN and vehicle VIN do not match, the VIN can be registered or overwritten in the ECM
by following this procedure.
2. READ VIN
(a) Confirm the vehicle VIN.
(b) Connect the Techstream to the DLC3.
(c) Turn the ignition switch to ON.
(d) Turn the Techstream on.
(e) Enter the following menus: Powertrain / Engine and ECT / Utility / VIN / VIN Read.
3. WRITE VIN
(a) Confirm the vehicle VIN.
(b) Connect the Techstream to the DLC3.
(c) Turn the ignition switch to ON.
(d) Turn the Techstream on.
(e) Enter the following menus: Powertrain / Engine and ECT / Utility / VIN / VIN Write.
Page 5969
Page 6196
3. REMOVE FRONT SEAT ASSEMBLY LH (for Power Seat)
(a) Remove the front seat LH See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Power
Seat)/Removal.
4. REMOVE FRONT SEAT ASSEMBLY RH (for Power Seat)
HINT Use the same procedures described for the LH side.
5. REMOVE CENTER FRONT SEAT ASSEMBLY
(a) Remove the center front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Center
Seat)/Removal.
6. REMOVE POWER OUTLET SOCKET ASSEMBLY
(a) Disconnect the power outlet socket connector.
(b) Using a screwdriver, detach the claw and remove the power outlet socket.
HINT Tape the screwdriver tip before use.
7. REMOVE POWER OUTLET SOCKET COVER
(a) Detach the 2 claws and remove the power outlet socket cover.
8. REMOVE CENTER SEATBACK PANEL (for Double Cab) See: Body and Frame/Seats/Service
and Repair/Overhaul/Front Seat Assembly (for
Center Seat)/Disassembly
9. REMOVE REAR POWER OUTLET SOCKET ASSEMBLY (for Double Cab)
(a) Using a screwdriver, detach the claw and remove the power outlet socket.
Page 7260
Page 3713
J. When Cal 1 has completed the update process turn ignition OFF for a minimum of 10 seconds.
Then click Next.
K. Turn ignition to the ON position. Then click Start.
L. Do NOT disturb the vehicle during flash reprogramming.
Page 1975
Engine Room R/B, J/B - Engine Compartment Left
Page 5396
Control Module: Service and Repair Removal
JF1A TRANSFER: 4WD CONTROL ECU: REMOVAL
1. REMOVE FRONT DOOR SCUFF PLATE RH (for Regular Cab)
(a) Remove the front door scuff plate RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Removal.
HINT Use the same procedures described for the LH side.
2. REMOVE FRONT DOOR SCUFF PLATE RH (for Double Cab, for CrewMax)
(a) Remove the front door scuff plate RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Removal.
HINT Use the same procedures described for the LH side.
3. REMOVE COWL SIDE TRIM BOARD RH
(a) Remove the cowl side trim board RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Removal.
HINT Use the same procedures described for the LH side.
4. REMOVE INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal
5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and
Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument
Panel Safety Pad (for Column Shift Type)/Removal
6. REMOVE 4WD CONTROL ECU
(a) Disconnect the 2 ECU connectors.
(b) Remove the bolt and ECU.
Locations
Tire Pressure Sensor: Locations
TIRE AND WHEEL: TIRE PRESSURE WARNING SYSTEM: PARTS LOCATION
Page 5771
28. INSTALL FRONT NO. 2 EXHAUST PIPE ASSEMBLY (for 1GR-FE)
(a) for Regular Cab Standard Deck:
Install the front No. 2 exhaust pipe See: Engine, Cooling and Exhaust/Exhaust System/Exhaust
Pipe/Service and Repair/Exhaust Pipe (for Regular Cab Standard Deck)/Installation.
(b) except Regular Cab Standard Deck:
Install the front No. 2 exhaust pipe See: Engine, Cooling and Exhaust/Exhaust System/Exhaust
Pipe/Service and Repair/Exhaust Pipe (Except Regular Cab Standard Deck)/Installation.
29. INSTALL FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY (for 1GR-FE)
(a) for Regular Cab Standard Deck:
Install the front No. 3 exhaust pipe See: Engine, Cooling and Exhaust/Exhaust System/Exhaust
Pipe/Service and Repair/Exhaust Pipe (for Regular Cab Standard Deck)/Installation.
30. INSTALL FRONT NO. 2 EXHAUST PIPE ASSEMBLY (for 1UR-FE)
(a) for Regular Cab Standard Deck:
Install the front No. 2 exhaust pipe See: Engine, Cooling and Exhaust/Exhaust System/Exhaust
Pipe/Service and Repair/Exhaust Pipe (for Regular Cab Standard Deck)/Installation.
(b) except Regular Cab Standard Deck:
Install the front No. 2 exhaust pipe See: Engine, Cooling and Exhaust/Exhaust System/Exhaust
Pipe/Service and Repair/Exhaust Pipe (Except Regular Cab Standard Deck)/Installation.
31. INSTALL FRONT NO. 2 EXHAUST PIPE ASSEMBLY (for 3UR-FE)
(a) for Regular Cab Standard Deck:
Install the front No. 2 exhaust pipe See: Engine, Cooling and Exhaust/Exhaust System/Exhaust
Pipe/Service and Repair/Exhaust Pipe (for Regular Cab Standard Deck)/Installation.
(b) except Regular Cab Standard Deck:
Page 6977
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: ELECTRONIC
CIRCUIT INSPECTION PROCEDURE
1. BASIC INSPECTION
(a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS
(1) Unless otherwise stated, all resistance measurements should be made at an ambient
temperature of 20°C (68°F). Resistance measurements
may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been
running. Measurements should be made after the engine has cooled down.
(b) HANDLING CONNECTORS
(1) When disconnecting a connector, first squeeze the mating halves tightly together to release the
lock, and then press the lock claw and
separate the connector.
(2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly
and separate it.
(3) Before connecting a connector, check that there are no deformed, damaged, loose or missing
terminals.
(4) When connecting a connector, press firmly until it locks with a "click" sound.
(5) If checking a connector with a TOYOTA electrical tester, check the connector from the backside
(harness side) using a mini test lead.
NOTICE: *
As a waterproof connector cannot be checked from the backside, check it by connecting a
sub-harness.
* Do not damage the terminals by moving the inserted tester needle.
(c) CHECKING CONNECTORS
(1) Checking when a connector is connected: Squeeze the connectors together to confirm that they
are fully connected and locked.
(2) Checking when a connector is disconnected: Check by pulling the wire harness lightly from the
backside of the connector. Look for
unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for
corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or
deformed terminals.
(3) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a
female terminal, and check for ample tension
Page 9107
Remove the blown fuse and disconnect all loads of the fuse.
Connect a test light in place of the fuse.
Establish conditions in which the test light comes on.
Example:
- [A] - Ignition SW on
- [B] - Ignition SW and SW1 on
- [C] - Ignition SW, SW1 and Relay on (Connect the Relay) and SW2 off (or Disconnect SW2)
Disconnect and reconnect the connectors while watching the test light.
Page 7349
3. REMOVE REAR WHEEL
4. DISCONNECT NO. 3 PARKING BRAKE CABLE ASSEMBLY
(a) Remove the 3 bolts and disconnect the cable from the vehicle.
5. DISCONNECT REAR SHOCK ABSORBER ASSEMBLY LH
(a) Support the rear axle housing with a jack using a wooden block to avoid damage.
(b) Remove the bolt and nut, and disconnect the shock absorber lower side from the axle housing.
6. REMOVE REAR SPRING U BOLT
(a) Remove the 4 nuts, 4 washers and spring seat.
(b) Remove the 2 U bolts.
7. REMOVE REAR SPRING BUMPER SUB-ASSEMBLY
(a) Remove the spring bumper.
Page 3031
Air Flow Meter/Sensor: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: INSTALLATION
1. INSTALL MASS AIR FLOW METER
(a) Install the MAF meter with the 2 screws.
Torque : 1.7 Nm (17 kgf-cm, 15 in-lbf)
(b) Connect the MAF connector.
Page 8050
Clockspring Assembly / Spiral Cable: Service and Repair Removal
SUPPLEMENTAL RESTRAINT SYSTEM: SPIRAL CABLE: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
2. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
3. REMOVE LOWER NO. 3 STEERING WHEEL COVER See: Air Bag/Service and
Repair/Removal and Replacement/Steering Pad/Removal
4. REMOVE LOWER NO. 2 STEERING WHEEL COVER See: Air Bag/Service and
Repair/Removal and Replacement/Steering Pad/Removal
5. REMOVE STEERING PAD See: Air Bag/Service and Repair/Removal and
Replacement/Steering Pad/Removal
6. REMOVE STEERING WHEEL ASSEMBLY See: Steering and Suspension/Steering/Steering
Column/Service and Repair/Removal and
Replacement/Steering Column Assembly (for Manual Tilt)/Removal
7. REMOVE LOWER STEERING COLUMN COVER See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Removal and
Replacement/Steering Column Assembly (for Manual Tilt)/Removal
8. REMOVE UPPER STEERING COLUMN COVER See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Removal and
Replacement/Steering Column Assembly (for Manual Tilt)/Removal
9. REMOVE SPIRAL CABLE
(a) Disconnect the connectors from the spiral cable with steering sensor.
NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness.
(b) Detach the 3 claws and remove the spiral cable with steering sensor.
NOTICE: *
Do not replace the spiral cable sub-assembly when the ignition switch is ON and the battery cable
is connected.
* Do not rotate the spiral cable when the ignition switch is ON and the battery cable is connected.
* Make sure the steering wheel is installed and centered before rotating the steering angle sensor
when performing steering angle sensor operation inspections (inspecting for abnormal noise,
diagnosis inspections, etc.).
* Do not remove the steering angle sensor from the spiral cable.
Locations
Brake Light Switch: Locations
LIGHTING: LIGHTING SYSTEM: PARTS LOCATION
Page 272
"Case1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (/\ Mark) and pull the terminal retainer
up to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Page 4996
1. INSTALL SHIFT SOLENOID VALVE S3
(a) Install the shift solenoid valve with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
2. INSTALL SHIFT SOLENOID VALVE S2
3. INSTALL SHIFT SOLENOID VALVE S4
(a) Install the shift solenoid valve with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
4. INSTALL SHIFT SOLENOID VALVE S1
(a) Install the shift solenoid valve and valve body wire harness clamp with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
5. INSTALL SHIFT SOLENOID VALVE SR
Page 3546
NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- REPLACE POWER STEERING ECU See: Relays and Modules/Relays and Modules Steering and Suspension/Relays and Modules - Steering/Steering Control Module/Service and
Repair/Removal
Main Body ECU Communication Stop Mode
CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: Main Body ECU Communication
Stop Mode - Main Body ECU Communication Stop Mode
DESCRIPTION
WIRING DIAGRAM
INSPECTION PROCEDURE
HINT Operating the ignition switch, any switches or any doors triggers related ECU and sensor
communication with the CAN, which causes resistance variation.
PROCEDURE
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
(a) Disconnect the cable from the negative (-) battery terminal before measuring the resistances of
the main wire and the branch wire.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
NEXT -- Continue to next step.
Page 7008
J/B No.6 Assembly Inner Circuit
Inspection
Variable Valve Timing Actuator: Testing and Inspection Inspection
1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT OIL CONTROL VALVE: INSPECTION
1. INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) If the result is not as specified, replace the camshaft timing oil control valve assembly.
(c) Connect the battery's positive (+) lead to terminal 1 and the negative (-) lead to terminal 2, and
check the movement of the valve.
OK:
(d) If the result is not as specified, replace the camshaft timing oil control valve assembly. If the
valve cannot return properly because of foreign
matter, a small pressure leak in the advanced direction may occur and a DTC may be output.
Page 1814
C. Choose desired ECU group(s) in the Health Check dialog box.
D. Click Next.
E. Click Continue to view Health Check results.
F. Available calibration updates are indicated by a link in the Cal. Update? column. Click the link to
access the appropriate service bulletin on TIS.
NOTE
^ Note any DTCs stored in Systems that will be flash reprogrammed.
^ Clicking the link will automatically launch TIS and perform a calibration search.
G. Log in to TIS. (If already logged in skip this step.)
H. To review the TSB and access the calibration file click the service bulletin link in the Document
Title column of the Calibration Search Result
portlet.
Page 7578
Blower Motor: Diagnostic Aids
Continuity and Resistance Check
CONTINUITY AND RESISTANCE CHECK
Disconnect the battery terminal or wire so there is no voltage between the check points.
Contact the two leads of an ohmmeter to each of the check points.
Page 90
(h) If the result is not as specified, the seat heater control may have a malfunction.
2. INSPECT SEAT HEATER CONTROL SUB-ASSEMBLY RH
(a) Disconnect the Y8 connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(c) If the result is not as specified, there may be a malfunction on the wire harness side.
(d) Measure the voltage according to the value(s) in the table below.
Standard voltage:
(e) If the result is not as specified, there may be a malfunction on the wire harness side.
(f) Connect the Y8 connector.
(g) Measure the voltage according to the value(s) in the table below.
Standard voltage:
Engine Controls - Techstream(R) ECU Re-Flash
Procedure
PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls Techstream(R) ECU Re-Flash Procedure
T-SB-0064-10
February 4, 2010
Techstream ECU Flash Reprogramming Procedure
Service Category Engine/Hybrid System
Section Engine Control
Market USA
Applicability
TSB SUPERSESSION NOTICE
The information contained in this TSB supersedes TSB No. SS002-07.
^ Applicability has been updated to include 2009 - 2011 model year Toyota vehicles.
^ A new section, Techstream Preparation, has been added.
^ Techstream Lite has been added as an option in Required Tools & Materials.
^ Process Overview and Operation Procedure sections have been updated.
TSB No. SS002-07 is Obsolete and any printed versions should be discarded. Be sure to review
the entire content of this service bulletin before proceeding.
Introduction
Flash reprogramming allows the ECU software to be updated without replacing the ECU. Flash
calibration updates for specific vehicle models/ECUs are released as field-fix procedures described
in individual service bulletins. This bulletin details the Techstream ECU flash reprogramming
process and outlines use of the Technical Information System (TIS) and the Calibration Update
Wizard (CUW). Flash calibration updates can only be applied to the vehicle/ECU combination for
which they are intended. ECUs have internal security that will not allow them to be programmed
with another ECU's information.
ECU
Electronic Control Unit (ECU) is a Toyota term used to describe integrated computerized devices
responsible for managing the operation of a system or subsystem. For the purposes of this bulletin,
the term "ECU" is used as a generic label for the following SAE J1930 standard references:
^ Powertrain Control Module (PCM)
Locations
Tilt Wheel Switch: Locations
STEERING COLUMN: POWER TILT AND POWER TELESCOPIC STEERING COLUMN
SYSTEM: PARTS LOCATION
Page 6942
J/B No.5 - Instrument Panel Center
Page 6925
General Information
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: GENERAL
INFORMATION
* A large number of ECU controlled systems are used in the TOYOTA TUNDRA. In general, ECU
controlled systems are considered to be very intricate, requiring a high level of technical knowledge
to troubleshoot. However, most problem checking procedures only involve inspecting the ECU
controlled system's circuits one by one. An adequate understanding of the system and a basic
knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and
necessary repairs.
1. TROUBLESHOOTING PROCEDURES
* The troubleshooting procedures consist of diagnosis procedures for when a DTC is stored and
diagnosis procedures for when no DTC is stored. The basic idea is explained in the following table.
* Vehicle systems are complex and use many ECUs that are difficult to inspect independently.
Therefore, a process of elimination is used, where components that can be inspected individually
are inspected, and if no problems are found in these components, the related ECU is identified as
the problem and replaced.
* It is extremely important to ask the customer about the environment and the conditions present
when the problem occurred (Customer Problem Analysis). This makes it possible to simulate the
conditions and confirm the symptom. If the symptom cannot be confirmed or the DTC does not
recur, the malfunctioning part may not be identified using the troubleshooting procedure, and the
ECU for the related system may be replaced even though it is not defective. If this happens, the
original problem will not be solved.
* In order to prevent endless expansion of troubleshooting procedures, the troubleshooting
procedures are written with the assumption that multiple malfunctions do not occur simultaneously
for a single problem symptom.
* To identify the malfunctioning part, troubleshooting procedures narrow down the target by
separating components, ECUs and wire harnesses during the inspection. If the wire harness is
identified as the cause of the problem, it is necessary to inspect not only the connections to
components and ECUs but also all of the wire harness connectors between the component and the
ECU.
DIAGNOSTIC TESTER
2. DESCRIPTION
System data and the Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector
3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the Techstream* to
check for a malfunction and perform repairs.
HINT *: Techstream is the name for the diagnostic tester in North America.
3. DATA LINK CONNECTOR 3 (DLC3)
(a) The vehicle's ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of
the DLC3 complies with SAE J1962 and
matches the ISO 15765-4 format.
Page 7348
Removal
SUSPENSION: REAR LEAF SPRING: REMOVAL
HINT *
Use the same procedures for the RH side and LH side.
* The procedures listed below are for the LH side.
1. SUPPORT BODY WITH SAFETY STANDS
(a) Jack up and support the body on safety stands.
(b) Lower the axle housing until the leaf spring tension is free, and keep it at this position.
2. REMOVE SPARE TIRE
Page 8363
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
4. REMOVE UPPER CONSOLE REAR PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
5. REMOVE REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
6. REMOVE CONSOLE BOX CARPET
7. REMOVE REAR CONSOLE BOX ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal
8. REMOVE FRONT CONSOLE BOX See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal
and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal
9. REMOVE CENTER AIRBAG SENSOR ASSEMBLY
(a) Disconnect the holder (with connectors).
(b) Remove the 3 bolts and airbag sensor.
Installation
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift
Type): INSTALLATION
1. INSTALL CENTER AIRBAG SENSOR ASSEMBLY
(a) Check that the ignition switch is OFF.
(b) Check that the cable is disconnected from the battery negative (-) terminal.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
(c) Install the airbag sensor with the 3 bolts.
Torque : 18 Nm (184 kgf-cm, 13 ft-lbf)
NOTICE: *
If the center airbag sensor has been dropped, or there are any cracks, dents or other defects in the
case, bracket or connector, replace it with a new one.
* When installing the center airbag sensor, be careful that the SRS wiring does not interfere with
other parts and that it is not pinched between other parts.
(d) Check that there is no looseness in the installation parts of the center airbag sensor.
Page 1331
If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness
or connector in that circuit in the past. Check the wire harness and connectors.
B -- SYSTEM NORMAL
A -- TROUBLESHOOTING OF EACH PROBLEM SYMPTOM
The problem is still occurring in a place other than the diagnostic circuit (the DTC displayed first is
either for a past problem or a secondary problem).
4. SYMPTOM SIMULATION
HINT The most difficult case in troubleshooting is when no problem symptoms occur. In such a
case, a thorough problem analysis must be carried out. A simulation of the same or similar
conditions and environment in which the problem occurred in the customer's vehicle should be
carried out. No matter how much skill or experience a technician has, troubleshooting without
confirming the problem symptoms will lead to important repairs being overlooked and mistakes or
delays.
For example:
With a problem that only occurs when the engine is cold or as a result of vibration caused by the
road during driving, the problem can never be determined if the symptoms are being checked on a
stationary vehicle or on a vehicle with a warmed-up engine. Vibration, heat or water penetration
(moisture) is difficult to reproduce. The symptom simulation tests below are effective substitutes for
the conditions and can be applied on a stationary vehicle.
Important points in the symptom simulation test:
In the symptom simulation test, the problem symptoms as well as the problem area or parts must
be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then,
connect the tester and carry out the symptom simulation test, judging whether the circuit being
tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the
problem symptoms table for each system to narrow down the possible causes.
To reproduce DTCs, it is necessary to satisfy the respective DTC detection conditions.
(a) VIBRATION METHOD:
When a malfunction seems to occur as a result of vibration.
(1) PART AND SENSOR
Apply slight vibration with a finger to the part of the sensor suspected to be the cause of the
problem, and check whether or not the malfunction occurs.
NOTICE: Applying strong vibration to relays may open them.
Page 1620
Heated Glass Element Switch: Locations Window Defogger System
WINDSHIELD / WINDOWGLASS: WINDOW DEFOGGER SYSTEM: PARTS LOCATION
Disassembly
Parking Brake Warning Switch: Service and Repair Disassembly
PARKING BRAKE: PARKING BRAKE PEDAL: DISASSEMBLY
1. REMOVE PARKING BRAKE SWITCH ASSEMBLY
(a) Remove the screw and switch.
Locations
Air Flow Meter/Sensor: Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 8115
(a) Disconnect the holder (with connectors).
(b) Remove the 3 bolts and airbag sensor.
Installation
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Column
Shift Type): INSTALLATION
1. INSTALL CENTER AIRBAG SENSOR ASSEMBLY
(a) Check that the ignition switch is OFF.
(b) Check that the cable is disconnected from the battery negative (-) terminal.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
(c) Install the airbag sensor with the 3 bolts.
Torque : 18 Nm (184 kgf-cm, 13 ft-lbf)
NOTICE: *
If the center airbag sensor has been dropped, or there are any cracks, dents or other defects in the
case, bracket or connector, replace it with a new one.
* When installing the center airbag sensor, be careful that the SRS wiring does not interfere with
other parts and that it is not pinched between other parts.
(d) Check that there is no looseness in the installation parts of the center airbag sensor.
(e) Connect the holder (with connectors).
(f) Check that the waterproof sheet is properly set.
2. INSTALL CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service
and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
NOTICE: Some systems need to be initialized after the cable is reconnected See: Testing and
Inspection/Programming and Relearning
4. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
Page 2567
(a) Apply a light coat of engine oil to the O-ring.
(b) Install a new O-ring to the oil control valve.
(c) Install the oil control valve with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(d) Connect the oil control valve connector.
5. INSTALL AIR CLEANER HOSE ASSEMBLY See: Service and Repair/Removal and
Replacement/Engine Assembly/Installation
6. INSTALL V-BANK COVER SUB-ASSEMBLY See: Service and Repair/Removal and
Replacement/Engine Assembly/Installation
Page 939
Evaporator Temperature Sensor / Switch: Service and Repair Reassembly
AIR CONDITIONING: FRONT EVAPORATOR TEMPERATURE SENSOR: REASSEMBLY
1. INSTALL NO. 1 COOLER THERMISTOR
NOTICE: If reusing the evaporator, do not insert the sensor into a location where the sensor was
previously inserted.
(a) Install the sensor to a location that is 1 fin to the right or left of its previous location.
2. INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY
(a) Install the evaporator to the blower case (front side).
(b) Install the blower case (back side).
Page 2306
(c) Uniformly loosen and remove the 18 bearing cap bolts in the sequence shown in the illustration.
NOTICE: Uniformly loosen the bolts while keeping the camshaft level.
(d) Remove the 6 bearing caps.
HINT Arrange the removed parts in the correct order.
(e) Remove the No. 3 and No. 4 camshafts.
9. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH
(a) Remove the camshaft housing by prying between the cylinder head and camshaft housing with
a screwdriver.
HINT Tape the screwdriver tip before use.
NOTICE: Be careful not to damage the contact surfaces of the cylinder head and camshaft
housing.
Installation
1UR-FE ENGINE MECHANICAL: CAMSHAFT (for Bank 1): INSTALLATION
1. INSTALL CAMSHAFT BEARING CAP LH
(a) Apply a light coat of engine oil to the camshaft journals, camshaft housings and bearing caps.
(b) Install the No. 3 and No. 4 camshafts to the camshaft housing.
(c) Confirm the marks and numbers on the camshaft bearing caps and place them in their proper
positions and directions.
(d) Temporarily install the 10 bolts in the order shown in the illustration.
Page 7058
Standard caster inclination (unloaded vehicle):
for Double Cab of Long Deck
Page 2085
Engine Room R/B, J/B - Engine Compartment Left
Page 5766
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
(b) Connect the No. 3 parking brake cable to the intermediate lever and install the 5 bolts.
for bolt A - Torque : 19 Nm (194 kgf-cm, 14 ft-lbf)
for bolt B - Torque : 14 Nm (138 kgf-cm, 10 ft-lbf)
NOTICE: Do not bend and twist the parking brake cable.
4. INSTALL PARKING BRAKE SHOE LEVER LH See: Service and Repair/Reassembly
5. INSTALL NO. 2 PARKING BRAKE SHOE ASSEMBLY LH See: Service and Repair/Reassembly
6. INSTALL NO. 1 PARKING BRAKE SHOE ASSEMBLY LH See: Service and Repair/Reassembly
7. INSTALL PARKING BRAKE SHOE RETURN SPRING LH See: Service and Repair/Reassembly
8. CHECK PARKING BRAKE INSTALLATION See: Service and Repair/Reassembly
9. INSTALL REAR DISC LH See: Disc Brake System/Service and Repair/Removal and
Replacement/Rear Brake/Installation
10. ADJUST PARKING BRAKE SHOE CLEARANCE See: Adjustments
11. CONNECT REAR DISC BRAKE CYLINDER ASSEMBLY LH See: Service and
Repair/Reassembly
12. INSTALL REAR WHEEL LH See: Steering and Suspension/Suspension/Suspension Strut /
Shock Absorber/Service and Repair/Removal and
Replacement/Rear Shock Absorber/Installation
13. INSTALL NO. 2 PARKING BRAKE CABLE ASSEMBLY
Page 7763
2. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY
(a) Install the instrument panel reinforcement.
(1) Temporarily install the instrument panel reinforcement.
(2) for Passenger Side:
Using a 12 mm hexagon wrench, install the 2 collars.
Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)
(3) for Passenger Side:
Using a T40 "TORX" socket, install the 2 "TORX" bolts.
Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)
Page 5726
(b) Using a union nut wrench, connect the flexible hose to the brake tube and wheel cylinder tube
while holding the flexible hose with a wrench.
without union nut wrench - Torque : 15 Nm (155 kgf-cm, 11 ft-lbf)
with union nut wrench - Torque : 14 Nm (145 kgf-cm, 10 ft-lbf)
HINT *
Use a torque wrench with a fulcrum length of 300 mm (11.8 in.).
* This torque value is effective when union nut wrench is parallel to the torque wrench.
NOTICE: *
Do not bend or damage the brake tube and wheel cylinder tube.
* Do not allow any foreign matter such as dirt and dust to enter the brake tube and wheel cylinder
tube from the connecting points.
2. BLEED BRAKE LINE See: Brake Bleeding/Service and Repair/Bleeding
3. INSTALL FRONT WHEEL See: Steering and Suspension/Suspension/Suspension Strut / Shock
Absorber/Service and Repair/Removal and
Replacement/Front Shock Absorber/Installation
Page 6244
Page 3544
Result
E -- REPAIR OR REPLACE HARNESS OR CONNECTOR
D -- REPLACE ECM See: Engine Control Module/Service and Repair/Removal
C -- REPLACE ECM See: Engine Control Module/Service and Repair/Removal
B -- REPLACE ECM See: Engine Control Module/Service and Repair/Removal
A -- REPLACE ECM
Power Steering ECU Communication Stop Mode
CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: Power Steering ECU
Communication Stop Mode - Power Steering ECU Communication Stop Mode
DESCRIPTION
WIRING DIAGRAM
INSPECTION PROCEDURE
HINT
Engine - Controls - Non-Linear Acceleration From A Stop
Engine Control Module: All Technical Service Bulletins Engine - Controls - Non-Linear Acceleration
From A Stop
T-SB-0273-10
September 28, 2010
Non-Linear Acceleration from a Stop
Service Category Engine/Hybrid System
Section Engine Control
Market USA
Applicability
Introduction
Some 2010 model year Tundra vehicles with the 1UR-FE (4.6 L) engine may exhibit non-linear
acceleration from a stop under certain conditions of low engine rpm with high engine load. The
Engine Control Module/ECM (SAE term: Powertrain Control Module/PCM) logic has been revised
to address this condition. Use the following repair procedure to recalibrate the ECM (PCM).
Calibration Information
Warranty Information
Applicable Warranty
^ This repair is covered under the Toyota Federal Emission Warranty. This warranty is in effect for
96 months or 80,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Page 8588
Parking Assist Switch: Service and Repair Installation
PARK ASSIST / MONITORING: CLEARANCE SONAR MAIN SWITCH: INSTALLATION
1. INSTALL DRIVE MONITOR SWITCH
(a) Attach the 2 claws to install the monitor switch.
2. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Panel,
Gauges and Warning Indicators/Instrument Cluster
/ Carrier/Service and Repair/Combination Meter/Installation
Page 8657
Page 3566
14. CHECK BUS BUFFER ECU
HINT For vehicles with a bus buffer ECU only.
(a) Disconnect the J59 ECU connector.
(b) Measure the resistance according to the value(s) in the table below.
15. CHECK FRONT POWER SEAT CONTROL ECU AND SWITCH LH
HINT For vehicles with a front power seat control system (w/ Seat Memory) only.
(a) Disconnect the Z9 and Z10 ECU connectors.
(b) Measure the resistance according to the value(s) in the table below.
Page 5185
4. DISCONNECT FRONT SPEED SENSOR LH
(a) Disconnect the front speed sensor LH See: Brakes and Traction Control/Antilock Brakes /
Traction Control Systems/Wheel Speed
Sensor/Service and Repair/Front Speed Sensor/Removal.
5. REMOVE FRONT AXLE HUB GREASE CAP See: Wheel Hub/Service and Repair/Removal and
Replacement/Removal
6. REMOVE AXLE HUB NUT See: Wheel Hub/Service and Repair/Removal and
Replacement/Removal
7. REMOVE TIE ROD END SUB-ASSEMBLY See: Steering and Suspension/Steering/Steering
Gear/Service and Repair/Removal and
Replacement/Removal
8. DISCONNECT FRONT LOWER BALL JOINT ATTACHMENT LH See: Steering and
Suspension/Suspension/Control Arm/Service and
Repair/Removal and Replacement/Front Lower Suspension Arm/Removal
9. DISCONNECT FRONT DRIVE SHAFT ASSEMBLY LH
(a) Using plastic-faced hammer, disconnect the drive shaft from the axle hub side.
(b) Push the steering knuckle outward and disconnect the drive shaft from the steering knuckle.
10. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH
(a) Using SST, remove the drive shaft.
SST : 09520-01010
SST : 09520-24010
09520-32040
NOTICE: Be careful not to damage the dust cover and oil seal.
(b) Using a screwdriver, remove the snap ring from the inboard joint shaft.
Installation
DRIVE SHAFT: FRONT DRIVE SHAFT ASSEMBLY (for 4WD): INSTALLATION
HINT *
Use the same procedures for the RH side and LH side.
* The procedures listed below are for the LH side.
* A bolt without a torque specification is shown in the standard bolt chart See:
Specifications/Mechanical Specifications/Standard Bolt - Specified Torque For Standard Bolts
1. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH (for Front Differential Side)
Page 3781
Air Flow Meter/Sensor: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: INSTALLATION
1. INSTALL MASS AIR FLOW METER
(a) Install the MAF meter with the 2 screws.
Torque : 1.7 Nm (17 kgf-cm, 15 in-lbf)
(b) Connect the MAF connector.
Page 7289
09613-22011
15. REMOVE POWER STEERING CYLINDER TUBE OIL SEAL
(a) Using SST and a press, remove the cylinder tube oil seal.
SST : 09950-60010
09951-00320
SST : 09950-70010
09951-07360
16. REMOVE RACK STEERING PISTON RING
(a) Using a screwdriver, remove the piston ring and O-ring.
NOTICE: Be careful not to damage the groove for the piston ring.
Reassembly
POWER STEERING: STEERING GEAR: REASSEMBLY
NOTICE: When installing, coat the parts indicated by the arrows with power steering fluid See:
Removal and Replacement/Components
1. INSTALL RACK STEERING PISTON RING
(a) Coat a new O-ring with power steering fluid and install it onto the power steering rack.
(b) Expand a new piston ring with your fingers.
NOTICE: Be careful not to over expand the rack steering piston ring.
Locations
Actuator: Locations
JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION
Page 5058
SST : 09950-60020
09951-00680
SST : 09950-70010
09951-07150
(b) Using SST and a press, press out the outer race and plate washer from the differential carrier.
SST : 09950-60020
09951-00680
SST : 09950-70010
09951-07150
19. REMOVE DIFFERENTIAL RING GEAR
(a) Place matchmarks on the ring gear and differential case.
(b) Remove the 12 bolts.
(c) Using a plastic-faced hammer, tap on the ring gear to separate it from the differential case.
20. REMOVE FRONT DIFFERENTIAL CASE BEARING
(a) Using SST, remove the 2 bearings (inner race).
Page 22
Alarm Module: Service and Repair Removal
THEFT DETERRENT: THEFT WARNING ECU: REMOVAL
1. REMOVE FRONT DOOR SCUFF PLATE LH
(a) for Regular Cab:
Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular Cab)/Removal.
(b) for Double Cab:
Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Removal.
(c) for CrewMax:
Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for CrewMax)/Removal.
2. REMOVE COWL SIDE TRIM BOARD LH
(a) for Regular Cab:
Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular Cab)/Removal.
(b) for Double Cab:
Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Removal.
(c) for CrewMax:
Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for CrewMax)/Removal.
3. REMOVE INSTRUMENT SIDE PANEL LH
(a) for Column Shift Type:
Remove the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Column Shift Type)/Removal.
(b) for Floor Shift Type:
Remove the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Floor Shift Type)/Removal.
4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH
(a) for Column Shift Type:
Remove the instrument panel finish panel See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument
Panel Safety Pad (for Column Shift Type)/Removal.
(b) for Floor Shift Type:
Remove the instrument panel finish panel See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument
Panel Safety Pad (for Floor Shift Type)/Removal.
5. REMOVE GLASS BREAKAGE SENSOR ECU
Page 3293
^ Power Supply Mode is used to maintain battery voltage at 13.5 volts while flash reprogramming
the vehicle.
^ For details on how to use the GR8 Battery Diagnostic Station, refer to the located on TIS,
Diagnostics - Tools & Equipment - Battery Diagnostics.
3. Click the appropriate calibration ID and reprogram the vehicle's ECU with Techstream.
A. After reviewing the procedures outlined in the selected TSB, click the appropriate calibration ID
link by matching the vehicle's current
calibration ID to the Previous Calibration ID in the Calibration Identification Chart.
NOTE
^ Calibration files are embedded as live links in the service bulletin.
^ Some vehicles require special preparation - please review the selected TSB carefully.
B. Click Open to load calibration file information.
Techstream pulls calibration files as needed to ensure the latest calibration file is used. Do NOT
save calibrations locally on the hard drive or other media.
NOTICE
Errors during the flash reprogramming process can permanently damage the vehicle ECU.
Minimize the risk by following the steps below.
^ Battery voltage MUST NOT FALL BELOW 11.4 volts during reprogramming. Confirm battery
voltage is higher than 11.4 volts, but be sure voltage DOES NOT RISE ABOVE 16.0 volts during
reprogramming.
^ Turn OFF all vehicle accessories (e.g. audio system, A/C, interior lights, DRL, etc.). Do NOT add
to or significantly change the vehicle's electrical
Page 2079
Page 7325
If the holes for the cotter pin are not aligned, tighten the nut further up to 60°.
Disassembly
SUSPENSION: FRONT UPPER SUSPENSION ARM: DISASSEMBLY
1. REMOVE FRONT SUSPENSION UPPER ARM BUSH
(a) Using a hammer and chisel, strike and bend the entire flange of the upper arm bush as shown
in the illustration.
(b) Using SST and a press, press out the bush.
SST : 09613-26010
SST : 09710-22021
09710-01031
SST : 09950-00020
2. REMOVE FRONT UPPER BALL JOINT DUST COVER LH
(a) Using a snap ring expander, remove the dust cover set ring.
Reassembly
SUSPENSION: FRONT UPPER SUSPENSION ARM: REASSEMBLY
1. INSTALL FRONT UPPER BALL JOINT DUST COVER LH
Page 4101
Positive Crankcase Ventilation Valve: Service and Repair Installation
1UR-FE EMISSION CONTROL: PCV VALVE: INSTALLATION
1. INSTALL PCV VALVE SUB-ASSEMBLY
(a) Apply a light coat of engine oil to the O-ring.
HINT *
When reusing the PCV valve, inspect the O-ring.
* If the O-ring has scratches or cuts, replace the PCV valve.
(b) Install the PCV valve.
Torque : 3.5 Nm (36 kgf-cm, 31 in-lbf)
2. CONNECT PCV VALVE HOSE
3. INSTALL NO. 3 ENGINE COVER
(a) Install the No. 3 engine cover.
4. INSTALL NO. 4 ENGINE COVER
(a) Install the No. 4 engine cover.
5. INSTALL INTAKE MANIFOLD
(a) Install the intake manifold See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service
and Repair/Installation.
Body - Tube Step Step Pad Lifting/Cracking
Auxiliary Step / Running Board: Customer Interest Body - Tube Step Step Pad Lifting/Cracking
T-SB-0164-10
June 28, 2010
Tube Step - Step Pad Lifting/Cracked
Service Category Vehicle Exterior
Section Exterior Panels/Trim
Market USA
Applicability
Introduction
Some 2007 - 2010 model year Tundra vehicles equipped with PPO/DIO tube steps may exhibit a
condition where the step pad has lifted or cracked. To improve the serviceability of the tube step
the step pad is now available as a separate service part. Follow the procedure in this bulletin to
replace the step pad. Removal of the tube step is not required to perform step pad replacement.
Parts Information
Warranty Information
APPLICABLE WARRANTY
^ Toyota accessories installed as original equipment are covered under the Toyota Comprehensive
Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the
vehicle's in-service date.
^ Toyota accessories installed after the new vehicle purchase are warranted for 12 months,
regardless of mileage, from the date of installation on the vehicle, or the remainder of the
applicable New Vehicle Limited Warranty, whichever provides the greater coverage.
^ Toyota accessories purchased over-the-counter are covered for 12 months from the date of
purchase.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Repair Procedure
Page 6821
Page 6973
Push the terminal retainer down to the temporary lock position.
Page 6105
Starter Motor: Testing and Inspection Starter (for 2.0 Kw Type)
1UR-FE STARTING: STARTER (for 2.0 kW Type): INSPECTION
1. INSPECT STARTER ASSEMBLY
CAUTION: As a large electric current passes through the cable during this inspection, a thick cable
must be used.
If not, the cable may became hot and cause injury.
NOTICE: The following tests must be performed within 3 to 5 to prevent the coil from burning out.
(a) Perform a pull-in test.
(1) Disconnect the field coil wire from terminal C.
(2) Connect the battery to the magnet starter switch as shown in the illustration. Check that the
clutch pinion gear moves outward.
If the clutch pinion gear does not move outward, replace the magnet starter switch assembly.
(b) Perform a holding test.
(1) Disconnect the negative (-) lead from terminal C with the condition specified in the pull-in test
above being maintained. Check that the
pinion gear remains out.
If the clutch pinion gear moves inward, replace the magnet starter switch assembly.
(c) Inspect clutch pinion gear return.
(1) Disconnect the negative (-) lead from the starter body. Check that the clutch pinion gear moves
inward.
If the clutch pinion gear does not move inward, replace the magnet starter switch assembly.
Page 3178
(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(2) If the result is not as specified, replace the MAF meter.
Page 5680
Brake Bleeding: Service and Repair Replacement
BRAKE: BRAKE FLUID: REPLACEMENT
NOTICE: *
Perform fluid replacement with the parking brake applied.
* Perform fluid replacement while maintaining the brake fluid level between the MIN/MAX level on
the brake fluid reservoir.
* Do not allow brake fluid to contact the vehicle's paint surfaces. If contact occurs, clean it off
immediately.
* Add fluid to the brake fluid reservoir as necessary so that the fluid does not decrease below the
MIN level.
1. REPLACE BRAKE FLUID
(a) Replace the brake fluid.
(1) Remove the brake master cylinder reservoir filler cap assembly.
(2) Add brake fluid into the reservoir between MAX and MIN level on the brake fluid reservoir.
Brake fluid:
SAE J1703 or FMVSS No. 116 DOT3
(3) Connect a vinyl tube to the bleeder plug of the front disc brake cylinder RH.
(4) Depress the brake pedal several times, and then loosen the bleeder plug with the pedal
depressed.*1
(5) When fluid stops coming out, tighten the bleeder plug, and then release the brake pedal.*2
(6) Repeat *1 and *2 until all the air in the brake fluid is completely bled out and the new brake fluid
comes out.
(7) Tighten the bleeder plug completely.
Torque : 11 Nm (110 kgf-cm, 8 ft-lbf)
(8) Replace the brake fluid from the front disc brake cylinder LH using the same procedure as for
RH.
(9) Connect a vinyl tube to the bleeder plug of the rear disc brake cylinder RH.
(10)Depress the brake pedal several times, and then loosen the bleeder plug with the pedal
depressed.*1
(11)When fluid stops coming out, tighten the bleeder plug, and then release the brake pedal.*2
(12)Repeat *1 and *2 until all the air in the brake fluid is completely bled out and the new brake
fluid comes out.
(13)Tighten the bleeder plug completely.
Torque : 11 Nm (110 kgf-cm, 8 ft-lbf)
(14)Replace the brake fluid from the rear disc brake cylinder LH using the same procedure as for
RH.
(b) Check and bleed brake system.
(1) If the following malfunction symptoms occur, air may have entered the brake fluid line. Perform
the following air bleed procedures.
* Low pedal or spongy pedal.
* Brake pedal is depressed firmly but braking is insufficient.
(c) Inspect for the brake fluid leak.
(d) Check and adjust brake fluid level in reservoir See: Hydraulic System/Brake Fluid/Testing and
Inspection.
Page 9134
Trailer Towing Part 2
Tools and Equipment
Fuel Supply Line: Tools and Equipment
Niss./Toy. Line Disconnect Tool
AST tool# 8026
5/16"Fuel Line Disconnect Tool. Used for disconnecting the fuel line from the fuel rail. Applicable to
2004 and newer Nissan and Toyota Models
- 5/16" Fuel Line Disconnect Tool
- Quick Line Removal*Green-Anodized Aluminum Construction
- See Application Chart
- Included in the #8110 Line Disconnect Set.
Contact AST for pricing.
Assenmacher Specialty Tools 1-800-525-2943
This Tool is also available in the following kits:
Page 9020
when inserting and after full engagement.
NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal.
(d) REPAIR METHOD OF CONNECTOR TERMINAL
(1) If there is any foreign matter on the terminal, clean the contact point using an air gun or cloth.
Never rub the contact point using sandpaper
as the plating may come off.
(2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is
gold-plated (gold color), use a gold-plated female
terminal; if it is silver-plated (silver color), use a silver-plated female terminal.
(3) Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock
into the housing, the housing may have to be
replaced.
(e) HANDLING OF WIRE HARNESS
(1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be
restored in the same way.
(2) Never twist, pull or slacken the wire harness more than necessary.
(3) The wire harness should never come into contact with a high temperature part, or rotating,
moving, vibrating or sharp-edged parts. Avoid
contact with panel edges, screw tips and other sharp items.
(4) When installing parts, never pinch the wire harness.
(5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with
vinyl tape.
2. CHECK FOR OPEN CIRCUIT
Components
Variable Valve Timing Actuator Position Sensor: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: VVT SENSOR: COMPONENTS
Page 8529
11. INSTALL FRONT DOOR SCUFF PLATE LH
(a) for Regular Cab:
Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular Cab)/Installation.
(b) for Double Cab:
Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Installation.
(c) for CrewMax:
Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for CrewMax)/Installation.
Page 7217
Steering Column Control Module: Service and Repair Installation
STEERING COLUMN: MULTIPLEX TILT AND TELESCOPIC ECU (for Power Tilt and Power
Telescopic Steering Column): INSTALLATION
1. INSTALL MULTIPLEX TILT AND TELESCOPIC ECU
(a) Install the ECU with the 2 screws.
Torque : 1.5 Nm (15 kgf-cm, 13 in-lbf)
(b) Connect the 2 ECU connectors.
2. INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY See: Steering Column/Service and
Repair/Removal and Replacement/Steering Column
Assembly (for Power Tilt and Power Telescopic Steering Column)/Removal
3. INSTALL LOWER NO. 1 INSTRUMENT PANEL AIR BAG ASSEMBLY See: Restraint
Systems/Air Bag Systems/Air Bag/Service and
Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Installation
4. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Floor Shift Type)/Removal
5. INSTALL HOOD LOCK CONTROL LEVER SUB-ASSEMBLY See: Body and Frame/Doors,
Hood and Trunk/Hood/Hood Latch Release
Cable/Service and Repair/Installation
6. INSTALL LOWER STEERING COLUMN COVER
(a) Attach the 2 claws to install the steering column lower cover.
7. INSTALL UPPER STEERING COLUMN COVER
Page 1356
Diagram Information and Instructions
Ignition Switch: Diagram Information and Instructions
Wiring Color Codes
Abbreviations Used Within Diagrams
Abbreviations Used Within Diagrams
Page 2165
Tire Pressure Warning Reset Switch: Testing and Inspection
TIRE AND WHEEL: TIRE PRESSURE WARNING RESET SWITCH: INSPECTION
1. CHECK TIRE PRESSURE WARNING RESET SWITCH
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the switch.
Page 1676
for Double Cab of Long Deck
for CrewMax of standard deck
Page 7975
Components
Traction Control Switch: Service and Repair Components
BRAKE CONTROL: VSC OFF SWITCH: COMPONENTS
Page 5428
Control Module: Service and Repair Removal
JF1A TRANSFER: 4WD CONTROL ECU: REMOVAL
1. REMOVE FRONT DOOR SCUFF PLATE RH (for Regular Cab)
(a) Remove the front door scuff plate RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Removal.
HINT Use the same procedures described for the LH side.
2. REMOVE FRONT DOOR SCUFF PLATE RH (for Double Cab, for CrewMax)
(a) Remove the front door scuff plate RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Removal.
HINT Use the same procedures described for the LH side.
3. REMOVE COWL SIDE TRIM BOARD RH
(a) Remove the cowl side trim board RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Removal.
HINT Use the same procedures described for the LH side.
4. REMOVE INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal
5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and
Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument
Panel Safety Pad (for Column Shift Type)/Removal
6. REMOVE 4WD CONTROL ECU
(a) Disconnect the 2 ECU connectors.
(b) Remove the bolt and ECU.
Page 1311
DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector.
Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
Engine Controls - ECM Update For Shift Performance
PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - ECM
Update For Shift Performance
T-SB-0285-10
October 12, 2010
ECM Calibration: Enhancement to Shifting Performance
Service Category Drivetrain
Section Automatic Transmission/Transaxle
Market USA
Applicability
Introduction
Some vehicles may exhibit the following shifting conditions:
^ Harsh shift on acceleration below 20 mph during the 2-1 downshift.
^ Excessive lock-up operation at freeway speeds about 50 - 60 mph, sometimes referred to as
"busy shifting".
The Engine Control Module/ECM (SAE term: Powertrain Control Module/PCM) calibration has
been revised. Use the following repair procedure to address these conditions.
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Federal Emission Warranty. This warranty is in effect for
96 months or 80,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Page 4930
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to disable the SRS system.
2. REMOVE FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Removal
3. REMOVE FRONT DOOR SCUFF PLATE LH (for Double Cab, CrewMax) See: Body and
Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Removal
4. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Removal
5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Removal
6. REMOVE LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY See: Restraint
Systems/Air Bag Systems/Air Bag/Service and
Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Removal
7. REMOVE CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service
and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Removal
8. REMOVE STEERING PAD (w/o Steering Pad Switch) See: Restraint Systems/Air Bag
Systems/Air Bag/Service and Repair/Removal and
Replacement/Steering Pad/Removal
9. REMOVE STEERING PAD (w/ Steering Pad Switch) See: Restraint Systems/Air Bag
Systems/Air Bag/Service and Repair/Removal and
Replacement/Steering Pad/Removal
10. REMOVE STEERING WHEEL ASSEMBLY See: Steering and Suspension/Steering/Steering
Column/Service and Repair/Removal and
Replacement/Steering Column Assembly (for Manual Tilt)/Removal
11. REMOVE LOWER STEERING COLUMN COVER See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Removal and
Replacement/Steering Column Assembly (for Manual Tilt)/Removal
12. REMOVE UPPER STEERING COLUMN COVER See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Removal and
Replacement/Steering Column Assembly (for Manual Tilt)/Removal
13. REMOVE FRONT SEAT ASSEMBLY LH
(a) for Manual Seat Type:
Remove the front seat LH See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Manual Seat)/Removal.
(b) for Power Seat Type:
Remove the front seat LH See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Power Seat)/Removal.
(c) for Center Seat:
Remove the front seat LH See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Center Seat)/Removal.
(d) for Fold Down Seat:
Remove the front seat LH See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Fold Down Seat Type)/Removal.
14. REMOVE COLUMN SHIFT TRANSMISSION CONTROL CABLE ASSEMBLY
Page 6825
Page 5278
(2) Subtract the angle of the transfer flange (A) measured before installing the propeller shaft from
the angle of the intermediate shaft (C) to
calculate the No. 1 joint angle.
No. 1 joint angle:
Angle of intermediate shaft (C) - Angle of transfer flange (A)
Measured Value (Reference):
HINT *
Using the following chart, check if the calculated No. 1 joint angle is within the specified value.
* The tolerance is +/-0°60' (1.00°).
Standard No. 1 joint angle:
Page 3466
B -- GO TO CAN MAIN WIRE FOR DISCONNECTION See: Symptom Related Diagnostic
Procedures/CAN Communication System/Open In CAN Main Wire
C -- GO TO CHECK CAN BUS LINES FOR SHORT CIRCUIT See: Symptom Related Diagnostic
Procedures/CAN Communication System/Short in CAN Bus Lines A -- Continue to next step.
6. CHECK V BUS CIRCUIT +B (CANH, CANL - BAT)
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- GO TO CHECK CAN BUS LINE FOR SHORT TO +B See: Symptom Related Diagnostic
Procedures/CAN Communication System/Short to B+ in CAN Bus Line OK -- Continue to next
step.
7. CHECK V BUS CIRCUIT GND (CANH, CANL - CG)
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- GO TO CHECK CAN BUS LINE FOR SHORT TO GND See: Symptom Related Diagnostic
Procedures/CAN Communication System/Short to GND in CAN Bus Line OK -- Continue to next
step.
8. CHECK ECUS CONNECTED TO CAN BUS (USING TECHSTREAM)*
(a) Select "CAN Bus Check" from the "System Select".
Windshield Deicer System
Heated Glass Element Relay: Locations Windshield Deicer System
WINDSHIELD / WINDOWGLASS: WINDSHIELD DEICER SYSTEM: PARTS LOCATION
Page 3390
6. PROBLEM SYMPTOMS TABLE
When a "Normal" code is output during a DTC check but the problem is still occurring, use the
Problem Symptoms Table. The suspected areas (circuits or parts) for each problem symptom are
in the table. The suspected areas are listed in order of probability. A description of each of the
chart's columns is below.
HINT In some cases, the problem is not detected by the diagnostic system even though a problem
symptom is present. It is possible that the problem is occurring outside the detection range of the
diagnostic system, or that the problem is occurring in a completely different system.
7. CIRCUIT INSPECTION
A description of the main areas of each circuit inspection is below.
Page 9293
Service and Repair
Fuel Pressure Release: Service and Repair
1UR-FE FUEL: FUEL SYSTEM: PRECAUTION
CAUTION: *
Before working on the fuel system, disconnect the cable from the negative (-) battery terminal.
* Do not smoke or be near an open flame when working on the fuel system.
* Keep gasoline away from rubber and leather parts.
1. DISCHARGE FUEL SYSTEM PRESSURE
CAUTION: *
Do not disconnect any part of the fuel system until you have discharged the fuel system pressure.
* After discharging the fuel pressure, place a cloth or equivalent over fittings as you separate them
to reduce the risk of fuel spray on yourself or in the engine compartment.
(a) Disconnect the cable from the negative (-) battery terminal.
(b) Disconnect the 2 fuel pump ECU connectors.
(c) Connect the cable to the negative (-) battery terminal.
(d) Start the engine. After the engine has stopped on its own, turn the ignition switch OFF.
HINT DTC P0171/0174 (system too lean) may be set.
(e) Crank the engine again, then check that the engine does not start.
(f) Loosen the fuel tank cap, then discharge the pressure in the fuel tank completely.
(g) Connect the 2 fuel pump ECU connectors.
2. FUEL SYSTEM
(a) When disconnecting the high fuel pressure line, a large amount of gasoline will spill out. Follow
these procedures.
(1) Perform the "DISCHARGE FUEL SYSTEM PRESSURE" procedures above.
(2) Put a container under the connecting part of the pressure line.
(3) Slowly loosen the connection.
(4) Disconnect the connection.
(5) Plug the connection with a rubber plug.
(b) Observe these precautions when removing and installing the injectors:
Components
Four Wheel Drive Selector Switch: Service and Repair Components
JF1A TRANSFER: 4WD CONTROL SWITCH: COMPONENTS
Page 918
Cabin Temperature Sensor / Switch: Service and Repair Installation
AIR CONDITIONING: ROOM TEMPERATURE SENSOR (for Automatic Air Conditioning System):
INSTALLATION
1. INSTALL ROOM TEMPERATURE SENSOR
(a) Attach the 2 claws to install the sensor.
2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH
(a) for Column Shift Type:
Remove the instrument panel finish panel See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument
Panel Safety Pad (for Column Shift Type)/Installation.
(b) for Floor Shift Type:
Remove the instrument panel finish panel See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument
Panel Safety Pad (for Floor Shift Type)/Installation.
3. INSTALL INSTRUMENT SIDE PANEL LH
(a) for Column Shift Type:
Remove the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Column Shift Type)/Installation.
(b) for Floor Shift Type:
Remove the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Floor Shift Type)/Installation.
4. INSTALL COWL SIDE TRIM BOARD LH
(a) for Regular Cab:
Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular Cab)/Installation.
(b) for Double Cab:
Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Installation.
(c) for CrewMax:
Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for CrewMax)/Installation.
5. INSTALL FRONT DOOR SCUFF PLATE LH
(a) for Regular Cab:
Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular
Body - Bumper Component Repair
Front Bumper Reinforcement: Technical Service Bulletins Body - Bumper Component Repair
COLLISION REPAIR INFORMATION FOR THE COLLISION REPAIR PROFESSIONAL
TITLE: BUMPER COMPONENT REPAIR
SECTION: EXTERIOR BULLETIN # 172
MODELS: ALL TOYOTA LEXUS and SCION
DATE: MARCH 2009
While it may seem cost effective to repair damaged bumper components specifically impact energy
absorbers and reinforcements there is no way to certify that a repaired part will function as
originally intended under all future operating conditions and subsequent collisions. Original
Equipment bumper components comply with Federal Motor Vehicle Safety Standards established
under the National Highway Traffic Safety Administration Title 49 Part 581. Therefore it is
recommended to replace damaged bumper impact energy absorbers and reinforcements with
genuine new original equipment replacement parts only.
For more information on collision damage repair topics please refer to Collision Repair Information
Bulletin # 161 Collision Damage Repair Precautions and plan to attend Toyota Collision Repair &
Refinish Training. Visit www.crrtraining.com for training information.
Page 709
Power Seat Switch: Testing and Inspection Front Power Seat Lumbar Switch (for Power Seat)
SEAT: FRONT POWER SEAT LUMBAR SWITCH (for Power Seat): INSPECTION
1. INSPECT FRONT POWER SEAT LUMBAR SWITCH LH
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the switch.
2. INSPECT FRONT POWER SEAT LUMBAR SWITCH RH
Page 8616
1. Please compare customer's iPod(TM) with the compatible models table listed below. If the
customers' iPod(TM) is NOT listed, this TSB does NOT
apply.
2. Verify the condition.
NOTE
If USB device error occurs during every use, visually inspect the port.
3. Verify the error condition continues when using a known good USB cable.
4. Replace the Multi-Media Interface ECU by following procedures in the Repair Manual.
Page 52
Removal
DOOR LOCK: DOOR CONTROL RECEIVER (for Regular Cab): REMOVAL
1. REMOVE UPPER BACK PANEL GARNISH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining
(For Regular Cab)/Removal
2. REMOVE LUGGAGE COMPARTMENT BOX LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof
Headlining (For Regular Cab)/Removal
3. REMOVE LUGGAGE COMPARTMENT BOX RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof
Headlining (For Regular Cab)/Removal
4. REMOVE FRONT DOOR SCUFF PLATE RH
Page 9238
Page 4043
(b) Disconnect the 6 air pump insulators.
Page 5293
SST : 09955-04100
HINT Make sure the claws of SST are securely attached to the universal joint yoke.
(h) Clamp the protruding universal joint spider bearing in a vise.
(i) Using a brass bar and hammer, tap the universal joint yoke to remove the universal joint spider
bearing.
NOTICE: Do not tap the intermediate shaft tube.
HINT Use the same removal procedure for the universal joint spider bearing on the opposite side.
(j) Disconnect the intermediate shaft from the propeller shaft.
(k) Using SST, pull out the universal joint spider bearing from the propeller shaft yoke.
SST : 09331-60010
SST : 09950-40011
09951-04010
09952-04010
09953-04020
09954-04010
09957-04010
09958-04011
Page 8210
Seat Belt: Testing and Inspection
Front Seat Inner Belt Assembly
SEAT BELT: FRONT SEAT INNER BELT ASSEMBLY: INSPECTION
1. INSPECT FRONT SEAT INNER BELT ASSEMBLY (for Driver Side)
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
* If the result is not as specified, replace the inner belt assembly.
Front Seat Outer Belt Assembly (for Center Seat)
SEAT BELT: FRONT SEAT OUTER BELT ASSEMBLY (for Center Seat): INSPECTION
1. INSPECT CENTER FRONT SEAT BELT ASSEMBLY RH
CAUTION: Do not disassemble the retractor.
(a) Before installing the seat belt, check the ELR.
(1) When the inclination of the retractor is 15° or less, check that the belt can be pulled from the
retractor. When the inclination of the retractor
is over 45°, check that the belt locks. If the operation is not as specified, replace the seat belt
assembly.
(b) Check the fastening function of the child restraint system.
NOTICE:
Page 1636
Power Window Switch: Testing and Inspection Front Passenger Side Power Window Switch
WINDSHIELD / WINDOWGLASS: FRONT PASSENGER SIDE POWER WINDOW SWITCH:
INSPECTION
1. INSPECT POWER WINDOW REGULATOR SWITCH ASSEMBLY (w/o Jam Protection
Function)
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
* If the result is not as specified, replace the power window regulator switch.
2. INSPECT POWER WINDOW REGULATOR SWITCH ASSEMBLY (w/ Jam Protection Function)
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
Page 3442
NG -- REPAIR OR REPLACE CAN MAIN WIRE OR CONNECTOR (NO. 1 JUNCTION
CONNECTOR - NO. 2 JUNCTION CONNECTOR) OK -- Continue to next step.
6. CONNECT CONNECTOR
(a) Reconnect the J94 No. 1 junction connector connector.
(b) Reconnect the J113 No. 2 junction connector connector.
NEXT -- Continue to next step.
7. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (NO. 1 JUNCTION CONNECTOR COMBINATION METER ECU)
(a) Disconnect the J84 No. 1 junction connector connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- CHECK FOR SHORT TO B+ IN CAN BUS WIRE (COMBINATION METER ECU) OK -Continue to next step.
8. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (NO. 1 JUNCTION CONNECTOR - MAIN
BODY ECU)
(a) Disconnect the J96 No. 1 junction connector connector.
Airbag System
Air Bag Deactivation Switch: Locations Airbag System
SUPPLEMENTAL RESTRAINT SYSTEM: AIRBAG SYSTEM: PARTS LOCATION
Page 1061
Removal
LIGHTING: FRONT DOOR COURTESY SWITCH: REMOVAL
HINT *
Use the same procedures for the RH and LH side.
* The procedures listed below are for the LH side.
1. REMOVE FRONT DOOR COURTESY SWITCH
(a) Remove the bolt.
Page 5831
Traction Control Relay: Testing and Inspection
BRAKE CONTROL: STOP LIGHT CONTROL RELAY: ON-VEHICLE INSPECTION
1. CHECK STOP LIGHT CONTROL RELAY
(a) Remove the stop light control relay from the engine room relay block.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(c) If the result is not as specified, replace the relay.
(d) Install the stop light control relay.
Page 2340
Engine Controls - ECM Update For Shift Performance
PROM - Programmable Read Only Memory: Customer Interest Engine Controls - ECM Update For
Shift Performance
T-SB-0285-10
October 12, 2010
ECM Calibration: Enhancement to Shifting Performance
Service Category Drivetrain
Section Automatic Transmission/Transaxle
Market USA
Applicability
Introduction
Some vehicles may exhibit the following shifting conditions:
^ Harsh shift on acceleration below 20 mph during the 2-1 downshift.
^ Excessive lock-up operation at freeway speeds about 50 - 60 mph, sometimes referred to as
"busy shifting".
The Engine Control Module/ECM (SAE term: Powertrain Control Module/PCM) calibration has
been revised. Use the following repair procedure to address these conditions.
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Federal Emission Warranty. This warranty is in effect for
96 months or 80,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Oil Pressure Sender
Oil Pressure Sender: Diagrams Oil Pressure Sender
Page 8218
SST : 09082-00700
SST : 09082-00770
NOTICE: To avoid damaging SST connector and wire harness, do not lock the secondary lock of
the twin lock.
(3) Move SST at least 10 m (32.8 ft.) away from the front of the vehicle.
(4) Close all the doors and windows of the vehicle.
HINT Leave a gap in one of the windows for inserting SST wire harness.
NOTICE: Take care not to damage SST wire harness.
(5) Connect SST's red clip to the battery's positive (+) terminal and the black clip to the negative (-)
terminal.
(e) Activate the seat belt pretensioner.
(1) Confirm that no one is inside the vehicle or within 10 m (32.8 ft.) of the vehicle.
(2) Press SST activation switch to activate the seat belt pretensioner.
HINT The seat belt pretensioner operates at the same time SST activation switch's LED
illuminates.
(f) Dispose of the front seat outer belt (with the seat belt pretensioner).
CAUTION: *
Do not touch the front seat outer belt for at least 30 minutes after the seat belt pretensioner has
been activated. It is very hot.
* Use gloves and safety glasses when handling a front seat outer belt whose pretensioner has
been activated.
* Always wash your hands with water after completing the disposal.
* Do not apply water to a front seat outer belt that has an activated pretensioner.
HINT When scrapping a vehicle, activate the seat belt pretensioner, and then scrap the vehicle with
the activated front seat outer belt installed.
2. DISPOSE OF FRONT SEAT OUTER BELT ASSEMBLY (WHEN NOT INSTALLED IN
VEHICLE)
CAUTION: Be sure to follow the procedures listed below when activating the seat belt pretensioner.
(a) Remove the front seat outer belt.
Page 3268
Parts Information
Required Tools & Equipment
Repair Procedure
1. Confirm the condition matches the Introduction.
Page 1474
Remove the blown fuse and disconnect all loads of the fuse.
Connect a test light in place of the fuse.
Establish conditions in which the test light comes on.
Example:
- [A] - Ignition SW on
- [B] - Ignition SW and SW1 on
- [C] - Ignition SW, SW1 and Relay on (Connect the Relay) and SW2 off (or Disconnect SW2)
Disconnect and reconnect the connectors while watching the test light.
Page 1150
Camshaft Position Sensor: Diagrams
A/C Amplifier, A/C Blower Assembly
Control Module HVAC: Diagrams A/C Amplifier, A/C Blower Assembly
Page 5049
21. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
(a) Install the drive pinion, front bearing (inner race) and oil slinger.
(b) Using SST and the companion flange, install the bearing (inner race) and then remove the
companion flange.
SST : 09950-30012
09951-03010
09953-03010
09954-03010
09956-03050
SST : 09955-03050
22. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL
(a) Using SST and a plastic-faced hammer, tap in a new oil seal until its surface is flush with the
differential carrier end.
SST : 09316-12010
SST : 09649-17010
Standard oil seal depth:
Engine - MIL ON/DTC's P0012/P0022 Set
Variable Valve Timing Actuator: All Technical Service Bulletins Engine - MIL ON/DTC's
P0012/P0022 Set
T-SB-0019-10
January 20, 2010
MIL "ON" DTC P0012 and/or P0022
Service Category Engine/Hybrid System
Section Engine Control
Market USA
Applicability
Introduction
Some 2010 model year Sequoia and Tundra vehicles may exhibit a MIL "ON" condition for
Diagnostic Trouble Code (DTC) P0012 and/or P0022 ( Camshaft Position "A" - Timing
Over-Retarded Bank 1/2).
Please refer to the following repair procedure to address this condition.
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60
months or 60,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Production Change Information
Page 5920
1. INSTALL SKID CONTROL SENSOR WIRE
(a) Install the sensor clamp with the nut (labeled A).
Torque : 13 Nm (127 kgf-cm, 9 ft-lbf)
NOTICE: Make sure the clamp's rotation stopper touches the installation position.
(b) Install the sensor clamp with the bolt (labeled B).
Torque : 13 Nm (127 kgf-cm, 9 ft-lbf)
NOTICE: When installing the clamp, do not twist the wire harness.
(c) Attach the 7 clips (labeled C).
NOTICE: *
When installing the clamps, do not twist the wire harness.
* When installing the clamps, securely insert them as shown in the illustration.
(d) Connect the sensor connector (labeled D).
NOTICE: Securely connect the connector.
2. INSTALL REAR SPEED SENSOR LH
(a) Install the speed sensor (labeled A) with the nut (labeled B).
Torque : 11 Nm (107 kgf-cm, 8 ft-lbf)
(b) Connect the speed sensor connector (labeled C).
NOTICE: Securely connect the connector.
3. INSTALL REAR SPEED SENSOR RH
(a) Install the speed sensor (labeled A) with the nut (labeled B).
Page 8786
Speaker: Testing and Inspection
Floor Speaker (for CrewMax)
AUDIO / VISUAL: FLOOR SPEAKER (for CrewMax): INSPECTION
1. INSPECT NO. 1 BOX SPEAKER ASSEMBLY
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the speaker assembly.
Floor Speaker (for Double Cab)
AUDIO / VISUAL: FLOOR SPEAKER (for Double Cab): INSPECTION
1. INSPECT BOX SPEAKER ASSEMBLY
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the speaker assembly.
Front Door Speaker (for CrewMax)
AUDIO / VISUAL: FRONT DOOR SPEAKER (for CrewMax): INSPECTION
1. INSPECT FRONT NO. 1 SPEAKER ASSEMBLY (for Standard)
Page 959
Solar Sensor: Testing and Inspection
AIR CONDITIONING: SOLAR SENSOR (for Automatic Air Conditioning System): INSPECTION
1. INSPECT AUTOMATIC LIGHT CONTROL SENSOR (SOLAR SENSOR)
(a) Connect the battery's positive (+) lead to terminal 6 and the negative (-) lead to terminal 3, then
measure the voltage according to the value(s)
in the table below.
Standard voltage:
NOTICE: The connection procedure for using a digital tester such as a TOYOTA electrical tester is
shown above.
HINT *
As the inspection light is moved away from the sensor, the voltage decreases.
* Use an incandescent light for inspection. Bring it within 30 cm (11.8 in.) of the solar sensor.
(b) If the result is not as specified, replace the solar sensor.
Up to 11/2009
Traction Control Switch: Locations Up to 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 2690
Water Pump: Testing and Inspection
1UR-FE COOLING: WATER PUMP: ON-VEHICLE INSPECTION
1. INSPECT WATER PUMP ASSEMBLY
(a) Visually check the air hole and drain hole for coolant leakage.
(b) If leakage is found, replace the water pump assembly.
(c) Turn the pulley and check that the water pump bearing moves smoothly and quietly.
(d) If necessary, replace the water pump assembly.
Page 4166
Air Conditioning System (for Automatic Air Conditioning
System)
Evaporator Temperature Sensor / Switch: Locations Air Conditioning System (for Automatic Air
Conditioning System)
AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Automatic Air Conditioning System):
PARTS LOCATION
Page 7476
Tire Pressure Module: Diagrams
Page 60
Parking Assist Control Module: Service and Repair Removal
PARK ASSIST / MONITORING: CLEARANCE WARNING ECU: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to disable the SRS system.
2. REMOVE INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal
3. REMOVE NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY See: Body and
Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Column Shift Type)/Removal
4. REMOVE LOWER INSTRUMENT PANEL See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal
5. REMOVE LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY See: Restraint
Systems/Air Bag Systems/Air Bag/Service and
Repair/Removal and Replacement/Front Passenger Side Knee Airbag Assembly/Removal
6. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and
Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument
Panel Safety Pad (for Column Shift Type)/Removal
7. REMOVE CLEARANCE WARNING ECU WITH BRACKET
(a) Disconnect the ECU connectors and detach the harness clamp.
NOTICE: Do not apply excessive force to the wire harnesses.
(b) Remove the bolt, nut and ECU with bracket.
8. REMOVE CLEARANCE WARNING ECU ASSEMBLY
(a) Remove the 2 nuts and clearance warning ECU from the bracket.
NOTICE: *
Avoid any impact to the clearance warning ECU.
* Do not drop the ECU. If it is dropped, replace it with a new one.
Page 2096
Engine Room R/B And Engine Room J/B Inner Circuit
Page 8764
Remote Switch: Service and Repair Removal
AUDIO / VISUAL: STEERING PAD SWITCH: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE LOWER NO. 2 STEERING WHEEL COVER See: Restraint Systems/Air Bag
Systems/Air Bag/Service and Repair/Removal and
Replacement/Steering Pad/Removal
3. REMOVE LOWER NO. 3 STEERING WHEEL COVER See: Restraint Systems/Air Bag
Systems/Air Bag/Service and Repair/Removal and
Replacement/Steering Pad/Removal
4. REMOVE STEERING PAD See: Restraint Systems/Air Bag Systems/Air Bag/Service and
Repair/Removal and Replacement/Steering
Pad/Removal
5. REMOVE STEERING PAD SWITCH ASSEMBLY
(a) Disconnect the connector.
(b) Remove the 2 screws.
(c) Detach the 4 pins and remove the steering pad switch.
Page 7150
Tire Pressure Sensor: Service and Repair Removal
TIRE AND WHEEL: TIRE PRESSURE WARNING VALVE AND TRANSMITTER: REMOVAL
1. REMOVE TIRE
2. REMOVE TIRE PRESSURE WARNING VALVE AND TRANSMITTER
(a) Remove the valve core and cap, and release the air from the tire.
(b) After ensuring that a sufficient amount of air has been released, remove the nut and washer
that is used to secure the tire pressure warning
valve and transmitter. Then drop the tire pressure warning valve and transmitter inside the tire.
HINT Keep the removed cap, valve core, nut and washer.
(c) Disengage the bead using the shoe of a tire remover.
NOTICE: Be careful as the tire pressure warning valve and transmitter may become damaged due
to interference between the sensor and tire bead.
(d) Remove the bead on the upper side.
(e) Take out the tire pressure warning valve and transmitter from the tire, then remove the bead on
the lower side.
HINT *
The grommet is a non-reusable part.
* Check that there are no cracks or damage on the grommet. If any damage is found, replace the
washer and nut.
Page 8358
Door/Service and Repair/Front Door (for Double Cab)/Disassembly
4. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH (for Front Side) See: Body
and Frame/Doors, Hood and
Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly
5. REMOVE COURTESY LIGHT ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood
and Trunk/Doors/Front Door/Service and
Repair/Front Door (for Double Cab)/Disassembly
6. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Disassembly
7. REMOVE FRONT SIDE AIRBAG SENSOR
(a) Disconnect the connector.
(b) Remove the screw and side airbag sensor.
8. REMOVE REAR SEAT ASSEMBLY (for Rear Side)
(a) Remove the rear seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Rear Seat Assembly (for Double
Cab)/Removal.
9. REMOVE REAR DOOR SCUFF PLATE LH (for Rear Side) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and Repair/Roof
Headlining (For Double Cab)/Removal
10. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH (for Rear Side)
11. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY LH (for Rear Side) See: Body and
Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal
12. REMOVE REAR SIDE AIRBAG SENSOR
(a) Remove the bolt and side airbag sensor.
(b) Disconnect the connector.
Installation
SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Double Cab):
INSTALLATION
1. INSTALL FRONT SIDE AIRBAG SENSOR
(a) Check that the ignition switch is OFF.
(b) Check that the cable is disconnected from the battery negative (-) terminal.
CAUTION:
Page 7561
Ambient Temperature Sensor / Switch HVAC: Testing and Inspection
AIR CONDITIONING: AMBIENT TEMPERATURE SENSOR: INSPECTION
1. INSPECT AMBIENT TEMPERATURE SENSOR
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NOTICE: *
Touching the sensor even slightly may change the resistance value. Hold the connector of the
sensor.
* When measuring the resistance, the sensor temperature must be the same as the ambient
temperature.
HINT As the temperature increases, the resistance decreases (see the graph).
(b) If the result is not as specified, replace the ambient temperature sensor.
Page 7638
[A] For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
"Case1" Raise the terminal retainer up to the temporary lock position.
Page 6195
Removal
OTHER SYSTEM: CENTER POWER OUTLET SOCKET (for Column Shift Type): REMOVAL
1. REMOVE FRONT SEAT ASSEMBLY LH (for Manual Seat)
(a) Remove the front seat LH See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Manual
Seat)/Removal.
2. REMOVE FRONT SEAT ASSEMBLY RH (for Manual Seat)
HINT Use the same procedures described for the LH side.
Page 6399
Components
Air Flow Meter/Sensor: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: COMPONENTS
Emissions - MIL ON/Multiple Air Injection DTC's Set
Air Injection Pump: Customer Interest Emissions - MIL ON/Multiple Air Injection DTC's Set
T-SB-0350-09
Rev1
October 1, 2009
Air Injection Pump With Water Intrusion: MIL "ON" DTC P04181P0419 and/or P244 #
Service Category Engine/Hybrid System
Section Engine Control
Market USA
Applicability
TSB REVISION NOTICE
May 21, 2010 Rev1:
^ DTCs P0418 and P0419 have been added to the TSB.
^ The Applicable Warranty has been updated in the Warranty Information section. Any previous
printed versions of this service bulletin should be discarded.
Introduction
Some 2010 model year Tundra vehicles built in the Texas plant may exhibit a MIL "ON" condition
with Diagnostic Trouble Code (DTC) P0418, P0419, P2440, P2441, P2442, P2443, P2446, and/or
P2447. This concern may be caused by water intrusion into the air injection pump assembly. Use
the following procedure to address this condition.
Parts Information
Production Change Information
Page 3448
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO SKID CONTROL ECU
WITH ACTUATOR (CANH, CANL)
OK -- REPLACE SKID CONTROL ECU WITH ACTUATOR See: Brakes and Traction
Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock
Brakes/Service and Repair/Removal and Replacement/Removal
16. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (STEERING ANGLE SENSOR)
(a) Disconnect the J6 steering angle sensor connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO STEERING ANGLE
SENSOR (CANH, CANL)
OK -- REPLACE STEERING ANGLE SENSOR
17. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (POWER STEERING ECU)
(a) Disconnect the J101 power steering ECU connector.
Page 9071
NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do
not operate the ignition switch, any other switches, or the doors.
(a) If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the
harness and connector.
(b) Connect the cable of the Techstream to the DLC3, turn the ignition switch ON and attempt to
use the tester. If the display indicates that a
communication error has occurred, there is a problem either with the vehicle or with the tester.
HINT *
If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of
the original vehicle.
* If communication is still not possible when the tester is connected to another vehicle, the problem
may be in the tester itself. Consult the Service Department listed in the tester's instruction manual.
How To Proceed With Troubleshooting
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: HOW TO
PROCEED WITH TROUBLESHOOTING
1. OPERATION FLOW
HINT Perform troubleshooting in accordance with the procedures below. The following is an outline
of basic troubleshooting procedures. Confirm the troubleshooting procedures for the circuit you are
working on before beginning troubleshooting.
1. VEHICLE BROUGHT TO WORKSHOP
NEXT -- Continue to next step.
2. CUSTOMER PROBLEM ANALYSIS
(a) Ask the customer about the conditions and environment when the problem occurred.
NEXT -- Continue to next step.
3. INSPECT BATTERY VOLTAGE
Standard voltage:
11 to 14 V
If the voltage is below 11 V, recharge or replace the battery before proceeding.
NEXT -- Continue to next step.
Page 1890
Page 1284
Camshaft Position Sensor: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT POSITION SENSOR: REMOVAL
1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Removal
2. REMOVE CAMSHAFT POSITION SENSOR
(a) Disconnect the sensor connector.
(b) Remove the bolt and sensor.
Page 1714
Standard caster inclination (unloaded vehicle):
for Double Cab of Long Deck
Page 8952
HINT The type of claw on the top and bottom of the sensor are different. Observe the claws
carefully before removing the sensor.
14. REMOVE NO. 2 ULTRASONIC SENSOR RETAINER
(a) Detach the 2 claws and remove the sensor retainer from the rear bumper.
Installation
PARK ASSIST / MONITORING: ULTRASONIC SENSOR (for Rear Side): INSTALLATION
1. INSTALL NO. 1 ULTRASONIC SENSOR RETAINER
(a) Align the keyhole and protrusion as shown in the illustration.
(b) Install the sensor retainer to the rear bumper.
NOTICE: Do not damage the bumper with the protrusion when installing the retainer.
2. INSTALL NO. 1 ULTRASONIC SENSOR
(a) Attach the 2 claws to install the ultrasonic sensor.
Components
Engine Control Module: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: ECM: COMPONENTS
Page 3857
Power Steering Pressure Switch: Diagrams Power Steering Oil Pressure Switch
Page 5482
Actuator: Service and Repair Installation
DIFFERENTIAL: AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR (for 4WD):
INSTALLATION
1. INSTALL AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR
(a) Remove any old FIPG material and be careful not to drop oil on the contact surfaces of the
differential tube and actuator.
(b) Clean the contact surfaces with any residual FIPG material using gasoline or alcohol.
(c) Apply seal packing to the differential tube as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
HINT Install the actuator within 10 minutes of applying seal packing.
(d) Clean the threads of the 4 bolts and retainer bolt holes with toluene or trichloroethylene.
(e) Install the actuator onto the differential tube.
(f) Apply adhesive to 2 to 3 threads of each bolt end.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
(g) Install the 4 bolts.
Torque : 21 Nm (210 kgf-cm, 15 ft-lbf)
(h) Connect the actuator hose.
(i) Connect the actuator connector.
2. INSTALL NO. 1 ENGINE UNDER COVER See: Engine, Cooling and Exhaust/Engine/Drive
Belts, Mounts, Brackets and Accessories/Drive
Belt/Service and Repair/Installation
3. INSPECT AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR
(a) Inspect the automatic disconnecting differential actuator See: Transfer Case/Testing and
Inspection/Component Tests and General
Diagnostics/Touch Select 2-4 and High-Low System.
Page 4069
Evaporative Emission Control Canister: Service and Repair Installation
1UR-FE EMISSION CONTROL: CANISTER: INSTALLATION
1. INSTALL CANISTER ASSEMBLY
(a) Install the canister with the 4 bolts.
Torque : 29 Nm (296 kgf-cm, 21 ft-lbf)
(b) Connect the wire harness clamp.
(c) Connect the vent line hose.
(1) Push the hose into the port and push the retainer to lock it.
NOTICE: *
Check for damage or foreign objects on the connected part.
* After connecting, check that the vent hose and the valve are securely connected by pulling on
them.
(d) Connect the air inlet line hose.
NOTICE: *
Check for damage or foreign objects on the connected part.
* After connecting, check that the vent hose and the valve are securely connected by pulling on
them.
(e) Connect the purge line hose.
Page 144
(a) for Manual Air Conditioning System:
Disconnect the 2 connectors.
(b) for Automatic Air Conditioning System:
Disconnect the 3 connectors.
(c) Remove the 2 screws and amplifier.
Page 2853
Fuel Pump Control Unit: Locations Crew Max
Body
Page 6762
JQ1-LJ1
Page 3528
NOTICE: For vehicles without 4WD, go to "CHECK FOR SHORT TO GND IN CAN BUS WIRE
(NO. 2 JUNCTION CONNECTOR - ECM)".
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- CHECK FOR SHORT TO GND IN CAN BUS WIRE (4WD CONTROL ECU) OK -- Continue
to next step.
22. CHECK FOR SHORT TO GND IN CAN BUS WIRE (NO. 2 JUNCTION CONNECTOR - ECM)
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- CHECK FOR SHORT TO GND IN CAN BUS WIRE (ECM)
OK -- REPAIR OR REPLACE NO. 2 JUNCTION CONNECTOR
23. CHECK FOR SHORT TO GND IN CAN BUS WIRE (AIR CONDITIONING AMPLIFIER)
(a) Disconnect the J19 air conditioning amplifier connector.
Page 2990
Throttle Position Sensor: Diagrams
Locations
Shift Solenoid: Locations
A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS
LOCATION
Page 1722
8. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
NOTICE: *
Some systems need to be initialized after the cable is reconnected ( See: Testing and
Inspection/Programming and Relearning).
* After the ignition switch is turned OFF, the navigation system requires approximately 90 seconds
to record various types of memory and settings. As a result, after turning the ignition switch OFF,
wait 90 seconds or more before disconnecting the cable from the negative (-) battery terminal.
9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
NOTICE: Some systems need to be initialized after the cable is reconnected See: Testing and
Inspection/Programming and Relearning
10. PERFORM YAW RATE AND DECELERATION SENSOR ZERO POINT CALIBRATION
(a) Perform the yaw rate and deceleration sensor zero point calibration See: Brakes and Traction
Control/Antilock Brakes / Traction Control
Systems/Testing and Inspection/Programming and Relearning.
11. CHECK STEERING ANGLE SENSOR ZERO POINT CALIBRATION
Page 5741
Hydraulic Control Assembly - Antilock Brakes: Overhaul
Disassembly
BRAKE CONTROL: BRAKE ACTUATOR: DISASSEMBLY
1. REMOVE BRAKE ACTUATOR BRACKET ASSEMBLY
(a) Using a T30 "TORX" wrench, remove the 3 screws and actuator bracket.
Reassembly
BRAKE CONTROL: BRAKE ACTUATOR: REASSEMBLY
1. INSTALL BRAKE ACTUATOR BRACKET ASSEMBLY
(a) Using a T30 "TORX" wrench, install the actuator bracket with the 3 screws.
Torque : 9.5 Nm (97 kgf-cm, 84 in-lbf)
Page 3473
HINT *
o: DTC is memorized.
* *1: Only during failure status.
Page 6071
Ignition Switch: Service and Repair Removal
1UR-FE STARTING: IGNITION SWITCH: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE STEERING COLUMN ASSEMBLY
(a) for Manual Tilt:
Remove the steering column See: Steering and Suspension/Steering/Steering Column/Service and
Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Removal.
(b) for Manual Tilt and Manual Telescopic Steering Column:
Remove the steering column See: Steering and Suspension/Steering/Steering Column/Service and
Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt and Manual
Telescopic Steering Column)/Removal.
(c) for Power Tilt and Power Telescopic Steering Column:
Remove the steering column See: Steering and Suspension/Steering/Steering Column/Service and
Repair/Removal and Replacement/Steering Column Assembly (for Power Tilt and Power
Telescopic Steering Column)/Removal.
3. REMOVE UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Manual
Tilt) See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering Column Assembly
(for Manual Tilt)/Disassembly
4. REMOVE UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Manual Tilt
and Manual Telescopic Steering Column)
See: Steering and Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering
Column Assembly (for Manual Tilt and Manual Telescopic Steering Column)/Disassembly
5. REMOVE UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Power Tilt
and Power Telescopic Steering Column)
See: Steering and Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering
Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Disassembly
6. REMOVE IGNITION SWITCH ASSEMBLY
(a) Detach the 2 claws and remove the ignition switch from the steering lock.
Locations
Engine Temperature Sensor: Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 387
Engine Control Module: Pinout Values and Diagnostic Parameters
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: TERMINALS OF ECM
1. CHECK ECM
(a) Measure the voltage according to the value(s) in the table below.
HINT The standard voltage between each pair of ECM terminals is shown in the table below. The
appropriate conditions for checking each pair of terminals are also indicated. The result of checks
should be compared with the standard voltage for that pair of terminals, displayed in the Specified
Condition column. The illustration above can be used as a reference to identify the ECM terminal
locations.
Page 6151
"Case2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 621
Remote Switch: Locations Navigation System (w/ USB Audio System)
NAVIGATION: NAVIGATION SYSTEM (w/ USB Audio System): PARTS LOCATION
Page 7383
2. Install ChaSSiSEAR(TM) on the vehicle and attempt to isolate the source of the noise. Is the
noise loudest near the rear wheel bearing assembly?
^ YES - Go to step 3.
^ NO - This TSB does NOT apply. Continue diagnosis to isolate the source of the noise.
3. Replace the rear wheel bearing caliper bracket and related parts.
Refer to the Technical Information System (TIS) applicable model year Repair Manual:
4. Test drive the vehicle and confirm the noise is eliminated.
5. Re-check rear differential oil level and confirm NO leaks are present.
Page 6466
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION: Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC
terminals are touched, the IC may be destroyed by static electricity.)
When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact with the terminals of leads from the IC, etc. of the
replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown on the left.
DISCONNECT CONNECTOR
Components
Clockspring Assembly / Spiral Cable: Service and Repair Components
SUPPLEMENTAL RESTRAINT SYSTEM: SPIRAL CABLE: COMPONENTS
Page 3294
load while reprogramming.
^ Confirm the hood is open and ensure under hood temperature does NOT exceed 158°F (70°C).
^ Confirm cable connections between the vehicle and Techstream are secure.
^ Do NOT disconnect or turn off Techstream or vehicle ignition during reprogramming.
^ Set parking brake.
^ Complete ALL flash calibration updates provided for each ECU.
^ If the battery's state of charge or capacity are in question, test with SST. No. 00002-8150-KIT
"Digital Battery Analyze," and follow TSB No. PG001-06, "Battery Maintenance for In-Stock
Vehicles & Pre-Delivery" or the appropriate "Maintenance for HV & Auxiliary Batteries" service
bulletin.
^ The GR8 Battery Diagnostic Station MUST be used in Power Supply Mode to maintain battery
voltage at 13.5 volts while flash reprogramming the vehicle. For details on how to use the GR8
Battery Diagnostic Station, refer to the GR8 Instruction Manual located on TIS, Diagnostics - Tools
& Equipment - Battery Diagnostics.
3C. Click Next to start the calibration update process.
D. When using TIS Techstream select Techstream VIM as the desired programming device. Then
click Next.
Page 1285
Camshaft Position Sensor: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT POSITION SENSOR: INSTALLATION
1. INSTALL CAMSHAFT POSITION SENSOR
(a) Install the sensor with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(b) Connect the sensor connector.
2. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Installation
Page 3422
Standard resistance:
NG -- REPAIR OR REPLACE CAN BRANCH WIRE OR CONNECTOR (STEERING ANGLE
SENSOR)
OK -- REPLACE STEERING ANGLE SENSOR
8. CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (BUS BUFFER ECU)
NOTICE: For vehicles without a bus buffer ECU, go to "CHECK FOR OPEN IN ONE SIDE OF CAN
BRANCH WIRE (CENTER AIRBAG SENSOR)".
(a) Disconnect the J59 bus buffer ECU connector.
(b) Reconnect the cable to the negative (-) battery terminal.
(c) Select "CAN Bus Check" on the Techstream.
Result
B -- CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (CENTER AIRBAG SENSOR) A
-- Continue to next step.
9. CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (BUS BUFFER ECU BRANCH
WIRE)
(a) Measure the resistance according to the value(s) in the table below.
Page 2836
Engine Control Module: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: ECM: INSTALLATION
1. INSTALL GASKET
(a) Clean the ECM seal's surface with non-residue solvent.
(b) Attach a new gasket to the ECM.
2. INSTALL ECM
(a) Install the ECM with the 4 bolts.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
NOTICE: *
Make sure the gasket is not folded or caught on any area on the surrounding part.
* Make sure there is no foreign matter caught between the gasket and surrounding part.
* Do not damage the gasket.
(b) Connect the 2 ECM connectors and push each lock lever down to lock the ECM connectors.
NOTICE: *
Make sure that the lock lever is raised 90° before connecting the ECM connectors. Failure to do
this may cause the lock lever and terminals to break.
* Do not twist the wire harness when connecting the ECM connectors.
(c) Connect the wire harness clamp.
3. CONNECT CONNECTOR HOLDER BLOCK
(a) Connect the connector holder block with the 3 bolts.
Torque : 7.3 Nm (74 kgf-cm, 65 in-lbf)
Page 7309
Ball Joint: Testing and Inspection Front Upper Suspension Arm
SUSPENSION: FRONT UPPER SUSPENSION ARM: INSPECTION
1. INSPECT FRONT SUSPENSION UPPER ARM ASSEMBLY LH
(a) As shown in the illustration, flip the ball joint stud back and forth 5 times, before installing the
nut.
(b) Using a torque wrench, turn the nut continuously at a rate of 3 to 5 seconds per 1 turn and take
the torque reading on the fifth turn.
Standard turning torque:
0.98 to 4.41 N*m (1.0 to 45 kgf*cm, 9 to 39 in.*lbf)
Page 5869
Parking Brake Warning Switch: Locations From 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 6470
"Case1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (/\ Mark) and pull the terminal retainer
up to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Page 1453
Diagrams
Variable Valve Timing Actuator Position Sensor: Diagrams
Page 3994
This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown.
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60
months or 60,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Op Code EG9029 or EG9024: For California specification vehicles sold, registered, and operated
in California, Connecticut, Maine, Massachusetts, New Jersey, Oregon, Pennsylvania, Rhode
Island, Vermont, and Washington, this repair is covered under the California Emission Warranty.
This warranty is in effect for 84 months or 70,000 miles, whichever occurs first, from the vehicle's
in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Page 7632
Compressor HVAC: Diagnostic Aids
Continuity and Resistance Check
CONTINUITY AND RESISTANCE CHECK
Disconnect the battery terminal or wire so there is no voltage between the check points.
Contact the two leads of an ohmmeter to each of the check points.
Page 7991
(a) Disconnect the 3 airbag wire harness clamps from under the seat.
(b) Remove the 4 bolts and seatback.
11. REMOVE FRONT SEATBACK BOARD See: Body and Frame/Seats/Service and
Repair/Overhaul/Front Seat Assembly (for Fold Down Seat
Type)/Disassembly
12. REMOVE FRONT SEATBACK LOCK SUB-ASSEMBLY LH See: Body and
Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly
(for Fold Down Seat Type)/Disassembly
13. REMOVE FRONT SEATBACK LOCK SUB-ASSEMBLY RH See: Body and
Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly
(for Fold Down Seat Type)/Disassembly
14. REMOVE FRONT SEATBACK COVER WITH PAD RH See: Body and Frame/Seats/Service
and Repair/Overhaul/Front Seat Assembly (for
Fold Down Seat Type)/Disassembly
15. REMOVE FRONT SEAT SIDE AIRBAG ASSEMBLY
(a) Disconnect the clamp.
(b) Remove the 2 nuts and the front seat side airbag assembly.
CAUTION: *
The nuts must not be reused.
* Make sure that the seat frame assembly is not deformed. If it is, replace it with a new one.
Installation
SUPPLEMENTAL RESTRAINT SYSTEM: FRONT SEAT SIDE AIRBAG ASSEMBLY (for Fold
Down Seat Type): INSTALLATION
Page 719
Power Seat Switch: Service and Repair Front Power Seat Lumbar Switch (for Power Seat)
Components
SEAT: FRONT POWER SEAT LUMBAR SWITCH (for Power Seat): COMPONENTS
Page 7715
Control Module HVAC: Diagrams A/C Amplifier
Page 3529
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO AIR CONDITIONING
AMPLIFIER (CANH, CANL)
OK -- REPLACE AIR CONDITIONING AMPLIFIER ASSEMBLY
24. CHECK FOR SHORT TO GND IN CAN BUS WIRE (BUS BUFFER ECU)
(a) Disconnect the J59 bus buffer ECU connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO BUS BUFFER ECU (CAN+,
CAN-)
OK -- REPLACE BUS BUFFER ECU
25. CHECK FOR SHORT TO GND IN CAN BUS WIRE (4WD CONTROL ECU)
(a) Disconnect the A25 4WD control ECU connector.
Page 8673
Establish conditions in which voltage is present at the check point.
Example:
- [A] - Ignition SW on
- [B] - Ignition SW and SW1 on
- [C] - Ignition SW, SW1 and Relay on (SW2 off)
Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or component terminal.
This check can be done with a test light instead of a voltmeter.
Electronic Circuit Inspection Procedure
Page 5089
This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown.
Page 7534
Wheel Bearing: Tools and Equipment
Wheel Bearing Nut Socket
AST tool# TOY 185
For R and R of wheel bearing nut located on inboard side of wheel hub. Applicable: Newer Toyota
trucks and SUV's (2wd only).
- Made in USA
Contact AST for pricing.
Assenmacher Specialty Tools 1-800-525-2943
Page 8015
Air Bag Control Module: Service and Repair Center Airbag Sensor Assembly (for Floor Shift Type)
Components
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift
Type): COMPONENTS
Page 8225
(d) Activate the seat belt pretensioner.
(1) Connect SST's red clip to the battery's positive (+) terminal and the black clip to the battery's
negative (-) terminal.
(2) Check that no one is within 10 m (32.8 ft.) of the wheel.
(3) Press SST activation switch to activate the seat belt pretensioner.
HINT The seat belt pretensioner operates at the same time SST activation switch's LED
illuminates.
(e) Dispose of the front seat outer belt (with the seat belt pretensioner).
CAUTION: *
Do not touch the front seat outer belt for at least 30 minutes after the seat belt pretensioner has
been activated. It is very hot.
* Use gloves and safety glasses when handling a front seat outer belt whose pretensioner has
been activated.
* Always wash your hands with water after completing the disposal.
* Do not apply water to a front seat outer belt that has an activated pretensioner.
(1) Remove the tire (with wheel) and SST.
(2) Place the front seat outer belt in a plastic bag, tie the end tightly and dispose of it in the same
way as other general parts.
Front Seat Outer Belt Assembly (for Regular Cab)
SEAT BELT: FRONT SEAT OUTER BELT ASSEMBLY (for Regular Cab): DISPOSAL
HINT When scrapping vehicles equipped with a seat belt pretensioner or disposing of a front seat
outer belt (with seat belt pretensioner), always first activate the seat belt pretensioner in
accordance with the procedures described below. If any abnormality occurs during activation of the
seat belt pretensioner, contact the SERVICE DEPARTMENT of TOYOTA MOTOR SALES, U.S.A.,
INC.
CAUTION:
* Never dispose of a front seat outer belt that has a non-activated pretensioner.
* The seat belt pretensioner produces a loud, exploding sound when it activates. Perform the
operation where it will not be a nuisance to nearby people.
* When activating a front seat outer belt (with seat belt pretensioner), stand at least 10 m (32.8 ft.)
away from the front seat outer belt.
* Use gloves and safety glasses when handling a front seat outer belt with an activated
pretensioner.
* Always wash your hands with water after completing the disposal.
* Do not apply water to a front seat outer belt that has an activated pretensioner.
* Perform procedures in a place away from electrical interference.
* When activating the seat belt pretensioner, always use the specified SST (SRS airbag
deployment tool).
1. DISPOSE OF FRONT SEAT OUTER BELT ASSEMBLY (WHEN INSTALLED IN VEHICLE)
HINT
Page 7923
(b) With the lower No. 2 instrument panel airbag removed from the vehicle, perform a visual check.
If there are any defects as mentioned below,
replace the lower No. 2 instrument panel airbag with a new one:
* Cuts, minute cracks or marked discoloration on the lower No. 2 instrument panel airbag.
* Cracks or other damage to the connector.
* Deformation or cracks on the instrument panel reinforcement.
CAUTION: For removal and installation procedures of the lower No. 2 instrument panel airbag, be
sure to follow the correct procedure.
Curtain Shield Airbag Assembly
SUPPLEMENTAL RESTRAINT SYSTEM: CURTAIN SHIELD AIRBAG ASSEMBLY: ON-VEHICLE
INSPECTION
1. CHECK CURTAIN SHIELD AIRBAG ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION)
(a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnosis System.
(b) With the curtain shield airbag installed on the vehicle, perform a visual check. If any of the
defects mentioned below are present, replace the
curtain shield airbag with a new one:
Cuts, minute cracks or marked discoloration on the curtain shield airbag.
2. CHECK CURTAIN SHIELD AIRBAG ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND
AIRBAG HAS NOT DEPLOYED)
(a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnosis System.
(b) With the curtain shield airbag removed from the vehicle, perform a visual check. If there are any
defects as mentioned below, replace the
curtain shield airbag with a new one:
* Cuts, minute cracks or marked discoloration on the curtain shield airbag.
* Cracks or other damage to the connectors.
CAUTION: For removal and installation procedures of the curtain shield airbag, be sure to follow
the correct procedure.
Curtain Shield Airbag Assembly (for CrewMax)
SUPPLEMENTAL RESTRAINT SYSTEM: CURTAIN SHIELD AIRBAG ASSEMBLY (for CrewMax):
ON-VEHICLE INSPECTION
1. CHECK CURTAIN SHIELD AIRBAG ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION)
(a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnosis System.
Page 5956
Push the terminal retainer down to the temporary lock position.
Page 1576
Transmission Mode Switch: Diagrams Tow/Haul Pattern Select Switch
Page 6364
6. PROBLEM SYMPTOMS TABLE
When a "Normal" code is output during a DTC check but the problem is still occurring, use the
Problem Symptoms Table. The suspected areas (circuits or parts) for each problem symptom are
in the table. The suspected areas are listed in order of probability. A description of each of the
chart's columns is below.
HINT In some cases, the problem is not detected by the diagnostic system even though a problem
symptom is present. It is possible that the problem is occurring outside the detection range of the
diagnostic system, or that the problem is occurring in a completely different system.
7. CIRCUIT INSPECTION
A description of the main areas of each circuit inspection is below.
Page 3073
[A] For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
"Case1" Raise the terminal retainer up to the temporary lock position.
Page 6279
(1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be
checked by conducting a voltage check.
With each connector still connected, measure the voltage between the body ground and these
terminals (in this order): 1) terminal 1 of connector A; 2) terminal 1 of connector B; and 3) terminal
1 of connector C.
Standard voltage (Fig. 4):
* If the results match the examples above, an open circuit exists in the wire harness between
terminal 1 of connector B and terminal 1 of connector C.
3. CHECK FOR SHORT CIRCUIT
(a) If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance
check with the body ground (below).
(b) Check the resistance with the body ground.
(1) Disconnect connectors A and C and measure the resistance.
Standard resistance (Fig. 6):
HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally.
If your results match the examples above, a short circuit exists between terminal 1 of connector A
and terminal 1 of connector C.
Page 3433
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE CAN MAIN WIRE CONNECTED TO COMBINATION METER ECU
(CANH, CANL)
OK -- REPLACE COMBINATION METER ASSEMBLY
14. CHECK FOR SHORT IN CAN BUS WIRES (MAIN BODY ECU)
(a) Disconnect the J2 main body ECU connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO MAIN BODY ECU (CANH,
CANL)
OK -- REPLACE MAIN BODY ECU
15. CHECK FOR SHORT IN CAN BUS WIRES (SKID CONTROL ECU WITH ACTUATOR)
(a) Disconnect the A17 skid control ECU with actuator connector.
Page 7063
Standard steering axis inclination (unloaded vehicle):
for CrewMax of standard deck
Page 3456
Standard resistance:
NG -- REPAIR OR REPLACE BUS BUFFER ECU BRANCH WIRE OR CONNECTOR (CAN+,
CAN-)
OK -- REPLACE BUS BUFFER ECU
Center Airbag Sensor Communication Stop Mode
CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: Center Airbag Sensor
Communication Stop Mode - Center Airbag Sensor Communication Stop Mode
DESCRIPTION
WIRING DIAGRAM
INSPECTION PROCEDURE
HINT
Page 8645
2. INSTALL NO. 2 CONSOLE BOX REGISTER ASSEMBLY See: Body and Frame/Seats/Service
and Repair/Overhaul/Front Seat Assembly (for
Center Seat)/Reassembly
3. INSTALL NO. 1 CONSOLE BOX REGISTER ASSEMBLY See: Body and Frame/Seats/Service
and Repair/Overhaul/Front Seat Assembly (for
Center Seat)/Reassembly
4. INSTALL CENTER SEAT BACK PANEL See: Body and Frame/Seats/Service and
Repair/Overhaul/Front Seat Assembly (for Center
Seat)/Reassembly
5. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Page 7752
Hose/Line HVAC: Tools and Equipment
A/C Clamp Remover
AST tool# TOY 200
Page 6980
(1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be
checked by conducting a voltage check.
With each connector still connected, measure the voltage between the body ground and these
terminals (in this order): 1) terminal 1 of connector A; 2) terminal 1 of connector B; and 3) terminal
1 of connector C.
Standard voltage (Fig. 4):
* If the results match the examples above, an open circuit exists in the wire harness between
terminal 1 of connector B and terminal 1 of connector C.
3. CHECK FOR SHORT CIRCUIT
(a) If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance
check with the body ground (below).
(b) Check the resistance with the body ground.
(1) Disconnect connectors A and C and measure the resistance.
Standard resistance (Fig. 6):
HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally.
If your results match the examples above, a short circuit exists between terminal 1 of connector A
and terminal 1 of connector C.
Testing and Inspection
Parking Assist Switch: Testing and Inspection
PARK ASSIST / MONITORING: CLEARANCE SONAR MAIN SWITCH: INSPECTION
1. INSPECT DRIVE MONITOR SWITCH
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) If the result is not as specified, replace the monitor switch.
(c) Inspect the switch illumination.
(1) Connect the positive (+) lead of the battery to terminal 1 (ILL+) and the negative (-) lead to
terminal 6 (ILL-).
(2) Check that the LED comes on.
OK:
LED comes on.
(3) If the result is not as specified, replace the monitor switch.
Page 1812
4. Attach the Authorized Vehicle Modification Label.
Modifications to ECU calibrations MUST be recorded and properly displayed on the vehicle using
the Authorized Modification Label.
Techstream Preparation
Selecting the TIS Techstream VIM or the Mongoose MFC VIM.
Techstream software requires a VIM selection before you can use the Mongoose MFC VIM.
If using TIS Techstream no changes are needed.
Perform the following:
1. Select Setup from the Techstream Main Menu screen.
2. Select VIM Select from the Setup drop down menu.
3. Select the correct Interface Setup from the drop down list.
^ If using Techstream Lite select Mongoose MFC.
NOTE
Page 6258
Page 4470
Throttle Position Sensor: Diagrams
Page 1429
Page 8670
Push the terminal retainer down to the temporary lock position.
Page 7323
(a) Using a chisel and hammer, pry the flange of the bush outward.
(b) Using SST, remove the bush.
SST : 09950-40011
09951-04010
09952-04010
09953-04020
09954-04020
09955-04011
09957-04010
09958-04011
SST : 09950-60010
09951-00650
3. REMOVE FRONT NO. 1 SPRING BUMPER LH
(a) Remove the No. 1 spring bumper from the vehicle.
Reassembly
SUSPENSION: FRONT LOWER SUSPENSION ARM: REASSEMBLY
1. INSTALL FRONT NO. 1 SPRING BUMPER LH
(a) Install the No. 1 spring bumper to the vehicle.
Torque : 31 Nm (316 kgf-cm, 23 ft-lbf)
Page 3530
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO 4WD CONTROL ECU
(CANH, CANL)
OK -- REPLACE 4WD CONTROL ECU
26. CHECK FOR SHORT TO GND IN CAN BUS WIRE (ECM)
(a) Disconnect the A24 ECM connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
Result
E -- REPAIR OR REPLACE CAN MAIN WIRE CONNECTED TO ECM (CANH, CANL)
D -- REPLACE ECM
Page 6406
Tailgate Wire
Front Seat Wire
Page 3248
6. PROBLEM SYMPTOMS TABLE
When a "Normal" code is output during a DTC check but the problem is still occurring, use the
Problem Symptoms Table. The suspected areas (circuits or parts) for each problem symptom are
in the table. The suspected areas are listed in order of probability. A description of each of the
chart's columns is below.
HINT In some cases, the problem is not detected by the diagnostic system even though a problem
symptom is present. It is possible that the problem is occurring outside the detection range of the
diagnostic system, or that the problem is occurring in a completely different system.
7. CIRCUIT INSPECTION
A description of the main areas of each circuit inspection is below.
Page 3365
Use a volt/ohmmeter with high impedance (10 kohms/V minimum) for troubleshooting of the
electrical circuit.
Disconnection of Male and Female Connectors
DISCONNECTION OF MALE AND FEMALE CONNECTORS
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Finding A Short Circuit
FINDING A SHORT CIRCUIT
Page 7001
Junction Connector (CAN No.2) - Lower Finish Panel
Page 717
(a) Disconnect the switch connector.
(b) Remove the 3 screws and switch.
Installation
SEAT: POWER SEAT SWITCH (w/o Seat Position Memory System): INSTALLATION
HINT *
Use the same procedures for the LH side and RH side.
* The procedures listed below are for the LH side.
1. INSTALL FRONT POWER SEAT SWITCH LH
(a) Install the switch with the 3 screws.
(b) Connect the switch connector.
2. INSTALL LEG SUPPORT ADJUSTMENT SWITCH (w/ Leg Support Adjustment Switch)
(a) Connect the switch connector.
(b) Install the switch with the 2 screws.
(c) Attach the 2 wire harness clamps.
3. INSTALL FRONT SEAT CUSHION SHIELD LH See: Body and Frame/Seats/Service and
Repair/Overhaul/Front Seat Assembly (for Power
Seat)/Reassembly
4. INSTALL RECLINING POWER SEAT SWITCH KNOB LH See: Body and Frame/Seats/Service
and Repair/Overhaul/Front Seat Assembly
(for Power Seat)/Reassembly
5. INSTALL SLIDE AND VERTICAL POWER SEAT SWITCH KNOB LH See: Body and
Frame/Seats/Service and Repair/Overhaul/Front Seat
Assembly (for Power Seat)/Reassembly
6. INSTALL FRONT SEAT ASSEMBLY LH
(a) Install the front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Power
Page 1860
Step 4. Remove the cover by sliding up while pulling toward you
Step 5. Remove the filter cover.
Page 7236
Power Steering Pressure Switch: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: POWER STEERING OIL PRESSURE SWITCH:
REMOVAL
1. REMOVE FAN AND GENERATOR V BELT
(a) Remove the fan and generator V belt See: Engine, Cooling and Exhaust/Engine/Drive Belts,
Mounts, Brackets and Accessories/Drive
Belt/Service and Repair/Removal.
2. REMOVE FRONT WHEEL
3. REMOVE FRONT FENDER APRON SEAL RH See: Engine, Cooling and Exhaust/Exhaust
System/Exhaust Manifold/Service and
Repair/Removal
4. DRAIN POWER STEERING FLUID
5. REMOVE POWER STEERING OIL PRESSURE SWITCH
(a) Disconnect the power steering oil pressure switch connector.
(b) Remove the power steering oil pressure switch.
(c) Remove the O-ring.
Page 999
Fuel Gauge Sender: Testing and Inspection
1UR-FE FUEL: FUEL SENDER GAUGE ASSEMBLY: INSPECTION
1. INSPECT FUEL SENDER GAUGE ASSEMBLY
(a) Check that the float moves smoothly between F and E.
(b) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(c) If the result is not as specified, replace the fuel sender gauge assembly.
Page 7601
Page 5149
Page 5990
Neutral Safety Switch: Service and Repair Removal
A760F AUTOMATIC TRANSMISSION: PARK / NEUTRAL POSITION SWITCH: REMOVAL
1. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY
(a) Remove the nut and disconnect the cable.
2. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY
(a) Disconnect the switch connector.
(b) Remove the nut, spring washer and transmission control shaft lever RH.
(c) Using a screwdriver, bend the tabs of the lock washer.
(d) Remove the lock nut and lock washer.
(e) Remove the bolt and switch.
Page 8075
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE BATTERY
(a) Disconnect the cable from the positive (+) battery terminal.
(b) Loosen the nut, move the stay off the battery, and remove the battery.
3. REMOVE FRONT AIRBAG SENSOR
(a) Remove the nut and front airbag sensor from the body.
(b) Disconnect the connector.
Installation
SUPPLEMENTAL RESTRAINT SYSTEM: FRONT AIRBAG SENSOR: INSTALLATION
1. INSTALL FRONT AIRBAG SENSOR
(a) Check that the ignition switch is OFF.
(b) Check that the cable is disconnected from the battery negative (-) terminal.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
(c) Connect the connector.
(d) Install the front airbag sensor with the nut.
Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)
Page 8360
9. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH (for Rear Side)
10. INSTALL REAR DOOR SCUFF PLATE LH (for Rear Side) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and Repair/Roof
Headlining (For Double Cab)/Installation
11. INSTALL REAR SEAT ASSEMBLY (for Rear Side)
(a) Install the rear seat assembly See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Rear Seat Assembly (for Double
Cab)/Installation.
12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
13. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Air Bag Systems/Testing and Inspection/Initial Inspection
and Diagnostic Overview/Diagnosis System.
Page 4345
Page 1470
Page 6343
[A] For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
"Case1" Raise the terminal retainer up to the temporary lock position.
Page 3924
Variable Valve Timing Actuator Position Sensor: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: VVT SENSOR: REMOVAL
1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Removal
2. REMOVE AIR CLEANER HOSE ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Removal
3. REMOVE VVT SENSOR
(a) Disconnect the 4 sensor connectors.
(b) Remove the 4 bolts and 4 sensors.
Page 4195
Recall - Floor Mat/Accelerator Pedal Interferance
Technical Service Bulletin # SSC90L Date: 091001
Page 9118
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: ELECTRONIC
CIRCUIT INSPECTION PROCEDURE
1. BASIC INSPECTION
(a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS
(1) Unless otherwise stated, all resistance measurements should be made at an ambient
temperature of 20°C (68°F). Resistance measurements
may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been
running. Measurements should be made after the engine has cooled down.
(b) HANDLING CONNECTORS
(1) When disconnecting a connector, first squeeze the mating halves tightly together to release the
lock, and then press the lock claw and
separate the connector.
(2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly
and separate it.
(3) Before connecting a connector, check that there are no deformed, damaged, loose or missing
terminals.
(4) When connecting a connector, press firmly until it locks with a "click" sound.
(5) If checking a connector with a TOYOTA electrical tester, check the connector from the backside
(harness side) using a mini test lead.
NOTICE: *
As a waterproof connector cannot be checked from the backside, check it by connecting a
sub-harness.
* Do not damage the terminals by moving the inserted tester needle.
(c) CHECKING CONNECTORS
(1) Checking when a connector is connected: Squeeze the connectors together to confirm that they
are fully connected and locked.
(2) Checking when a connector is disconnected: Check by pulling the wire harness lightly from the
backside of the connector. Look for
unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for
corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or
deformed terminals.
(3) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a
female terminal, and check for ample tension
Page 8617
Refer to the Technical Information System (TIS) applicable model and model year Repair Manual:
5. Verify normal USB operation after repair.
Page 1713
Standard caster inclination (unloaded vehicle):
for Regular Cab of Long Deck
Standard caster inclination (unloaded vehicle):
for Double Cab of Standard Deck
Page 3506
Standard resistance:
NG -- CHECK FOR SHORT TO B+ IN CAN BUS WIRE (SKID CONTROL ECU WITH ACTUATOR)
OK -- Continue to next step.
10. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (NO. 1 JUNCTION CONNECTOR STEERING ANGLE SENSOR)
(a) Disconnect the J87 No. 1 junction connector connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- CHECK FOR SHORT TO B+ IN CAN BUS WIRE (STEERING ANGLE SENSOR) OK -Continue to next step.
11. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (NO. 1 JUNCTION CONNECTOR - POWER
STEERING ECU)
NOTICE: For vehicles without a power steering ECU, go to "CHECK FOR SHORT TO B+ IN CAN
BUS WIRE (NO. 1 JUNCTION CONNECTOR - CENTER AIRBAG SENSOR)".
(a) Disconnect the J115 No. 1 junction connector connector.
Page 2030
Driver Side J/B - Cowl Side Left
Components
Tire Pressure Monitor Receiver / Transponder: Service and Repair Components
TIRE AND WHEEL: TIRE PRESSURE WARNING RECEIVER: COMPONENTS
Page 2490
NOTICE: Do not damage the surface of the oil seal press fit hole and crankshaft.
HINT Tape the screwdriver tip before use.
Up to 11/2009
Traction Control Relay: Locations Up to 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Components
Tire Pressure Module: Service and Repair Components
TIRE AND WHEEL: TIRE PRESSURE WARNING ECU: COMPONENTS
Page 6526
"Case2" Open the secondary locking device.
[B] For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray
Gray or White : Black
Page 182
DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector.
Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
Page 7941
Wire harness:
Stripped wire harness section
1.25 mm2 or more (0.00193 in.2 or more)
CAUTION: If the wire harness is too thin or an alternative object is used to tie down the curtain
shield airbag, it may be snapped by the shock when the airbag is deployed. Always use a wire
harness for vehicle use with an area of at least 1.25 mm2 (0.00193 in.2).
HINT To calculate the area of the stripped wire harness section:
Area = 3.14 x (Diameter)2 divided by 4
(1) Position the curtain shield airbag inside the tire as shown in the illustration.
Tire size:
Must exceed the following dimensions
Width 185 mm (7.28 in.)
Inner diameter 360 mm (1.18 ft.)
(2) Tie the curtain shield airbag to the tire with several wire harnesses.
CAUTION: Make sure that the wire harnesses are tight. If there is slack in the wire harnesses, the
curtain shield airbag may become loose due to the shock when the airbag is deployed.
NOTICE: As the tires may be damaged by the airbag deployment, use a tire that you are planning
to throw away.
(e) Install SST.
(1) After connecting SST each other, connect them to the curtain shield airbag.
SST : 09082-00802
09082-10801
09082-40800
Page 536
Tire Pressure Monitor Receiver / Transponder: Service and Repair Installation
TIRE AND WHEEL: TIRE PRESSURE WARNING RECEIVER: INSTALLATION
1. INSTALL TIRE PRESSURE WARNING ANTENNA AND RECEIVER
(a) Install the receiver with the bolt.
Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
(b) Connect the receiver connector.
2. INSTALL ROOF HEADLINING ASSEMBLY
(a) for Regular Cab:
Install the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Installation.
(b) for Double Cab:
Install the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Double Cab)/Installation.
(c) for CrewMax:
Install the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (for CrewMax)/Installation.
Page 1518
(g) Hold the switch in position and tighten the bolt.
Torque : 13 Nm (130 kgf-cm, 9 ft-lbf)
(h) Using a screwdriver, bend the tabs of the lock washer.
(i) Install the transmission control shaft lever RH with the spring washer and nut.
Torque : 16 Nm (160 kgf-cm, 12 ft-lbf)
(j) Connect the switch connector.
2. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY
(a) Connect the cable with the nut.
Torque : 14 Nm (143 kgf-cm, 10 ft-lbf)
NOTICE: When connecting the cable to the transmission control shaft lever, make sure the L
bracket of the cable faces the inside of the vehicle.
3. ADJUST SHIFT LEVER POSITION (for Column Shift Type) See: Transmission and
Drivetrain/Automatic Transmission/Transaxle/Shifter
A/T/Adjustments/SHIFT LEVER ASSEMBLY (for Column Shift Type)
4. ADJUST SHIFT LEVER POSITION (for Floor Shift Type) See: Transmission and
Drivetrain/Automatic Transmission/Transaxle/Shifter
A/T/Adjustments/SHIFT LEVER ASSEMBLY (for Floor Shift Type)
Page 4608
6. PROBLEM SYMPTOMS TABLE
When a "Normal" code is output during a DTC check but the problem is still occurring, use the
Problem Symptoms Table. The suspected areas (circuits or parts) for each problem symptom are
in the table. The suspected areas are listed in order of probability. A description of each of the
chart's columns is below.
HINT In some cases, the problem is not detected by the diagnostic system even though a problem
symptom is present. It is possible that the problem is occurring outside the detection range of the
diagnostic system, or that the problem is occurring in a completely different system.
7. CIRCUIT INSPECTION
A description of the main areas of each circuit inspection is below.
Page 8041
Clockspring Assembly / Spiral Cable: Diagrams Spiral Cable, Driver Side Squib 2nd Step Circuit
Page 9259
4. INSTALL REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY
(a) Attach the 4 claws to install the control switch.
5. INSTALL REAR UPPER DOOR ARMREST BASE PANEL LH
(a) Connect the connector.
(b) Attach the 2 clips to install the rear upper door armrest base panel.
6. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG LH
(a) Attach the 4 claws to install the bezel plug.
Page 7924
(b) With the curtain shield airbag installed on the vehicle, perform a visual check. If any of the
defects mentioned below are present, replace the
curtain shield airbag with a new one:
Cuts, minute cracks or marked discoloration on the curtain shield airbag.
2. CHECK CURTAIN SHIELD AIRBAG ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND
AIRBAG HAS NOT DEPLOYED)
(a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnosis System.
(b) With the curtain shield airbag removed from the vehicle, perform a visual check. If there are any
defects as mentioned below, replace the
curtain shield airbag with a new one:
* Cuts, minute cracks or marked discoloration on the curtain shield airbag.
* Cracks or other damage to the connectors.
CAUTION: For removal and installation procedures of the curtain shield airbag, be sure to follow
the correct procedure.
Driver Side Knee Airbag Assembly
SUPPLEMENTAL RESTRAINT SYSTEM: DRIVER SIDE KNEE AIRBAG ASSEMBLY:
ON-VEHICLE INSPECTION
1. CHECK LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY (VEHICLE NOT
INVOLVED IN COLLISION)
(a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnosis System.
(b) With the lower No. 1 instrument panel airbag installed on the vehicle, perform a visual check. If
there are any defects as mentioned below,
replace the lower No. 1 instrument panel airbag with a new one:
Cuts, minute cracks or marked discoloration on the lower No. 1 instrument panel airbag.
2. CHECK LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY (VEHICLE INVOLVED IN
COLLISION AND AIRBAG HAS NOT
DEPLOYED)
(a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnosis System.
Page 142
Control Module HVAC: Service and Repair Removal
AIR CONDITIONING: AIR CONDITIONING AMPLIFIER: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE FRONT DOOR SCUFF PLATE RH
(a) for Regular Cab:
Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular Cab)/Removal.
(b) for Double Cab:
Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Removal.
(c) for CrewMax:
Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for CrewMax)/Removal.
3. REMOVE COWL SIDE TRIM BOARD RH
(a) for Regular Cab:
Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular Cab)/Removal.
(b) for Double Cab:
Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Removal.
(c) for CrewMax:
Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for CrewMax)/Removal.
4. REMOVE NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY
(a) for Column Shift Type:
Remove the No. 2 instrument panel under cover sub-assembly See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and
Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal.
(b) for Floor Shift Type:
Remove the No. 2 instrument panel under cover sub-assembly See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and
Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal.
5. REMOVE INSTRUMENT SIDE PANEL RH
(a) for Column Shift Type:
Remove the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Column Shift Type)/Removal.
(b) for Floor Shift Type:
Page 1187
Manifold Pressure/Vacuum Sensor: Testing and Inspection
1UR-FE ENGINE CONTROL SYSTEM: MANIFOLD ABSOLUTE PRESSURE SENSOR:
INSPECTION
1. INSPECT MANIFOLD ABSOLUTE PRESSURE SENSOR
(a) Check the resistance.
(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(2) If the result is not as specified, replace the manifold absolute pressure sensor.
Page 3624
SST : 09224-00010
without SST - Torque : 44 Nm (449 kgf-cm, 32 ft-lbf)
with SST - Torque : 40 Nm (408 kgf-cm, 30 ft-lbf)
HINT *
Use a torque wrench with a fulcrum length of 30 cm (11.8 in.). When using a torque wrench with a
fulcrum length that is not 30 cm (11.8 in.), calculate the torque specification for the torque wrench
and SST based on the "without SST" torque specification See: Service Precautions
* Make sure SST and the wrench are connected in a straight line.
3. INSTALL PROPELLER SHAFT HEAT INSULATOR (for 4WD) See: Transmission and
Drivetrain/Drive/Propeller Shafts, Bearings and
Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Front Propeller Shaft
Assembly/Installation
4. INSPECT FOR EXHAUST GAS LEAK See: Engine, Cooling and Exhaust/Exhaust
System/Exhaust Manifold/Service and Repair/Installation
Page 4918
5. INSTALL COLUMN SHIFT SHIFT LEVER SUB-ASSEMBLY
(a) Apply MP grease to the 2 lever selecting bushes as shown in the illustration.
(b) Install the 2 lever selecting bushes and shift lever to the column shift control shift lever retainer.
(c) Pass the wire harness of the shift lever through the control shaft tube clamp.
(d) Attach the control shaft tube clamp to the column shift control shift lever retainer.
(e) Securely connect the 3 wire terminals to terminal 4 (SFTD-), 5 (SFTU+) and 11 (E) of the
transmission control switch connector. Then push in
the connector housing retainer to lock it.
Page 5643
Wheel Speed Sensor: Locations From 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 6777
Page 6276
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: ELECTRONIC
CIRCUIT INSPECTION PROCEDURE
1. BASIC INSPECTION
(a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS
(1) Unless otherwise stated, all resistance measurements should be made at an ambient
temperature of 20°C (68°F). Resistance measurements
may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been
running. Measurements should be made after the engine has cooled down.
(b) HANDLING CONNECTORS
(1) When disconnecting a connector, first squeeze the mating halves tightly together to release the
lock, and then press the lock claw and
separate the connector.
(2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly
and separate it.
(3) Before connecting a connector, check that there are no deformed, damaged, loose or missing
terminals.
(4) When connecting a connector, press firmly until it locks with a "click" sound.
(5) If checking a connector with a TOYOTA electrical tester, check the connector from the backside
(harness side) using a mini test lead.
NOTICE: *
As a waterproof connector cannot be checked from the backside, check it by connecting a
sub-harness.
* Do not damage the terminals by moving the inserted tester needle.
(c) CHECKING CONNECTORS
(1) Checking when a connector is connected: Squeeze the connectors together to confirm that they
are fully connected and locked.
(2) Checking when a connector is disconnected: Check by pulling the wire harness lightly from the
backside of the connector. Look for
unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for
corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or
deformed terminals.
(3) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a
female terminal, and check for ample tension
Page 3519
NG -- REPAIR OR REPLACE CAN MAIN WIRE OR CONNECTOR (NO. 1 JUNCTION
CONNECTOR - NO. 2 JUNCTION CONNECTOR) OK -- Continue to next step.
6. CONNECT CONNECTOR
(a) Reconnect the J94 No. 1 junction connector connector.
(b) Reconnect the J113 No. 2 junction connector connector.
NEXT -- Continue to next step.
7. CHECK FOR SHORT TO GND IN CAN BUS WIRE (NO. 1 JUNCTION CONNECTOR COMBINATION METER ECU)
(a) Disconnect the J84 No. 1 junction connector connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- CHECK FOR SHORT TO GND IN CAN BUS WIRE (COMBINATION METER ECU) OK -Continue to next step.
8. CHECK FOR SHORT TO GND IN CAN BUS WIRE (NO. 1 JUNCTION CONNECTOR - MAIN
BODY ECU)
(a) Disconnect the J96 No. 1 junction connector connector.
Page 3297
^ Figure 17 shows an example of the update procedure for a two-processor ECU.
G. Turn ignition OFF. Then click Next.
H. Confirm the following:
^ Ignition is ON and engine is OFF or "READY" OFF (hybrid vehicles).
^ Hood is open.
^ All accessories are OFF.
^ Battery voltage is above 11.4 volts.
NOTICE
Verify the vehicle is connected to a battery charger before continuing - If battery voltage falls below
11.4 volts, ECU damage may occur.
Page 1210
5. REMOVE PROPELLER SHAFT HEAT INSULATOR (for 4WD) See: Transmission and
Drivetrain/Drive/Propeller Shafts, Bearings and
Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Front Propeller Shaft
Assembly/Removal
6. REMOVE FRONT NO. 2 EXHAUST PIPE ASSEMBLY (for 4WD)
(a) Disconnect the heated oxygen sensor connector.
(b) Disconnect the air fuel ratio sensor connector.
(c) Disconnect the front No. 2 exhaust pipe from the exhaust pipe support.
(d) Remove the 3 nuts, front No. 2 exhaust pipe and gasket from the exhaust manifold LH.
7. REMOVE AIR FUEL RATIO SENSOR (for Bank 1 Sensor 1)
(a) for 2WD:
Disconnect the air fuel ratio sensor connector.
(b) Using SST, remove the sensor.
SST : 09224-00010
Installation
1UR-FE ENGINE CONTROL SYSTEM: AIR FUEL RATIO SENSOR: INSTALLATION
1. INSTALL AIR FUEL RATIO SENSOR (for Bank 1 Sensor 1)
(a) Install the sensor to the exhaust pipe by hand.
(b) Using SST, tighten the sensor.
SST : 09224-00010
Page 6965
Use a volt/ohmmeter with high impedance (10 kohms/V minimum) for troubleshooting of the
electrical circuit.
Disconnection of Male and Female Connectors
DISCONNECTION OF MALE AND FEMALE CONNECTORS
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Finding A Short Circuit
FINDING A SHORT CIRCUIT
Page 5023
Removal
DIFFERENTIAL: DIFFERENTIAL CARRIER ASSEMBLY (for 1GR-FE, 1UR-FE): REMOVAL
1. REMOVE REAR WHEEL
2. REMOVE PROPELLER SHAFT ASSEMBLY
(a) Remove the propeller shaft for 2WD See: Drive/Propeller Shafts, Bearings and
Joints/Drive/Propeller Shaft/Service and Repair/Removal and
Replacement/Propeller Shaft Assembly/Removal.
(b) Remove the propeller shaft for 4WD See: Drive/Propeller Shafts, Bearings and
Joints/Drive/Propeller Shaft/Service and Repair/Removal and
Replacement/Propeller Shaft Assembly/Removal.
Page 9072
4. SYMPTOM CONFIRMATION AND DTC (INCLUDING FREEZE FRAME DATA) CHECK
(a) Visually check the wire harnesses, connectors and fuses for open and short circuits.
(b) Warm up the engine to the normal operating temperature.
(c) Confirm the problem symptoms and conditions, and check for DTCs.
B -- Go to step 6 A -- Continue to next step.
5. DTC CHART
(a) Check the results obtained in the DTC check. Then find the output DTC in the DTC chart. Look
at the "Trouble Area" column for a list of
potentially malfunctioning circuits and / or parts.
NEXT -- Go to step 7
6. PROBLEM SYMPTOMS TABLE
(a) Check the results obtained in the symptom confirmation. Then find the problem symptoms in
the problem symptoms table. Look at the
"Suspected Area" column for a list of potentially malfunctioning circuits and / or parts.
NEXT -- Continue to next step.
7. CIRCUIT INSPECTION OR PARTS INSPECTION
(a) Confirm the malfunctioning circuit or part.
NEXT -- Continue to next step.
8. ADJUST, REPAIR OR REPLACE
(a) Adjust, repair or replace the malfunctioning circuit or parts.
NEXT -- Continue to next step.
9. CONFIRMATION TEST
(a) After the adjustment, repairs or replacement, confirm that the malfunction no longer exists. If the
malfunction does not reoccur, perform a
confirmation test under the same conditions and in the same environment as when the malfunction
occurred the first time.
NEXT -- END
2. CUSTOMER PROBLEM ANALYSIS
HINT *
In troubleshooting, confirm that the problem symptoms have been accurately identified.
Preconceptions should be discarded in order to make an accurate judgment. To clearly understand
what the problem symptoms are, it is extremely important to ask the customer about the problem
and the conditions at the time the malfunction occurred.
* Gather as much information as possible for reference. Past problems that seem unrelated may
also help in some cases.
* The following 5 questions are important points in the problem analysis:
Page 288
* In the DTC check, it is very important to determine whether the problem indicated by the DTC is
either: 1) still occurring; or 2) occurred in the past but has since returned to normal. In addition, the
DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs
should be checked before and after confirmation of symptoms (i.e., whether or not problem
symptoms exist) to determine current system conditions, as shown in the flowchart below.
* Never skip the DTC check. Failing to check DTCs may, depending on the case, result in
unnecessary troubleshooting for systems operating normally or lead to repairs not related to the
problem. Follow the procedures listed in the flowchart in the correct order.
* The following flowchart shows how to proceed with troubleshooting using the DTC check.
Directions from the flowchart will indicate how to proceed either to DTC troubleshooting or to the
troubleshooting of each problem symptom.
1. DTC CHECK
NEXT -- Continue to next step.
2. MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR MEMORY
NEXT -- Continue to next step.
3. SYMPTOM CONFIRMATION
B -- Go to step 5 A -- Continue to next step.
4. SIMULATION TEST USING SYMPTOM SIMULATION METHODS
NEXT -- Continue to next step.
5. DTC CHECK
B -- TROUBLESHOOTING OF PROBLEM INDICATED BY DTC A -- Continue to next step.
6. SYMPTOM CONFIRMATION
Side Airbag Sensor
Impact Sensor: Diagrams Side Airbag Sensor
Page 7570
Blower Motor: Locations Air Conditioning System (for Manual Air Conditioning System)
AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Manual Air Conditioning System):
PARTS LOCATION
Page 5632
Traction Control Switch: Locations From 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 1060
Page 5567
* The zero point calibration is performed only once after the system enters test mode.
* Calibration cannot be performed again until the stored data is cleared once.
(2) Check that the buzzer sounds for 3 seconds and DTC C1336 is erased.
(3) Turn the ignition switch OFF.
4. CLEAR ZERO POINT CALIBRATION DATA (WHEN USING SST CHECK WIRE)
(a) Turn the ignition switch to ON.
(b) Using SST, connect and disconnect terminals 12 (TS) and 4 (CG) of the DLC3 4 times or more
within 8 seconds.
SST : 09843-18040
(c) Check that the SLIP indicator light comes on.
(d) Using a check wire, perform the zero point calibration of the deceleration sensor.
5. PERFORM ZERO POINT CALIBRATION OF MASTER CYLINDER PRESSURE SENSOR AND
DECELERATION SENSOR (WHEN
USING SST CHECK WIRE)
NOTICE: *
While obtaining the zero point, do not vibrate the vehicle by tilting, moving or shaking it and keep it
stationary. (Do not start the engine.)
* While obtaining the zero point, do not depress the brake pedal.
* Obtain the zero point on a level surface (with an inclination of 1° or less).
(a) Enter Test Mode.
(1) Turn the ignition switch off.
(2) Check that the shift lever is in parking or neutral and apply the parking brake.
CAUTION: Application of the parking brake is not necessary for entering test mode. However,
apply the parking brake for safety.
(3) Using SST, connect terminals 12 (TS) and 4 (CG) of the DLC3.
SST : 09843-18040
(4) Turn the ignition switch to ON.
NOTICE: Do not start the engine.
(b) Obtain the zero points of the master cylinder pressure sensor and deceleration sensor.
Page 6481
General Information
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: GENERAL
INFORMATION
* A large number of ECU controlled systems are used in the TOYOTA TUNDRA. In general, ECU
controlled systems are considered to be very intricate, requiring a high level of technical knowledge
to troubleshoot. However, most problem checking procedures only involve inspecting the ECU
controlled system's circuits one by one. An adequate understanding of the system and a basic
knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and
necessary repairs.
1. TROUBLESHOOTING PROCEDURES
* The troubleshooting procedures consist of diagnosis procedures for when a DTC is stored and
diagnosis procedures for when no DTC is stored. The basic idea is explained in the following table.
* Vehicle systems are complex and use many ECUs that are difficult to inspect independently.
Therefore, a process of elimination is used, where components that can be inspected individually
are inspected, and if no problems are found in these components, the related ECU is identified as
the problem and replaced.
* It is extremely important to ask the customer about the environment and the conditions present
when the problem occurred (Customer Problem Analysis). This makes it possible to simulate the
conditions and confirm the symptom. If the symptom cannot be confirmed or the DTC does not
recur, the malfunctioning part may not be identified using the troubleshooting procedure, and the
ECU for the related system may be replaced even though it is not defective. If this happens, the
original problem will not be solved.
* In order to prevent endless expansion of troubleshooting procedures, the troubleshooting
procedures are written with the assumption that multiple malfunctions do not occur simultaneously
for a single problem symptom.
* To identify the malfunctioning part, troubleshooting procedures narrow down the target by
separating components, ECUs and wire harnesses during the inspection. If the wire harness is
identified as the cause of the problem, it is necessary to inspect not only the connections to
components and ECUs but also all of the wire harness connectors between the component and the
ECU.
DIAGNOSTIC TESTER
2. DESCRIPTION
System data and the Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector
3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the Techstream* to
check for a malfunction and perform repairs.
HINT *: Techstream is the name for the diagnostic tester in North America.
3. DATA LINK CONNECTOR 3 (DLC3)
(a) The vehicle's ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of
the DLC3 complies with SAE J1962 and
matches the ISO 15765-4 format.
Page 7972
Air Bag: Removal and Replacement
Components
SUPPLEMENTAL RESTRAINT SYSTEM: CURTAIN SHIELD AIRBAG ASSEMBLY (for CrewMax):
COMPONENTS
Removal
SUPPLEMENTAL RESTRAINT SYSTEM: CURTAIN SHIELD AIRBAG ASSEMBLY (for CrewMax):
REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION:
Page 740
Seat Heater Switch: Service and Repair Removal
SEAT: SEAT HEATER SWITCH (w/ Seat Heater System or Climate Control Seat System):
REMOVAL
1. REMOVE FRONT DOOR SCUFF PLATE LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining
(for CrewMax)/Removal
2. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for
CrewMax)/Removal
3. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal
4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Floor Shift Type)/Removal
5. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
6. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal
7. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding
/ Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
8. REMOVE REAR UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
9. REMOVE CENTER LOWER INSTRUMENT PANEL FINISH PANEL See: Body and
Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
10. REMOVE INTEGRATION CONTROL AND PANEL ASSEMBLY See: Heating and Air
Conditioning/Control Assembly/Service and
Repair/Air Conditioning Panel (for Floor Shift Type)/Removal
11. REMOVE SEAT HEATER SWITCH
(a) w/ Seat Heater System:
Detach the 4 claws and remove the 2 seat heater switches.
(b) w/ Climate Control Seat System:
Detach the 8 claws and remove the 2 seat heater switches.
Page 6522
Remove the blown fuse and disconnect all loads of the fuse.
Connect a test light in place of the fuse.
Establish conditions in which the test light comes on.
Example:
- [A] - Ignition SW on
- [B] - Ignition SW and SW1 on
- [C] - Ignition SW, SW1 and Relay on (Connect the Relay) and SW2 off (or Disconnect SW2)
Disconnect and reconnect the connectors while watching the test light.
Page 3470
The steering angle sensor is connected to the CAN communication system but CAN
communication DTCs are not output.
(h) CENTER AIRBAG SENSOR
HINT The center airbag sensor is connected to the CAN communication system but CAN
communication DTCs are not output.
(i) POWER STEERING ECU
For vehicles with a power steering ECU only.
HINT The power steering ECU is connected to the CAN communication system but CAN
communication DTCs are not output.
(j) 4WD CONTROL ECU
For vehicles with 4WD only.
HINT The 4WD control ECU is connected to the CAN communication system but CAN
communication DTCs are not output.
(k) BUS BUFFER ECU
For vehicles with a bus buffer ECU only.
HINT The bus buffer ECU is connected to the CAN communication system but CAN
communication DTCs are not output.
(l) FRONT POWER SEAT CONTROL ECU AND SWITCH LH
For vehicles with a front power seat control system (w/ Seat Memory) only.
HINT The front power control seat ECU and switch LH is connected to the CAN communication
system but CAN communication DTCs are not output.
(m)OUTER MIRROR CONTROL ECU
For vehicles with a front power seat control system (w/ Seat Memory) only.
HINT The outer mirror control ECU and switch LH is connected to the CAN communication system
but CAN communication DTCs are not output.
4. DTC COMBINATION TABLE
Page 5994
5. INSPECT PARK/NEUTRAL POSITION SWITCH ASSEMBLY
(a) Inspect the switch See: Testing and Inspection/Initial Inspection and Diagnostic Overview.
Page 2598
This TSB applies to all Sequoia and Tundra vehicles equipped with lUR-FE (4.6L) 2UZ-FE (4.7L)
and 3UR-FE/FBE (5.7L) engines produced BEFORE the Production Change Effective VINs shown.
Repair Procedure
1. Remove and replace the air cleaner lid.
2. Remove and replace the front right hand (RH) fender liner.
Page 737
(f) If the result is not as specified, replace the switch.
Page 6439
Power Distribution Module: Diagrams Voltage Inverter
Page 7691
Condenser HVAC: Service and Repair Installation
AIR CONDITIONING: CONDENSER: INSTALLATION
1. INSTALL COOLER DRYER
(a) Using pliers, install the cooler dryer.
(b) Apply a sufficient amount of compressor oil to the contact surfaces of a new O-ring and the cap.
Compressor oil:
ND-OIL 8 or equivalent
(c) Install the O-ring to the cap.
(d) Using a 14 mm socket hexagon wrench, install the cap to the modulator.
Torque : 2.9 Nm (30 kgf-cm, 26 in-lbf)
2. INSTALL COOLER CONDENSER ASSEMBLY
(a) Install the cooler condenser with the 2 bolts, as shown in the illustration.
Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)
Page 6981
(2) Disconnect connector B and measure the resistance.
Standard resistance (Fig. 7):
* If the results match the examples above, a short circuit exists between terminal 1 of connector B2
and terminal 1 of connector C.
4. CHECK AND REPLACE ECU
NOTICE: *
The connector should not be disconnected from the ECU. Perform the inspection from the backside
of the connector on the wire harness side.
* When no measuring condition is specified, perform the inspection with the engine stopped and
the ignition switch ON.
* Check that the connectors are fully seated. Check for loose, corroded or broken wires.
(a) First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be
faulty. Temporarily replace the ECU with a
normally functioning one and check if the symptoms occur. If the trouble symptoms disappear,
replace the original ECU.
(1) Measure the resistance between the ECU ground terminal and body ground.
Standard resistance:
Below 1 Ohms
(2) Disconnect the ECU connector. Check the ground terminal on the ECU side and wire harness
side for bending, corrosion or foreign matter.
Lastly, check the contact pressure of the female terminals.
Page 2400
(a) Hook the engine under cover to the vehicle body as shown in the illustration.
(b) Install the 3 screws and 5 bolts.
for bolt - Torque : 29 Nm (296 kgf-cm, 21 ft-lbf)
for screw - Torque : 3.0 Nm (31 kgf-cm, 27 in-lbf)
Page 6106
(d) Perform the operation test without load.
(1) Connect the field coil wire to terminal C with the nut. Make sure that the lead is not grounded.
Torque : 6.5 Nm (66 kgf-cm, 57 in-lbf)
(2) Clamp the starter in a vise.
(3) Connect the battery and an ammeter to the starter as shown in the illustration.
(4) Check that the starter rotates smoothly and steadily while the pinion gear is moving out.
Then measure the current.
Standard current:
190 A or less at 11.5 V
(5) If the result is not as specified, replace the starter assembly.
2. INSPECT STARTER ARMATURE ASSEMBLY
(a) Check the surface of the commutator for dirt and burns.
If the surface is dirty or burnt, correct it with sandpaper (No. 400) or a lathe.
(b) Inspect the commutator for an open circuit.
(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(2) If the result is not as specified, replace the starter armature assembly.
(c) Inspect the commutator for a short circuit.
(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
Page 2854
Fuel Pump Control Unit: Locations Engine Control System - SFI System
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 252
Power Distribution Relay: Testing and Inspection ACC Relay
1UR-FE STARTING: ACC RELAY: ON-VEHICLE INSPECTION
1. INSPECT MAIN BODY ECU (ACC RELAY)
(a) Measure the resistance of the ACC relay circuit.
(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(2) If the result is not as specified, replace the main body ECU.
Diagram Information and Instructions
Ignition Switch: Diagram Information and Instructions
Wiring Color Codes
Abbreviations Used Within Diagrams
Abbreviations Used Within Diagrams
Page 6366
Page 143
Remove the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Floor Shift Type)/Removal.
6. REMOVE LOWER INSTRUMENT PANEL
(a) for Column Shift Type:
Remove the lower instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Column Shift Type)/Removal.
(b) for Floor Shift Type:
Remove the lower instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Floor Shift Type)/Removal.
7. REMOVE LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY
(a) for Column Shift Type:
Remove the No. 2 instrument panel airbag assembly See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument
Panel Safety Pad (for Column Shift Type)/Removal.
(b) for Floor Shift Type:
Remove the No. 2 instrument panel airbag assembly See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument
Panel Safety Pad (for Floor Shift Type)/Removal.
8. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH
(a) for Column Shift Type:
Remove the instrument panel finish panel See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument
Panel Safety Pad (for Column Shift Type)/Removal.
(b) for Floor Shift Type:
Remove the instrument panel finish panel See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument
Panel Safety Pad (for Floor Shift Type)/Removal.
9. REMOVE NO. 2 AIR DUCT SUB-ASSEMBLY
(a) Remove the screw and duct.
10. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY
Testing and Inspection
Valve Body: Testing and Inspection
A760F AUTOMATIC TRANSMISSION: VALVE BODY ASSEMBLY: INSPECTION
1. INSPECT SHIFT SOLENOID VALVE SL1
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) Apply 12 V battery voltage to the shift solenoid valve and check that the valve moves and
makes an operating noise.
OK:
(c) If the result is not as specified, replace the solenoid valve.
2. INSPECT SHIFT SOLENOID VALVE S1
Page 7753
A/C Clamp Remover for removing special air condition line clamps. Applicable: 1998 and newer
Toyota models with the new style A/C clamps. Comparable to Toyota Tool numbers 09870-00015
and 09870-00025.
- Made in USA
- Fits both Toyota AC Clamps, used on high and low pressure lines.
- Applicable to: 1998 and newer Toyota models
- Stainless Steel release pins
- Identification and Instructions are laser marked on the handle
Contact AST for pricing.
Assenmacher Specialty Tools 1-800-525-2943
Page 2693
Water Pump: Service and Repair Removal
1UR-FE COOLING: WATER PUMP: REMOVAL
1. REMOVE FAN SHROUD
(a) Remove the fan shroud See: Radiator Cooling Fan/Service and Repair/Removal.
2. REMOVE WATER INLET SUB-ASSEMBLY WITH THERMOSTAT
(a) Remove the water inlet with thermostat See: Thermostat/Service and Repair/Removal.
3. REMOVE FRONT FENDER APRON SEAL LH See: Exhaust System/Exhaust Manifold/Service
and Repair/Removal
4. DISCONNECT COOLER COMPRESSOR ASSEMBLY (w/ Oil Cooler) See: Heating and Air
Conditioning/Compressor HVAC/Service and
Repair/Removal and Replacement/Removal
5. REMOVE WATER BY-PASS PIPE (w/ Oil Cooler)
(a) Remove the 2 bolts.
(b) Disconnect the 4 water hoses and remove the water by-pass pipe.
6. REMOVE NO. 1 WATER BY-PASS HOSE
(a) Remove the water by-pass hose.
7. DISCONNECT NO. 8 WATER BY-PASS HOSE
(a) Disconnect the water by-pass hose.
8. DISCONNECT NO. 5 WATER BY-PASS HOSE
(a) Disconnect the water by-pass hose.
9. REMOVE WATER INLET HOUSING
Page 3423
Standard resistance:
NG -- REPAIR OR REPLACE CAN BRANCH WIRE OR CONNECTOR (BUS BUFFER ECU)
OK -- REPLACE BUS BUFFER ECU
10. CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (CENTER AIRBAG SENSOR)
(a) Disconnect the J46 center airbag sensor connector.
(b) Reconnect the cable to the negative (-) battery terminal.
(c) Select "CAN Bus Check" on the Techstream.
Result
B -- CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (4WD CONTROL ECU) A -Continue to next step.
11. CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (CENTER AIRBAG SENSOR
BRANCH WIRE)
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
Page 1832
^ Calibration ID(s) [Refer to the Calibration Identification Chart for the NEW CALIBRATION ID]
^ Dealer Code
^ Repair Date
^ Change Authority [This TSB number]
B. Affix the Authorized Modifications Label to the vehicle at the location shown in Figure 1. The
Authorized Modifications Label is available
through the MDC P/N 00451-00001-LBL.
Diagrams
Trailer Brake Control Module: Diagrams
Page 3094
6. PROBLEM SYMPTOMS TABLE
When a "Normal" code is output during a DTC check but the problem is still occurring, use the
Problem Symptoms Table. The suspected areas (circuits or parts) for each problem symptom are
in the table. The suspected areas are listed in order of probability. A description of each of the
chart's columns is below.
HINT In some cases, the problem is not detected by the diagnostic system even though a problem
symptom is present. It is possible that the problem is occurring outside the detection range of the
diagnostic system, or that the problem is occurring in a completely different system.
7. CIRCUIT INSPECTION
A description of the main areas of each circuit inspection is below.
Page 1493
3. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE
HINT The diagnostic system in the TOYOTA TUNDRA has various functions.
* The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU
memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a
previous malfunction's DTC can be checked by a technician during troubleshooting.
* Another function is the Input Signal Check, which checks if the signals from various switches are
sent to the ECU correctly.
* By using these functions, the problem areas can be narrowed down and troubleshooting is more
effective. Diagnostic functions are incorporated in the following systems in the TOYOTA TUNDRA.
Page 6708
Use a volt/ohmmeter with high impedance (10 kohms/V minimum) for troubleshooting of the
electrical circuit.
Disconnection of Male and Female Connectors
DISCONNECTION OF MALE AND FEMALE CONNECTORS
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Finding A Short Circuit
FINDING A SHORT CIRCUIT
Door Control Switch (for Front LH)
Power Door Lock Switch: Service and Repair Door Control Switch (for Front LH)
Components
DOOR LOCK: DOOR CONTROL SWITCH (for Front LH): COMPONENTS
Page 4785
NOTE
Only Toyota Certified Technicians and above may access calibration files.
2. Connect the GR8 Battery Diagnostic Station.
A. Connect the GR8 Battery Diagnostic Station to the vehicle and turn it ON.
B. Select Power Supply Mode by following the screen flow below.
NOTICE
^ ECU damage may occur if the correct battery charger and mode setting are NOT used.
Page 542
Shift Interlock Control Module: Diagrams
Service and Repair
Fuel Pressure Release: Service and Repair
1UR-FE FUEL: FUEL SYSTEM: PRECAUTION
CAUTION: *
Before working on the fuel system, disconnect the cable from the negative (-) battery terminal.
* Do not smoke or be near an open flame when working on the fuel system.
* Keep gasoline away from rubber and leather parts.
1. DISCHARGE FUEL SYSTEM PRESSURE
CAUTION: *
Do not disconnect any part of the fuel system until you have discharged the fuel system pressure.
* After discharging the fuel pressure, place a cloth or equivalent over fittings as you separate them
to reduce the risk of fuel spray on yourself or in the engine compartment.
(a) Disconnect the cable from the negative (-) battery terminal.
(b) Disconnect the 2 fuel pump ECU connectors.
(c) Connect the cable to the negative (-) battery terminal.
(d) Start the engine. After the engine has stopped on its own, turn the ignition switch OFF.
HINT DTC P0171/0174 (system too lean) may be set.
(e) Crank the engine again, then check that the engine does not start.
(f) Loosen the fuel tank cap, then discharge the pressure in the fuel tank completely.
(g) Connect the 2 fuel pump ECU connectors.
2. FUEL SYSTEM
(a) When disconnecting the high fuel pressure line, a large amount of gasoline will spill out. Follow
these procedures.
(1) Perform the "DISCHARGE FUEL SYSTEM PRESSURE" procedures above.
(2) Put a container under the connecting part of the pressure line.
(3) Slowly loosen the connection.
(4) Disconnect the connection.
(5) Plug the connection with a rubber plug.
(b) Observe these precautions when removing and installing the injectors:
Page 1082
Headlamp Alignment Switch: Testing and Inspection
LIGHTING: HEADLIGHT LEVELING SWITCH: INSPECTION
1. INSPECT HEADLIGHT LEVELING SWITCH
(a) Connect the battery positive (+) lead to terminal 1 (B) and the negative (-) lead to terminal 5 (E).
(b) Measure the voltage according to the value(s) in the table below.
Standard Voltage:
(c) Apply battery voltage to the connector and check the LED illumination condition.
OK:
(d) If the result is not as specified, replace the headlight leveling switch.
Page 7215
Steering Column Control Module: Service and Repair Removal
STEERING COLUMN: MULTIPLEX TILT AND TELESCOPIC ECU (for Power Tilt and Power
Telescopic Steering Column): REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE UPPER STEERING COLUMN COVER
(a) Remove the 2 screws.
HINT Turn the steering wheel to the right and left as necessary to remove the 2 screws.
(b) Detach the 4 clips.
(c) Detach the claw to remove the upper steering column cover.
3. REMOVE LOWER STEERING COLUMN COVER
(a) Detach the 2 claws to remove the lower steering column cover.
4. REMOVE HOOD LOCK CONTROL LEVER SUB-ASSEMBLY See: Body and Frame/Doors,
Hood and Trunk/Hood/Hood Latch Release
Cable/Service and Repair/Removal
5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Removal
Page 8983
11. INSTALL FRONT DOOR SCUFF PLATE LH
(a) for Regular Cab:
Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular Cab)/Installation.
(b) for Double Cab:
Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Installation.
(c) for CrewMax:
Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for CrewMax)/Installation.
Page 6277
when inserting and after full engagement.
NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal.
(d) REPAIR METHOD OF CONNECTOR TERMINAL
(1) If there is any foreign matter on the terminal, clean the contact point using an air gun or cloth.
Never rub the contact point using sandpaper
as the plating may come off.
(2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is
gold-plated (gold color), use a gold-plated female
terminal; if it is silver-plated (silver color), use a silver-plated female terminal.
(3) Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock
into the housing, the housing may have to be
replaced.
(e) HANDLING OF WIRE HARNESS
(1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be
restored in the same way.
(2) Never twist, pull or slacken the wire harness more than necessary.
(3) The wire harness should never come into contact with a high temperature part, or rotating,
moving, vibrating or sharp-edged parts. Avoid
contact with panel edges, screw tips and other sharp items.
(4) When installing parts, never pinch the wire harness.
(5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with
vinyl tape.
2. CHECK FOR OPEN CIRCUIT
Page 8228
(f) Dispose of the front seat outer belt (with the seat belt pretensioner).
CAUTION: *
Do not touch the front seat outer belt for at least 30 minutes after the seat belt pretensioner has
been activated. It is very hot.
* Use gloves and safety glasses when handling a front seat outer belt whose pretensioner has
been activated.
* Always wash your hands with water after completing the disposal.
* Do not apply water to a front seat outer belt that has an activated pretensioner.
HINT When scrapping a vehicle, activate the seat belt pretensioner, and then scrap the vehicle with
the activated front seat outer belt installed.
2. DISPOSE OF FRONT SEAT OUTER BELT ASSEMBLY (WHEN NOT INSTALLED IN
VEHICLE)
CAUTION: Be sure to follow the procedures listed below when activating the seat belt pretensioner.
(a) Remove the front seat outer belt.
(1) Wind the seat belt with the retractor.
(2) When the seat belt is sufficiently wound, cut the seat belt approximately 100 mm (3.94 in.) from
the retractor, as shown in the illustration.
HINT The seat belt is designed so that winding the seat belt before pretensioner activation will
decrease the pulling power of the seat belt during pretensioner activation.
(b) Check if SST is functioning properly.
SST : 09082-00700
SST : 09082-00770
CAUTION: When activating a seat belt pretensioner, always use the specified SST.
Page 1257
Accelerator Pedal Position Sensor: Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 81
Power Mirror Control Module: Locations Crew Max
Body
Recall 11V185000 - TPMS Non-Compliance
Tire Pressure Module: All Technical Service Bulletins Recall 11V185000 - TPMS Non-Compliance
VEHICLE MAKE/MODEL: MODEL YEAR(S) Toyota/FJ Cruiser 2011
Toyota/Tundra 2009-2011
MANUFACTURER: Gulf States Toyota, Inc.
MFR'S REPORT DATE: March 16, 2011
NHTSA CAMPAIGN ID NUMBER: 11V185000
NHTSA ACTION NUMBER: N/A
COMPONENT: Tires: Pressure Monitoring and Regulating Systems
POTENTIAL NUMBER OF UNITS AFFECTED: 1,489
SUMMARY: Gulf States Toyota is recalling certain model year 2011 FJ Cruiser and model year
2009-2011 Tundra vehicles for failing to comply with the requirements of Federal Motor Vehicle
Safety Standard No. 138, "Tire Pressure Monitoring Systems." The TPMS on some vehicles may
not have been properly calibrated and as a result the low tire pressure warning lamp may not
illuminate should the inflation pressure in one or more of the vehicle's tires fall below the threshold
for when the low tire pressure warning lamp should illuminate.
CONSEQUENCE: Drivers will not receive a warning from the tire pressuring monitor that one or
more tires are underinflated increasing the risk that a vehicle will be driven with one or more
underinflated tires and increasing the risk of a tire failure that may lead to a crash.
REMEDY: Dealers will recalibrate the tire pressure monitoring system in accordance with the
regulation free of charge. The safety recall is expected to begin during April 2011. Owners may
contact Gulf State Toyota Customer Assistance Center toll free at 1-800-444-1074 Monday through
Thursday, 8:30 AM to 5:00 PM, or Friday 8:30 AM to 4:00 PM Central Standard Time.
NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle
Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov.
Page 9027
3. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE
HINT The diagnostic system in the TOYOTA TUNDRA has various functions.
* The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU
memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a
previous malfunction's DTC can be checked by a technician during troubleshooting.
* Another function is the Input Signal Check, which checks if the signals from various switches are
sent to the ECU correctly.
* By using these functions, the problem areas can be narrowed down and troubleshooting is more
effective. Diagnostic functions are incorporated in the following systems in the TOYOTA TUNDRA.
Page 943
(1) Insert the pin into the plate groove.
(2) Attach the claw to install the main plate.
(3) Install the 2 screws.
(c) Set the damper servo so that the cutout part engages with the tooth of the gear, and attach the
claw to install the damper servo.
(d) Install the 4 screws and connect the 2 connectors.
9. INSTALL AIR DUCT
(a) Install the duct with the 2 screws.
10. INSTALL BLOWER WITH FAN MOTOR SUB-ASSEMBLY
Page 6468
[A] For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
"Case1" Raise the terminal retainer up to the temporary lock position.
Page 8680
Garage Door Opener Transmitter: Description and Operation
GARAGE DOOR OPENER: GARAGE DOOR OPENER SYSTEM: SYSTEM DIAGRAM
GARAGE DOOR OPENER: GARAGE DOOR OPENER SYSTEM: SYSTEM DESCRIPTION
1. DESCRIPTION
(a) A maximum of 3 kinds of transmitter code based systems (example: garage doors, gates and
entry gates) can be registered with the vehicle's
garage door opener. After registration, the vehicle's garage door opener can mimic the signal of the
transmitter systems and the original transmitters of each transmitter system are not needed.
Page 8313
Air Bag Deactivation Switch: Locations Occupant Classification System
SUPPLEMENTAL RESTRAINT SYSTEM: OCCUPANT CLASSIFICATION SYSTEM: PARTS
LOCATION
Components
Transmission Speed Sensor: Service and Repair Components
A760F AUTOMATIC TRANSMISSION: SPEED SENSOR: COMPONENTS
Page 3405
C -- GO TO PROBLEM SYMPTOMS TABLE See: Symptom Related Diagnostic Procedures/CAN
Communication System/Problem Symptoms Table A -- Continue to next step.
10. CHECK DTC COMBINATION TABLE (V BUS CIRCUIT BRANCH WIRE OPEN PAST
MALFUNCTION)
(a) Based on the combination of stored CAN communication system DTCs, determine which ECUs
and sensors have a communication stop
malfunction See: CAN Communication System/Diagnosis System.
NEXT -- Continue to next step.
11. PERFORM MALFUNCTION SIMULATION TEST (V BUS CIRCUIT MAIN WIRE PAST
MALFUNCTION)*
(a) Using the Techstream, clear all DTCs.
(b) Perform a malfunction simulation test on all harnesses and connectors related to the V bus
circuit main wire.
(c) Check the DTCs that were output as a result of the malfunction simulation test. Then determine
the malfunctioning area.
NEXT -- Continue to next step.
12. ADJUST, REPAIR AND REPLACE
NEXT -- Continue to next step.
13. CONFIRMATION TEST
NEXT -- END
Diagnosis System
CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: DIAGNOSIS SYSTEM
1. BUS CHECK
(a) Select "CAN Bus Check" from the "System Select".
2. CHECK INSTALLED SYSTEMS (ECUS AND SENSORS) THAT USE CAN COMMUNICATION
(a) Systems (ECUs and sensors) that use CAN communication vary depending on the vehicle's
optional settings. Check which systems (ECUs and
sensors) are installed on the vehicle.
3. DTC TABLE BY ECU
HINT *
In the CAN communication system, CAN communication system DTCs output by the ECU can be
displayed by using the Techstream.
Engine Controls - Techstream(R) ECU Re-Flash
Procedure
Engine Control Module: All Technical Service Bulletins Engine Controls - Techstream(R) ECU
Re-Flash Procedure
T-SB-0064-10
February 4, 2010
Techstream ECU Flash Reprogramming Procedure
Service Category Engine/Hybrid System
Section Engine Control
Market USA
Applicability
TSB SUPERSESSION NOTICE
The information contained in this TSB supersedes TSB No. SS002-07.
^ Applicability has been updated to include 2009 - 2011 model year Toyota vehicles.
^ A new section, Techstream Preparation, has been added.
^ Techstream Lite has been added as an option in Required Tools & Materials.
^ Process Overview and Operation Procedure sections have been updated.
TSB No. SS002-07 is Obsolete and any printed versions should be discarded. Be sure to review
the entire content of this service bulletin before proceeding.
Introduction
Flash reprogramming allows the ECU software to be updated without replacing the ECU. Flash
calibration updates for specific vehicle models/ECUs are released as field-fix procedures described
in individual service bulletins. This bulletin details the Techstream ECU flash reprogramming
process and outlines use of the Technical Information System (TIS) and the Calibration Update
Wizard (CUW). Flash calibration updates can only be applied to the vehicle/ECU combination for
which they are intended. ECUs have internal security that will not allow them to be programmed
with another ECU's information.
ECU
Electronic Control Unit (ECU) is a Toyota term used to describe integrated computerized devices
responsible for managing the operation of a system or subsystem. For the purposes of this bulletin,
the term "ECU" is used as a generic label for the following SAE J1930 standard references:
^ Powertrain Control Module (PCM)
Page 1010
Parking Brake Warning Switch: Diagrams
Page 4866
Transmission Position Switch/Sensor: Diagrams
Page 266
Use a volt/ohmmeter with high impedance (10 kohms/V minimum) for troubleshooting of the
electrical circuit.
Disconnection of Male and Female Connectors
DISCONNECTION OF MALE AND FEMALE CONNECTORS
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Finding A Short Circuit
FINDING A SHORT CIRCUIT
Page 7585
"Case2" Open the secondary locking device.
[B] For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray
Gray or White : Black
Recall 10V017000: Accelerator Pedal Sticking
Accelerator Pedal Position Sensor: All Technical Service Bulletins Recall 10V017000: Accelerator
Pedal Sticking
VEHICLE MAKE/MODEL: MODEL YEAR(S): Toyota/Avalon 2005-2010 Toyota/Camry 2007-2010
Toyota/Corolla 2009-2010 Toyota/Corolla Matrix 2009-2010 Toyota/Highlander 2010 Toyota/ RAV4
2009-2010 Toyota/Sequoia 2008-2010 Toyota/Tundra 2007-2010 MANUFACTURER: Toyota
Motor North America, Inc.
MFR'S REPORT DATE: January 21, 2010
NHTSA CAMPAIGN ID NUMBER: 10V017000
NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Accelerator Assembly:
Pedal/Linkage
POTENTIAL NUMBER OF UNITS AFFECTED: ?
SUMMARY: Toyota is recalling certain model year 2005-2010 Avalon, model year 2007-2010
Camry, model year 2009-2010 Corolla, Corolla Matrix, RAV4, model year 2010 Highlander, model
year 2008-2010 Sequoia, and model year 2007-2010 Tundra. due to the manner in which the
friction lever interacts with the sliding surface of the accelerator pedal inside the pedal sensor
assembly, the sliding surface of the lever may become smooth during vehicle operation. In this
condition, if condensation occurs on the surface, as may occur from heater operation (without A/C)
when the pedal assembly is cold, the friction when the accelerator pedal is operated may increase,
which may result in the accelerator pedal becoming harder to depress, slower to return, or, in the
worst case, mechanically stuck in a partially depressed position.
CONSEQUENCE: The accelerator pedal may become hard to depress, slow to return to idle, or, in
the worst case, mechanically stuck in a partially depressed position, increasing the risk of a crash.
REMEDY: Toyota has not yet provided a remedy plan or an owner notification schedule. Owners
may contact Toyota at 1-800-331-4331.
NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle
Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov.
Page 7945
(1) Check that no one is inside the vehicle or within a 10 m (32.8 ft.) radius of the vehicle.
(2) Press SST activation switch to deploy the airbag.
CAUTION: *
When deploying the airbag, make sure that no one is near the vehicle.
* The lower No. 1 instrument panel airbag becomes extremely hot when the airbag is deployed, so
do not touch it for at least 30 minutes after deployment.
* Use gloves and safety glasses when handling a lower No. 1 instrument panel airbag with a
deployed airbag.
* Do not apply water to a lower No. 1 instrument panel airbag with a deployed airbag.
* Always wash your hands with water after completing the operation.
HINT The airbag is deployed as the LED of SST activation switch comes on.
2. DISPOSE OF LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY (WHEN NOT
INSTALLED IN VEHICLE)
NOTICE: Be sure to follow the procedure detailed below when deploying the airbag.
HINT Prepare a battery as the power source to deploy the airbag.
(a) Check the function of SST See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
(b) Remove the lower No. 1 instrument panel airbag See: Removal and Replacement/Driver Side
Knee Airbag Assembly/Removal.
CAUTION: *
When removing the lower No. 1 instrument panel airbag, wait at least 90 seconds after the ignition
switch is turned off and the cable is disconnected from the negative (-) battery terminal before
starting work.
* When storing the lower No. 1 instrument panel airbag, keep the airbag deployment side facing
upward.
(c) Using a service-purpose wire harness for the vehicle, tie down the lower No. 1 instrument panel
airbag to a tire.
Cross-sectional area of stripped wire harness section:
1.25 mm2 or more (0.00192 in.2 or more)
CAUTION: If the wire harness is too thin or an alternative object is used to tie down the lower No. 1
instrument panel airbag, it may be snapped by the shock when the airbag is deployed. Always use
a wire harness for vehicle use with a cross-sectional area of at least 1.25 mm2 (0.00192 in.2).
HINT To calculate the cross-sectional area of the stripped wire harness section: Cross-sectional
area = 3.14 x (Diameter)2 / 4
(1) Position the lower No. 1 instrument panel airbag inside a tire with the airbag deployment side
facing inside.
Page 457
Air Bag Control Module: Testing and Inspection Center Airbag Sensor Assembly (for Floor Shift
Type)
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift
Type): ON-VEHICLE INSPECTION
1. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION)
(a) Perform a diagnostic system check See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
2. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND
AIRBAG HAS NOT DEPLOYED)
(a) Perform a diagnostic system check See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
3. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND
AIRBAG IS DEPLOYED)
(a) Replace the center airbag sensor.
CAUTION: For removal and installation procedures of the center airbag sensor, be sure to follow
the correct procedure.
HINT The center airbag sensor should be replaced after any of the airbags has deployed, as it has
been subjected to the impact.
Page 6654
Removal
OTHER SYSTEM: POWER OUTLET SOCKET (for CrewMax Floor Shift Type): REMOVAL
1. REMOVE REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
2. REMOVE CONSOLE BOX BEZEL
Page 354
^ Engine Control Module (ECM)
^ Transmission Control Module (TCM)
^ Or any other Toyota specific control unit
Warranty Information
Parts Information
Required Tools & Equipment
NOTE
Additional SSTs may be ordered by calling 1-800-933-8335.
Process Overview
Techstream ECU flash reprogramming is a 4-step process:
1. Verify the vehicle's applicability for recalibration and locate desired calibration file by performing
the Techstream Health Check function.
NOTE
Techstream will automatically search TIS for the appropriate service bulletin using the current
Calibration ID from the vehicle. Calibration file links can be found embedded in the corresponding
service bulletin.
2. Connect the GR8 Battery Diagnostic Station using "Power Supply Mode" only.
The GR8 Battery Diagnostic Station includes a Power Supply Mode to help maintain battery
voltage at 13.5 volts during ECU reprogramming.
ECU damage may occur if the correct battery charger mode setting is NOT used.
3. Locate appropriate calibration ID and reprogram the vehicle ECU with Techstream.
Techstream uses the Calibration Update Wizard (CUW) application to open calibration files and
facilitate the ECU flash reprogramming process.
Page 2253
* The procedures listed below are for the LH side.
1. REMOVE FRONT WHEEL
2. DISCONNECT FRONT DISC BRAKE CALIPER ASSEMBLY LH See: Wheel Hub/Service and
Repair/Removal and Replacement/Removal
3. REMOVE FRONT DISC See: Brakes and Traction Control/Disc Brake System/Service and
Repair/Removal and Replacement/Front
Brake/Removal
4. REMOVE FRONT AXLE LH HUB BOLT
(a) Using SST and a screwdriver or equivalent to hold the axle hub, remove the front axle hub bolt.
SST : 09650-17011
NOTICE: Do not damage the threads of the hub bolts.
5. INSTALL FRONT AXLE LH HUB BOLT
(a) Temporarily install a washer and hub nut to a new hub bolt as shown in the illustration.
NOTICE: Install hub nuts to prevent damage to the hub bolts.
(b) Using a screwdriver or equivalent to hold the hub, turn the hub nut until the bottom surface of
the hub bolt head touches the axle hub.
(c) Remove the washer and hub nut.
NOTICE: Do not damage the threads of the hub bolts.
6. INSTALL FRONT DISC See: Brakes and Traction Control/Disc Brake System/Service and
Repair/Removal and Replacement/Front
Brake/Installation
7. CONNECT FRONT DISC BRAKE CALIPER ASSEMBLY LH See: Wheel Hub/Service and
Repair/Removal and Replacement/Installation
8. INSTALL FRONT WHEEL
for Aluminum Wheel - Torque : 131 Nm (1336 kgf-cm, 97 ft-lbf)
for Steel Wheel - Torque : 209 Nm (2131 kgf-cm, 154 ft-lbf)
Page 7943
(1) Connect SST connector.
SST : 09082-00700
NOTICE: To avoid damaging SST connector and wire harness, do not lock the secondary lock of
the twin lock. Also, secure some slack for SST wire harness inside the tire.
(h) Deploy the airbag.
(1) Connect the red clip of SST to the battery positive (+) terminal and the black clip of SST to the
battery negative (-) terminal.
(2) Check that no one is within a 10 m (32.8 ft.) radius of the tire which the curtain shield airbag is
tied to.
(3) Press SST activation switch and deploy the airbag.
CAUTION: When deploying the airbag, make sure that no one is near the tire.
HINT The airbag is deployed as the LED of SST activation switch comes on.
(i) Dispose of the curtain shield airbag.
CAUTION: *
The curtain shield airbag becomes extremely hot when the airbag is deployed, so do not touch it for
at least 30 minutes after deployment.
* Use gloves and safety glasses when handling a curtain shield airbag with a deployed airbag.
* Do not apply water to a curtain shield airbag with a deployed airbag.
* Always wash your hands with water after completing the operation.
(1) Remove the curtain shield airbag from the tire.
(2) Place the curtain shield airbag in a plastic bag, tie it tightly and dispose of it in the same way as
other general parts.
Driver Side Knee Airbag Assembly
SUPPLEMENTAL RESTRAINT SYSTEM: DRIVER SIDE KNEE AIRBAG ASSEMBLY: DISPOSAL
HINT When scrapping a vehicle equipped with the SRS or disposing of the lower No. 1 instrument
panel airbag, be sure to deploy the airbag first in accordance with the procedure described below.
If any abnormality occurs with the airbag deployment, contact the service dept. of the distributor.
CAUTION: *
Never dispose of a lower No. 1 instrument panel airbag that has an unactivated airbag.
* The airbag produces an exploding sound when it is deployed, so perform the operation outdoors
and where it will not create a nuisance to nearby residents.
* When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool).
Perform the operation in a place away from electrical noise.
* When deploying the airbag, perform the operation at least 10 m (32.8 ft.) away from the lower No.
1 instrument panel airbag.
* The lower No. 1 instrument panel airbag becomes extremely hot when the airbag is deployed, so
do not touch it for at least 30 minutes after deployment.
* Use gloves and safety glasses when handling a lower No. 1 instrument panel airbag with a
deployed airbag.
* Do not apply water, etc. to a lower No. 1 instrument panel airbag with a deployed airbag.
* Always wash your hands with water after completing the operation.
Page 4147
Page 5530
Transmission Speed Sensor: Service and Repair Removal
A760F AUTOMATIC TRANSMISSION: SPEED SENSOR: REMOVAL
1. REMOVE SPEED SENSOR NT
(a) Disconnect the sensor connector.
(b) Remove the bolt and sensor.
(c) Remove the O-ring from the sensor.
2. REMOVE SPEED SENSOR SP2
(a) Disconnect the sensor connector.
(b) Remove the bolt and sensor.
(c) Remove the O-ring from the sensor.
Page 5169
2. Install ChaSSiSEAR(TM) on the vehicle and attempt to isolate the source of the noise. Is the
noise loudest near the rear wheel bearing assembly?
^ YES - Go to step 3.
^ NO - This TSB does NOT apply. Continue diagnosis to isolate the source of the noise.
3. Replace the rear wheel bearing caliper bracket and related parts.
Refer to the Technical Information System (TIS) applicable model year Repair Manual:
4. Test drive the vehicle and confirm the noise is eliminated.
5. Re-check rear differential oil level and confirm NO leaks are present.
Page 4176
Page 7948
HINT When scrapping a vehicle equipped with the SRS or disposing of the front passenger airbag
assembly, be sure to deploy the airbag first in accordance with the procedure described below. If
any abnormality occurs with the airbag deployment, contact the SERVICE DEPT. of the TOYOTA
MOTOR SALES, U.S.A., INC.
CAUTION: *
Never dispose of a front passenger airbag that has an unactivated airbag.
* The airbag produces an exploding sound when it is deployed, so perform the operation outdoors
and where it will not create a nuisance to nearby residents.
* When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool).
Perform the operation in a place away from electrical noise.
* When deploying the airbag, perform the operation at least 10 m (32.8 ft.) away from the front
passenger airbag.
* The front passenger airbag becomes extremely hot when the airbag is deployed, so do not touch
it for at least 30 minutes after deployment.
* Use gloves and safety glasses when handling a front passenger airbag with a deployed airbag.
* Do not apply water to a front passenger airbag with a deployed airbag.
* Always wash your hands with water after completing the operation.
* An airbag or pretensioner may be activated by static electricity. To prevent this, be sure to touch a
metal surface with bare hands to discharge static electricity before performing this procedure.
1. DISPOSE OF FRONT PASSENGER AIRBAG ASSEMBLY (WHEN INSTALLED IN VEHICLE)
HINT Prepare a battery as the power source to deploy the airbag.
(a) Check the function of SST See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
(b) Read the precaution See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
(c) Disconnect the cable from the negative (-) battery terminal.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
(d) Remove the front passenger airbag See: Removal and Replacement/Front Passenger Airbag
Assembly/Removal.
(e) Install SST.
(1) Disconnect the connector.
NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness.
(2) Connect SST connector to the instrument panel wire assembly.
Page 3199
Camshaft Position Sensor: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT POSITION SENSOR: REMOVAL
1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Removal
2. REMOVE CAMSHAFT POSITION SENSOR
(a) Disconnect the sensor connector.
(b) Remove the bolt and sensor.
Page 1178
Knock Sensor: Testing and Inspection
1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: INSPECTION
1. INSPECT KNOCK SENSOR
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) If the result is not as specified, replace the knock sensor.
Page 6659
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
5. REMOVE POWER OUTLET SOCKET ASSEMBLY
(a) Using a screwdriver, detach the claw and remove the power outlet socket.
HINT Tape the screwdriver tip before use.
6. REMOVE POWER OUTLET SOCKET COVER
(a) Detach the 2 claws and remove the power outlet socket cover.
Installation
OTHER SYSTEM: POWER OUTLET SOCKET (for Floor Shift Type): INSTALLATION
1. INSTALL POWER OUTLET SOCKET COVER
(a) Attach the 2 claws to install the power outlet socket cover.
2. INSTALL POWER OUTLET SOCKET ASSEMBLY
(a) Attach the claw to install the power outlet socket.
3. INSTALL CENTER LOWER INSTRUMENT PANEL FINISH PANEL See: Body and
Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
Page 4874
Transmission Speed Sensor: Service and Repair Removal
A760F AUTOMATIC TRANSMISSION: SPEED SENSOR: REMOVAL
1. REMOVE SPEED SENSOR NT
(a) Disconnect the sensor connector.
(b) Remove the bolt and sensor.
(c) Remove the O-ring from the sensor.
2. REMOVE SPEED SENSOR SP2
(a) Disconnect the sensor connector.
(b) Remove the bolt and sensor.
(c) Remove the O-ring from the sensor.
Locations
Hood Sensor/Switch (For Alarm): Locations
THEFT DETERRENT: THEFT DETERRENT SYSTEM: PARTS LOCATION
Fuel Sender Gauge Assembly
Fuel Gauge Sender: Service and Repair Fuel Sender Gauge Assembly
Components
1UR-FE FUEL: FUEL SENDER GAUGE ASSEMBLY: COMPONENTS
Removal
1UR-FE FUEL: FUEL SENDER GAUGE ASSEMBLY: REMOVAL
1. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY
Camshaft (for Bank 1)
Camshaft: Service and Repair Camshaft (for Bank 1)
Components
1UR-FE ENGINE MECHANICAL: CAMSHAFT (for Bank 1): COMPONENTS
Removal
Page 7953
* The front passenger airbag becomes extremely hot when the airbag is deployed, so do not touch
it for at least 30 minutes after deployment.
* Use gloves and safety glasses when handling a front passenger airbag with a deployed airbag.
* Do not apply water to a front passenger airbag with a deployed airbag.
* Always wash your hands with water after completing the operation.
(1) Remove the front passenger airbag from the tire.
(2) Place the front passenger airbag in a plastic bag, tie it tightly and dispose of it in the same way
as other general parts.
Steering Pad
SUPPLEMENTAL RESTRAINT SYSTEM: STEERING PAD: DISPOSAL
HINT When scrapping a vehicle equipped with the SRS or disposing of the steering pad, be sure to
deploy the airbag first in accordance with the procedure described below. If any abnormality occurs
with the airbag deployment, contact the SERVICE DEPT. of TOYOTA MOTOR SALES, U.S.A.,
INC.
CAUTION: *
Never dispose of a steering pad that has an unactivated airbag.
* The airbag produces an exploding sound when it is deployed, so perform the operation outdoors
and where it will not create a nuisance to nearby residents.
* When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool).
Perform the operation in a place away from electrical noise.
* When deploying the airbag, perform the operation at least 10 m (32.8 ft.) away from the steering
pad.
* The steering pad becomes extremely hot when the airbag is deployed, so do not touch it for at
least 30 minutes after deployment.
* Use gloves and safety glasses when handling a steering pad with a deployed airbag.
* Do not apply water to a steering pad with a deployed airbag.
* Always wash your hands with water after completing the operation.
* An airbag or pretensioner may be activated by static electricity. To prevent this, be sure to touch a
metal surface with bare hands to discharge static electricity before performing this procedure.
1. DISPOSE OF STEERING PAD (WHEN INSTALLED IN VEHICLE)
HINT Prepare a battery as the power source to deploy the airbag.
(a) Check the function of SST.
SST : 09082-00700
CAUTION: When deploying the airbag, always use the specified SST (SRS Airbag Deployment
Tool).
(1) Connect SST to the battery. Connect the red clip of SST to the battery positive (+) terminal and
the black clip of SST to the battery
negative (-) terminal.
(2) Check the function of SST. Press SST activation switch, and check that the LED of SST
activation switch comes on.
Page 1897
Brake Fluid: Testing and Inspection
BRAKE: BRAKE FLUID: ON-VEHICLE INSPECTION
1. CHECK BRAKE FLUID LEVEL IN RESERVOIR
(a) Check the fluid level and add fluid if necessary.
Fluid:
SAE J1703 or FMVSS No. 116 DOT3
HINT The brake fluid level must always be adjust to the MAX line.
Inspection
Air Flow Meter/Sensor: Testing and Inspection Inspection
1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: INSPECTION
1. INSPECT MASS AIR FLOW METER
(a) Check the output voltage.
(1) Apply battery voltage across terminals 1 (+B) and 2 (E2G).
NOTICE: While using the battery during inspection, do not bring the positive and negative tester
probes too close to each other as a short circuit may occur.
(2) Using a voltmeter, connect the positive (+) tester probe to terminal 3 (VG), and negative (-)
tester probe to terminal 2 (E2G).
(3) Blow air into the MAF meter, and check that the voltage fluctuates.
If the result is not as specified, replace the MAF meter.
(b) Perform a visual check for any foreign matter on the platinum hot wire (heater) of the mass air
flow meter shown in the illustration.
OK:
There is no foreign material.
(c) If the result is not as specified, replace the mass air flow meter.
(d) Check the IAT sensor.
Up to 11/2009
Braking Sensor/Switch: Locations Up to 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 2051
Symbols Used Within Diagrams
Symbols Used Within Diagrams
Page 989
(b) Disconnect the connector and remove the courtesy switch.
Installation
LIGHTING: FRONT DOOR COURTESY SWITCH: INSTALLATION
HINT *
Use the same procedures for the RH and LH side.
* The procedures listed below are for the LH side.
* A bolt without a torque specification is shown in the standard bolt chart See:
Specifications/Mechanical Specifications/Standard Bolt - Specified Torque For Standard Bolts
1. INSTALL FRONT DOOR COURTESY SWITCH
(a) Connect the connector.
(b) Install the courtesy switch with the bolt.
Page 2290
Variable Valve Timing Actuator: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT OIL CONTROL VALVE: REMOVAL
1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Service and Repair/Removal and
Replacement/Engine Assembly/Removal
2. REMOVE AIR CLEANER HOSE ASSEMBLY See: Service and Repair/Removal and
Replacement/Engine Assembly/Removal
3. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side of Bank
1)
(a) Disconnect the oil control valve connector.
(b) Remove the bolt and oil control valve.
(c) Remove the O-ring from the oil control valve.
4. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side of Bank 1)
(a) Disconnect the oil control valve connector.
(b) Remove the bolt and oil control valve.
(c) Remove the O-ring from the oil control valve.
5. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side of Bank 2)
(a) Disconnect the oil control valve connector.
(b) Remove the bolt and oil control valve.
(c) Remove the O-ring from the oil control valve.
6. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side of Bank
2)
(a) Disconnect the oil control valve connector.
(b) Remove the bolt and oil control valve.
(c) Remove the O-ring from the oil control valve.
Page 2310
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
(b) Remove the hexagon wrench from the No. 1 chain tensioner.
8. TIGHTEN CAMSHAFT TIMING GEAR LH
(a) Using a wrench to hold the hexagonal portion of the No. 3 camshaft, tighten the camshaft timing
gear with the bolt.
Torque : 100 Nm (1020 kgf-cm, 74 ft-lbf)
(b) Using a wrench to hold the hexagonal portion of the No. 4 camshaft, tighten the camshaft timing
exhaust gear with the bolt.
Torque : 100 Nm (1020 kgf-cm, 74 ft-lbf)
9. CHECK NO. 1 CYLINDER TO TDC / COMPRESSION See: Service and
Repair/Overhaul/Reassembly
10. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY
(a) Install the timing chain cover See: Engine Lubrication/Oil Pump/Service and Repair/Removal
and Replacement/Installation.
11. INSPECT IGNITION TIMING See: Testing and Inspection/Engine
12. INSPECT ENGINE IDLE SPEED See: Testing and Inspection/Engine
Page 1720
(e) * for 5 leaf spring
7. ADJUST CAMBER AND CASTER
HINT After the camber has been adjusted, inspect the toe-in.
(a) Loosen the toe adjusting cam bolt and camber adjusting cam nut.
(b) Turn the toe adjusting cam and camber adjusting cam in both directions, and adjust the camber
and caster to the center value.
HINT The camber and caster should be as close as possible to the center value.
Recall 11V185000 - TPMS Non-Compliance
Tire Pressure Module: All Technical Service Bulletins Recall 11V185000 - TPMS Non-Compliance
VEHICLE MAKE/MODEL: MODEL YEAR(S) Toyota/FJ Cruiser 2011
Toyota/Tundra 2009-2011
MANUFACTURER: Gulf States Toyota, Inc.
MFR'S REPORT DATE: March 16, 2011
NHTSA CAMPAIGN ID NUMBER: 11V185000
NHTSA ACTION NUMBER: N/A
COMPONENT: Tires: Pressure Monitoring and Regulating Systems
POTENTIAL NUMBER OF UNITS AFFECTED: 1,489
SUMMARY: Gulf States Toyota is recalling certain model year 2011 FJ Cruiser and model year
2009-2011 Tundra vehicles for failing to comply with the requirements of Federal Motor Vehicle
Safety Standard No. 138, "Tire Pressure Monitoring Systems." The TPMS on some vehicles may
not have been properly calibrated and as a result the low tire pressure warning lamp may not
illuminate should the inflation pressure in one or more of the vehicle's tires fall below the threshold
for when the low tire pressure warning lamp should illuminate.
CONSEQUENCE: Drivers will not receive a warning from the tire pressuring monitor that one or
more tires are underinflated increasing the risk that a vehicle will be driven with one or more
underinflated tires and increasing the risk of a tire failure that may lead to a crash.
REMEDY: Dealers will recalibrate the tire pressure monitoring system in accordance with the
regulation free of charge. The safety recall is expected to begin during April 2011. Owners may
contact Gulf State Toyota Customer Assistance Center toll free at 1-800-444-1074 Monday through
Thursday, 8:30 AM to 5:00 PM, or Friday 8:30 AM to 4:00 PM Central Standard Time.
NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle
Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov.
Page 4978
Transmission Speed Sensor: Service and Repair Installation
A760F AUTOMATIC TRANSMISSION: SPEED SENSOR: INSTALLATION
1. INSTALL SPEED SENSOR SP2
(a) Coat a new O-ring with ATF and install it to the sensor.
(b) Install the sensor with the bolt.
Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)
(c) Connect the sensor connector.
2. INSTALL SPEED SENSOR NT
(a) Coat a new O-ring with ATF and install it to the sensor.
(b) Install the sensor with the bolt.
Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)
(c) Connect the sensor connector.
Page 6355
(2) Disconnect connector B and measure the resistance.
Standard resistance (Fig. 7):
* If the results match the examples above, a short circuit exists between terminal 1 of connector B2
and terminal 1 of connector C.
4. CHECK AND REPLACE ECU
NOTICE: *
The connector should not be disconnected from the ECU. Perform the inspection from the backside
of the connector on the wire harness side.
* When no measuring condition is specified, perform the inspection with the engine stopped and
the ignition switch ON.
* Check that the connectors are fully seated. Check for loose, corroded or broken wires.
(a) First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be
faulty. Temporarily replace the ECU with a
normally functioning one and check if the symptoms occur. If the trouble symptoms disappear,
replace the original ECU.
(1) Measure the resistance between the ECU ground terminal and body ground.
Standard resistance:
Below 1 Ohms
(2) Disconnect the ECU connector. Check the ground terminal on the ECU side and wire harness
side for bending, corrosion or foreign matter.
Lastly, check the contact pressure of the female terminals.
Page 535
Tire Pressure Monitor Receiver / Transponder: Service and Repair Removal
TIRE AND WHEEL: TIRE PRESSURE WARNING RECEIVER: REMOVAL
1. REMOVE ROOF HEADLINING ASSEMBLY
(a) for Regular Cab:
Remove the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Removal.
(b) for Double Cab:
Remove the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Double Cab)/Removal.
(c) for CrewMax:
Remove the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (for CrewMax)/Removal.
2. REMOVE TIRE PRESSURE WARNING ANTENNA AND RECEIVER
(a) Disconnect the receiver connector.
(b) Remove the bolt and receiver.
Page 1339
Ignition Switch: Service and Repair Removal
1UR-FE STARTING: IGNITION SWITCH: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE STEERING COLUMN ASSEMBLY
(a) for Manual Tilt:
Remove the steering column See: Steering and Suspension/Steering/Steering Column/Service and
Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Removal.
(b) for Manual Tilt and Manual Telescopic Steering Column:
Remove the steering column See: Steering and Suspension/Steering/Steering Column/Service and
Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt and Manual
Telescopic Steering Column)/Removal.
(c) for Power Tilt and Power Telescopic Steering Column:
Remove the steering column See: Steering and Suspension/Steering/Steering Column/Service and
Repair/Removal and Replacement/Steering Column Assembly (for Power Tilt and Power
Telescopic Steering Column)/Removal.
3. REMOVE UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Manual
Tilt) See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering Column Assembly
(for Manual Tilt)/Disassembly
4. REMOVE UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Manual Tilt
and Manual Telescopic Steering Column)
See: Steering and Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering
Column Assembly (for Manual Tilt and Manual Telescopic Steering Column)/Disassembly
5. REMOVE UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Power Tilt
and Power Telescopic Steering Column)
See: Steering and Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering
Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Disassembly
6. REMOVE IGNITION SWITCH ASSEMBLY
(a) Detach the 2 claws and remove the ignition switch from the steering lock.
Page 1601
Four Wheel Drive Selector Switch: Diagrams
Page 3001
Variable Valve Timing Actuator Position Sensor: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: VVT SENSOR: REMOVAL
1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Removal
2. REMOVE AIR CLEANER HOSE ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Removal
3. REMOVE VVT SENSOR
(a) Disconnect the 4 sensor connectors.
(b) Remove the 4 bolts and 4 sensors.
Page 5175
Required Tools & Equipment
Repair Procedure Overview
^ Confirm noise is coming from the rear of the vehicle and changes with vehicle speed.
^ Install ChaSSiSEAR(TM) (or equivalent) and isolate the noise to the rear wheel bearing.
^ Remove the rear axle shaft assembly.
^ Install new rear wheel bearing brake caliper bracket and seals.
^ Reinstall rear axle shaft assembly and confirm the noise is no longer present.
Repair Procedure
1. Test drive the vehicle and confirm the customer complaint.
Does the noise increase and decrease with vehicle speed?
^ YES - Go to step 2.
^ NO - This TSB does NOT apply. Refer to the Repair Manual for further diagnosis.
Service and Repair
Vehicle Lifting: Service and Repair
INTRODUCTION: REPAIR INSTRUCTION: VEHICLE LIFT AND SUPPORT LOCATIONS
1. NOTICE ABOUT VEHICLE CONDITION WHEN JACKING UP VEHICLE
(a) The vehicle must be unloaded before jacking up / lifting up the vehicle. Never jack up / lift up a
heavily loaded vehicle.
(b) When removing heavy parts such as the engine and transmission, the center of gravity of the
vehicle may shift. To stabilize the vehicle, place a
balance weight in a location where it will not roll or shift, or use a mission jack to hold the jacking
support.
2. NOTICE FOR USING 4 POST LIFT
(a) Follow the safety procedures outlined in the lift's instruction manual.
(b) Use precautionary measures to prevent the free wheel beam from damaging tires or wheels.
(c) Use wheel chocks to secure the vehicle.
3. NOTICE FOR USING JACK AND SAFETY STAND
(a) Work on a level surface. Use wheel chocks at all times.
(b) Use safety stands with rubber attachments as shown in the illustration.
(c) Set the jack and safety stands to the specified locations of the vehicle accurately.
(d) When jacking up the vehicle, first release the parking brake and move the shift lever to N.
(e) When jacking up the entire vehicle:
(1) When jacking up the front wheels first, make sure wheel chocks are behind the rear wheels.
(2) When jacking up the rear wheels first, make sure wheel chocks are in front of the front wheels.
(f) When jacking up only the front or rear wheels of the vehicle:
(1) Before jacking up the front wheels, place wheel chocks on both sides of the rear wheels.
(2) Before jacking up the rear wheels, place wheel chocks on both sides of the front wheels.
(g) When lowering a vehicle that only has its front or rear wheels jacked up:
(1) Before lowering the front wheels, make sure wheel chocks are in front of the rear wheels.
(2) Before lowering the rear wheels, make sure wheel chocks are behind the front wheels.
Page 1819
Then click Next.
F. Verify correct current calibration and new calibration information. Then click Next.
NOTE
^ The total number of calibration IDs in the calibration file corresponds to the number of
reprogrammable processors in the ECU.
^ Each calibration file may contain up to three separate calibrations.
Components
Air Flow Meter/Sensor: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: COMPONENTS
Page 2090
J/B No.3 - Instrument Panel Right
Page 1526
Power Steering Pressure Switch: Diagrams Power Steering Oil Pressure Switch
Page 2533
This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown.
Page 3553
CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: 4WD Control ECU Communication
Stop Mode - 4WD Control ECU Communication Stop Mode
DESCRIPTION
WIRING DIAGRAM
INSPECTION PROCEDURE
HINT Operating the ignition switch, any switches or any doors triggers related ECU and sensor
communication with the CAN, which causes resistance variation.
PROCEDURE
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
(a) Disconnect the cable from the negative (-) battery terminal before measuring the resistances of
the main wire and the branch wire.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
NEXT -- Continue to next step.
2. CHECK FOR OPEN IN CAN BUS WIRE (4WD CONTROL ECU BRANCH WIRE)
(a) Disconnect the A25 4WD control ECU connector.
Page 260
Page 2664
Radiator: Service and Repair Removal
1UR-FE COOLING: RADIATOR: REMOVAL
1. REMOVE FAN SHROUD
(a) Remove the fan shroud See: Radiator Cooling Fan/Service and Repair/Removal.
2. DISCONNECT OUTLET RADIATOR HOSE See: Thermostat/Service and Repair/Removal
3. REMOVE RADIATOR SIDE DEFLECTOR RH
(a) Using a clip remover, remove the 6 clips and side deflector.
4. REMOVE RADIATOR SIDE DEFLECTOR LH
(a) Using a clip remover, remove the 6 clips and side deflector.
(b) Disconnect the wire harness clamp.
5. REMOVE RADIATOR ASSEMBLY
(a) Remove the 4 bolts and radiator.
(b) Remove the radiator hose from the radiator.
Page 6182
(a) Attach the claw to install the power outlet socket.
(b) Connect the power outlet socket connector.
6. INSTALL CENTER FRONT SEAT ASSEMBLY
(a) Install the center front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Center
Seat)/Installation.
7. INSTALL FRONT SEAT ASSEMBLY LH (for Power Seat)
(a) Install the front seat LH See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Power
Seat)/Installation.
8. INSTALL FRONT SEAT ASSEMBLY RH (for Power Seat)
HINT Use the same procedures described for the LH side.
9. INSTALL FRONT SEAT ASSEMBLY LH (for Manual Seat)
(a) Install the front seat LH See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Manual
Seat)/Installation.
10. INSTALL FRONT SEAT ASSEMBLY RH (for Manual Seat)
HINT Use the same procedures described for the LH side.
Page 7431
(a) After repairs, confirm that the actual tire pressures are displayed in the DATA LIST See: Tire
Monitoring System/Testing and
Inspection/Scan Tool Testing and Procedures/Data List / Active Test.
Page 2021
3. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE
HINT The diagnostic system in the TOYOTA TUNDRA has various functions.
* The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU
memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a
previous malfunction's DTC can be checked by a technician during troubleshooting.
* Another function is the Input Signal Check, which checks if the signals from various switches are
sent to the ECU correctly.
* By using these functions, the problem areas can be narrowed down and troubleshooting is more
effective. Diagnostic functions are incorporated in the following systems in the TOYOTA TUNDRA.
Page 1346
Knock Sensor: Testing and Inspection
1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: INSPECTION
1. INSPECT KNOCK SENSOR
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) If the result is not as specified, replace the knock sensor.
Page 3596
Manifold Pressure/Vacuum Sensor: Testing and Inspection
1UR-FE ENGINE CONTROL SYSTEM: MANIFOLD ABSOLUTE PRESSURE SENSOR:
INSPECTION
1. INSPECT MANIFOLD ABSOLUTE PRESSURE SENSOR
(a) Check the resistance.
(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(2) If the result is not as specified, replace the manifold absolute pressure sensor.
Center Airbag Sensor Assembly (for Column Shift Type)
Air Bag Control Module: Testing and Inspection Center Airbag Sensor Assembly (for Column Shift
Type)
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Column
Shift Type): ON-VEHICLE INSPECTION
1. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION)
(a) Perform a diagnostic system check See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
2. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND
AIRBAG HAS NOT DEPLOYED)
(a) Perform a diagnostic system check See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
3. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND
AIRBAG IS DEPLOYED)
(a) Replace the center airbag sensor.
CAUTION: For removal and installation procedures of the center airbag sensor, be sure to follow
the correct procedure.
HINT The center airbag sensor should be replaced after any of the airbags has deployed, as it has
been subjected to the impact.
Page 6847
Locations
Power Distribution Module: Locations
Instrument Panel (Floor Shift)
Instrument Panel (Column Shift)
Page 684
Power Mirror Switch: Locations Power Mirror Control System (w/o Memory)
MIRROR: POWER MIRROR CONTROL SYSTEM (w/o Memory): PARTS LOCATION
Page 6210
Removal
OTHER SYSTEM: POWER OUTLET SOCKET (for CrewMax Floor Shift Type): REMOVAL
1. REMOVE REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
2. REMOVE CONSOLE BOX BEZEL
Page 6246
Page 7481
(a) After repairs, confirm that the actual tire pressures are displayed in the DATA LIST See: Testing
and Inspection/Scan Tool Testing and
Procedures/Data List / Active Test.
Locations
Accessory Relay: Locations
Instrument Panel (Floor Shift)
Instrument Panel (Column Shift)
Engine Controls - Techstream(R) ECU Re-Flash
Procedure
PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls Techstream(R) ECU Re-Flash Procedure
T-SB-0064-10
February 4, 2010
Techstream ECU Flash Reprogramming Procedure
Service Category Engine/Hybrid System
Section Engine Control
Market USA
Applicability
TSB SUPERSESSION NOTICE
The information contained in this TSB supersedes TSB No. SS002-07.
^ Applicability has been updated to include 2009 - 2011 model year Toyota vehicles.
^ A new section, Techstream Preparation, has been added.
^ Techstream Lite has been added as an option in Required Tools & Materials.
^ Process Overview and Operation Procedure sections have been updated.
TSB No. SS002-07 is Obsolete and any printed versions should be discarded. Be sure to review
the entire content of this service bulletin before proceeding.
Introduction
Flash reprogramming allows the ECU software to be updated without replacing the ECU. Flash
calibration updates for specific vehicle models/ECUs are released as field-fix procedures described
in individual service bulletins. This bulletin details the Techstream ECU flash reprogramming
process and outlines use of the Technical Information System (TIS) and the Calibration Update
Wizard (CUW). Flash calibration updates can only be applied to the vehicle/ECU combination for
which they are intended. ECUs have internal security that will not allow them to be programmed
with another ECU's information.
ECU
Electronic Control Unit (ECU) is a Toyota term used to describe integrated computerized devices
responsible for managing the operation of a system or subsystem. For the purposes of this bulletin,
the term "ECU" is used as a generic label for the following SAE J1930 standard references:
^ Powertrain Control Module (PCM)
Page 9055
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION: Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC
terminals are touched, the IC may be destroyed by static electricity.)
When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact with the terminals of leads from the IC, etc. of the
replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown on the left.
DISCONNECT CONNECTOR
Page 1420
Removal
SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Double Cab): REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Disassembly
3. REMOVE FRONT ARMREST BASE PANEL UPPER LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Page 8770
Speaker: Diagrams Front Door Speaker
Page 7225
Steering Control Module: Service and Repair Removal
POWER STEERING: POWER STEERING ECU (for 1UR-FE): REMOVAL
1. REMOVE FRONT DOOR SCUFF PLATE LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining
(For Double Cab)/Removal
2. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Removal
3. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal
4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Removal
5. REMOVE LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY See: Restraint
Systems/Air Bag Systems/Air Bag/Service and
Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Removal
6. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column
Shift Type)/Removal
7. REMOVE POWER STEERING ECU ASSEMBLY
(a) Disconnect the power steering ECU connector.
(b) Remove the nut and power steering ECU.
Page 1710
Standard camber inclination (unloaded vehicle):
for Double Cab of Long Deck
Page 6587
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Page 9396
13. Reinstall the body plugs for the cab mount bolt holes and then the carpet.
14. Test drive vehicle to confirm the condition has improved.
Page 584
Integrated Accessory Switch Assembly: Testing and Inspection
METER: DRIVE MONITOR SWITCH: INSPECTION
1. INSPECT DRIVE MONITOR SWITCH
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(a) If the result is not as specified, replace the monitor switch.
(b) Inspect the switch illumination.
(1) Connect the battery's positive (+) lead to terminal 1 (ILL+) and the negative (-) lead to terminal 6
(ILL-).
(2) Check that the light comes on.
OK:
LED comes on.
(3) If the result is not as specified, replace the monitor switch.
Components
Intake Manifold: Service and Repair Components
1UR-FE INTAKE: INTAKE MANIFOLD: COMPONENTS
Page 3339
Engine Control Module: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: ECM: INSTALLATION
1. INSTALL GASKET
(a) Clean the ECM seal's surface with non-residue solvent.
(b) Attach a new gasket to the ECM.
2. INSTALL ECM
(a) Install the ECM with the 4 bolts.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
NOTICE: *
Make sure the gasket is not folded or caught on any area on the surrounding part.
* Make sure there is no foreign matter caught between the gasket and surrounding part.
* Do not damage the gasket.
(b) Connect the 2 ECM connectors and push each lock lever down to lock the ECM connectors.
NOTICE: *
Make sure that the lock lever is raised 90° before connecting the ECM connectors. Failure to do
this may cause the lock lever and terminals to break.
* Do not twist the wire harness when connecting the ECM connectors.
(c) Connect the wire harness clamp.
3. CONNECT CONNECTOR HOLDER BLOCK
(a) Connect the connector holder block with the 3 bolts.
Torque : 7.3 Nm (74 kgf-cm, 65 in-lbf)
Page 4004
6. In some instances where water has entered the system DTCs P2440/P2441/P2442/P2443 may
set.
Refer to TIS 2010 model year Tundra Repair Manual to diagnose and inspect the emission control
valves if necessary:
7. If there is NO liquid found in the air pump assemblies or the DTC is still present after
replacement inspect the air injection system.
Refer to TIS 2010 model year Tundra Repair Manual:
8. Clear the DTC and road test the vehicle to confirm the condition has been corrected.
Page 7996
HINT Tape the screwdriver tip before use.
3. REMOVE LOWER NO. 2 STEERING WHEEL COVER
(a) w/ Cruise Control:
(1) Using a screwdriver, remove the No. 2 steering wheel cover.
HINT Tape the screwdriver tip before use.
(b) w/o Cruise Control:
(1) Using a screwdriver, remove the No. 2 steering wheel cover.
HINT Tape the screwdriver tip before use.
4. REMOVE STEERING PAD (w/ Steering Pad Switch)
(a) Using a T30 "TORX" socket wrench, loosen the 2 screws until the groove along the screw
circumference catches on the screw case.
Page 7739
(c) Install the 6 screws and attach the 4 claws.
(d) Install the packing.
3. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY
(a) Install the heater radiator unit.
(b) Attach the 3 claws to install the heater clamp.
(c) Install the plate with the 3 screws.
Page 9374
7. Raise the back of the cab from the pinch welds high enough to remove the No.3 cab mounts.
8. With the cab still raised install the new No.3 cab mounts.
9. Install the two bolts on top that were previously removed from the No.3 cab mount and torque to
specification.
Torque: 61 N*m (622 kgf*cm, 45 ft*lbf)
Page 3381
(2) Disconnect connector B and measure the resistance.
Standard resistance (Fig. 7):
* If the results match the examples above, a short circuit exists between terminal 1 of connector B2
and terminal 1 of connector C.
4. CHECK AND REPLACE ECU
NOTICE: *
The connector should not be disconnected from the ECU. Perform the inspection from the backside
of the connector on the wire harness side.
* When no measuring condition is specified, perform the inspection with the engine stopped and
the ignition switch ON.
* Check that the connectors are fully seated. Check for loose, corroded or broken wires.
(a) First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be
faulty. Temporarily replace the ECU with a
normally functioning one and check if the symptoms occur. If the trouble symptoms disappear,
replace the original ECU.
(1) Measure the resistance between the ECU ground terminal and body ground.
Standard resistance:
Below 1 Ohms
(2) Disconnect the ECU connector. Check the ground terminal on the ECU side and wire harness
side for bending, corrosion or foreign matter.
Lastly, check the contact pressure of the female terminals.
Page 7863
10. REMOVE DAMPER SERVO SUB-ASSEMBLY
(a) Disconnect the 2 connectors.
(b) Remove the 4 screws and damper servo.
(c) Remove the damper servo.
(1) Detach the claw and remove the main plate.
(2) Remove the 2 screws and damper servo.
(d) Remove the damper servo.
Page 3512
NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO CENTER AIRBAG
SENSOR (CANH, CANL)
OK -- REPLACE CENTER AIRBAG SENSOR
19. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (NO. 2 JUNCTION CONNECTOR - AIR
CONDITIONING AMPLIFIER)
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- CHECK FOR SHORT TO B+ IN CAN BUS WIRE (AIR CONDITIONING AMPLIFIER) OK -Continue to next step.
20. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (NO. 2 JUNCTION CONNECTOR - BUS
BUFFER ECU)
NOTICE: For vehicles without a bus buffer ECU, go to "CHECK FOR SHORT TO B+ IN CAN BUS
WIRE (NO. 2 JUNCTION CONNECTOR - 4WD CONTROL ECU)".
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- CHECK FOR SHORT TO B+ IN CAN BUS WIRE (BUS BUFFER ECU) OK -- Continue to
next step.
21. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (NO. 2 JUNCTION CONNECTOR - 4WD
CONTROL ECU)
Locations
Gear Sensor/Switch: Locations
JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION
Page 2033
J/B No.3 - Instrument Panel Right
Page 318
Page 968
Dimmer Switch: Diagrams
Page 6616
Auxiliary Power Outlet: Electrical Diagrams
Power Outlet [120V]
Power Outlet [120V]
Up to 11/2009
Brake Fluid Pump Relay: Locations Up to 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 6026
Torque : 133 Nm (1356 kgf-cm, 98 ft-lbf)
HINT Hold the adjustable wrench against the vise and tighten the nut securely.
(h) Remove SST 2 from the generator.
(i) Turn SST 1-B, and remove SST 1-A and B.
(j) Turn the pulley and check that the pulley moves smoothly.
Page 357
C. Choose desired ECU group(s) in the Health Check dialog box.
D. Click Next.
E. Click Continue to view Health Check results.
F. Available calibration updates are indicated by a link in the Cal. Update? column. Click the link to
access the appropriate service bulletin on TIS.
NOTE
^ Note any DTCs stored in Systems that will be flash reprogrammed.
^ Clicking the link will automatically launch TIS and perform a calibration search.
G. Log in to TIS. (If already logged in skip this step.)
H. To review the TSB and access the calibration file click the service bulletin link in the Document
Title column of the Calibration Search Result
portlet.
Page 6979
(a) For an open circuit in the wire harness in Fig. 1, check the resistance or voltage, as described
below.
(b) Check the resistance.
(1) Disconnect connectors A and C and measure the resistance between them.
Standard resistance (Fig. 2):
HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally.
If the results match the examples above, an open circuit exists between terminal 1 of connector A
and terminal 1 of connector C.
(2) Disconnect connector B and measure the resistance between the connectors.
Standard resistance (Fig. 3):
* If the results match the examples above, an open circuit exists between terminal 1 of connector
B2 and terminal 1 of connector C.
(c) Check the voltage.
Page 7546
* The procedures listed below are for the LH side.
1. REMOVE REAR WHEEL LH
2. DISCONNECT REAR DISC BRAKE CYLINDER ASSEMBLY LH See: Brakes and Traction
Control/Parking Brake System/Service and
Repair/Disassembly
3. REMOVE REAR DISC LH See: Brakes and Traction Control/Disc Brake System/Service and
Repair/Removal and Replacement/Rear
Brake/Removal
4. REMOVE PARKING BRAKE SHOE RETURN TENSION SPRING LH See: Brakes and Traction
Control/Parking Brake System/Service and
Repair/Disassembly
5. REMOVE NO. 1 PARKING BRAKE SHOE ASSEMBLY LH See: Brakes and Traction
Control/Parking Brake System/Service and
Repair/Disassembly
6. REMOVE NO. 2 PARKING BRAKE SHOE ASSEMBLY LH See: Brakes and Traction
Control/Parking Brake System/Service and
Repair/Disassembly
7. REMOVE PARKING BRAKE SHOE LEVER SUB-ASSEMBLY LH See: Brakes and Traction
Control/Parking Brake System/Service and
Repair/Disassembly
8. REMOVE REAR AXLE LH HUB BOLT
(a) Using SST and a screwdriver or equivalent to hold the axle hub, remove the hub bolt.
SST : 09650-17011
9. INSTALL REAR AXLE LH HUB BOLT
(a) Temporarily install a washer and hub nut to a new hub bolt as shown in the illustration.
NOTICE: Install hub nuts to prevent damage to the hub bolts.
(b) Using a screwdriver or equivalent to hold the hub, turn the hub nut until the bottom surface of
the hub bolt head touches the axle hub.
(c) Remove the washer and hub nut.
NOTICE: Do not damage the threads of the hub bolts.
10. INSTALL PARKING BRAKE SHOE LEVER SUB-ASSEMBLY LH See: Brakes and Traction
Control/Parking Brake System/Service and
Repair/Reassembly
11. INSTALL NO. 2 PARKING BRAKE SHOE ASSEMBLY LH See: Brakes and Traction
Control/Parking Brake System/Service and
Repair/Reassembly
Page 6285
Diagram Information and Instructions
Trailer Connector: Diagram Information and Instructions
Wiring Color Codes
Abbreviations Used Within Diagrams
Abbreviations Used Within Diagrams
Components
Ignition Switch: Service and Repair Components
1UR-FE STARTING: IGNITION SWITCH: COMPONENTS
Page 6167
If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness
or connector in that circuit in the past. Check the wire harness and connectors.
B -- SYSTEM NORMAL
A -- TROUBLESHOOTING OF EACH PROBLEM SYMPTOM
The problem is still occurring in a place other than the diagnostic circuit (the DTC displayed first is
either for a past problem or a secondary problem).
4. SYMPTOM SIMULATION
HINT The most difficult case in troubleshooting is when no problem symptoms occur. In such a
case, a thorough problem analysis must be carried out. A simulation of the same or similar
conditions and environment in which the problem occurred in the customer's vehicle should be
carried out. No matter how much skill or experience a technician has, troubleshooting without
confirming the problem symptoms will lead to important repairs being overlooked and mistakes or
delays.
For example:
With a problem that only occurs when the engine is cold or as a result of vibration caused by the
road during driving, the problem can never be determined if the symptoms are being checked on a
stationary vehicle or on a vehicle with a warmed-up engine. Vibration, heat or water penetration
(moisture) is difficult to reproduce. The symptom simulation tests below are effective substitutes for
the conditions and can be applied on a stationary vehicle.
Important points in the symptom simulation test:
In the symptom simulation test, the problem symptoms as well as the problem area or parts must
be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then,
connect the tester and carry out the symptom simulation test, judging whether the circuit being
tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the
problem symptoms table for each system to narrow down the possible causes.
To reproduce DTCs, it is necessary to satisfy the respective DTC detection conditions.
(a) VIBRATION METHOD:
When a malfunction seems to occur as a result of vibration.
(1) PART AND SENSOR
Apply slight vibration with a finger to the part of the sensor suspected to be the cause of the
problem, and check whether or not the malfunction occurs.
NOTICE: Applying strong vibration to relays may open them.
Page 4840
Standard condition:
Indicator light [D] remains illuminated for 2 seconds and then turns off.
(f) When using the Techstream:
Return the shift lever to P and terminate the Active Test on the Techstream.
(g) When not using the Techstream:
Return the shift lever to P and disconnect SST from the DLC3.
(h) Allow the engine to idle until the fluid temperature reaches 53 to 59°C (127 to 138°F).
HINT The indicator [D] will come on again when the fluid temperature reaches 53°C (127°F) and
will blink if it is higher than 59°C (138°F).
(i) Remove the overflow plug and gasket with the engine idling.
(j) Wait until the overflow slows to a trickle.
NOTICE: If the fluid does not overflow, perform the following:
(1) Remove the refill plug and gasket.
(2) Refill the transmission through the refill hole until fluid begins to trickle out of the overflow tube.
(3) Wait until the overflow slows to a trickle.
(4) Install a new gasket and the refill plug.
Torque : 39 Nm (400 kgf-cm, 29 ft-lbf)
(k) Install a new gasket and the overflow plug.
Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)
6. COMPLETE
(a) Turn the ignition switch off.
Page 9130
(2) CONNECTORS
Slightly shake the connector vertically and horizontally.
(3) WIRE HARNESS
Slightly shake the wire harness vertically and horizontally.
HINT The connector joint and fulcrum of the vibration are the major areas that should be checked
thoroughly.
(b) HEAT METHOD:
When a malfunction seems to occur when the area in question is heated.
(1) Heat the component that is the possible cause of the malfunction with a hair dryer or similar
device. Check if the malfunction occurs.
NOTICE: *
Do not heat to more than 60°C (140°F). Exceeding this temperature may damage components.
* Do not apply heat directly to the parts in the ECU.
(c) WATER SPRINKLING METHOD:
When a malfunction seems to occur on a rainy day or in high-humidity.
(1) Sprinkle water onto the vehicle and check if the malfunction occurs.
NOTICE: *
Never sprinkle water directly into the engine compartment. Indirectly change the temperature and
humidity by spraying water onto the front of the radiator.
* Never apply water directly onto the electronic components.
HINT If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU
or connections. Look for evidence of corrosion or short circuits. Proceed with caution during water
tests.
(d) HIGH ELECTRICAL LOAD METHOD:
When a malfunction seems to occur when the electrical load is excessive.
(1) Turn on the heater blower, headlights, rear window defogger and all other electrical loads.
Check if the malfunction reoccurs.
5. DIAGNOSTIC TROUBLE CODE CHART
Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate
section's Diagnostic Trouble Code Chart. Use the chart to determine the trouble area and the
proper inspection procedure. A description of each of the chart's columns is below.
Page 2454
Capacity Specifications
Coolant: Capacity Specifications
Cooling System Capacity
Without towing package ......................................................................................................................
.......................................................... 12.8 qt (12.1L) With towing package ........................................
.............................................................................................................................................. 13.9 qt
(13.2L)
Page 7574
Page 988
Removal
LIGHTING: FRONT DOOR COURTESY SWITCH: REMOVAL
HINT *
Use the same procedures for the RH and LH side.
* The procedures listed below are for the LH side.
1. REMOVE FRONT DOOR COURTESY SWITCH
(a) Remove the bolt.
Page 293
Engine Room R/B, J/B - Engine Compartment Left
Page 7354
(a) Install a new bush to the leaf spring.
(1) Install the bushing while aligning it with the matchmarks so that its openings are as shown in the
illustration.
NOTICE: Be sure to install each bushing to the correct positions.
(b) Use SST and a press, press both bushes into the leaf spring.
SST : 09710-28012
09710-07062
SST : 09710-30041
09710-03211
NOTICE: Align SST, which presses the bush, to the outer casing of the bush.
LIN Communication System
Information Bus: Locations LIN Communication System
MULTIPLEX COMMUNICATION: LIN COMMUNICATION SYSTEM: PARTS LOCATION
Page 1987
Page 4615
Ignition Switch: Service and Repair Installation
1UR-FE STARTING: IGNITION SWITCH: INSTALLATION
1. INSTALL IGNITION SWITCH ASSEMBLY
(a) Attach the 2 claws to install the ignition switch to the steering lock.
2. INSTALL UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Manual Tilt)
See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering Column Assembly
(for Manual Tilt)/Reassembly
3. INSTALL UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Manual Tilt
and Manual Telescopic Steering Column)
See: Steering and Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering
Column Assembly (for Manual Tilt and Manual Telescopic Steering Column)/Reassembly
4. INSTALL UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Power Tilt
and Power Telescopic Steering Column)
See: Steering and Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering
Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Reassembly
5. INSTALL STEERING COLUMN ASSEMBLY
(a) for Manual Tilt:
Install the steering column See: Steering and Suspension/Steering/Steering Column/Service and
Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Installation.
(b) for Manual Tilt and Manual Telescopic Steering Column:
Install the steering column See: Steering and Suspension/Steering/Steering Column/Service and
Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt and Manual
Telescopic Steering Column)/Installation.
(c) for Power Tilt and Power Telescopic Steering Column:
Install the steering column See: Steering and Suspension/Steering/Steering Column/Service and
Repair/Removal and Replacement/Steering Column Assembly (for Power Tilt and Power
Telescopic Steering Column)/Installation.
6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Page 9019
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: ELECTRONIC
CIRCUIT INSPECTION PROCEDURE
1. BASIC INSPECTION
(a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS
(1) Unless otherwise stated, all resistance measurements should be made at an ambient
temperature of 20°C (68°F). Resistance measurements
may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been
running. Measurements should be made after the engine has cooled down.
(b) HANDLING CONNECTORS
(1) When disconnecting a connector, first squeeze the mating halves tightly together to release the
lock, and then press the lock claw and
separate the connector.
(2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly
and separate it.
(3) Before connecting a connector, check that there are no deformed, damaged, loose or missing
terminals.
(4) When connecting a connector, press firmly until it locks with a "click" sound.
(5) If checking a connector with a TOYOTA electrical tester, check the connector from the backside
(harness side) using a mini test lead.
NOTICE: *
As a waterproof connector cannot be checked from the backside, check it by connecting a
sub-harness.
* Do not damage the terminals by moving the inserted tester needle.
(c) CHECKING CONNECTORS
(1) Checking when a connector is connected: Squeeze the connectors together to confirm that they
are fully connected and locked.
(2) Checking when a connector is disconnected: Check by pulling the wire harness lightly from the
backside of the connector. Look for
unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for
corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or
deformed terminals.
(3) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a
female terminal, and check for ample tension
Page 6905
Page 5061
28. REMOVE FRONT DIFFERENTIAL SIDE GEAR SHAFT RH BEARING
(a) Using a snap ring expander, remove the snap ring.
(b) Using SST, a brass bar and press, press out the bearing.
SST : 09950-00020
SST : 09950-70010
09951-07100
SST : 09950-60010
09951-00450
NOTICE: Do not damage the bearing.
29. INSPECT DIFFERENTIAL CLUTCH SLEEVE AND DIFFERENTIAL CLUTCH HUB
(a) Check for wear and damage to the clutch hub and clutch sleeve.
(b) If necessary, replace them.
(c) Check that the clutch sleeve slides smoothly on the clutch hub.
Page 6484
3. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE
HINT The diagnostic system in the TOYOTA TUNDRA has various functions.
* The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU
memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a
previous malfunction's DTC can be checked by a technician during troubleshooting.
* Another function is the Input Signal Check, which checks if the signals from various switches are
sent to the ECU correctly.
* By using these functions, the problem areas can be narrowed down and troubleshooting is more
effective. Diagnostic functions are incorporated in the following systems in the TOYOTA TUNDRA.
Page 3189
Body Control Module: Diagrams
Page 9060
"Case2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 8464
(a) for Column Shift Type:
Remove the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Column Shift Type)/Installation.
(b) for Floor Shift Type:
Remove the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Floor Shift Type)/Installation.
4. INSTALL COWL SIDE TRIM BOARD LH
(a) for Regular Cab:
Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular Cab)/Installation.
(b) for Double Cab:
Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Installation.
(c) for CrewMax:
Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for CrewMax)/Installation.
5. INSTALL FRONT DOOR SCUFF PLATE LH
(a) for Regular Cab:
Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular Cab)/Installation.
(b) for Double Cab:
Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Installation.
(c) for CrewMax:
Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for CrewMax)/Installation.
Page 2069
Establish conditions in which voltage is present at the check point.
Example:
- [A] - Ignition SW on
- [B] - Ignition SW and SW1 on
- [C] - Ignition SW, SW1 and Relay on (SW2 off)
Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or component terminal.
This check can be done with a test light instead of a voltmeter.
Electronic Circuit Inspection Procedure
Diagram Information and Instructions
Auxiliary Power Outlet: Diagram Information and Instructions
Wiring Color Codes
Abbreviations Used Within Diagrams
Abbreviations Used Within Diagrams
Page 7764
(4) for Driver Side:
Install the 3 bolts.
Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)
(5) for Driver Side:
Install the 3 caps.
(b) Attach the clamps and connectors to the wire harness.
(c) Install the 8 bolts, 2 screws and 4 nuts.
3. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY
(a) for Column Shift Type:
Install the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column
Shift Type)/Installation.
Page 7784
Refrigerant: Fluid Type Specifications
REFRIGERANT TYPE
Refrigerant............................................................................................................................................
......................................................HFC-134a (R134a)
Page 2157
Tire Pressure Sensor: Service and Repair Installation
TIRE AND WHEEL: TIRE PRESSURE WARNING VALVE AND TRANSMITTER: INSTALLATION
1. INSTALL TIRE PRESSURE WARNING VALVE AND TRANSMITTER
(a) Insert the tire pressure warning valve into the valve installation hole from the inside of the rim so
that the print surface can be seen.
NOTICE: *
Check that there is no visible deformation, damage or other abnormalities on the tire pressure
warning valve and transmitter.
* Check that there is no foreign matter on the inner grommet and around the rim hole.
* If the tire pressure warning valve and transmitter is installed in the reverse direction, it may be
damaged or fail to transmit signals when running at a high speed.
* If installing a new tire pressure warning valve and transmitter, write down the transmitter ID before
installation.
* The transmitter ID registration must be performed for all tire pressure warning valve and
transmitters, regardless of the number of tire pressure warning valve and transmitters replaced. If
all of the tire pressure warning valve and transmitters do not need to be replaced, check the DATA
LIST and write down the transmitter IDs of the tire pressure warning valve and transmitters that do
not need to be replaced before performing the transmitter ID registration See: Tire Monitoring
System/Testing and Inspection/Programming and Relearning/Registration
* It is necessary to perform initialization See: Tire Monitoring System/Testing and
Inspection/Programming and Relearning/Initialization after registration See: Tire Monitoring
System/Testing and Inspection/Programming and Relearning/Registration of the transmitter IDs
into the tire pressure warning ECU after the tire pressure warning valve and transmitter has been
replaced.
(b) If reusing the tire pressure warning valve and transmitter:
Install a new grommet.
HINT A new tire pressure warning valve and transmitter is supplied with a grommet.
(c) Install the washer on the tire pressure warning valve from the rim side and tighten the nut.
Page 9350
(c) w/o Rear Fender Mudguard:
Remove the rear wheel house liner (rear).
(1) Remove the 2 screws.
(2) Remove the 7 clips and wheel house liner.
(d) w/ Rear Fender Mudguard:
Remove the rear wheel house liner (rear).
(1) Remove the mudguard See: Spoilers, Flaps, and Air Dams/Mud Flap/Service and
Repair/Removal.
(2) Remove the screw.
(3) Remove the 7 clips and wheel house liner.
Page 506
Steering Control Module: Service and Repair Removal
POWER STEERING: POWER STEERING ECU (for 1UR-FE): REMOVAL
1. REMOVE FRONT DOOR SCUFF PLATE LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining
(For Double Cab)/Removal
2. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Removal
3. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal
4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Removal
5. REMOVE LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY See: Restraint
Systems/Air Bag Systems/Air Bag/Service and
Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Removal
6. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column
Shift Type)/Removal
7. REMOVE POWER STEERING ECU ASSEMBLY
(a) Disconnect the power steering ECU connector.
(b) Remove the nut and power steering ECU.
Page 3086
General Information
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: GENERAL
INFORMATION
* A large number of ECU controlled systems are used in the TOYOTA TUNDRA. In general, ECU
controlled systems are considered to be very intricate, requiring a high level of technical knowledge
to troubleshoot. However, most problem checking procedures only involve inspecting the ECU
controlled system's circuits one by one. An adequate understanding of the system and a basic
knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and
necessary repairs.
1. TROUBLESHOOTING PROCEDURES
* The troubleshooting procedures consist of diagnosis procedures for when a DTC is stored and
diagnosis procedures for when no DTC is stored. The basic idea is explained in the following table.
* Vehicle systems are complex and use many ECUs that are difficult to inspect independently.
Therefore, a process of elimination is used, where components that can be inspected individually
are inspected, and if no problems are found in these components, the related ECU is identified as
the problem and replaced.
* It is extremely important to ask the customer about the environment and the conditions present
when the problem occurred (Customer Problem Analysis). This makes it possible to simulate the
conditions and confirm the symptom. If the symptom cannot be confirmed or the DTC does not
recur, the malfunctioning part may not be identified using the troubleshooting procedure, and the
ECU for the related system may be replaced even though it is not defective. If this happens, the
original problem will not be solved.
* In order to prevent endless expansion of troubleshooting procedures, the troubleshooting
procedures are written with the assumption that multiple malfunctions do not occur simultaneously
for a single problem symptom.
* To identify the malfunctioning part, troubleshooting procedures narrow down the target by
separating components, ECUs and wire harnesses during the inspection. If the wire harness is
identified as the cause of the problem, it is necessary to inspect not only the connections to
components and ECUs but also all of the wire harness connectors between the component and the
ECU.
DIAGNOSTIC TESTER
2. DESCRIPTION
System data and the Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector
3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the Techstream* to
check for a malfunction and perform repairs.
HINT *: Techstream is the name for the diagnostic tester in North America.
3. DATA LINK CONNECTOR 3 (DLC3)
(a) The vehicle's ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of
the DLC3 complies with SAE J1962 and
matches the ISO 15765-4 format.
Page 9046
Symbols Used Within Diagrams
Symbols Used Within Diagrams
Page 4284
NOTE
On some models, DTCs may set as a result of reprogramming. If DTCs are present, clear codes
and run the Health Check again. Troubleshoot any remaining Current, Pending, or History codes.
Permanent codes will not be cleared using Techstream. Permanent codes do not illuminate the MIL
and do not require troubleshooting. They will clear during normal driving once the Universal Trip
Drive Pattern is performed.
4. Attach the Authorized Modifications Label.
A. Using a permanent marker or ball point pen complete the Authorized Modifications Label and
attach to the vehicle. The Authorized
Modifications Label is available through the MDC P/N 00451-00001-LBL.
B. Attach the label under the hood in the location determined by the specific TSB or Campaign.
NOTE
Wait 60 - 90 seconds for ink to set before handling.
Engine Control System - SFI System
Camshaft Position Sensor: Locations Engine Control System - SFI System
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 5898
Traction Control Switch: Service and Repair Removal
BRAKE CONTROL: VSC OFF SWITCH: REMOVAL
1. REMOVE FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Removal
2. REMOVE FRONT DOOR SCUFF PLATE LH (for Double Cab, CrewMax) See: Body and
Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Removal
3. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Removal
4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Removal
5. REMOVE VSC OFF SWITCH
(a) Disconnect the VSC OFF switch connector.
(b) Using a screwdriver, detach the 2 claws and remove the VSC OFF switch from the lower
instrument panel finish panel LH.
Page 6204
5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Removal
6. REMOVE CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service
and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Removal
7. REMOVE FRONT ASH RECEPTACLE BOX SUB-ASSEMBLY
8. REMOVE LOWER INSTRUMENT CLUSTER FINISH PANEL See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column
Shift Type)/Removal
9. REMOVE POWER OUTLET SOCKET ASSEMBLY
(a) Using a screwdriver, detach the claw and remove the power outlet socket.
HINT Tape the screwdriver tip before use.
10. REMOVE POWER OUTLET SOCKET COVER
(a) Detach the 2 claws and remove the power outlet socket cover.
Installation
OTHER SYSTEM: POWER OUTLET SOCKET (for Column Shift Type): INSTALLATION
1. INSTALL POWER OUTLET SOCKET COVER
(a) Attach the 2 claws to install the power outlet socket cover.
2. INSTALL POWER OUTLET SOCKET ASSEMBLY
Page 5192
(b) Install the O-ring to the axle shaft.
(c) Install the rear axle shaft and parking brake plate with the 4 nuts.
Torque : 60 Nm (612 kgf-cm, 44 ft-lbf)
3. CONNECT REAR SPEED SENSOR LH See: Brakes and Traction Control/Antilock Brakes /
Traction Control Systems/Wheel Speed
Sensor/Service and Repair/Rear Speed Sensor/Installation
4. CONNECT NO. 3 PARKING BRAKE CABLE ASSEMBLY See: Brakes and Traction
Control/Parking Brake System/Service and
Repair/Reassembly
5. INSTALL PARKING BRAKE SHOE LEVER SUB-ASSEMBLY LH See: Brakes and Traction
Control/Parking Brake System/Service and
Repair/Reassembly
6. INSTALL NO. 2 PARKING BRAKE SHOE ASSEMBLY LH See: Brakes and Traction
Control/Parking Brake System/Service and
Repair/Reassembly
7. INSTALL NO. 1 PARKING BRAKE SHOE ASSEMBLY LH See: Brakes and Traction
Control/Parking Brake System/Service and
Repair/Reassembly
8. INSTALL PARKING BRAKE SHOE RETURN TENSION SPRING LH See: Brakes and Traction
Control/Parking Brake System/Service and
Repair/Reassembly
9. CHECK PARKING BRAKE INSTALLATION See: Brakes and Traction Control/Parking Brake
System/Service and Repair/Reassembly
10. INSTALL REAR DISC LH See: Brakes and Traction Control/Disc Brake System/Service and
Repair/Removal and Replacement/Rear
Brake/Installation
11. ADJUST PARKING BRAKE SHOE CLEARANCE See: Brakes and Traction Control/Parking
Brake System/Adjustments
12. CONNECT REAR DISC BRAKE CYLINDER ASSEMBLY LH
(a) Connect the rear disc brake cylinder and install 2 new bolts.
Torque : 95 Nm (969 kgf-cm, 70 ft-lbf)
NOTICE: *
Do not twist the flexible hose.
* Make sure that the bolts are free from damage and foreign matter.
* Do not overtighten the bolts.
13. CONNECT REAR BRAKE FLEXIBLE HOSE
(a) Set the flexible hose to the connecting point with the brake tube, and then install a new clip.
Page 7021
*: for 5 leaf spring
Standard Toe-in
for Regular Cab of Standard Deck
Page 8384
between other parts.
(d) Check that there is no looseness in the installation parts of the side airbag sensor.
(e) Connect the connector.
9. INSTALL FRONT DOOR SCUFF PLATE LH (for Rear Side) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Installation
10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
11. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Air Bag Systems/Testing and Inspection/Initial Inspection
and Diagnostic Overview/Diagnosis System.
Components
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Column
Shift Type): COMPONENTS
Page 7261
Steering Column Control Module: Service and Repair Removal
STEERING COLUMN: MULTIPLEX TILT AND TELESCOPIC ECU (for Power Tilt and Power
Telescopic Steering Column): REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE UPPER STEERING COLUMN COVER
(a) Remove the 2 screws.
HINT Turn the steering wheel to the right and left as necessary to remove the 2 screws.
(b) Detach the 4 clips.
(c) Detach the claw to remove the upper steering column cover.
3. REMOVE LOWER STEERING COLUMN COVER
(a) Detach the 2 claws to remove the lower steering column cover.
4. REMOVE HOOD LOCK CONTROL LEVER SUB-ASSEMBLY See: Body and Frame/Doors,
Hood and Trunk/Hood/Hood Latch Release
Cable/Service and Repair/Removal
5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Removal
Page 317
Body Control Module: Diagrams
Page 7918
Air Bag: Testing and Inspection Front Seat Side Airbag Assembly (for Fold Down Seat Type)
SUPPLEMENTAL RESTRAINT SYSTEM: FRONT SEAT SIDE AIRBAG ASSEMBLY (for Fold
Down Seat Type): ON-VEHICLE INSPECTION
1. CHECK FRONT SEAT SIDE AIRBAG ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION)
(a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnosis System.
(b) With the front seat side airbag installed on the vehicle, perform a visual check. If there are any
defects as mentioned below, replace the front
seat with a new one:
Cuts, minute cracks or marked discoloration on the front seatback around the front seat side
airbag.
2. CHECK FRONT SEAT SIDE AIRBAG ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND
AIRBAG HAS NOT DEPLOYED)
(a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnosis System.
(b) With the front seat side airbag removed from the vehicle, perform a visual check. If there are
any defects as mentioned below, replace the front
seat side airbag with a new one:
* Cuts, minute cracks or marked discoloration on the front seat side airbag.
* Cracks or other damage to the wire harness or connector.
CAUTION: For removal and installation procedures of the front seat side airbag, be sure to follow
the correct procedure.
Page 1976
Engine Room R/B, J/B - Engine Compartment Left
Page 4181
Testing and Inspection
Thermostat: Testing and Inspection
1UR-FE COOLING: THERMOSTAT: INSPECTION
1. INSPECT WATER INLET SUB-ASSEMBLY WITH THERMOSTAT
HINT The valve opening temperature is stamped on the water inlet with thermostat.
(a) Immerse the water inlet with thermostat in water and gradually heat the water.
(b) Check the valve opening temperature.
Standard valve opening temperature:
80 to 84°C (176 to 183°F)
(c) If the valve opening temperature is not within the specified range, replace the water inlet
sub-assembly with thermostat.
(d) Check the valve lift.
Standard valve lift:
10 mm (0.394 in.) or more at 95°C (203°F)
(e) If the valve lift is not as specified, replace the water inlet sub-assembly with thermostat.
(f) Check that the valve is fully closed when the water inlet with thermostat is at a low temperature
(below 77°C (171°F)).
If it is not fully closed, replace the water inlet sub-assembly with thermostat.
Locations
Leak Detection Pump: Locations
1UR-FE EMISSION CONTROL: EMISSION CONTROL SYSTEM: PARTS LOCATION
Page 4298
2. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in
Figure 1. Confirm if the ECM (PCM) calibration has
been updated. If the calibration ID listed is NOT the latest ECM (PCM) calibration - go to step 3.
3. Flash reprogram the ECM (PCM).
NOTE
^ The GR8 Battery Diagnostic Station MUST be used in Power Supply Mode to maintain battery
voltage at 13.5 volts while flash reprogramming the vehicle.
^ For details on how to use the GR8 Battery Diagnostic Station, refer to the located on the
Technical Information System (TIS), Diagnostics - Battery
Follow the procedures outlined in TSB No. T-SB-0064-10, "Techstream ECU Flash
Reprogramming Procedure1⁄4 and flash the ECM (PCM) with the NEW calibration file update.
4. Install the Authorized Modifications Label.
A. Using a permanent marker enter the following information on the label:
^ ECM part number [Refer to the Parts Information section for the CURRENT PART NUMBER]
^ Calibration ID(s) [Refer to the Calibration Identification Chart for the NEW CALIBRATION ID]
^ Dealer Code
^ Repair Date
^ Change Authority [This TSB number]
B. Affix the Authorized Modifications Label to the vehicle at the location shown in Figure 1. The
Authorized Modifications Label is available
through the MDC P/N 00451-00001-LBL.
5. Test drive the vehicle to confirm proper vehicle operation.
Page 7912
Air Bag: Diagrams Curtain Shield Airbag Squib Circuit
Page 7067
(a) Check the steering angle sensor zero point calibration See: Powertrain
Management/Computers and Control Systems/Testing and
Inspection/Diagnostic Trouble Code Tests and Associated Procedures/C Code Charts/C1290.
Page 6850
Tailgate Wire
Front Seat Wire
Page 5518
Transmission Mode Switch: Diagrams Tow/Haul Pattern Select Switch
Page 3591
B -- GO TO VC OUTPUT CIRCUIT See: Testing and Inspection/Component Tests and General
Diagnostics/VC Output Circuit A -- Continue to next step.
7. CHECK HARNESS AND CONNECTOR (COMBINATION METER - ECM)
(a) Disconnect the ECM connector.
(b) Disconnect the combination meter connector.
(c) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- REPLACE COMBINATION METER ASSEMBLY See: Instrument Panel, Gauges and
Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Combination Meter/Removal
Page 4042
(1) Disconnect the clamp and No. 3 air injection system hose.
(2) Using a clip remover, remove the clamp from the body panel.
(b) Front Fender RH Inside:
(1) Disconnect the No. 3 air injection system hose from the air pump.
(2) Using a clip remover, remove the clamp from the body panel.
5. REMOVE AIR PUMP ASSEMBLY WITH BRACKET
(a) Disconnect the 2 air pump connectors and detach the 3 wire harness claws.
(b) Remove the 2 bolts, 2 nuts and air pump.
6. REMOVE AIR PUMP INLET
(a) Remove the 2 bolts, slide the 2 clips off of the No. 1 air injection system hoses, disconnect the
hoses and remove the air pump inlet.
7. DISCONNECT NO. 1 AIR INJECTION SYSTEM HOSE
(a) Disconnect the 2 No. 1 air injection system hoses.
8. REMOVE AIR PUMP ASSEMBLY
(a) Using a clip remover, detach the 2 clamps and remove the air pump from the bracket.
Page 3075
"Case1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (/\ Mark) and pull the terminal retainer
up to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Locations
Door Sensor/Switch (For Alarm): Locations
THEFT DETERRENT: THEFT DETERRENT SYSTEM: PARTS LOCATION
Page 3796
Crankshaft Position Sensor: Locations Ignition System
1UR-FE IGNITION: IGNITION SYSTEM: PARTS LOCATION
Page 5915
Torque : 13 Nm (127 kgf-cm, 9 ft-lbf)
NOTICE: *
When installing the clamp, do not twist the wire harness.
* Make sure the clamp's rotation stopper touches the installation position.
(d) Attach the 3 clips (labeled E).
NOTICE: *
When installing the clips, do not twist the wire harness.
* When installing the clips, securely insert them as shown in the illustration.
(e) Connect the speed sensor connector (labeled F).
NOTICE: Securely connect the connector.
4. INSTALL FRONT SKID CONTROL SENSOR CLAMP RH
(a) Install the skid control sensor clamp (labeled A) with the bolt (labeled B).
Torque : 13 Nm (127 kgf-cm, 9 ft-lbf)
NOTICE: Install the bracket so that the rotation stopper (labeled C) touches the knuckle.
5. INSTALL FRONT SPEED SENSOR RH
(a) Install the speed sensor (labeled D) with the hexagon socket head cap bolt (labeled E).
Locations
Shift Interlock Control Module: Locations
Instrument Panel (Floor Shift)
Instrument Panel (Column Shift)
Page 7642
Push the terminal retainer down to the temporary lock position.
Page 7645
Establish conditions in which voltage is present at the check point.
Example:
- [A] - Ignition SW on
- [B] - Ignition SW and SW1 on
- [C] - Ignition SW, SW1 and Relay on (SW2 off)
Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or component terminal.
This check can be done with a test light instead of a voltmeter.
Electronic Circuit Inspection Procedure
Page 3355
Page 2815
(e) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR OK -- Continue to next step.
6. INSPECT IGNITION SWITCH See: Computers and Control Systems/Testing and
Inspection/Diagnostic Trouble Code Tests and Associated
Procedures/P Code Charts/P0617
NG -- REPLACE IGNITION SWITCH See: Ignition System/Sensors and Switches - Ignition
System/Ignition Switch/Service and Repair/Removal OK -- Continue to next step.
7. CHECK HARNESS AND CONNECTOR (INTEGRATION RELAY - ECM, BATTERY AND BODY
GROUND)
(a) Disconnect the ECM connector.
(b) Disconnect the cable from the battery positive terminal.
(c) Remove the integration relay from the engine room relay block.
(d) Disconnect the integration relay connectors.
Airbag Cutoff Switch
Air Bag Deactivation Switch: Diagrams Airbag Cutoff Switch
Page 70
Removal
DOOR LOCK: DOOR CONTROL RECEIVER (for Double Cab): REMOVAL
1. REMOVE LUGGAGE COMPARTMENT SIDE COVER SUB-ASSEMBLY LH See: Body and
Frame/Seats/Service and Repair/Removal and
Replacement/Rear Seat Assembly (for Double Cab)/Removal
2. REMOVE LUGGAGE COMPARTMENT SIDE COVER SUB-ASSEMBLY RH See: Body and
Frame/Seats/Service and Repair/Removal and
Replacement/Rear Seat Assembly (for Double Cab)/Removal
3. REMOVE SEAT FLOOR BOX See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Rear Seat Assembly (for Double
Cab)/Removal
4. REMOVE REAR SEAT ASSEMBLY See: Body and Frame/Seats/Service and Repair/Removal
and Replacement/Rear Seat Assembly (for
Page 2557
2. Install ChaSSiSEAR(TM) on the vehicle and attempt to isolate the source of the noise. Is the
noise loudest near the rear wheel bearing assembly?
^ YES - Go to step 3.
^ NO - This TSB does NOT apply. Continue diagnosis to isolate the source of the noise.
3. Replace the rear wheel bearing caliper bracket and related parts.
Refer to the Technical Information System (TIS) applicable model year Repair Manual:
4. Test drive the vehicle and confirm the noise is eliminated.
5. Re-check rear differential oil level and confirm NO leaks are present.
Page 5404
Fluid - Transfer Case: Service and Repair
JF1A TRANSFER: TRANSFER OIL: REPLACEMENT
1. DRAIN TRANSFER OIL
(a) Remove the 4 bolts and lower transfer case protector.
(b) Remove the filler plug and gasket.
(c) Remove the drain plug and gasket, and drain the transfer oil.
2. ADD TRANSFER OIL
(a) Install a new gasket and the drain plug.
Torque : 37 Nm (377 kgf-cm, 27 ft-lbf)
(b) Pour oil so that the oil level is between 0 to 5.0 mm (0 to 0.197 in.) from the bottom lip of the
filler plug hole.
NOTICE: *
Pour oil slowly.
* Pour oil a little at a time, waiting several minutes between each addition of oil.
(c) Wait approximately 5 minutes and check that the oil level has not changed.
(d) Install a new gasket and the filler plug.
Torque : 37 Nm (377 kgf-cm, 27 ft-lbf)
(e) Install the lower transfer case protector with the 4 bolts.
Torque : 18 Nm (184 kgf-cm, 13 ft-lbf)
Locations
Transmission Mode Switch: Locations
A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS
LOCATION
Page 8442
Antenna, Radio: Service and Repair Satellite Radio Antenna
Components
AUDIO / VISUAL: SATELLITE RADIO ANTENNA: COMPONENTS
Removal
AUDIO / VISUAL: SATELLITE RADIO ANTENNA: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE ROOF HEADLINING ASSEMBLY
(a) for Double Cab:
Remove the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Double Cab)/Removal.
(b) for CrewMax:
Remove the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (for CrewMax)/Removal.
(c) for Regular Cab:
Remove the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Removal.
3. REMOVE SATELLITE RADIO ANTENNA ASSEMBLY
(a) Disconnect the connector.
(b) Detach the 3 clamps.
(c) Remove the nut.
Page 5957
Release the locking lug from terminal and pull the terminal out from rear.
INSTALL TERMINAL TO CONNECTOR
Insert the terminal.
HINT: Make sure the terminal is positioned correctly.
Insert the terminal until the locking lug locks firmly.
Insert the terminal with terminal retainer in the temporary lock position.
Page 5978
Page 7054
Standard camber inclination (unloaded vehicle):
for Double Cab of Long Deck
Page 6945
Relay Box: Electrical Diagrams
Engine Room R/B And Engine Room J/B Inner Circuit
Page 7078
6. REMOVE LOWER NO. 1 INSTRUMENT PANEL AIR BAG ASSEMBLY See: Restraint
Systems/Air Bag Systems/Air Bag/Service and
Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Removal
7. REMOVE NO. 1 AIR DUCT SUB-ASSEMBLY See: Steering/Steering Column/Service and
Repair/Removal and Replacement/Steering Column
Assembly (for Manual Tilt)/Removal
8. REMOVE MULTIPLEX TILT AND TELESCOPIC ECU
(a) Disconnect the 2 ECU connectors.
(b) Remove the 2 screws and ECU.
Page 7088
Steering Control Module: Service and Repair Installation
POWER STEERING: POWER STEERING ECU (for 1UR-FE): INSTALLATION
1. INSTALL POWER STEERING ECU ASSEMBLY
(a) Install the power steering ECU with the nut.
Torque : 8.5 Nm (87 kgf-cm, 75 in-lbf)
(b) Connect the power steering ECU connector.
2. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column
Shift Type)/Installation
3. INSTALL LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY See: Restraint
Systems/Air Bag Systems/Air Bag/Service and
Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Installation
4. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Installation
5. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
6. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Installation
7. INSTALL FRONT DOOR SCUFF PLATE LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining
(For Regular Cab)/Installation
Page 6473
Release the locking lug from terminal and pull the terminal out from rear.
INSTALL TERMINAL TO CONNECTOR
Insert the terminal.
HINT: Make sure the terminal is positioned correctly.
Insert the terminal until the locking lug locks firmly.
Insert the terminal with terminal retainer in the temporary lock position.
Page 7870
7. INSTALL DAMPER SERVO SUB-ASSEMBLY
(a) Install the damper servo with the 3 screws.
(b) Connect the connector.
8. INSTALL DAMPER SERVO SUB-ASSEMBLY
(a) Install the servo motor.
(1) Set the plate so that the cutout part engages with the tooth of the gear, and attach the claw to
install the main plate.
(2) Install the 2 screws.
(b) Install the servo motor.
Air Conditioning System (for Automatic Air Conditioning
System)
Compressor Speed Sensor: Locations Air Conditioning System (for Automatic Air Conditioning
System)
AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Automatic Air Conditioning System):
PARTS LOCATION
Page 3179
Air Flow Meter/Sensor: Testing and Inspection On-Vehicle Inspection
1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: ON-VEHICLE INSPECTION
1. CHECK MASS AIR FLOW METER
(a) Check the mass air flow value.
(1) Connect the Techstream to the DLC3.
(2) Turn the ignition switch to ON.
(3) Turn the Techstream main switch ON.
(4) Enter the following menus: Powertrain / Engine / Data List / All Data / MAF.
(5) Blow air into the MAF meter, and check that the MAF value fluctuates.
(6) If the result is not as specified, check the MAF meter See: Inspection, or wiring and ECM See:
Testing and Inspection/Diagnostic
Trouble Code Tests and Associated Procedures/P Code Charts/P0102.
Page 2970
Removal
1UR-FE ENGINE CONTROL SYSTEM: AIR FUEL RATIO SENSOR: REMOVAL
CAUTION: *
Wear protective gloves when removing the exhaust pipe.
* The exhaust pipe is extremely hot immediately after the engine has stopped.
* Confirm that the exhaust pipe has cooled down before removing it.
1. REMOVE TAILPIPE ASSEMBLY See: Engine, Cooling and Exhaust/Exhaust System/Exhaust
Pipe/Service and Repair/Exhaust Pipe (for
Regular Cab Standard Deck)/Removal
2. REMOVE CENTER EXHAUST PIPE ASSEMBLY See: Engine, Cooling and Exhaust/Exhaust
System/Exhaust Pipe/Service and
Repair/Exhaust Pipe (for Regular Cab Standard Deck)/Removal
3. REMOVE FRONT EXHAUST PIPE ASSEMBLY
(a) Disconnect the heated oxygen sensor connector and 2 clamps.
(b) Disconnect the air fuel ratio sensor connector.
(c) Remove the 3 nuts, front exhaust pipe and gasket from the exhaust manifold RH.
4. REMOVE AIR FUEL RATIO SENSOR (for Bank 2 Sensor 1)
(a) Using SST, remove the sensor.
SST : 09224-00010
Page 8211
The check should be performed with the outer belt installed.
(1) When the belt is pulled out fully, the belt should automatically start to retract.
(2) After the belt has fully retracted, the belt should be able to be pulled out and retracted again.
If the operation is not as specified, replace the belt assembly.
Front Seat Outer Belt Assembly (for CrewMax)
SEAT BELT: FRONT SEAT OUTER BELT ASSEMBLY (for CrewMax): INSPECTION
1. INSPECT FRONT SEAT OUTER BELT ASSEMBLY
CAUTION: Do not disassemble the retractor.
(a) Before installing the seat belt, check the ELR.
(1) When the inclination of the retractor is 15° or less, check that the belt can be pulled from the
retractor. When the inclination of the retractor
is over 45°, check that the belt locks. If the operation is not as specified, replace the seat belt
assembly.
(b) for Passenger's Seat only:
Check the fastening function of the child restraint system.
NOTICE: The check should be performed with the outer belt installed.
(1) When the belt is pulled out fully, the belt should automatically start to retract.
(2) After the belt has fully retracted, the belt should be able to be pulled out and retracted again.
If the operation is not as specified, replace the belt assembly.
Front Seat Outer Belt Assembly (for Double Cab)
SEAT BELT: FRONT SEAT OUTER BELT ASSEMBLY (for Double Cab): INSPECTION
1. INSPECT FRONT SEAT OUTER BELT ASSEMBLY
CAUTION: Do not disassemble the retractor.
(a) Before installing the seat belt, check the ELR.
(1) When the inclination of the retractor is 15° or less, check that the belt can be pulled from the
retractor. When the inclination of the retractor
Recall 10V017000: Accelerator Pedal Sticking
Accelerator Pedal Position Sensor: Recalls Recall 10V017000: Accelerator Pedal Sticking
VEHICLE MAKE/MODEL: MODEL YEAR(S): Toyota/Avalon 2005-2010 Toyota/Camry 2007-2010
Toyota/Corolla 2009-2010 Toyota/Corolla Matrix 2009-2010 Toyota/Highlander 2010 Toyota/ RAV4
2009-2010 Toyota/Sequoia 2008-2010 Toyota/Tundra 2007-2010 MANUFACTURER: Toyota
Motor North America, Inc.
MFR'S REPORT DATE: January 21, 2010
NHTSA CAMPAIGN ID NUMBER: 10V017000
NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Accelerator Assembly:
Pedal/Linkage
POTENTIAL NUMBER OF UNITS AFFECTED: ?
SUMMARY: Toyota is recalling certain model year 2005-2010 Avalon, model year 2007-2010
Camry, model year 2009-2010 Corolla, Corolla Matrix, RAV4, model year 2010 Highlander, model
year 2008-2010 Sequoia, and model year 2007-2010 Tundra. due to the manner in which the
friction lever interacts with the sliding surface of the accelerator pedal inside the pedal sensor
assembly, the sliding surface of the lever may become smooth during vehicle operation. In this
condition, if condensation occurs on the surface, as may occur from heater operation (without A/C)
when the pedal assembly is cold, the friction when the accelerator pedal is operated may increase,
which may result in the accelerator pedal becoming harder to depress, slower to return, or, in the
worst case, mechanically stuck in a partially depressed position.
CONSEQUENCE: The accelerator pedal may become hard to depress, slow to return to idle, or, in
the worst case, mechanically stuck in a partially depressed position, increasing the risk of a crash.
REMEDY: Toyota has not yet provided a remedy plan or an owner notification schedule. Owners
may contact Toyota at 1-800-331-4331.
NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle
Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov.
Locations
Switch: Locations
JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION
Locations
Shock Sensor: Locations
THEFT DETERRENT: THEFT DETERRENT SYSTEM: PARTS LOCATION
Page 1480
"Case2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Diode (Front Door Courtesy Light)
Diode: Diagrams Diode (Front Door Courtesy Light)
Page 6286
* In the DTC check, it is very important to determine whether the problem indicated by the DTC is
either: 1) still occurring; or 2) occurred in the past but has since returned to normal. In addition, the
DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs
should be checked before and after confirmation of symptoms (i.e., whether or not problem
symptoms exist) to determine current system conditions, as shown in the flowchart below.
* Never skip the DTC check. Failing to check DTCs may, depending on the case, result in
unnecessary troubleshooting for systems operating normally or lead to repairs not related to the
problem. Follow the procedures listed in the flowchart in the correct order.
* The following flowchart shows how to proceed with troubleshooting using the DTC check.
Directions from the flowchart will indicate how to proceed either to DTC troubleshooting or to the
troubleshooting of each problem symptom.
1. DTC CHECK
NEXT -- Continue to next step.
2. MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR MEMORY
NEXT -- Continue to next step.
3. SYMPTOM CONFIRMATION
B -- Go to step 5 A -- Continue to next step.
4. SIMULATION TEST USING SYMPTOM SIMULATION METHODS
NEXT -- Continue to next step.
5. DTC CHECK
B -- TROUBLESHOOTING OF PROBLEM INDICATED BY DTC A -- Continue to next step.
6. SYMPTOM CONFIRMATION
Page 5912
(d) Remove the 3 bolts (labeled E), 3 harness clamps (labeled F) and sensor wire.
4. REMOVE FRONT SPEED SENSOR LH
(a) Remove the hexagon socket head cap bolt (labeled A) and speed sensor (labeled B) from the
knuckle.
5. REMOVE FRONT SKID CONTROL SENSOR CLAMP LH
(a) Remove the bolt (labeled C) and skid control sensor clamp (labeled D) from the knuckle.
6. REMOVE FRONT SKID CONTROL SENSOR WIRE RH
(a) Disconnect the connector (labeled A) from the front speed sensor.
(b) Detach the 3 clips (labeled B) and remove the clamp bolt (labeled C).
Page 283
General Information
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: GENERAL
INFORMATION
* A large number of ECU controlled systems are used in the TOYOTA TUNDRA. In general, ECU
controlled systems are considered to be very intricate, requiring a high level of technical knowledge
to troubleshoot. However, most problem checking procedures only involve inspecting the ECU
controlled system's circuits one by one. An adequate understanding of the system and a basic
knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and
necessary repairs.
1. TROUBLESHOOTING PROCEDURES
* The troubleshooting procedures consist of diagnosis procedures for when a DTC is stored and
diagnosis procedures for when no DTC is stored. The basic idea is explained in the following table.
* Vehicle systems are complex and use many ECUs that are difficult to inspect independently.
Therefore, a process of elimination is used, where components that can be inspected individually
are inspected, and if no problems are found in these components, the related ECU is identified as
the problem and replaced.
* It is extremely important to ask the customer about the environment and the conditions present
when the problem occurred (Customer Problem Analysis). This makes it possible to simulate the
conditions and confirm the symptom. If the symptom cannot be confirmed or the DTC does not
recur, the malfunctioning part may not be identified using the troubleshooting procedure, and the
ECU for the related system may be replaced even though it is not defective. If this happens, the
original problem will not be solved.
* In order to prevent endless expansion of troubleshooting procedures, the troubleshooting
procedures are written with the assumption that multiple malfunctions do not occur simultaneously
for a single problem symptom.
* To identify the malfunctioning part, troubleshooting procedures narrow down the target by
separating components, ECUs and wire harnesses during the inspection. If the wire harness is
identified as the cause of the problem, it is necessary to inspect not only the connections to
components and ECUs but also all of the wire harness connectors between the component and the
ECU.
DIAGNOSTIC TESTER
2. DESCRIPTION
System data and the Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector
3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the Techstream* to
check for a malfunction and perform repairs.
HINT *: Techstream is the name for the diagnostic tester in North America.
3. DATA LINK CONNECTOR 3 (DLC3)
(a) The vehicle's ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of
the DLC3 complies with SAE J1962 and
matches the ISO 15765-4 format.
Page 4348
(c) Check for leakage.
(1) In the condition above, disconnect the tester probes of SST (wire) from the battery and check
for fuel leakage from the injector.
Standard fuel drop:
1 drop or less in 12 minutes
Page 3249
Data Link Connector: Connector Views
Page 3371
"Case1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (/\ Mark) and pull the terminal retainer
up to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Page 7496
Tire Pressure Sensor: Service and Repair Removal
TIRE AND WHEEL: TIRE PRESSURE WARNING VALVE AND TRANSMITTER: REMOVAL
1. REMOVE TIRE
2. REMOVE TIRE PRESSURE WARNING VALVE AND TRANSMITTER
(a) Remove the valve core and cap, and release the air from the tire.
(b) After ensuring that a sufficient amount of air has been released, remove the nut and washer
that is used to secure the tire pressure warning
valve and transmitter. Then drop the tire pressure warning valve and transmitter inside the tire.
HINT Keep the removed cap, valve core, nut and washer.
(c) Disengage the bead using the shoe of a tire remover.
NOTICE: Be careful as the tire pressure warning valve and transmitter may become damaged due
to interference between the sensor and tire bead.
(d) Remove the bead on the upper side.
(e) Take out the tire pressure warning valve and transmitter from the tire, then remove the bead on
the lower side.
HINT *
The grommet is a non-reusable part.
* Check that there are no cracks or damage on the grommet. If any damage is found, replace the
washer and nut.
Page 1332
(2) CONNECTORS
Slightly shake the connector vertically and horizontally.
(3) WIRE HARNESS
Slightly shake the wire harness vertically and horizontally.
HINT The connector joint and fulcrum of the vibration are the major areas that should be checked
thoroughly.
(b) HEAT METHOD:
When a malfunction seems to occur when the area in question is heated.
(1) Heat the component that is the possible cause of the malfunction with a hair dryer or similar
device. Check if the malfunction occurs.
NOTICE: *
Do not heat to more than 60°C (140°F). Exceeding this temperature may damage components.
* Do not apply heat directly to the parts in the ECU.
(c) WATER SPRINKLING METHOD:
When a malfunction seems to occur on a rainy day or in high-humidity.
(1) Sprinkle water onto the vehicle and check if the malfunction occurs.
NOTICE: *
Never sprinkle water directly into the engine compartment. Indirectly change the temperature and
humidity by spraying water onto the front of the radiator.
* Never apply water directly onto the electronic components.
HINT If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU
or connections. Look for evidence of corrosion or short circuits. Proceed with caution during water
tests.
(d) HIGH ELECTRICAL LOAD METHOD:
When a malfunction seems to occur when the electrical load is excessive.
(1) Turn on the heater blower, headlights, rear window defogger and all other electrical loads.
Check if the malfunction reoccurs.
5. DIAGNOSTIC TROUBLE CODE CHART
Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate
section's Diagnostic Trouble Code Chart. Use the chart to determine the trouble area and the
proper inspection procedure. A description of each of the chart's columns is below.
Page 3846
Removal
1UR-FE ENGINE CONTROL SYSTEM: AIR FUEL RATIO SENSOR: REMOVAL
CAUTION: *
Wear protective gloves when removing the exhaust pipe.
* The exhaust pipe is extremely hot immediately after the engine has stopped.
* Confirm that the exhaust pipe has cooled down before removing it.
1. REMOVE TAILPIPE ASSEMBLY See: Engine, Cooling and Exhaust/Exhaust System/Exhaust
Pipe/Service and Repair/Exhaust Pipe (for
Regular Cab Standard Deck)/Removal
2. REMOVE CENTER EXHAUST PIPE ASSEMBLY See: Engine, Cooling and Exhaust/Exhaust
System/Exhaust Pipe/Service and
Repair/Exhaust Pipe (for Regular Cab Standard Deck)/Removal
3. REMOVE FRONT EXHAUST PIPE ASSEMBLY
(a) Disconnect the heated oxygen sensor connector and 2 clamps.
(b) Disconnect the air fuel ratio sensor connector.
(c) Remove the 3 nuts, front exhaust pipe and gasket from the exhaust manifold RH.
4. REMOVE AIR FUEL RATIO SENSOR (for Bank 2 Sensor 1)
(a) Using SST, remove the sensor.
SST : 09224-00010
Page 9330
This TSB applies to all Sequoia and Tundra vehicles equipped with lUR-FE (4.6L) 2UZ-FE (4.7L)
and 3UR-FE/FBE (5.7L) engines produced BEFORE the Production Change Effective VINs shown.
Repair Procedure
1. Remove and replace the air cleaner lid.
2. Remove and replace the front right hand (RH) fender liner.
Page 6014
(b) If necessary, replace the generator rotor assembly.
Page 1029
Brake Light Switch: Testing and Inspection
LIGHTING: STOP LIGHT SWITCH: INSPECTION
1. INSPECT STOP LIGHT SWITCH ASSEMBLY
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the switch assembly.
Page 3430
NEXT -- Continue to next step.
7. CHECK FOR SHORT IN CAN BUS WIRES (NO. 1 JUNCTION CONNECTOR - COMBINATION
METER ECU)
(a) Disconnect the J84 No. 1 junction connector connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- CHECK FOR SHORT IN CAN BUS WIRES (COMBINATION METER ECU) OK -- Continue
to next step.
8. CHECK FOR SHORT IN CAN BUS WIRES (NO. 1 JUNCTION CONNECTOR - MAIN BODY
ECU)
(a) Disconnect the J96 No. 1 junction connector connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- CHECK FOR SHORT IN CAN BUS WIRES (MAIN BODY ECU) OK -- Continue to next step.
9. CHECK FOR SHORT IN CAN BUS WIRES (NO. 1 JUNCTION CONNECTOR - SKID
CONTROL ECU WITH ACTUATOR)
(a) Disconnect the A46 No. 1 junction connector connector.
Page 4543
Knock Sensor: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: INSTALLATION
1. INSTALL KNOCK SENSOR
(a) Install the 4 sensors with the 4 bolts so that the sensors are angled as shown in the illustration.
Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)
NOTICE: The acceptable installation angle of the sensor is between 10° upward and downward
from the horizontal position.
(b) Connect the 4 sensor connectors.
2. INSTALL SEPARATOR CASE
(a) Install the separator case with the 4 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
3. INSTALL INTAKE MANIFOLD
(a) Install the intake manifold See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service
and Repair/Installation.
Page 3483
A -- Continue to next step.
5. CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (SKID CONTROL ECU WITH
ACTUATOR BRANCH WIRE)
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE CAN BRANCH WIRE OR CONNECTOR (SKID CONTROL ECU
WITH ACTUATOR)
OK -- REPLACE SKID CONTROL ECU WITH ACTUATOR See: Brakes and Traction
Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock
Brakes/Service and Repair/Removal and Replacement/Removal
6. CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (STEERING ANGLE SENSOR)
(a) Disconnect the J6 steering angle sensor connector.
(b) Reconnect the cable to the negative (-) battery terminal.
(c) Select "CAN Bus Check" on the Techstream.
Result
B -- CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (BUS BUFFER ECU) A -Continue to next step.
7. CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (STEERING ANGLE SENSOR
BRANCH WIRE)
(a) Measure the resistance according to the value(s) in the table below.
Page 422
Fuel Pump Control Unit: Locations Crew Max
Body
Specifications
Fuel Pressure: Specifications
FUEL PRESSURE
Page 1697
Alignment: Service and Repair
SUSPENSION: FRONT WHEEL ALIGNMENT: ADJUSTMENT
NOTICE: For vehicles equipped with VSC, if wheel alignment has been adjusted, and if suspension
or underbody components have been removed/installed or replaced, be sure to perform the
following initialization procedure in order for the system to function normally:
* Check that the steering wheel is in the centered position.
* Disconnect the negative battery terminal for more than 2 seconds.
* Reconnect the negative battery terminal.
* Perform zero point calibration of the yaw rate and deceleration sensor and test mode inspection
See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Testing and
Inspection/Programming and Relearning
1. INSPECT TIRE
(a) Inspect the tires See: Wheels and Tires/Testing and Inspection/Component Tests and General
Diagnostics.
2. MEASURE VEHICLE HEIGHT
NOTICE: Before inspecting the wheel alignment, adjust the vehicle height to the specification.
(a) Press down on the vehicle several times to stabilize the suspension, and then measure the
vehicle height.
Standard vehicle height (unloaded vehicle):
for Regular Cab of Standard Deck
Engine Control System - SFI System
Crankshaft Position Sensor: Locations Engine Control System - SFI System
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Stereo Jack Adapter Assembly (for Column Shift Type)
Auxiliary Input / Output Jack: Service and Repair Stereo Jack Adapter Assembly (for Column Shift
Type)
Components
AUDIO / VISUAL: STEREO JACK ADAPTER ASSEMBLY (for Column Shift Type):
COMPONENTS
Specifications
Axle Nut: Specifications
FRONT AXLE HUB NUT LH (for 4WD)
Using a 39 mm socket wrench, install the hub nut.
Torque..................................................................................................................................................
...............................338 Nm (3446 kgf-cm, 249 ft-lbf)
Components
Central Control Module: Service and Repair Components
AUDIO / VISUAL: MULTI-MEDIA INTERFACE ECU: COMPONENTS
Page 9110
[A] For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
"Case1" Raise the terminal retainer up to the temporary lock position.
Page 4327
Air Flow Meter/Sensor: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: REMOVAL
1. REMOVE MASS AIR FLOW METER
(a) Disconnect the MAF connector.
(b) Remove the 2 screws and MAF meter.
Page 7451
Tire Pressure Sensor: Service and Repair Disposal
TIRE AND WHEEL: TIRE PRESSURE WARNING VALVE AND TRANSMITTER: DISPOSAL
HINT The tire pressure warning valve is powered by a lithium battery. When disposing of the tire
pressure warning valve and transmitter, remove the battery and dispose of it correctly.
1. DISPOSE OF TIRE PRESSURE WARNING VALVE AND TRANSMITTER
(a) Use the tip of a screwdriver to pry off the back cover.
(b) The battery and base board are exposed. While taking out the battery, cut the 2 terminals that
connect the battery to the base board.
Page 6233
Page 8896
2. REMOVE REAR DOOR SCUFF PLATE RH
(a) Detach the 8 claws and 2 clips, and remove the scuff plate.
3. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP RH
4. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY RH See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (for CrewMax)/Removal
5. REMOVE DOOR CONTROL RECEIVER
(a) Disconnect the door control receiver connector.
(b) Remove the bolt and receiver.
Installation
DOOR LOCK: DOOR CONTROL RECEIVER (for CrewMax): INSTALLATION
1. INSTALL DOOR CONTROL RECEIVER
(a) Install the receiver with the bolt.
(b) Connect the door control receiver connector.
2. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY RH See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (for CrewMax)/Installation
3. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP RH
4. INSTALL REAR DOOR SCUFF PLATE RH
Page 4768
1. Test drive the vehicle and confirm there is a harsh shift on acceleration below 20 mph and or
excessive lock-up operation at freeway speeds about 50
- 60 mph.
2. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in
Figure 1. Confirm if the ECM (PCM) calibration has
been updated. If the calibration ID listed is NOT the latest ECM (PCM) calibration - go to step 3.
3. Flash reprogram the ECM (PCM).
NOTE
^ The GR8 Battery Diagnostic Station MUST be used in Power Supply Mode to maintain battery
voltage at 13.5 volts while flash reprogramming the vehicle.
^ For details on how to use the GR8 Battery Diagnostic Station, refer to the GR8 Instruction Manual
located on the Technical Information System (TIS), Diagnostics - Battery.
Follow the procedures outlined in TSB No. T-SB-0064-10, "Techstream ECU Flash
Reprogramming Procedure", and flash the ECM (PCM) with the NEW calibration file update.
4. Start the engine and warm it up to normal operating temperature before test driving.
5. Test drive the vehicle to confirm proper vehicle operation and ECM (PCM) initial learning. Refer
to the Technical Information System (TIS) 2010
Tundra Repair Manual:
Drivetrain - Automatic Transmission/Transaxle - "A760E / A760F Automatic
Transmission/Transaxle: Automatic Transmission System: Initialization"
6. Install the Authorized Modifications Label.
A. Using a permanent marker enter the following information on the label:
^ ECM part number [Refer to the Parts Information section for the CURRENT PART NUMBER]
Page 7606
Blower Motor: Connector Views
Page 4108
(m)Measure the fuel pressure.
Standard fuel pressure:
281 to 287 kPa (2.87 to 2.93 kgf/cm2, 41 to 42 psi)
(n) If the pressure is not as specified, check the fuel pump, pressure regulator and/or injectors.
(o) Stop the engine.
(p) Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped.
Standard fuel pressure:
147 kPa (1.5 kgf/cm2, 21 psi) or higher
(q) If the pressure is not as specified, check the fuel pump, pressure regulator and/or injectors.
(r) After checking the fuel pressure, disconnect the cable from the negative (-) battery terminal and
carefully remove SST and the fuel tube
connector to prevent gasoline from spraying.
(s) Reconnect the fuel tube (fuel tube connector).
(t) Check for fuel leak.
(1) Check that there are no fuel leaks after performing maintenance anywhere on the system.
If there are fuel leaks, repair or replace parts as necessary.
Page 6928
3. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE
HINT The diagnostic system in the TOYOTA TUNDRA has various functions.
* The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU
memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a
previous malfunction's DTC can be checked by a technician during troubleshooting.
* Another function is the Input Signal Check, which checks if the signals from various switches are
sent to the ECU correctly.
* By using these functions, the problem areas can be narrowed down and troubleshooting is more
effective. Diagnostic functions are incorporated in the following systems in the TOYOTA TUNDRA.
Page 8252
(a) Attach the 7 clips and 2 claws to install the pillar garnish.
(b) Install the seat belt anchor with the bolt.
Torque : 42 Nm (428 kgf-cm, 31 ft-lbf)
(c) Attach the 2 claws to install the cover.
4. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Double Cab)/Installation
5. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Double Cab)/Installation
6. INSTALL FRONT DOOR SCUFF PLATE See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Installation
7. INSTALL REAR DOOR SCUFF PLATE See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Installation
8. INSTALL FRONT SEAT ASSEMBLY
(a) for Manual Seat:
Install the front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Manual Seat)/Installation.
(b) for Power Seat:
Install the front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Power Seat)/Installation.
Page 6215
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
5. REMOVE POWER OUTLET SOCKET ASSEMBLY
(a) Using a screwdriver, detach the claw and remove the power outlet socket.
HINT Tape the screwdriver tip before use.
6. REMOVE POWER OUTLET SOCKET COVER
(a) Detach the 2 claws and remove the power outlet socket cover.
Installation
OTHER SYSTEM: POWER OUTLET SOCKET (for Floor Shift Type): INSTALLATION
1. INSTALL POWER OUTLET SOCKET COVER
(a) Attach the 2 claws to install the power outlet socket cover.
2. INSTALL POWER OUTLET SOCKET ASSEMBLY
(a) Attach the claw to install the power outlet socket.
3. INSTALL CENTER LOWER INSTRUMENT PANEL FINISH PANEL See: Body and
Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
Page 8253
9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Components
SEAT BELT: FRONT SEAT OUTER BELT ASSEMBLY (for Regular Cab): COMPONENTS
Locations
Power Steering Pressure Control Valve: Locations
POWER STEERING: POWER STEERING SYSTEM (for 1UR-FE): PARTS LOCATION
Locations
Starter Relay: Locations
1UR-FE STARTING: STARTING SYSTEM: PARTS LOCATION
Specifications
Power Steering Fluid: Specifications
Power Steering Fluid Type
Type
.........................................................................................................................................................
Automatic Transmission Fluid DEXRON II or III
Page 7169
Page 5302
NOTICE: When measuring dimension B, fix the spider and spider bearings in a vise and hold them
firmly together.
(d) w/o Grease Fitting Spider Bearing:
(1) Select snap rings to make dimensions A and B the same.
Snap ring type for steel yoke:
Snap ring type for aluminum yoke:
NOTICE: *
Use new snap rings.
* If possible, use snap rings of the same thickness for both sides.
(e) w/ Grease Fitting Spider Bearing:
(1) Select snap rings to make dimensions A and B the same.
Snap ring type:
NOTICE:
Page 7353
Suspension Spring ( Coil / Leaf ): Overhaul
Disassembly
SUSPENSION: REAR LEAF SPRING: DISASSEMBLY
1. REMOVE REAR SPRING LEAF BUSH
(a) Put matchmarks on the bush on the front side of the vehicle.
(1) Align the leaf spring with the openings and put matchmarks.
(b) Use SST and a press, press out the bushes on both sides of the vehicle.
SST : 09950-60010
09951-00350
SST : 09950-70010
09951-07150
NOTICE: Do not erase the matchmark on the leaf spring when removing the bush on the front side
of the vehicle.
Reassembly
SUSPENSION: REAR LEAF SPRING: REASSEMBLY
1. INSTALL REAR SPRING LEAF BUSH
Page 3175
Air Flow Meter/Sensor: Diagrams
Page 7750
Hose/Line HVAC: Service and Repair From 11/2009
AIR CONDITIONING: REFRIGERANT LINE: COMPONENTS
Page 8866
Alarm Module: Locations Theft Deterrent System
THEFT DETERRENT: THEFT DETERRENT SYSTEM: PARTS LOCATION
Page 8382
Door/Service and Repair/Front Door (for Regular Cab)/Disassembly
4. REMOVE FRONT DOOR WINDOW REGULATOR HANDLE ASSEMBLY (for Front Side) See:
Body and Frame/Doors, Hood and
Trunk/Doors/Front Door/Service and Repair/Front Door (for Regular Cab)/Disassembly
5. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH (for Front Side) See: Body
and Frame/Doors, Hood and
Trunk/Doors/Front Door/Service and Repair/Front Door (for Regular Cab)/Disassembly
6. REMOVE COURTESY LIGHT ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood
and Trunk/Doors/Front Door/Service and
Repair/Front Door (for Regular Cab)/Disassembly
7. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Regular Cab)/Disassembly
8. REMOVE FRONT SIDE AIRBAG SENSOR
(a) Disconnect the connector.
(b) Remove the screw and side airbag sensor.
9. REMOVE FRONT DOOR SCUFF PLATE LH (for Rear Side) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Removal
10. REMOVE REAR SIDE AIRBAG SENSOR
(a) Remove the bolt and side airbag sensor from the body.
(b) Disconnect the connector.
Installation
SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Regular Cab):
INSTALLATION
1. INSTALL FRONT SIDE AIRBAG SENSOR
(a) Check that the ignition switch is OFF.
Page 452
Page 7257
Steering Column Control Module: Diagrams
Page 5299
NOTICE: *
Use new snap rings.
* If possible, use snap rings of the same thickness for both sides.
(f) Temporarily install the spider and 2 universal joint spider bearings into the flange yoke.
(g) Using SST, press the universal joint spider bearing into the flange yoke until the groove can be
seen.
SST : 09950-40011
09951-04020
09952-04010
09953-04020
09954-04020
09955-04051
09957-04010
SST : 09950-60010
09951-00290
SST : 09336-16010
NOTICE: Confirm that the universal joint spider moves smoothly while pressing in the bearing.
(h) Using needle-nose pliers, install the previously selected snap ring into the groove of the yoke.
HINT
Locations
Power Distribution Module: Locations
Instrument Panel (Floor Shift)
Instrument Panel (Column Shift)
Page 1317
Release the locking lug from terminal and pull the terminal out from rear.
INSTALL TERMINAL TO CONNECTOR
Insert the terminal.
HINT: Make sure the terminal is positioned correctly.
Insert the terminal until the locking lug locks firmly.
Insert the terminal with terminal retainer in the temporary lock position.
Page 5168
Required Tools & Equipment
Repair Procedure Overview
^ Confirm noise is coming from the rear of the vehicle and changes with vehicle speed.
^ Install ChaSSiSEAR(TM) (or equivalent) and isolate the noise to the rear wheel bearing.
^ Remove the rear axle shaft assembly.
^ Install new rear wheel bearing brake caliper bracket and seals.
^ Reinstall rear axle shaft assembly and confirm the noise is no longer present.
Repair Procedure
1. Test drive the vehicle and confirm the customer complaint.
Does the noise increase and decrease with vehicle speed?
^ YES - Go to step 2.
^ NO - This TSB does NOT apply. Refer to the Repair Manual for further diagnosis.
Page 8103
Page 3548
NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- REPLACE MAIN BODY ECU
Skid Control ECU Communication Stop Mode
CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: Skid Control ECU Communication
Stop Mode - Skid Control ECU Communication Stop Mode
DESCRIPTION
WIRING DIAGRAM
INSPECTION PROCEDURE
HINT Operating the ignition switch, any switches or any doors triggers related ECU and sensor
communication with the CAN, which causes
Page 6657
(a) for AC Power Supply:
Connect the clamp.
(b) Install the bezel with the 3 screws.
5. INSTALL REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
Components
OTHER SYSTEM: POWER OUTLET SOCKET (for Floor Shift Type): COMPONENTS
Page 9385
8. With the cab still raised install the new No.3 cab mounts
9. Install the two bolts on top that were previously removed from the No.3 cab mount and torque to
specification.
Torque: 61 N*m (622 kgf*cm, 45 ft*lbf)
10. Lower the cab back onto the No.3 cab mount.
11. Install the new bolt through the No.3 cab mount and install the NEW larger washer and NEW
nut and torque to specifications.
Torque: 54 N*m (551 kgf*cm, 40 ft*lbf)
Locations
Manifold Pressure/Vacuum Sensor: Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 1824
NOTE
On some models, DTCs may set as a result of reprogramming. If DTCs are present, clear codes
and run the Health Check again. Troubleshoot any remaining Current, Pending, or History codes.
Permanent codes will not be cleared using Techstream. Permanent codes do not illuminate the MIL
and do not require troubleshooting. They will clear during normal driving once the Universal Trip
Drive Pattern is performed.
4. Attach the Authorized Modifications Label.
A. Using a permanent marker or ball point pen complete the Authorized Modifications Label and
attach to the vehicle. The Authorized
Modifications Label is available through the MDC P/N 00451-00001-LBL.
B. Attach the label under the hood in the location determined by the specific TSB or Campaign.
NOTE
Wait 60 - 90 seconds for ink to set before handling.
Page 7867
Evaporator Temperature Sensor / Switch: Service and Repair Reassembly
AIR CONDITIONING: FRONT EVAPORATOR TEMPERATURE SENSOR: REASSEMBLY
1. INSTALL NO. 1 COOLER THERMISTOR
NOTICE: If reusing the evaporator, do not insert the sensor into a location where the sensor was
previously inserted.
(a) Install the sensor to a location that is 1 fin to the right or left of its previous location.
2. INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY
(a) Install the evaporator to the blower case (front side).
(b) Install the blower case (back side).
Components
Control Module: Service and Repair Components
JF1A TRANSFER: 4WD CONTROL ECU: COMPONENTS
Page 9407
Standard:
2. INSTALL RADIATOR GRILLE (OR FRONT PANEL) EMBLEM
(a) Attach the 3 claws to install the radiator grille (or front panel) emblem.
Page 1407
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
4. REMOVE UPPER CONSOLE REAR PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
5. REMOVE REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
6. REMOVE CONSOLE BOX CARPET
7. REMOVE REAR CONSOLE BOX ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal
8. REMOVE FRONT CONSOLE BOX See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal
and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal
9. REMOVE CENTER AIRBAG SENSOR ASSEMBLY
(a) Disconnect the holder (with connectors).
(b) Remove the 3 bolts and airbag sensor.
Installation
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift
Type): INSTALLATION
1. INSTALL CENTER AIRBAG SENSOR ASSEMBLY
(a) Check that the ignition switch is OFF.
(b) Check that the cable is disconnected from the battery negative (-) terminal.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
(c) Install the airbag sensor with the 3 bolts.
Torque : 18 Nm (184 kgf-cm, 13 ft-lbf)
NOTICE: *
If the center airbag sensor has been dropped, or there are any cracks, dents or other defects in the
case, bracket or connector, replace it with a new one.
* When installing the center airbag sensor, be careful that the SRS wiring does not interfere with
other parts and that it is not pinched between other parts.
(d) Check that there is no looseness in the installation parts of the center airbag sensor.
Page 4613
Page 5992
Neutral Safety Switch: Service and Repair Installation
A760F AUTOMATIC TRANSMISSION: PARK / NEUTRAL POSITION SWITCH: INSTALLATION
1. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY
(a) Install the switch to the manual valve shaft.
(b) Temporarily install the bolt.
(c) Install a new lock washer and the nut.
Torque : 6.9 Nm (70 kgf-cm, 61 in-lbf)
(d) Temporarily install the control shaft lever RH.
(e) Turn the control shaft lever RH counterclockwise until it stops, and then turn it clockwise 2
notches to set it to the N position.
(f) Align the groove with the neutral basic line.
Page 7292
(d) Install the rack bush onto the power steering rack.
5. INSTALL CYLINDER END STOPPER
(a) Align the installation hole for the wire of the cylinder end stopper with the slot of the rack
housing.
(b) Install a new wire into the cylinder end stopper.
(c) Using a screwdriver, turn the cylinder end stopper clockwise by 400 to 500°.
6. AIR TIGHT TEST
(a) Install SST onto the rack housing.
(b) Apply a vacuum of 53 kPa (400 mmHg, 15.75 in.Hg) for about 30 seconds.
(c) Check that there is no change in the vacuum.
If there is any change in the vacuum, check whether the oil seals are installed correctly.
7. INSTALL POWER STEERING CONTROL VALVE UPPER OIL SEAL
(a) Coat the control valve upper bearing and a new control valve upper oil seal with power steering
fluid.
(b) Using SST and a press, install the control valve upper oil seal.
SST : 09950-60010
Page 955
Refrigerant Pressure Sensor / Switch: Service and Repair Installation
AIR CONDITIONING: PRESSURE SWITCH: INSTALLATION
1. INSTALL PRESSURE SWITCH
(a) Sufficiently apply compressor oil to a new O-ring and the fitting surface of the pressure switch.
Compressor oil:
ND-OIL 8 or equivalent
(b) Install the O-ring on the pressure switch.
(c) Install the switch.
Torque : 10.8 Nm (110 kgf-cm, 8 ft-lbf)
(d) Connect the connector.
2. CHARGE REFRIGERANT See: Heating and Air Conditioning/Service and Repair
3. WARM UP ENGINE See: Heating and Air Conditioning/Service and Repair
4. CHECK FOR LEAKAGE OF REFRIGERANT See: Heating and Air Conditioning/Service and
Repair
Page 8737
Additional SSTs may be ordered by calling 1-800-933-8335.
Repair Procedure
1. Verify the condition in the Introduction.
2. Perform diagnostic troubleshooting to confirm the problem is related to the condition described in
this TSB.
Refer to the Technical Information System (TIS), Accessory - Accessory Diagnostic Guide "2004-2011 All Vehicles XM Satellite Radio Tuner 86180-0W030 Troubleshooting Guide"
3. Order a replacement XM Satellite Radio Receiver through the Pioneer exchange program.
For information regarding the satellite radio warranty, refer to TIS, Reference Information Warranty Policy & Procedures -"Policy 4.28: Satellite Radio Warranty"
Locations
Trailer Lighting Relay: Locations
LIGHTING: LIGHTING SYSTEM: PARTS LOCATION
Page 3362
Locations
Relay Box: Locations
Engine Compartment
Page 7107
Tire Pressure Module: Service and Repair Removal
TIRE AND WHEEL: TIRE PRESSURE WARNING ECU: REMOVAL
NOTICE: *
It is necessary to perform initialization See: Wheels and Tires/Tire Monitoring System/Testing and
Inspection/Programming and Relearning/Initialization after registration See: Wheels and Tires/Tire
Monitoring System/Testing and Inspection/Programming and Relearning/Registration of the
transmitter IDs into the tire pressure warning ECU after the ECU has been replaced.
* When replacing the tire pressure warning ECU, read the transmitter IDs stored in the old ECU
using the intelligent tester or Techstream and write them down before removal.
1. REMOVE FRONT DOOR SCUFF PLATE RH (for Regular Cab)
(a) Remove the front door scuff plate RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Removal.
HINT Use the same procedures described for the LH side.
2. REMOVE FRONT DOOR SCUFF PLATE RH (for Double Cab, for CrewMax)
(a) Remove the front door scuff plate RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Removal.
HINT Use the same procedures described for the LH side.
3. REMOVE COWL SIDE TRIM BOARD RH
(a) Remove the cowl side trim board RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Removal.
HINT Use the same procedures described for the LH side.
4. REMOVE INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal
5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and
Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument
Panel Safety Pad (for Column Shift Type)/Removal
6. REMOVE TIRE PRESSURE WARNING ECU
(a) Disconnect the ECU connector.
(b) Remove the 2 nuts and ECU.
Page 601
Removal
PARK ASSIST / MONITORING: ULTRASONIC SENSOR (for Front Side): REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE FRONT END PANEL LH (for Resin Type Bumper) See: Body and
Frame/Bumper/Front Bumper/Service and Repair/Removal and
Replacement/Front Bumper (for Resin Type Bumper)/Removal
3. REMOVE FRONT END PANEL RH (for Resin Type Bumper) See: Body and
Frame/Bumper/Front Bumper/Service and Repair/Removal and
Replacement/Front Bumper (for Resin Type Bumper)/Removal
4. REMOVE FRONT BUMPER COVER (for Resin Type Bumper) See: Body and
Frame/Bumper/Front Bumper/Service and Repair/Removal and
Replacement/Front Bumper (for Resin Type Bumper)/Removal
5. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH (for Steel Type Bumper)
See: Body and Frame/Bumper/Front
Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Steel Type
Bumper)/Removal
6. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH (for Steel Type Bumper)
See: Body and Frame/Bumper/Front
Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Steel Type
Bumper)/Removal
7. REMOVE FRONT END PANEL LH (for Steel Type Bumper) See: Body and
Frame/Bumper/Front Bumper/Service and Repair/Removal and
Replacement/Front Bumper (for Steel Type Bumper)/Removal
8. REMOVE FRONT END PANEL RH (for Steel Type Bumper) See: Body and
Frame/Bumper/Front Bumper/Service and Repair/Removal and
Replacement/Front Bumper (for Steel Type Bumper)/Removal
9. REMOVE FRONT LOWER BUMPER COVER (for Steel Type Bumper) See: Body and
Frame/Bumper/Front Bumper/Service and
Repair/Removal and Replacement/Front Bumper (for Steel Type Bumper)/Removal
10. REMOVE FRONT BUMPER BAR (for Steel Type Bumper) See: Body and
Frame/Bumper/Front Bumper/Service and Repair/Removal and
Replacement/Front Bumper (for Steel Type Bumper)/Removal
11. REMOVE NO. 1 ULTRASONIC SENSOR
(a) While pushing down on the lever with a finger to release the one claw, detach the claw on the
other side to remove the ultrasonic sensor.
Capacity Specifications
Refrigerant: Capacity Specifications
REFRIGERANT
Standard...............................................................................................................................................
........................................600 +/-30 g (21.2 +/-1.1 oz.)
Page 6469
"Case2" Open the secondary locking device.
[B] For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray
Gray or White : Black
Page 5005
(a) Remove the 2 bolts and 2 temperature sensor clamps.
(b) Disconnect the 2 ATF temperature sensors.
(c) Disconnect the 9 solenoid valve connectors.
(d) Detach the wire harness from the 2 clamps.
5. REMOVE TRANSMISSION WIRE
(a) Disconnect the wire connector.
(1) Detach the claw, press down the lever, and then disconnect the transmission wire connector.
(b) Remove the bolt and pull out the transmission wire.
(c) Remove the O-ring from the transmission wire connector.
Page 8898
Keyless Entry Module: Service and Repair Door Control Receiver (for Double Cab)
Components
DOOR LOCK: DOOR CONTROL RECEIVER (for Double Cab): COMPONENTS
Page 6146
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION: Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC
terminals are touched, the IC may be destroyed by static electricity.)
When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact with the terminals of leads from the IC, etc. of the
replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown on the left.
DISCONNECT CONNECTOR
Page 7955
(3) Move SST at least 10 m (32.8 ft.) away from the vehicle front side window.
(4) Maintaining enough clearance for SST wire harness in the front side window, close all doors
and windows of the vehicle.
NOTICE: Take care not to damage SST wire harness.
(5) Connect the red clip of SST to the battery positive (+) terminal and the black clip of SST to the
negative (-) terminal.
(f) Deploy the airbag.
(1) Check that no one is inside the vehicle or within a 10 m (32.8 ft.) radius of the vehicle.
(2) Press SST activation switch and deploy the airbag.
CAUTION: *
When deploying the airbag, make sure that no one is near the vehicle.
* The steering pad becomes extremely hot when the airbag is deployed, so do not touch it for at
least 30 minutes after deployment.
* Use gloves and safety glasses when handling a steering pad with a deployed airbag.
* Do not apply water to a steering pad with a deployed airbag.
* Always wash your hands with water after completing the operation.
HINT The airbag is deployed as the LED of SST activation switch comes on.
2. DISPOSE OF STEERING PAD (WHEN NOT INSTALLED IN VEHICLE)
CAUTION: Be sure to follow the procedure detailed below when deploying the airbag.
HINT Prepare a battery as the power source to deploy the airbag.
(a) Check the function of SST See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
SST : 09082-00700
SST : 09082-00820
(b) Remove the steering pad See: Removal and Replacement/Steering Pad/Removal.
CAUTION: *
When removing the steering pad, work must be started 90 seconds after the ignition switch is
turned OFF and the negative (-) terminal cable is disconnected from the battery.
* When storing the steering pad, keep the airbag deployment side facing upward.
(c) Using a service-purpose wire harness for the vehicle, tie down the steering pad to the disc
wheel.
Page 9254
(b) Disconnect the connector.
6. REMOVE REAR DOOR ARMREST COVER LH
7. REMOVE REAR DOOR TRIM BOARD SUB-ASSEMBLY LH
(a) Remove the 2 screws.
(b) Using a clip remover, remove the clip.
(c) Detach the 9 clips and remove the trim cover. Then disconnect the connector.
(d) Disconnect the 2 cables from the inside handle.
From 11/2009
ENGINE HOOD / DOOR: REAR DOOR (for Double Cab): DISASSEMBLY
REAR DOOR TRIM BOARD SUB-ASSEMBLY LH
1. REMOVE REAR DOOR INSIDE HANDLE BEZEL PLUG LH
(a) Using a screwdriver, detach the 4 claws and remove the inside handle bezel.
HINT Tape the screwdriver tip before use.
Page 8378
Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to
prevent airbag and seat belt pretensioner activation.
(c) Install the door airbag sensor with the screw.
Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)
NOTICE: *
If the door airbag sensor has been dropped, or there are any cracks, dents or other defects in the
case, bracket or connector, replace it with a new one.
* When installing the door airbag sensor, be careful that the SRS wiring does not interfere with
other parts and that it is not pinched between other parts.
(d) Check that there is no looseness in the installation parts of the door airbag sensor.
(e) Connect the connector.
2. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Reassembly
3. INSTALL COURTESY LIGHT ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood
and Trunk/Doors/Front Door/Service and
Repair/Front Door (for Double Cab)/Reassembly
4. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH LH (for Front Side) See: Body
and Frame/Doors, Hood and
Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly
5. INSTALL FRONT ARMREST BASE PANEL UPPER LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Reassembly
6. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Reassembly
7. INSTALL REAR SIDE AIRBAG SENSOR
(a) Check that the ignition switch is OFF.
(b) Check that the cable is disconnected from the battery negative (-) terminal.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
(c) Install the side airbag sensor with the bolt.
Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)
NOTICE: *
If the side airbag sensor has been dropped, or there are any cracks, dents or other defects in the
case, bracket or connector, replace it with a new one.
* When installing the side airbag sensor, be careful that the SRS wiring does not interfere with
other parts and that it is not pinched between other parts.
(d) Check that there is no looseness in the installation parts of the side airbag sensor.
(e) Connect the connector.
8. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY LH (for Rear Side) See: Body and
Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation
Page 2772
J. When Cal 1 has completed the update process turn ignition OFF for a minimum of 10 seconds.
Then click Next.
K. Turn ignition to the ON position. Then click Start.
L. Do NOT disturb the vehicle during flash reprogramming.
Page 8873
Alarm Module: Service and Repair Removal
THEFT DETERRENT: THEFT WARNING ECU: REMOVAL
1. REMOVE FRONT DOOR SCUFF PLATE LH
(a) for Regular Cab:
Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular Cab)/Removal.
(b) for Double Cab:
Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Removal.
(c) for CrewMax:
Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for CrewMax)/Removal.
2. REMOVE COWL SIDE TRIM BOARD LH
(a) for Regular Cab:
Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular Cab)/Removal.
(b) for Double Cab:
Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Removal.
(c) for CrewMax:
Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for CrewMax)/Removal.
3. REMOVE INSTRUMENT SIDE PANEL LH
(a) for Column Shift Type:
Remove the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Column Shift Type)/Removal.
(b) for Floor Shift Type:
Remove the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Floor Shift Type)/Removal.
4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH
(a) for Column Shift Type:
Remove the instrument panel finish panel See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument
Panel Safety Pad (for Column Shift Type)/Removal.
(b) for Floor Shift Type:
Remove the instrument panel finish panel See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument
Panel Safety Pad (for Floor Shift Type)/Removal.
5. REMOVE GLASS BREAKAGE SENSOR ECU
Page 4080
EGR Cooler: Service and Repair Removal
1UR-FE EMISSION CONTROL: EGR COOLER: REMOVAL
1. REMOVE INTAKE MANIFOLD ASSEMBLY
(a) Remove the intake manifold See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service
and Repair/Removal.
2. REMOVE NO. 3 WATER BY-PASS PIPE SUB-ASSEMBLY
(a) Disconnect the No. 4 water by-pass hose.
(b) Disconnect the hose and remove the 2 bolts and No. 3 water by-pass pipe.
3. DISCONNECT NO. 8 WATER BY-PASS HOSE
(a) Disconnect the No. 8 water by-pass hose.
4. DISCONNECT NO. 11 WATER BY-PASS HOSE
(a) Disconnect the No. 11 water by-pass hose.
5. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Exhaust
System/Exhaust Manifold/Service and
Repair/Removal
6. REMOVE EGR COOLER ASSEMBLY
(a) Remove the 2 bolts and EGR cooler.
7. REMOVE NO. 2 EGR PIPE SUB-ASSEMBLY
(a) Remove the 2 bolts, No. 2 EGR pipe and gasket.
Page 9227
6. REMOVE FRONT LOWER DOOR FRAME BRACKET GARNISH LH
(a) Detach the 3 clips and front lower door frame bracket garnish.
7. REMOVE COURTESY LIGHT ASSEMBLY (w/ Power Window)
(a) Detach the claw and remove the courtesy light.
(b) Disconnect the connector.
8. REMOVE FRONT DOOR ARMREST COVER LH
9. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH
(a) Remove the 2 screws.
(b) Using a clip remover, remove the clip.
(c) Detach the 10 clips and remove the trim cover. Then disconnect the connector.
(d) Disconnect the 2 cables from the inside handle.
Page 1310
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION: Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC
terminals are touched, the IC may be destroyed by static electricity.)
When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact with the terminals of leads from the IC, etc. of the
replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown on the left.
DISCONNECT CONNECTOR
Page 6584
Page 5264
Drive/Propeller Shaft: Component Tests and General Diagnostics
Front Propeller Shaft Assembly
PROPELLER SHAFT: FRONT PROPELLER SHAFT ASSEMBLY: INSPECTION
1. INSPECT FRONT PROPELLER SHAFT ASSEMBLY
(a) Check that the propeller shaft is not damaged or deformed.
* If necessary, replace the propeller shaft.
(b) Using a dial indicator, check the propeller shaft runout.
Maximum runout:
0.61 mm (0.0240 in.)
2. INSPECT UNIVERSAL JOINT SPIDER BEARING
(a) Check that the joints move smoothly.
(b) Check the spider bearings for wear and damage.
(c) Check the spider bearing axial play by turning the yoke while holding the shaft tightly.
Maximum bearing axial play:
0.05 mm (0.00197 in.)
* If necessary, replace the spider bearing.
Propeller Shaft Assembly
PROPELLER SHAFT: PROPELLER SHAFT ASSEMBLY (for 4WD): INSPECTION
1. INSPECT PROPELLER SHAFT ASSEMBLY (for 2 Joint Type)
(a) Using a dial indicator, measure the propeller shaft runout.
Maximum runout:
1.02 mm (0.0402 in.)
* If the shaft runout is more than the maximum, replace the propeller shaft assembly.
Page 4260
^ Calibration ID(s) [Refer to the Calibration Identification Chart for the NEW CALIBRATION ID]
^ Dealer Code
^ Repair Date
^ Change Authority [This TSB number]
B. Affix the Authorized Modifications Label to the vehicle at the location shown in Figure 1. The
Authorized Modifications Label is available
through the MDC P/N 00451-00001-LBL.
Page 7841
Cabin Temperature Sensor / Switch: Testing and Inspection
AIR CONDITIONING: ROOM TEMPERATURE SENSOR (for Automatic Air Conditioning System):
INSPECTION
1. INSPECT ROOM TEMPERATURE SENSOR
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
HINT As the temperature increases, the resistance decreases (see the graph).
(b) If the result is not as specified, replace the thermistor.
NOTICE: *
Touching the sensor even slightly may change the resistance value. Hold the connector of the
sensor.
* When measuring the resistance, the sensor temperature must be the same as the ambient
temperature.
Page 6724
(2) Disconnect connector B and measure the resistance.
Standard resistance (Fig. 7):
* If the results match the examples above, a short circuit exists between terminal 1 of connector B2
and terminal 1 of connector C.
4. CHECK AND REPLACE ECU
NOTICE: *
The connector should not be disconnected from the ECU. Perform the inspection from the backside
of the connector on the wire harness side.
* When no measuring condition is specified, perform the inspection with the engine stopped and
the ignition switch ON.
* Check that the connectors are fully seated. Check for loose, corroded or broken wires.
(a) First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be
faulty. Temporarily replace the ECU with a
normally functioning one and check if the symptoms occur. If the trouble symptoms disappear,
replace the original ECU.
(1) Measure the resistance between the ECU ground terminal and body ground.
Standard resistance:
Below 1 Ohms
(2) Disconnect the ECU connector. Check the ground terminal on the ECU side and wire harness
side for bending, corrosion or foreign matter.
Lastly, check the contact pressure of the female terminals.
Page 1457
Seat Position Sensor: Service and Repair Removal
SUPPLEMENTAL RESTRAINT SYSTEM: SEAT POSITION SENSOR: REMOVAL
1. REMOVE FRONT SEAT ASSEMBLY LH
(a) Remove the front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Fold Down Seat
Type)/Removal.
2. REMOVE SEAT POSITION SENSOR
(a) Using a T30 "TORX" socket wrench, remove the screw and seat position sensor with sensor
protector.
(b) Disconnect the connector.
(c) Remove the seat slide position sensor protector from the seat position sensor.
Page 7935
* Always wash your hands with water after completing the operation.
HINT The airbag is deployed as the LED of SST activation switch comes on.
2. DISPOSE OF FRONT SEAT SIDE AIRBAG ASSEMBLY (WHEN NOT INSTALLED IN
VEHICLE)
NOTICE: Be sure to follow the procedure detailed below when deploying the airbag.
HINT Prepare a battery as the power source to deploy the airbag.
(a) Check the function of SST See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
(b) Remove the front seat side airbag See: Removal and Replacement/Front Seat Side Airbag
Assembly (except Fold Down Seat Type)/Removal
.
(c) Using a service-purpose wire harness for the vehicle, tie down the front seat side airbag to the
tire.
Wire harness:
Stripped wire harness section
1.25 mm2 or more (0.00193 in.2 or more)
CAUTION: If the wire harness is too thin or an alternative object is used to tie down the curtain
shield airbag, it may be snapped by the shock when the airbag is deployed. Always use a wire
harness for vehicle use with an area of at least 1.25 mm2 (0.00193 in.2).
HINT To calculate the area of the stripped wire harness section:
Area = 3.14 x (Diameter)2 divided by 4
(1) Install the 2 nuts to the front seat side airbag.
Recall 10V017000: Accelerator Pedal Sticking
Accelerator Pedal Position Sensor: All Technical Service Bulletins Recall 10V017000: Accelerator
Pedal Sticking
VEHICLE MAKE/MODEL: MODEL YEAR(S): Toyota/Avalon 2005-2010 Toyota/Camry 2007-2010
Toyota/Corolla 2009-2010 Toyota/Corolla Matrix 2009-2010 Toyota/Highlander 2010 Toyota/ RAV4
2009-2010 Toyota/Sequoia 2008-2010 Toyota/Tundra 2007-2010 MANUFACTURER: Toyota
Motor North America, Inc.
MFR'S REPORT DATE: January 21, 2010
NHTSA CAMPAIGN ID NUMBER: 10V017000
NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Accelerator Assembly:
Pedal/Linkage
POTENTIAL NUMBER OF UNITS AFFECTED: ?
SUMMARY: Toyota is recalling certain model year 2005-2010 Avalon, model year 2007-2010
Camry, model year 2009-2010 Corolla, Corolla Matrix, RAV4, model year 2010 Highlander, model
year 2008-2010 Sequoia, and model year 2007-2010 Tundra. due to the manner in which the
friction lever interacts with the sliding surface of the accelerator pedal inside the pedal sensor
assembly, the sliding surface of the lever may become smooth during vehicle operation. In this
condition, if condensation occurs on the surface, as may occur from heater operation (without A/C)
when the pedal assembly is cold, the friction when the accelerator pedal is operated may increase,
which may result in the accelerator pedal becoming harder to depress, slower to return, or, in the
worst case, mechanically stuck in a partially depressed position.
CONSEQUENCE: The accelerator pedal may become hard to depress, slow to return to idle, or, in
the worst case, mechanically stuck in a partially depressed position, increasing the risk of a crash.
REMEDY: Toyota has not yet provided a remedy plan or an owner notification schedule. Owners
may contact Toyota at 1-800-331-4331.
NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle
Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov.
Page 1684
*: for 5 leaf spring
Standard Camber Inclination
for Regular Cab of Standard Deck
Page 3064
Page 9201
Page 7232
Power Steering Pressure Switch: Diagrams Power Steering Oil Pressure Switch
System Diagnosis
Radiator Cooling Fan: Testing and Inspection
1UR-FE COOLING: FAN: INSPECTION
1. INSPECT FLUID COUPLING ASSEMBLY
(a) Check the fluid coupling for damage or silicon oil leaks.
If necessary, replace the fluid coupling assembly.
Page 5042
(c) Install the 2 adjusting nut locks with the 2 bolts.
(d) Using a dial indicator, measure the runout of the ring gear.
Maximum runout:
0.05 mm (0.00197 in.)
(e) If the runout is greater than the maximum, replace the ring gear.
(f) Remove the 2 bolts and adjusting nut locks.
(g) Remove the 2 bearing caps, 2 adjusting nuts and differential case assembly.
7. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
(a) Using SST and a press, press in the bearing (outer race).
SST : 09950-60020
09951-00710
SST : 09950-70010
09951-07150
8. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING
(a) Using SST and a press, press in the bearing (outer race).
SST : 09950-60020
09951-00890
SST : 09950-70010
09951-07150
9. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING
(a) Install the plate washer onto the drive pinion.
Page 3731
HINT *: The ECM terminal voltage is constant regardless of the output voltage from the sensor.
(b) WAVEFORM 1:
Page 8004
Air Bag Control Module: Locations Airbag System
SUPPLEMENTAL RESTRAINT SYSTEM: AIRBAG SYSTEM: PARTS LOCATION
Page 4272
4. Attach the Authorized Vehicle Modification Label.
Modifications to ECU calibrations MUST be recorded and properly displayed on the vehicle using
the Authorized Modification Label.
Techstream Preparation
Selecting the TIS Techstream VIM or the Mongoose MFC VIM.
Techstream software requires a VIM selection before you can use the Mongoose MFC VIM.
If using TIS Techstream no changes are needed.
Perform the following:
1. Select Setup from the Techstream Main Menu screen.
2. Select VIM Select from the Setup drop down menu.
3. Select the correct Interface Setup from the drop down list.
^ If using Techstream Lite select Mongoose MFC.
NOTE
Windshield Deicer System
Heated Glass Element Switch: Locations Windshield Deicer System
WINDSHIELD / WINDOWGLASS: WINDSHIELD DEICER SYSTEM: PARTS LOCATION
Components
Fuel Pump Control Unit: Service and Repair Components
1UR-FE FUEL: FUEL PUMP ECU: COMPONENTS
Page 1206
Oxygen Sensor: Testing and Inspection Air Fuel Ratio Sensor
1UR-FE ENGINE CONTROL SYSTEM: AIR FUEL RATIO SENSOR: ON-VEHICLE INSPECTION
1. INSPECT AIR FUEL RATIO SENSOR
(a) Disconnect the 2 sensor connectors.
(b) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(c) If the result is not as specified, replace the air fuel ratio sensor.
(d) Connect the 2 sensor connectors.
Page 7962
SST : 09082-00700
SST : 09082-00802
09082-10801
09082-40800
NOTICE: To avoid damaging SST connector and wire harness, do not lock the secondary lock of
the twin lock.
(3) Move SST at least 10 m (32.8 ft.) away from the vehicle rear side window.
(4) Maintaining enough clearance for SST wire harness in the rear side window, close all doors and
windows of the vehicle.
NOTICE: Take care not to damage SST wire harness.
(5) Connect the red clip of SST to the battery positive (+) terminal and black clip of SST to the
battery negative (-) terminal.
(f) Deploy the airbag.
(1) Check that no one is inside the vehicle or within a 10 m (32.8 ft.) radius of the vehicle.
(2) Press SST activation switch and deploy the airbag.
CAUTION: *
When deploying the airbag, make sure that no one is near the vehicle.
* The curtain shield airbag becomes extremely hot when the airbag is deployed, so do not touch it
for at least 30 minutes after deployment.
* Use gloves and safety glasses when handling a curtain shield airbag with a deployed airbag.
* Do not apply water to a curtain shield airbag with a deployed airbag.
* Always wash your hands with water after completing the operation.
HINT The airbag is deployed as the LED of SST activation switch comes on.
2. DISPOSE OF CURTAIN SHIELD AIRBAG ASSEMBLY (WHEN NOT INSTALLED IN VEHICLE)
CAUTION: Be sure to follow the procedure detailed below when deploying the airbag.
HINT Prepare a battery as the power source to deploy the airbag.
(a) Check the function of SST See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
Page 1941
(f) Remove the oil filter element and O-ring from the oil filter cap.
NOTICE: Be sure to remove the O-ring for the cap by hand, without using any tools, to prevent
damage to the cap's O-ring groove.
4. INSTALL OIL FILTER ELEMENT
(a) Clean the inside of the oil filter cap, its threads and its O-ring groove.
(b) Apply a small amount of engine oil to a new O-ring and install it to the oil filter cap.
(c) Set a new oil filter element to the oil filter cap.
(d) Remove any dirt or foreign matter from the installation surface of the engine.
(e) Apply a small amount of engine oil to the O-ring again and temporarily install the oil filter cap.
(f) Using SST, tighten the oil filter cap.
SST : 09228-06501
Torque : 25 Nm (255 kgf-cm, 18 ft-lbf)
NOTICE: *
When tightening the oil filter cap, do not remove the oil filter bracket clip.
* Make sure that the oil filter is installed securely as shown in the illustration.
* Be careful that the O-ring does not get caught between any surrounding parts.
Page 3223
Use a volt/ohmmeter with high impedance (10 kohms/V minimum) for troubleshooting of the
electrical circuit.
Disconnection of Male and Female Connectors
DISCONNECTION OF MALE AND FEMALE CONNECTORS
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Finding A Short Circuit
FINDING A SHORT CIRCUIT
Page 208
Page 1751
(3) Check for dirt or mud on the pipe and around the connector before disconnection. Clean if
necessary.
(4) Pinch the connector and disconnect the connector and pipe.
(5) If the connector and the pipe are stuck together, pinch the connector, push and pull the pipe to
disconnect the pipe and pull it out.
NOTICE: Do not use any tools.
(6) Check for dirt or mud on the seal surface of the disconnected pipe. Clean if necessary.
(7) To protect the disconnected pipe and connector from damage and contamination, cover it with a
plastic bag.
(e) Observe these precautions when connecting the fuel tube connector (for Quick Type).
(1) Check that there is no damage or contamination in the connected part of the pipe.
(2) Align the axis of the connector with the axis of the pipe. Push the pipe into the connector until
the connector makes a "click" sound. If the
connection is tight, apply a small amount of fresh spindle oil or gasoline on the tip of the pipe.
(3) After having finished the connection, try to pull apart the pipe and the connector to confirm that
they are securely connected.
Page 8677
(1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be
checked by conducting a voltage check.
With each connector still connected, measure the voltage between the body ground and these
terminals (in this order): 1) terminal 1 of connector A; 2) terminal 1 of connector B; and 3) terminal
1 of connector C.
Standard voltage (Fig. 4):
* If the results match the examples above, an open circuit exists in the wire harness between
terminal 1 of connector B and terminal 1 of connector C.
3. CHECK FOR SHORT CIRCUIT
(a) If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance
check with the body ground (below).
(b) Check the resistance with the body ground.
(1) Disconnect connectors A and C and measure the resistance.
Standard resistance (Fig. 6):
HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally.
If your results match the examples above, a short circuit exists between terminal 1 of connector A
and terminal 1 of connector C.
Page 290
(2) CONNECTORS
Slightly shake the connector vertically and horizontally.
(3) WIRE HARNESS
Slightly shake the wire harness vertically and horizontally.
HINT The connector joint and fulcrum of the vibration are the major areas that should be checked
thoroughly.
(b) HEAT METHOD:
When a malfunction seems to occur when the area in question is heated.
(1) Heat the component that is the possible cause of the malfunction with a hair dryer or similar
device. Check if the malfunction occurs.
NOTICE: *
Do not heat to more than 60°C (140°F). Exceeding this temperature may damage components.
* Do not apply heat directly to the parts in the ECU.
(c) WATER SPRINKLING METHOD:
When a malfunction seems to occur on a rainy day or in high-humidity.
(1) Sprinkle water onto the vehicle and check if the malfunction occurs.
NOTICE: *
Never sprinkle water directly into the engine compartment. Indirectly change the temperature and
humidity by spraying water onto the front of the radiator.
* Never apply water directly onto the electronic components.
HINT If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU
or connections. Look for evidence of corrosion or short circuits. Proceed with caution during water
tests.
(d) HIGH ELECTRICAL LOAD METHOD:
When a malfunction seems to occur when the electrical load is excessive.
(1) Turn on the heater blower, headlights, rear window defogger and all other electrical loads.
Check if the malfunction reoccurs.
5. DIAGNOSTIC TROUBLE CODE CHART
Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate
section's Diagnostic Trouble Code Chart. Use the chart to determine the trouble area and the
proper inspection procedure. A description of each of the chart's columns is below.
Page 6243
Page 1382
Impact Sensor: Testing and Inspection
Center Airbag Sensor Assembly (for Column Shift Type)
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Column
Shift Type): ON-VEHICLE INSPECTION
1. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION)
(a) Perform a diagnostic system check See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
2. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND
AIRBAG HAS NOT DEPLOYED)
(a) Perform a diagnostic system check See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
3. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND
AIRBAG IS DEPLOYED)
(a) Replace the center airbag sensor.
CAUTION: For removal and installation procedures of the center airbag sensor, be sure to follow
the correct procedure.
HINT The center airbag sensor should be replaced after any of the airbags has deployed, as it has
been subjected to the impact.
Center Airbag Sensor Assembly (for Floor Shift Type)
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift
Type): ON-VEHICLE INSPECTION
1. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION)
(a) Perform a diagnostic system check See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
2. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND
AIRBAG HAS NOT DEPLOYED)
(a) Perform a diagnostic system check See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
3. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND
AIRBAG IS DEPLOYED)
(a) Replace the center airbag sensor.
CAUTION: For removal and installation procedures of the center airbag sensor, be sure to follow
the correct procedure.
HINT The center airbag sensor should be replaced after any of the airbags has deployed, as it has
been subjected to the impact.
Front Airbag Sensor
SUPPLEMENTAL RESTRAINT SYSTEM: FRONT AIRBAG SENSOR: ON-VEHICLE
INSPECTION
1. CHECK FRONT AIRBAG SENSOR (VEHICLE NOT INVOLVED IN COLLISION)
(a) Perform a diagnostic system check See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
2. CHECK FRONT AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS
NOT DEPLOYED)
(a) Perform a diagnostic system check See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
Page 379
Engine Control Module: Diagrams
Locations
Switch: Locations
JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION
Page 5863
Braking Sensor/Switch: Locations From 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Air Conditioning System (for Automatic Air Conditioning
System)
Control Module HVAC: Locations Air Conditioning System (for Automatic Air Conditioning System)
AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Automatic Air Conditioning System):
PARTS LOCATION
Page 721
(a) Install the switch with the 2 screws.
2. INSTALL FRONT SEAT CUSHION SHIELD LH See: Body and Frame/Seats/Service and
Repair/Overhaul/Front Seat Assembly (for Power
Seat)/Reassembly
3. INSTALL RECLINING POWER SEAT SWITCH KNOB LH See: Body and Frame/Seats/Service
and Repair/Overhaul/Front Seat Assembly
(for Power Seat)/Reassembly
4. INSTALL SLIDE AND VERTICAL POWER SEAT SWITCH KNOB LH See: Body and
Frame/Seats/Service and Repair/Overhaul/Front Seat
Assembly (for Power Seat)/Reassembly
5. INSTALL FRONT SEAT ASSEMBLY LH
(a) Install the front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Power
Seat)/Installation.
Page 7846
Cabin Temperature Sensor / Switch: Service and Repair Installation
AIR CONDITIONING: ROOM TEMPERATURE SENSOR (for Automatic Air Conditioning System):
INSTALLATION
1. INSTALL ROOM TEMPERATURE SENSOR
(a) Attach the 2 claws to install the sensor.
2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH
(a) for Column Shift Type:
Remove the instrument panel finish panel See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument
Panel Safety Pad (for Column Shift Type)/Installation.
(b) for Floor Shift Type:
Remove the instrument panel finish panel See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument
Panel Safety Pad (for Floor Shift Type)/Installation.
3. INSTALL INSTRUMENT SIDE PANEL LH
(a) for Column Shift Type:
Remove the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Column Shift Type)/Installation.
(b) for Floor Shift Type:
Remove the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Floor Shift Type)/Installation.
4. INSTALL COWL SIDE TRIM BOARD LH
(a) for Regular Cab:
Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular Cab)/Installation.
(b) for Double Cab:
Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Installation.
(c) for CrewMax:
Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for CrewMax)/Installation.
5. INSTALL FRONT DOOR SCUFF PLATE LH
(a) for Regular Cab:
Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular
Components
Power Steering Pressure Switch: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: POWER STEERING OIL PRESSURE SWITCH:
COMPONENTS
Page 2027
Fuse Block: Connector Views
Engine Room R/B, J/B - Engine Compartment Left
Page 5436
2. REMOVE FRONT PROPELLER SHAFT ASSEMBLY
(a) Remove the front propeller shaft See: Drive/Propeller Shafts, Bearings and
Joints/Drive/Propeller Shaft/Service and Repair/Removal and
Replacement/Front Propeller Shaft Assembly/Removal.
3. REMOVE FRONT OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY See: Service and
Repair/Overhaul/Disassembly
4. REMOVE TRANSFER CASE FRONT OIL SEAL
(a) Using SST, tap out the oil seal.
SST : 09308-00010
NOTICE: Be careful not to damage the oil seal and transfer front case contact surface.
5. INSTALL TRANSFER CASE FRONT OIL SEAL
(a) Apply transfer oil to the spline area of the output shaft.
(b) Using SST and a hammer, tap in the oil seal until its surface is 1 to 1.5 mm (0.0394 to 0.0591
in.) from the case upper surface.
SST : 09316-60011
09316-00011
6. INSTALL FRONT OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY See: Service and
Repair/Overhaul/Reassembly
7. INSTALL FRONT PROPELLER SHAFT ASSEMBLY
(a) Install the front propeller shaft See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller
Shaft/Service and Repair/Removal and
Replacement/Front Propeller Shaft Assembly/Installation.
8. ADD TRANSFER OIL See: Fluid - Transfer Case/Service and Repair
9. CHECK TRANSFER OIL See: Fluid - Transfer Case/Testing and Inspection
10. CHECK FOR TRANSFER OIL LEAK
Page 8849
From 11/2009
AUDIO / VISUAL: REAR DOOR SPEAKER (for Double Cab): COMPONENTS
Locations
Door Sensor/Switch (For Alarm): Locations
THEFT DETERRENT: THEFT DETERRENT SYSTEM: PARTS LOCATION
Page 8385
Page 8847
4. REMOVE REAR UPPER DOOR ARMREST BASE PANEL LH See: Body and Frame/Doors,
Hood and Trunk/Doors/Rear Door/Service and
Repair/Rear Door (for CrewMax)/Disassembly
5. REMOVE COURTESY LIGHT ASSEMBLY See: Body and Frame/Doors, Hood and
Trunk/Doors/Rear Door/Service and Repair/Rear Door
(for CrewMax)/Disassembly
6. REMOVE REAR DOOR ARMREST COVER LH
7. REMOVE REAR DOOR TRIM BOARD SUB-ASSEMBLY LH See: Body and Frame/Doors, Hood
and Trunk/Doors/Rear Door/Service and
Repair/Rear Door (for CrewMax)/Disassembly
8. REMOVE REAR NO. 1 SPEAKER ASSEMBLY
(a) Disconnect the speaker connector.
(b) Remove the 3 screws and speaker.
NOTICE: Do not touch the cone part of the speaker.
9. REMOVE REAR NO. 2 SPEAKER ASSEMBLY (for 12 Speakers)
(a) Detach the 3 claws and remove the speaker.
Installation
AUDIO / VISUAL: REAR DOOR SPEAKER (for CrewMax): INSTALLATION
HINT *
Use the same procedures for the LH side and RH side.
* The procedures listed below are for the LH side.
1. INSTALL REAR NO. 2 SPEAKER ASSEMBLY (for 12 Speakers)
(a) Attach the 3 claws to install the speaker to the door trim board.
2. INSTALL REAR NO. 1 SPEAKER ASSEMBLY
Page 195
(2) Disconnect connector B and measure the resistance.
Standard resistance (Fig. 7):
* If the results match the examples above, a short circuit exists between terminal 1 of connector B2
and terminal 1 of connector C.
4. CHECK AND REPLACE ECU
NOTICE: *
The connector should not be disconnected from the ECU. Perform the inspection from the backside
of the connector on the wire harness side.
* When no measuring condition is specified, perform the inspection with the engine stopped and
the ignition switch ON.
* Check that the connectors are fully seated. Check for loose, corroded or broken wires.
(a) First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be
faulty. Temporarily replace the ECU with a
normally functioning one and check if the symptoms occur. If the trouble symptoms disappear,
replace the original ECU.
(1) Measure the resistance between the ECU ground terminal and body ground.
Standard resistance:
Below 1 Ohms
(2) Disconnect the ECU connector. Check the ground terminal on the ECU side and wire harness
side for bending, corrosion or foreign matter.
Lastly, check the contact pressure of the female terminals.
Page 9342
Front Fender Liner: Service and Repair Installation
EXTERIOR: FENDER LINER (for Front Side): INSTALLATION
HINT *
Use the same procedures for the RH side and LH side.
* The procedures listed below are for the LH side.
1. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH
(a) for Steel Type Bumper:
Install the front fender splash shield.
(1) Install the fender splash shield with the 2 screws, clip and 2 new clips labeled A.
Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)
(b) for Resin Type Bumper:
Install the front fender splash shield.
(1) Install the fender splash shield with the 2 screws and 2 clips.
Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)
(2) Install the pin hold clip so that its groove is vertical.
2. INSTALL FENDER APRON MUDGUARD SEAL LH
(a) for Steel Type Bumper:
Install the fender apron mudguard seal.
(1) Install the fender apron mudguard with the 3 clips and 15 new clips labeled A.
Page 9120
(a) For an open circuit in the wire harness in Fig. 1, check the resistance or voltage, as described
below.
(b) Check the resistance.
(1) Disconnect connectors A and C and measure the resistance between them.
Standard resistance (Fig. 2):
HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally.
If the results match the examples above, an open circuit exists between terminal 1 of connector A
and terminal 1 of connector C.
(2) Disconnect connector B and measure the resistance between the connectors.
Standard resistance (Fig. 3):
* If the results match the examples above, an open circuit exists between terminal 1 of connector
B2 and terminal 1 of connector C.
(c) Check the voltage.
Components
Actuator: Service and Repair Components
DIFFERENTIAL: AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR (for 4WD):
COMPONENTS
Page 2042
Driver Side J/B Inner Circuit
Components
Refrigerant Pressure Sensor / Switch: Service and Repair Components
AIR CONDITIONING: PRESSURE SWITCH: COMPONENTS
Front Door Courtesy Switch
Door Switch: Service and Repair Front Door Courtesy Switch
Components
LIGHTING: FRONT DOOR COURTESY SWITCH: COMPONENTS
Page 7873
15. INSTALL NO. 3 AIR DUCT SUB-ASSEMBLY
(a) Attach the 4 claws to install the duct.
16. INSTALL LOWER DEFROSTER NOZZLE ASSEMBLY
(a) Attach the 4 claws to install the nozzle.
17. INSTALL AIR CONDITIONING UNIT
(a) Install the air conditioning unit See: Housing Assembly HVAC/Service and Repair/Removal and
Replacement/Installation.
Page 7191
(a) Install the bracket with the bolt.
7. INSTALL RADIATOR ASSEMBLY
(a) Install the radiator assembly See: Engine, Cooling and Exhaust/Cooling
System/Radiator/Service and Repair/Installation.
8. ADD POWER STEERING FLUID
9. BLEED POWER STEERING FLUID See: Testing and Inspection/Component Tests and General
Diagnostics/Power Steering
System/On-Vehicle Inspection
10. INSPECT FOR POWER STEERING FLUID LEAK
Inspection
Air Flow Meter/Sensor: Testing and Inspection Inspection
1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: INSPECTION
1. INSPECT MASS AIR FLOW METER
(a) Check the output voltage.
(1) Apply battery voltage across terminals 1 (+B) and 2 (E2G).
NOTICE: While using the battery during inspection, do not bring the positive and negative tester
probes too close to each other as a short circuit may occur.
(2) Using a voltmeter, connect the positive (+) tester probe to terminal 3 (VG), and negative (-)
tester probe to terminal 2 (E2G).
(3) Blow air into the MAF meter, and check that the voltage fluctuates.
If the result is not as specified, replace the MAF meter.
(b) Perform a visual check for any foreign matter on the platinum hot wire (heater) of the mass air
flow meter shown in the illustration.
OK:
There is no foreign material.
(c) If the result is not as specified, replace the mass air flow meter.
(d) Check the IAT sensor.
Page 5265
2. INSPECT PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY (for 3 Joint Type)
(a) Using a dial indicator, measure the intermediate shaft runout.
Maximum runout:
0.61 mm (0.0240 in.)
* If the intermediate shaft runout is more than the maximum, replace the propeller with center
bearing shaft assembly.
(b) Using a dial indicator, measure the propeller shaft runout.
Maximum runout:
1.02 mm (0.0402 in.)
* If the propeller shaft runout is more than the maximum, replace the propeller with center bearing
shaft assembly.
3. INSPECT PROPELLER SHAFT UNIVERSAL JOINT SPIDER BEARING
(a) Mount the propeller shaft in a vise.
NOTICE: Be careful not to grip the propeller shaft tube too tightly in a vise as this will cause
deformation.
(b) Inspect the spider bearing for wear or damage.
(c) Using a dial indicator, measure the spider bearing axial play by turning the yoke of the flange
while holding the shaft tightly.
Maximum runout:
0.05 mm (0.00197 in.)
* If the spider bearing axial play is more than the maximum, replace the spider bearing.
Page 6528
"Case2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 3074
"Case2" Open the secondary locking device.
[B] For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray
Gray or White : Black
Page 9123
General Information
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: GENERAL
INFORMATION
* A large number of ECU controlled systems are used in the TOYOTA TUNDRA. In general, ECU
controlled systems are considered to be very intricate, requiring a high level of technical knowledge
to troubleshoot. However, most problem checking procedures only involve inspecting the ECU
controlled system's circuits one by one. An adequate understanding of the system and a basic
knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and
necessary repairs.
1. TROUBLESHOOTING PROCEDURES
* The troubleshooting procedures consist of diagnosis procedures for when a DTC is stored and
diagnosis procedures for when no DTC is stored. The basic idea is explained in the following table.
* Vehicle systems are complex and use many ECUs that are difficult to inspect independently.
Therefore, a process of elimination is used, where components that can be inspected individually
are inspected, and if no problems are found in these components, the related ECU is identified as
the problem and replaced.
* It is extremely important to ask the customer about the environment and the conditions present
when the problem occurred (Customer Problem Analysis). This makes it possible to simulate the
conditions and confirm the symptom. If the symptom cannot be confirmed or the DTC does not
recur, the malfunctioning part may not be identified using the troubleshooting procedure, and the
ECU for the related system may be replaced even though it is not defective. If this happens, the
original problem will not be solved.
* In order to prevent endless expansion of troubleshooting procedures, the troubleshooting
procedures are written with the assumption that multiple malfunctions do not occur simultaneously
for a single problem symptom.
* To identify the malfunctioning part, troubleshooting procedures narrow down the target by
separating components, ECUs and wire harnesses during the inspection. If the wire harness is
identified as the cause of the problem, it is necessary to inspect not only the connections to
components and ECUs but also all of the wire harness connectors between the component and the
ECU.
DIAGNOSTIC TESTER
2. DESCRIPTION
System data and the Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector
3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the Techstream* to
check for a malfunction and perform repairs.
HINT *: Techstream is the name for the diagnostic tester in North America.
3. DATA LINK CONNECTOR 3 (DLC3)
(a) The vehicle's ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of
the DLC3 complies with SAE J1962 and
matches the ISO 15765-4 format.
Page 4934
NOTICE: When connecting the cable to the transmission control shaft lever, make sure the L
bracket of the cable faces the inside of the vehicle.
(i) Connect the transmission control cable support with the nut.
Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)
2. INSTALL FRONT SEAT ASSEMBLY LH
(a) for Manual Seat Type:
Install the front seat LH See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Manual Seat)/Installation.
(b) for Power Seat Type:
Install the front seat LH See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Power Seat)/Installation.
(c) for Center Seat:
Install the front seat LH See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Center Seat)/Installation.
(d) for Fold Down Seat:
Install the front seat LH See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Fold Down Seat Type)/Installation.
3. ADJUST SHIFT LEVER POSITION See: Shifter A/T/Adjustments/SHIFT LEVER ASSEMBLY
(for Column Shift Type)
4. INSPECT SHIFT LEVER POSITION See: Shifter A/T/Adjustments/SHIFT LEVER ASSEMBLY
(for Column Shift Type)
5. INSTALL UPPER STEERING COLUMN COVER See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Removal and
Replacement/Steering Column Assembly (for Manual Tilt)/Installation
6. INSTALL LOWER STEERING COLUMN COVER See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Removal and
Replacement/Steering Column Assembly (for Manual Tilt)/Installation
7. INSTALL STEERING WHEEL ASSEMBLY See: Steering and Suspension/Steering/Steering
Column/Service and Repair/Removal and
Replacement/Steering Column Assembly (for Manual Tilt)/Installation
8. INSTALL STEERING PAD (w/ Steering Pad Switch) See: Restraint Systems/Air Bag
Systems/Air Bag/Service and Repair/Removal and
Replacement/Steering Pad/Installation
9. INSTALL STEERING PAD (w/o Steering Pad Switch) See: Restraint Systems/Air Bag
Systems/Air Bag/Service and Repair/Removal and
Replacement/Steering Pad/Installation
10. INSTALL CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service
and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
11. INSTALL LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY See: Restraint
Systems/Air Bag Systems/Air Bag/Service and
Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Installation
12. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
Up to 11/2009
Brake Fluid Pressure Sensor/Switch: Locations Up to 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 8876
(a) for Column Shift Type:
Remove the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Column Shift Type)/Installation.
(b) for Floor Shift Type:
Remove the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Floor Shift Type)/Installation.
4. INSTALL COWL SIDE TRIM BOARD LH
(a) for Regular Cab:
Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular Cab)/Installation.
(b) for Double Cab:
Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Installation.
(c) for CrewMax:
Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for CrewMax)/Installation.
5. INSTALL FRONT DOOR SCUFF PLATE LH
(a) for Regular Cab:
Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular Cab)/Installation.
(b) for Double Cab:
Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Installation.
(c) for CrewMax:
Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for CrewMax)/Installation.
Page 4936
Shift Cable: Service and Repair Transmission Control Cable (for Floor Shift Type)
Components
A760F AUTOMATIC TRANSMISSION: TRANSMISSION CONTROL CABLE (for Floor Shift Type):
COMPONENTS
Page 6652
Installation
OTHER SYSTEM: POWER OUTLET SOCKET (for CrewMax Column Shift Type): INSTALLATION
1. INSTALL REAR POWER POINT SOCKET (for AC Power Supply)
(a) Attach the 2 claws to install the power outlet socket.
2. INSTALL REAR POWER OUTLET SOCKET COVER (for Standard)
(a) Attach the 2 claws to install the power outlet socket cover.
3. INSTALL REAR POWER OUTLET SOCKET (for Standard)
(a) Attach the claw to install the power outlet socket.
4. INSTALL NO. 2 SEATBACK LOCK CONTROL BEZEL
Exhaust Pipe (Except Regular Cab Standard Deck)
Exhaust Pipe: Service and Repair Exhaust Pipe (Except Regular Cab Standard Deck)
Components
1UR-FE EXHAUST: EXHAUST PIPE (except Regular Cab Standard Deck): COMPONENTS
Page 7921
Air Bag: Testing and Inspection
Front Seat Side Airbag Assembly (except Fold Down Seat Type)
SUPPLEMENTAL RESTRAINT SYSTEM: FRONT SEAT SIDE AIRBAG ASSEMBLY (except Fold
Down Seat Type): ON-VEHICLE INSPECTION
1. CHECK FRONT SEAT SIDE AIRBAG ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION)
(a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnosis System.
(b) With the front seat side airbag installed on the vehicle, perform a visual check. If there are any
defects as mentioned below, replace the front
seat with a new one:
Cuts, minute cracks or marked discoloration on the front seatback around the front seat side
airbag.
2. CHECK FRONT SEAT SIDE AIRBAG ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND
AIRBAG HAS NOT DEPLOYED)
(a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnosis System.
(b) With the front seat side airbag removed from the vehicle, perform a visual check. If there are
any defects as mentioned below, replace the front
seat side airbag with a new one:
* Cuts, minute cracks or marked discoloration on the front seat side airbag.
* Cracks or other damage to the wire harness or connector.
CAUTION: For removal and installation procedures of the front seat side airbag, be sure to follow
the correct procedure.
Front Seat Side Airbag Assembly (for Fold Down Seat Type)
SUPPLEMENTAL RESTRAINT SYSTEM: FRONT SEAT SIDE AIRBAG ASSEMBLY (for Fold
Down Seat Type): ON-VEHICLE INSPECTION
1. CHECK FRONT SEAT SIDE AIRBAG ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION)
(a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnosis System.
Page 8064
Impact Sensor: Testing and Inspection Front Airbag Sensor
SUPPLEMENTAL RESTRAINT SYSTEM: FRONT AIRBAG SENSOR: ON-VEHICLE
INSPECTION
1. CHECK FRONT AIRBAG SENSOR (VEHICLE NOT INVOLVED IN COLLISION)
(a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnosis System.
2. CHECK FRONT AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS
NOT DEPLOYED)
(a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnosis System.
(b) When the front bumper of the vehicle or its area is damaged, check if there is any damage to
the front airbag sensor. If the front airbag sensor
has defects as mentioned below, replace it with a new one:
* Cracks, dents or chips on the sensor housing.
* Cracks or other damage to the connector.
* Peeling off of the label or damage to the serial number.
CAUTION: For removal and installation procedures of the front airbag sensor, be sure to follow the
correct procedure.
3. CHECK FRONT AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS
DEPLOYED)
(a) Replace the front airbag sensor.
CAUTION: *
For removal and installation procedures of the front airbag sensor, be sure to follow the correct
procedure.
* If the airbags have deployed, replace the front airbag sensor on the side in which the collision
occurred. Replace both if necessary.
Page 7989
2. INSTALL FRONT SEATBACK COVER WITH PAD LH (for Manual Seat) See: Body and
Frame/Seats/Service and Repair/Overhaul/Front
Seat Assembly (for Manual Seat)/Reassembly
3. INSTALL FRONT SEAT HEADREST ASSEMBLY LH (for Manual Seat)
4. INSTALL INNER FRONT SEAT CUSHION SHIELD LH (for Manual Seat) See: Body and
Frame/Seats/Service and Repair/Overhaul/Front
Seat Assembly (for Manual Seat)/Reassembly
5. INSTALL FRONT SEAT CUSHION SHIELD LH (for Manual Seat) See: Body and
Frame/Seats/Service and Repair/Overhaul/Front Seat
Assembly (for Manual Seat)/Reassembly
6. INSTALL RECLINING ADJUSTER RELEASE HANDLE LH (for Manual Seat) See: Body and
Frame/Seats/Service and
Repair/Overhaul/Front Seat Assembly (for Manual Seat)/Reassembly
7. INSTALL VERTICAL SEAT ADJUSTER KNOB LH (for 8 Way Seat) See: Body and
Frame/Seats/Service and Repair/Overhaul/Front Seat
Assembly (for Manual Seat)/Reassembly
8. INSTALL VERTICAL ADJUSTING HANDLE LH (for 8 Way Seat) See: Body and
Frame/Seats/Service and Repair/Overhaul/Front Seat
Assembly (for Manual Seat)/Reassembly
9. INSTALL FRONT SEAT ASSEMBLY LH (for Manual Seat)
(a) Install the front seat assembly LH See: Body and Frame/Seats/Service and Repair/Removal
and Replacement/Front Seat Assembly (for
Manual Seat)/Installation.
10. INSTALL FRONT SEATBACK COVER WITH PAD LH (for Power Seat) See: Body and
Frame/Seats/Service and Repair/Overhaul/Front Seat
Assembly (for Power Seat)/Reassembly
11. INSTALL INNER FRONT SEAT CUSHION SHIELD LH (for Power Seat) See: Body and
Frame/Seats/Service and Repair/Overhaul/Front Seat
Assembly (for Power Seat)/Reassembly
12. INSTALL FRONT SEAT INNER BELT ASSEMBLY LH (for Power Seat) See: Seat Belt
Systems/Seat Belt/Service and Repair/Removal and
Replacement/Front Seat Inner Belt Assembly/Installation
13. INSTALL FRONT SEAT CUSHION SHIELD LH (for Power Seat) See: Body and
Frame/Seats/Service and Repair/Overhaul/Front Seat
Assembly (for Power Seat)/Reassembly
14. INSTALL RECLINING POWER SEAT SWITCH KNOB LH (for Power Seat) See: Body and
Frame/Seats/Service and Repair/Overhaul/Front
Seat Assembly (for Power Seat)/Reassembly
15. INSTALL SLIDE AND VERTICAL POWER SEAT SWITCH KNOB LH (for Power Seat) See:
Body and Frame/Seats/Service and
Repair/Overhaul/Front Seat Assembly (for Power Seat)/Reassembly
16. INSTALL FRONT SEAT ASSEMBLY LH (for Power Seat)
(a) Install the front seat assembly LH See: Body and Frame/Seats/Service and Repair/Removal
and Replacement/Front Seat Assembly (for
Power Seat)/Installation.
17. PERFORM INITIALIZATION
NOTICE: Some systems need initialization after reconnecting the cable to the negative battery
terminal See: Testing and Inspection/Programming and Relearning
Components
SUPPLEMENTAL RESTRAINT SYSTEM: FRONT SEAT SIDE AIRBAG ASSEMBLY (for Fold
Down Seat Type): COMPONENTS
Power Window Control System (w/ Jam Protection
Function)
Power Window Switch: Locations Power Window Control System (w/ Jam Protection Function)
WINDSHIELD / WINDOWGLASS: POWER WINDOW CONTROL SYSTEM (w/ Jam Protection
Function): PARTS LOCATION
Page 1149
Camshaft Position Sensor: Locations Ignition System
1UR-FE IGNITION: IGNITION SYSTEM: PARTS LOCATION
Page 7690
(a) Using a 14 mm socket hexagon wrench, remove the cap from the modulator.
(b) Remove the O-ring from the cap.
(c) Using pliers, remove the cooler dryer.
Air Conditioning System (for Automatic Air Conditioning
System)
Refrigerant Pressure Sensor / Switch: Locations Air Conditioning System (for Automatic Air
Conditioning System)
AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Automatic Air Conditioning System):
PARTS LOCATION
Page 8112
between other parts.
(d) Check that there is no looseness in the installation parts of the side airbag sensor.
(e) Connect the connector.
9. INSTALL FRONT DOOR SCUFF PLATE LH (for Rear Side) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Installation
10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
11. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
Components
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Column
Shift Type): COMPONENTS
Page 5999
Starter Relay: Testing and Inspection
1UR-FE STARTING: STARTER RELAY: ON-VEHICLE INSPECTION
1. REMOVE STARTER RELAY (ST)
(a) Remove the engine room relay box cover.
(b) Remove the starter relay from the engine room relay block.
2. INSPECT STARTER RELAY
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) If the result is not as specified, replace the relay.
3. INSTALL STARTER RELAY
Page 6072
Ignition Switch: Service and Repair Installation
1UR-FE STARTING: IGNITION SWITCH: INSTALLATION
1. INSTALL IGNITION SWITCH ASSEMBLY
(a) Attach the 2 claws to install the ignition switch to the steering lock.
2. INSTALL UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Manual Tilt)
See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering Column Assembly
(for Manual Tilt)/Reassembly
3. INSTALL UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Manual Tilt
and Manual Telescopic Steering Column)
See: Steering and Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering
Column Assembly (for Manual Tilt and Manual Telescopic Steering Column)/Reassembly
4. INSTALL UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Power Tilt
and Power Telescopic Steering Column)
See: Steering and Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering
Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Reassembly
5. INSTALL STEERING COLUMN ASSEMBLY
(a) for Manual Tilt:
Install the steering column See: Steering and Suspension/Steering/Steering Column/Service and
Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Installation.
(b) for Manual Tilt and Manual Telescopic Steering Column:
Install the steering column See: Steering and Suspension/Steering/Steering Column/Service and
Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt and Manual
Telescopic Steering Column)/Installation.
(c) for Power Tilt and Power Telescopic Steering Column:
Install the steering column See: Steering and Suspension/Steering/Steering Column/Service and
Repair/Removal and Replacement/Steering Column Assembly (for Power Tilt and Power
Telescopic Steering Column)/Installation.
6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Drivetrian - Rear End Howling/Growling Noises
Wheel Bearing: All Technical Service Bulletins Drivetrian - Rear End Howling/Growling Noises
T-SB-0151-10
June11, 2010
Rear Axle Bearing Abnormal Noise
Service Category Drivetrain
Section Axle/Differential
Market USA
Applicability
Introduction
Some 2007 - 2010 model year Tundra vehicles may exhibit a howling or growling noise from the
rear of the vehicle that increases with vehicle speed. Changes have been made to the rear axle
bearing to correct this condition. Follow the procedure in the bulletin to address customer concerns.
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60
months or 60,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Parts Information
Page 6781
Multiple Junction Connector: Diagnostic Aids
Continuity and Resistance Check
CONTINUITY AND RESISTANCE CHECK
Disconnect the battery terminal or wire so there is no voltage between the check points.
Contact the two leads of an ohmmeter to each of the check points.
Page 6282
NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do
not operate the ignition switch, any other switches, or the doors.
(a) If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the
harness and connector.
(b) Connect the cable of the Techstream to the DLC3, turn the ignition switch ON and attempt to
use the tester. If the display indicates that a
communication error has occurred, there is a problem either with the vehicle or with the tester.
HINT *
If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of
the original vehicle.
* If communication is still not possible when the tester is connected to another vehicle, the problem
may be in the tester itself. Consult the Service Department listed in the tester's instruction manual.
How To Proceed With Troubleshooting
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: HOW TO
PROCEED WITH TROUBLESHOOTING
1. OPERATION FLOW
HINT Perform troubleshooting in accordance with the procedures below. The following is an outline
of basic troubleshooting procedures. Confirm the troubleshooting procedures for the circuit you are
working on before beginning troubleshooting.
1. VEHICLE BROUGHT TO WORKSHOP
NEXT -- Continue to next step.
2. CUSTOMER PROBLEM ANALYSIS
(a) Ask the customer about the conditions and environment when the problem occurred.
NEXT -- Continue to next step.
3. INSPECT BATTERY VOLTAGE
Standard voltage:
11 to 14 V
If the voltage is below 11 V, recharge or replace the battery before proceeding.
NEXT -- Continue to next step.
Recall 10V017000: Accelerator Pedal Sticking
Accelerator Pedal Position Sensor: Recalls Recall 10V017000: Accelerator Pedal Sticking
VEHICLE MAKE/MODEL: MODEL YEAR(S): Toyota/Avalon 2005-2010 Toyota/Camry 2007-2010
Toyota/Corolla 2009-2010 Toyota/Corolla Matrix 2009-2010 Toyota/Highlander 2010 Toyota/ RAV4
2009-2010 Toyota/Sequoia 2008-2010 Toyota/Tundra 2007-2010 MANUFACTURER: Toyota
Motor North America, Inc.
MFR'S REPORT DATE: January 21, 2010
NHTSA CAMPAIGN ID NUMBER: 10V017000
NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Accelerator Assembly:
Pedal/Linkage
POTENTIAL NUMBER OF UNITS AFFECTED: ?
SUMMARY: Toyota is recalling certain model year 2005-2010 Avalon, model year 2007-2010
Camry, model year 2009-2010 Corolla, Corolla Matrix, RAV4, model year 2010 Highlander, model
year 2008-2010 Sequoia, and model year 2007-2010 Tundra. due to the manner in which the
friction lever interacts with the sliding surface of the accelerator pedal inside the pedal sensor
assembly, the sliding surface of the lever may become smooth during vehicle operation. In this
condition, if condensation occurs on the surface, as may occur from heater operation (without A/C)
when the pedal assembly is cold, the friction when the accelerator pedal is operated may increase,
which may result in the accelerator pedal becoming harder to depress, slower to return, or, in the
worst case, mechanically stuck in a partially depressed position.
CONSEQUENCE: The accelerator pedal may become hard to depress, slow to return to idle, or, in
the worst case, mechanically stuck in a partially depressed position, increasing the risk of a crash.
REMEDY: Toyota has not yet provided a remedy plan or an owner notification schedule. Owners
may contact Toyota at 1-800-331-4331.
NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle
Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov.
Page 6294
Driver Side J/B - Cowl Side Left
Components
Engine Control Module: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: ECM: COMPONENTS
Service Precautions
Seat Belt: Service Precautions
SEAT BELT: FRONT SEAT OUTER BELT ASSEMBLY (for Regular Cab): PRECAUTION
CAUTION: Replace the faulty parts of the seat belt systems (outer belt, inner belt, bolts, nuts,
adjustable shoulder anchor, tether anchor hardware and other related parts). When inspecting a
vehicle that was in a collision, be sure to check all of the seat belt systems regardless of whether or
not the system was activated in the collision. Replace any damaged or malfunctioning systems.
1. RUNNING TEST (IN SAFE AREA)
CAUTION: Conduct this test in a safe area.
(a) Fasten the front seat belt.
(b) Drive the vehicle at 16 km/h (10 mph) and firmly depress the brake pedal. Check that the belts
lock and cannot be extended at this time.
If a belt does not lock, replace the seat belt assembly See: Service and Repair/Removal and
Replacement/Front Seat Outer Belt Assembly (for Regular Cab)/Removal.
HINT Inspect a seat belt assembly before installing it See: Testing and Inspection/Front Seat Outer
Belt Assembly (for Regular Cab)
Page 1805
Parts Information
Required Tools & Equipment
Repair Procedure
1. Confirm the condition matches the Introduction.
Locations
Brake Lamp Relay: Locations
Engine Room R/B, J/B - Engine Compartment Left
Page 668
Power Door Lock Switch: Testing and Inspection Unlock Warning Switch
DOOR LOCK: UNLOCK WARNING SWITCH: INSPECTION
1. INSPECT UNLOCK WARNING SWITCH ASSEMBLY
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the unlock warning switch assembly.
Page 8627
Auxiliary Input / Output Jack: Service and Repair Stereo Jack Adapter Assembly (for Floor Shift
Type)
Components
AUDIO / VISUAL: STEREO JACK ADAPTER ASSEMBLY (for Floor Shift Type): COMPONENTS
Page 7597
General Information
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: GENERAL
INFORMATION
* A large number of ECU controlled systems are used in the TOYOTA TUNDRA. In general, ECU
controlled systems are considered to be very intricate, requiring a high level of technical knowledge
to troubleshoot. However, most problem checking procedures only involve inspecting the ECU
controlled system's circuits one by one. An adequate understanding of the system and a basic
knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and
necessary repairs.
1. TROUBLESHOOTING PROCEDURES
* The troubleshooting procedures consist of diagnosis procedures for when a DTC is stored and
diagnosis procedures for when no DTC is stored. The basic idea is explained in the following table.
* Vehicle systems are complex and use many ECUs that are difficult to inspect independently.
Therefore, a process of elimination is used, where components that can be inspected individually
are inspected, and if no problems are found in these components, the related ECU is identified as
the problem and replaced.
* It is extremely important to ask the customer about the environment and the conditions present
when the problem occurred (Customer Problem Analysis). This makes it possible to simulate the
conditions and confirm the symptom. If the symptom cannot be confirmed or the DTC does not
recur, the malfunctioning part may not be identified using the troubleshooting procedure, and the
ECU for the related system may be replaced even though it is not defective. If this happens, the
original problem will not be solved.
* In order to prevent endless expansion of troubleshooting procedures, the troubleshooting
procedures are written with the assumption that multiple malfunctions do not occur simultaneously
for a single problem symptom.
* To identify the malfunctioning part, troubleshooting procedures narrow down the target by
separating components, ECUs and wire harnesses during the inspection. If the wire harness is
identified as the cause of the problem, it is necessary to inspect not only the connections to
components and ECUs but also all of the wire harness connectors between the component and the
ECU.
DIAGNOSTIC TESTER
2. DESCRIPTION
System data and the Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector
3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the Techstream* to
check for a malfunction and perform repairs.
HINT *: Techstream is the name for the diagnostic tester in North America.
3. DATA LINK CONNECTOR 3 (DLC3)
(a) The vehicle's ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of
the DLC3 complies with SAE J1962 and
matches the ISO 15765-4 format.
Page 5329
Control Module: Service and Repair Installation
JF1A TRANSFER: 4WD CONTROL ECU: INSTALLATION
1. INSTALL 4WD CONTROL ECU
(a) Install the ECU with the bolt.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
(b) Connect the 2 ECU connectors.
2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Installation
3. INSTALL INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
4. INSTALL COWL SIDE TRIM BOARD RH
(a) Install the cowl side trim board RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Installation.
HINT Use the same procedures described for the LH side.
5. INSTALL FRONT DOOR SCUFF PLATE RH (for Regular Cab)
(a) Install the front door scuff plate RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Installation.
HINT Use the same procedures described for the LH side.
6. INSTALL FRONT DOOR SCUFF PLATE RH (for Double Cab, for CrewMax)
(a) Install the front door scuff plate RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Installation.
HINT Use the same procedures described for the LH side.
Page 963
Solar Sensor: Service and Repair Installation
AIR CONDITIONING: SOLAR SENSOR (for Automatic Air Conditioning System): INSTALLATION
1. INSTALL AUTOMATIC LIGHT CONTROL SENSOR (SOLAR SENSOR)
(a) Connect the connector.
(b) Attach the 2 claws to install the sensor.
2. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY
(a) for Column Shift Type:
Install the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column
Shift Type)/Installation.
(b) for Floor Shift Type:
Install the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation.
Page 5652
(c) Disconnect the connector (labeled D).
(d) Remove the connector (labeled D) from the skid control sensor clamp (labeled H).
(e) Remove the 2 bolts (labeled E) and 2 harness clamps (labeled F).
(f) Remove the bolt (labeled G) and skid control sensor clamp (labeled H).
7. REMOVE FRONT SPEED SENSOR RH
(a) Remove the hexagon socket head cap bolt (labeled A) and speed sensor (labeled B) from the
knuckle.
8. REMOVE FRONT SKID CONTROL SENSOR CLAMP RH
(a) Remove the bolt (labeled C) and skid control sensor clamp (labeled D) from the knuckle.
Installation
BRAKE CONTROL: FRONT SPEED SENSOR: INSTALLATION
1. INSTALL FRONT SKID CONTROL SENSOR CLAMP LH
(a) Install the skid control sensor clamp (labeled A) with the bolt (labeled B).
Torque : 13 Nm (127 kgf-cm, 9 ft-lbf)
NOTICE: Install the bracket so that the rotation stopper (labeled C) touches the knuckle.
Page 5349
Transmission Speed Sensor: Testing and Inspection
A760F AUTOMATIC TRANSMISSION: SPEED SENSOR: INSPECTION
1. INSPECT SPEED SENSOR NT
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) If the result is not as specified, replace the sensor.
2. INSPECT SPEED SENSOR SP2
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) If the result is not as specified, replace the sensor.
Page 2685
Thermostat: Service and Repair Installation
1UR-FE COOLING: THERMOSTAT: INSTALLATION
1. INSTALL WATER INLET SUB-ASSEMBLY WITH THERMOSTAT
(a) Install a new gasket and the water inlet with thermostat with the 3 nuts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
2. CONNECT OUTLET RADIATOR HOSE
(a) Connect the radiator hose.
HINT The direction of hose clamp is indicated in the illustration.
3. INSTALL AIR TUBE SUB-ASSEMBLY LH
(a) Connect the air hose to the air switching valve LH, and install the air tube LH with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(b) Connect the vacuum sensor connector and clamp.
(c) Connect the air tube LH to the water inlet housing with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(d) Connect the air hose.
Page 6346
"Case2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 8359
Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to
prevent airbag and seat belt pretensioner activation.
(c) Install the door airbag sensor with the screw.
Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)
NOTICE: *
If the door airbag sensor has been dropped, or there are any cracks, dents or other defects in the
case, bracket or connector, replace it with a new one.
* When installing the door airbag sensor, be careful that the SRS wiring does not interfere with
other parts and that it is not pinched between other parts.
(d) Check that there is no looseness in the installation parts of the door airbag sensor.
(e) Connect the connector.
2. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Reassembly
3. INSTALL COURTESY LIGHT ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood
and Trunk/Doors/Front Door/Service and
Repair/Front Door (for Double Cab)/Reassembly
4. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH LH (for Front Side) See: Body
and Frame/Doors, Hood and
Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly
5. INSTALL FRONT ARMREST BASE PANEL UPPER LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Reassembly
6. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Reassembly
7. INSTALL REAR SIDE AIRBAG SENSOR
(a) Check that the ignition switch is OFF.
(b) Check that the cable is disconnected from the battery negative (-) terminal.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
(c) Install the side airbag sensor with the bolt.
Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)
NOTICE: *
If the side airbag sensor has been dropped, or there are any cracks, dents or other defects in the
case, bracket or connector, replace it with a new one.
* When installing the side airbag sensor, be careful that the SRS wiring does not interfere with
other parts and that it is not pinched between other parts.
(d) Check that there is no looseness in the installation parts of the side airbag sensor.
(e) Connect the connector.
8. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY LH (for Rear Side) See: Body and
Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation
Page 3600
Manifold Pressure/Vacuum Sensor: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: MANIFOLD ABSOLUTE PRESSURE SENSOR:
INSTALLATION
1. INSTALL MANIFOLD ABSOLUTE PRESSURE SENSOR
(a) Install a new O-ring to the manifold absolute pressure sensor.
(b) Install the manifold absolute pressure sensor with the screw.
Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)
(c) Connect the manifold absolute pressure sensor connector.
2. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Installation
Page 4028
Required Tools & Equipment
Repair Procedure
1. Using TIS Techstream check if DTC P0418, P0419, P2440, P2441, P2442, P2443, P2446
and/or P2447 are present.
2. Using Techstream perform the manual Air Injection Test (options 1 and 2) to verify if the signal
from the air injection control driver is reaching the
air pumps.
^ The pumps should be heard turning on at this point and there should be battery voltage on pin 2
of the pumps during this test.
^ If there is NO voltage refer to the Repair Manual for air injection control driver diagnosis.
Refer to the Technical Information System (TIS) 2010 model year Tundra Repair Manual:
3. If during the test voltage is present at the pump and the pump is NOT running or the Air
Pressure (gauge) value did NOT increase from 0 to 1 psi on
TIS Techstream with the pump running remove the air pump assemblies for inspection.
Refer to TIS 2010 model year Tundra Repair Manual:
4. With the pumps removed from the vehicle verify if there is liquid or evidence that liquid entered
the pumps.
^ YES - If there is liquid evidence go to step 5.
^ NO - If there is NO evidence of liquid go to step 7.
5. If liquid is present replace the affected pump assembly.
Refer to TIS 2010 model year Tundra Repair Manual:
Locations
Engine Temperature Sensor: Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Airbag System
Seat Occupant Sensor: Locations Airbag System
SUPPLEMENTAL RESTRAINT SYSTEM: AIRBAG SYSTEM: PARTS LOCATION
Page 9062
Release the locking lug from terminal and pull the terminal out from rear.
INSTALL TERMINAL TO CONNECTOR
Insert the terminal.
HINT: Make sure the terminal is positioned correctly.
Insert the terminal until the locking lug locks firmly.
Insert the terminal with terminal retainer in the temporary lock position.
Engine - MIL ON/DTC's P0012/P0022 Set
Variable Valve Timing Actuator: Customer Interest Engine - MIL ON/DTC's P0012/P0022 Set
T-SB-0019-10
January 20, 2010
MIL "ON" DTC P0012 and/or P0022
Service Category Engine/Hybrid System
Section Engine Control
Market USA
Applicability
Introduction
Some 2010 model year Sequoia and Tundra vehicles may exhibit a MIL "ON" condition for
Diagnostic Trouble Code (DTC) P0012 and/or P0022 ( Camshaft Position "A" - Timing
Over-Retarded Bank 1/2).
Please refer to the following repair procedure to address this condition.
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60
months or 60,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Production Change Information
Page 6520
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Page 5403
Fluid - Transfer Case: Testing and Inspection
JF1A TRANSFER: TRANSFER OIL: ON-VEHICLE INSPECTION
1. CHECK TRANSFER OIL
(a) Remove the filler plug and gasket.
(b) Check that the oil level is between 0 to 5.0 mm (0 to 0.197 in.) from the bottom lip of the filler
plug hole.
(c) If the result is not as specified, add transfer oil.
Oil grade:
GL-4 or GL-5
Viscosity:
SAE 75W-90
Standard capacity:
1.1 +/- 0.06 liters (1.2 +/- 0.06 US qts, 1.0 +/- 0.05 Imp. qts)
NOTICE: *
After changing the oil, drive the vehicle and check the oil level again.
* Too much or too little oil will lead to transfer problems.
(d) When the oil level is too low, check for oil leak.
(e) Install a new gasket into the filler plug and then tighten the plug.
2. ADD TRANSFER OIL
(a) Remove the filler plug and gasket.
(b) Pour oil so that the oil level is between 0 to 5.0 mm (0 to 0.197 in.) from the bottom lip of the
case plug (for filler) hole.
NOTICE: *
When adding oil, pour it slowly.
* Add oil a little at a time, waiting several minutes between each addition of oil.
(c) Wait approximately 5 minutes and check that the oil level has not changed.
(d) Install a new gasket and the filler plug.
Torque : 37 Nm (377 kgf-cm, 27 ft-lbf)
Components
Seat Memory Switch: Service and Repair Components
SEAT: SEAT MEMORY SWITCH (w/ Seat Position Memory System): COMPONENTS
Diagram Information and Instructions
Fuse Block: Diagram Information and Instructions
Wiring Color Codes
Abbreviations Used Within Diagrams
Abbreviations Used Within Diagrams
Page 8839
(b) Temporarily install the speaker by aligning the positioning pins of the speaker with the
instrument panel.
(c) Install the speaker with the 2 bolts.
NOTICE: *
Do not touch the cone part of the speaker.
* When installing the speaker to the instrument panel, be careful that the wires do not get caught
between the parts.
4. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY LH
(a) Connect the speaker connector.
(b) Temporarily install the speaker by aligning the positioning pins of the speaker with the
instrument panel.
(c) Install the speaker with the 2 bolts.
NOTICE: *
Do not touch the cone part of the speaker.
* When installing the speaker to the instrument panel, be careful that the wires do not get caught
between the parts.
5. INSTALL NO. 2 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY
(a) Attach the 4 clips and claw to install the speaker panel.
6. INSTALL NO. 1 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY
Page 9207
(e) Remove the inside handle.
Reassembly
ENGINE HOOD / DOOR: FRONT DOOR (for CrewMax): REASSEMBLY
FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH
HINT *
Use the same procedures for the RH side and LH side.
* The procedures listed below are for the LH side.
* A bolt without a torque specification is shown in the standard bolt chart See:
Specifications/Mechanical Specifications/Standard Bolt - Specified Torque For Standard Bolts
1. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH
(a) Connect the 2 cables to the inside handle.
(b) Connect the connector.
(c) Attach the inside handle's knob to the door trim board.
(d) Attach the 9 clips to install the door trim board.
(e) Install the inside handle and door trim board to the door trim panel with the screw.
(f) Install the door trim board to the door panel with the screw.
(g) Install the clip.
2. INSTALL FRONT DOOR ARMREST COVER LH
Locations
Cabin Temperature Sensor / Switch: Locations
AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Automatic Air Conditioning System):
PARTS LOCATION
Page 6992
Engine Room R/B, J/B - Engine Compartment Left
Page 2153
Tire Pressure Sensor: Diagrams
Page 6625
HINT Tape the screwdriver tip before use.
10. REMOVE REAR POWER OUTLET SOCKET COVER (for Double Cab)
(a) Detach the 2 claws and remove the power outlet socket cover.
Installation
OTHER SYSTEM: CENTER POWER OUTLET SOCKET (for Column Shift Type): INSTALLATION
1. INSTALL REAR POWER OUTLET SOCKET COVER (for Double Cab)
(a) Attach the 2 claws to install the power outlet socket cover.
2. INSTALL REAR POWER OUTLET SOCKET ASSEMBLY (for Double Cab)
(a) Attach the claw to install the power outlet socket.
3. INSTALL CENTER SEATBACK PANEL (for Double Cab) See: Body and Frame/Seats/Service
and Repair/Overhaul/Front Seat Assembly (for
Center Seat)/Reassembly
4. INSTALL POWER OUTLET SOCKET COVER
(a) Attach the 2 claws to install the power outlet socket cover.
5. INSTALL POWER OUTLET SOCKET ASSEMBLY
Page 3087
NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do
not operate the ignition switch, any other switches, or the doors.
(a) If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the
harness and connector.
(b) Connect the cable of the Techstream to the DLC3, turn the ignition switch ON and attempt to
use the tester. If the display indicates that a
communication error has occurred, there is a problem either with the vehicle or with the tester.
HINT *
If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of
the original vehicle.
* If communication is still not possible when the tester is connected to another vehicle, the problem
may be in the tester itself. Consult the Service Department listed in the tester's instruction manual.
How To Proceed With Troubleshooting
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: HOW TO
PROCEED WITH TROUBLESHOOTING
1. OPERATION FLOW
HINT Perform troubleshooting in accordance with the procedures below. The following is an outline
of basic troubleshooting procedures. Confirm the troubleshooting procedures for the circuit you are
working on before beginning troubleshooting.
1. VEHICLE BROUGHT TO WORKSHOP
NEXT -- Continue to next step.
2. CUSTOMER PROBLEM ANALYSIS
(a) Ask the customer about the conditions and environment when the problem occurred.
NEXT -- Continue to next step.
3. INSPECT BATTERY VOLTAGE
Standard voltage:
11 to 14 V
If the voltage is below 11 V, recharge or replace the battery before proceeding.
NEXT -- Continue to next step.
Page 4383
Fuel Pump Control Unit: Service and Repair Installation
1UR-FE FUEL: FUEL PUMP ECU: INSTALLATION
1. INSTALL FUEL PUMP ECU
(a) Install the fuel pump ECU with the 2 bolts.
Torque : 20 Nm (199 kgf-cm, 14 ft-lbf)
NOTICE: Do not use the fuel pump ECU if it has been subjected to physical shocks such as being
dropped, etc.
(b) Connect the 2 fuel pump ECU connectors.
Page 130
Compressor Clutch Relay: Locations Air Conditioning System (for Manual Air Conditioning System)
AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Manual Air Conditioning System):
PARTS LOCATION
Glass Breakage Sensor (for Floor Shift Type)
Ultrasonic Sensor: Service and Repair Glass Breakage Sensor (for Floor Shift Type)
Components
THEFT DETERRENT: GLASS BREAKAGE SENSOR (for Floor Shift Type): COMPONENTS
Removal
THEFT DETERRENT: GLASS BREAKAGE SENSOR (for Floor Shift Type): REMOVAL
1. REMOVE FRONT DOOR SCUFF PLATE LH
Page 4987
(c) If the result is not as specified, replace the solenoid valve.
6. INSPECT SHIFT SOLENOID VALVE SL2
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) Apply 12 V battery voltage to the shift solenoid valve and check that the valve moves and
makes an operating noise.
OK:
(c) If the result is not as specified, replace the solenoid valve.
7. INSPECT SHIFT SOLENOID VALVE SR
Page 7682
Compressor Speed Sensor: Locations Air Conditioning System (for Manual Air Conditioning
System)
AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Manual Air Conditioning System):
PARTS LOCATION
Locations
Parking Assist Distance Sensor: Locations
PARK ASSIST / MONITORING: INTUITIVE PARKING ASSIST SYSTEM: PARTS LOCATION
Page 7980
(b) Detach the 2 claws and disconnect the DLC3.
(c) Disconnect the connector.
NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness.
Installation
SUPPLEMENTAL RESTRAINT SYSTEM: DRIVER SIDE KNEE AIRBAG ASSEMBLY:
INSTALLATION
1. INSTALL LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY
(a) Connect the connector.
NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness.
(b) Attach the 2 claws to install the DLC3.
(c) Install the 4 bolts to install the instrument panel airbag.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Installation
3. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
4. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Installation
5. INSTALL FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Installation
6. INSTALL FRONT DOOR SCUFF PLATE LH (for Double Cab, CrewMax) See: Body and
Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Installation
7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
8. CHECK SRS WARNING LIGHT
Page 8844
(a) Remove the 2 bolts.
(b) Remove the speaker and disconnect the connector.
NOTICE: Do not touch the cone part of the speaker.
Installation
AUDIO / VISUAL: INSTRUMENT PANEL SPEAKER (for Regular Cab): INSTALLATION
1. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY RH
(a) Connect the speaker connector.
(b) Temporarily install the speaker by aligning the positioning pins of the speaker with the
instrument panel.
(c) Install the speaker with the 2 bolts.
NOTICE: *
Do not touch the cone part of the speaker.
* When installing the speaker to the instrument panel, be careful that the wires do not get caught
between the parts.
2. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY LH
(a) Connect the speaker connector.
(b) Temporarily install the speaker by aligning the positioning pins of the speaker with the
instrument panel.
(c) Install the speaker with the 2 bolts.
NOTICE: *
Do not touch the cone part of the speaker.
* When installing the speaker to the instrument panel, be careful that the wires do not get caught
between the parts.
3. INSTALL NO. 2 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY
Page 9022
(1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be
checked by conducting a voltage check.
With each connector still connected, measure the voltage between the body ground and these
terminals (in this order): 1) terminal 1 of connector A; 2) terminal 1 of connector B; and 3) terminal
1 of connector C.
Standard voltage (Fig. 4):
* If the results match the examples above, an open circuit exists in the wire harness between
terminal 1 of connector B and terminal 1 of connector C.
3. CHECK FOR SHORT CIRCUIT
(a) If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance
check with the body ground (below).
(b) Check the resistance with the body ground.
(1) Disconnect connectors A and C and measure the resistance.
Standard resistance (Fig. 6):
HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally.
If your results match the examples above, a short circuit exists between terminal 1 of connector A
and terminal 1 of connector C.
Components
Seat Occupant Classification Module - Air Bag: Service and Repair Components
SUPPLEMENTAL RESTRAINT SYSTEM: OCCUPANT CLASSIFICATION ECU: COMPONENTS
Page 6785
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION: Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC
terminals are touched, the IC may be destroyed by static electricity.)
When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact with the terminals of leads from the IC, etc. of the
replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown on the left.
DISCONNECT CONNECTOR
Page 6055
(1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be
checked by conducting a voltage check.
With each connector still connected, measure the voltage between the body ground and these
terminals (in this order): 1) terminal 1 of connector A; 2) terminal 1 of connector B; and 3) terminal
1 of connector C.
Standard voltage (Fig. 4):
* If the results match the examples above, an open circuit exists in the wire harness between
terminal 1 of connector B and terminal 1 of connector C.
3. CHECK FOR SHORT CIRCUIT
(a) If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance
check with the body ground (below).
(b) Check the resistance with the body ground.
(1) Disconnect connectors A and C and measure the resistance.
Standard resistance (Fig. 6):
HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally.
If your results match the examples above, a short circuit exists between terminal 1 of connector A
and terminal 1 of connector C.
Components
Steering Control Module: Service and Repair Components
POWER STEERING: POWER STEERING ECU (for 1UR-FE): COMPONENTS
Components
Knock Sensor: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: COMPONENTS
Page 6985
3. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE
HINT The diagnostic system in the TOYOTA TUNDRA has various functions.
* The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU
memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a
previous malfunction's DTC can be checked by a technician during troubleshooting.
* Another function is the Input Signal Check, which checks if the signals from various switches are
sent to the ECU correctly.
* By using these functions, the problem areas can be narrowed down and troubleshooting is more
effective. Diagnostic functions are incorporated in the following systems in the TOYOTA TUNDRA.
Page 7172
Front Steering Knuckle: Service and Repair Installation
AXLE: STEERING KNUCKLE: INSTALLATION
HINT *
Use the same procedures for the LH side and RH side.
* The procedures listed below are for the LH side.
1. INSTALL KNUCKLE GREASE RETAINER CAP LH (for 2WD)
(a) Using a brass bar and hammer, tap in a new retainer cap.
NOTICE: *
The retainer cap is a non-reusable part.
* Do not damage the retainer cap.
2. INSTALL STEERING KNUCKLE OIL SEAL LH
(a) Using SST and a press, press in a new oil seal.
SST : 09950-60020
09951-01030
SST : 09950-70010
09951-07100
NOTICE: *
The oil seal is a non-reusable part.
* Do not damage the steering knuckle oil seal.
3. INSTALL STEERING KNUCKLE LH
(a) Install the front suspension upper arm to the steering knuckle with the nut.
Torque : 110 Nm (1,122 kgf-cm, 81 ft-lbf)
(b) Install a new clip.
HINT If the holes for the clip are not aligned, tighten the nut up to another 60.
4. CONNECT FRONT LOWER BALL JOINT ATTACHMENT LH See: Suspension/Control
Arm/Service and Repair/Removal and
Replacement/Front Lower Suspension Arm/Installation
5. CONNECT TIE ROD END SUB-ASSEMBLY LH See: Steering Gear/Service and
Repair/Removal and Replacement/Installation
Page 3532
2. CHECK DLC3
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NOTICE: When the measured value is higher than 132 Ohms and a CAN communication system
DTC is output, there may be a problem besides disconnection of the DLC3 branch wire. For that
reason, troubleshooting should be performed again from "HOW TO PROCEED WITH
TROUBLESHOOTING" See: Initial Inspection and Diagnostic Overview/CAN Communication
System after repairing the trouble area.
NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO DLC3 (CANH, CANL) OK -Continue to next step.
3. CHECK FOR OPEN IN CAN BUS MAIN WIRE (NO. 1 JUNCTION CONNECTOR - ECM)
(a) Disconnect the J94 No. 1 junction connector connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- CONNECT CONNECTOR OK -- Continue to next step.
4. CHECK FOR OPEN IN CAN BUS MAIN WIRE (NO. 1 JUNCTION CONNECTOR COMBINATION METER ECU)
(a) Disconnect the J84 No. 1 junction connector connector.
Page 9000
Symbols Used Within Diagrams
Symbols Used Within Diagrams
Page 8105
Door/Service and Repair/Front Door (for Double Cab)/Disassembly
4. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH (for Front Side) See: Body
and Frame/Doors, Hood and
Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly
5. REMOVE COURTESY LIGHT ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood
and Trunk/Doors/Front Door/Service and
Repair/Front Door (for Double Cab)/Disassembly
6. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Disassembly
7. REMOVE FRONT SIDE AIRBAG SENSOR
(a) Disconnect the connector.
(b) Remove the screw and side airbag sensor.
8. REMOVE REAR SEAT ASSEMBLY (for Rear Side)
(a) Remove the rear seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Rear Seat Assembly (for Double
Cab)/Removal.
9. REMOVE REAR DOOR SCUFF PLATE LH (for Rear Side) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and Repair/Roof
Headlining (For Double Cab)/Removal
10. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH (for Rear Side)
11. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY LH (for Rear Side) See: Body and
Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal
12. REMOVE REAR SIDE AIRBAG SENSOR
(a) Remove the bolt and side airbag sensor.
(b) Disconnect the connector.
Installation
SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Double Cab):
INSTALLATION
1. INSTALL FRONT SIDE AIRBAG SENSOR
(a) Check that the ignition switch is OFF.
(b) Check that the cable is disconnected from the battery negative (-) terminal.
CAUTION:
Page 5027
Page 2337
Parts Information
Required Tools & Equipment
Additional TIS Techstream units may be ordered by calling Approved Dealer Equipment (ADE).
TSB Overview
1. Confirm that DTC P0012 and/or P0022 is stored in the ECM.
2. Diagnose the Oil Control Valves (OCVs) for proper operation.
3. If the OCVs operate correctly replace both intake VVTi gear assemblies following the Repair
Manual.
Diagnostic Procedure
1. Using TIS Techstream confirm that DTC P0012 and/or P0022 is stored in the ECM.
2. Remove the affected Oil Control Valve (OCV) and inspect for debris in the valve or evidence that
the valve is stuck.
3. Check valve operation by applying positive (+) battery voltage to terminal 1 and negative (-)
battery voltage to terminal 2. Valve should move
quickly when voltage is applied. If NOT valve should be replaced.
4. Reinstall the OCVs warm up the engine to over 167°F (75°C) and perform an Active Test using
Tech stream.
Powertrain / Engine and ECT / Active Test / Control the WT System (Bank 1) or (Bank 2)
5. If there is NO debris and the OCV moves with battery voltage and Active Test functions Replace both intake VVTi gears following the repair
procedure below.
Repair Procedure
1. Replace both intake VVTi gears.
Page 2194
Tire Pressure Monitor Receiver / Transponder: Diagrams
Specifications
Firing Order: Specifications
Firing Order
1-8-4-3-6-5-7-2
Page 6006
Above are items that should be checked periodically and their frequency.
Summary Chart for Long-Term Storage
A combination of proper Vehicle Receipt, Pre-Delivery Service and Vehicle Storage is the only way
to maintain factory fresh vehicles. Toyota's goal is to deliver 100% problem-free cars and trucks.
With your commitment to quality and customer satisfaction, we can reach that goal. Review this
TSB often and be sure new employees are aware of the policies and procedures out-lined herein,
as individual training in proper inspection, pre-delivery service, and storage and handling
techniques are essential to ensure high delivery quality.
Here is a list of additional resources, which will help you with vehicle receipt, inspection and
storage procedures.
Reference and Training Materials
^ CRIB # 165, Acid Rain Paint Finish Damage - Prevention and Repair
^ UoT e-Learning Course E257 Vehicle Delivery Quality - Paint Finish Repair
^ Dealer Delivery Quality Operations Guide, P/N 00116-DDQ0G-98
^ BO020-91, Prevention and Repair of Acid Rain Damage
^ BO05-04, New Vehicle Washing Schedule for Paint Protection
^ PG001-06, Battery Maintenance for In Stock Vehicle and Pre-Delivery
^ PA005-04, Iron Particle Rust Contamination Repair
^ PG005-94, Rapgard(TM) Removal Procedures
^ PG007-02, Wheel Film for Brake Rotor Rust Prevention
^ Maintenance for HV & Auxiliary Batteries, Refer to applicable HV models.
Page 297
Driver Side J/B - Cowl Side Left
Page 3063
Page 1051
Page 5195
(h) Using a brass bar and hammer, tap out the inner race.
NOTICE: Be careful not to damage the inner race.
(i) Remove the cage.
4. REMOVE INBOARD JOINT BOOT
(a) Remove the inboard joint boot from the outboard joint shaft.
5. REMOVE OUTBOARD JOINT BOOT CLAMP
(a) Using a side cutter, cut the 2 outboard joint boot clamps and remove them.
6. REMOVE OUTBOARD JOINT BOOT
(a) Remove the outboard joint boot from the outboard joint shaft.
7. REMOVE FRONT DRIVE SHAFT DUST COVER LH
(a) Using SST and a press, press out the dust cover.
SST : 09950-00020
8. REMOVE DUST SEAL
(a) Using SST and a press, press out the dust seal.
Page 8801
4. REMOVE FRONT UPPER ARMREST BASE PANEL LH See: Body and Frame/Doors, Hood
and Trunk/Doors/Front Door/Service and
Repair/Front Door (for CrewMax)/Disassembly
5. REMOVE FRONT DOOR ARMREST COVER LH
6. REMOVE COURTESY LIGHT ASSEMBLY See: Body and Frame/Doors, Hood and
Trunk/Doors/Front Door/Service and Repair/Front Door
(for CrewMax)/Disassembly
7. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH See: Body and Frame/Doors,
Hood and Trunk/Doors/Front Door/Service and
Repair/Front Door (for CrewMax)/Disassembly
8. REMOVE FRONT NO. 1 SPEAKER ASSEMBLY
(a) Disconnect the speaker connector.
(b) Remove the 4 screws and speaker.
NOTICE: Do not touch the cone part of the speaker.
9. REMOVE FRONT NO. 3 SPEAKER ASSEMBLY (for 12 Speakers)
(a) Remove the 3 screws and speaker with bracket.
(b) Detach the 3 claws and remove the speaker from the bracket.
NOTICE: Do not touch the cone part of the speaker.
Installation
AUDIO / VISUAL: FRONT DOOR SPEAKER (for CrewMax): INSTALLATION
HINT *
Use the same procedures for the LH side and RH side.
Page 8831
(b) Temporarily install the speaker by aligning the positioning pins of the speaker with the
instrument panel.
(c) Install the speaker with the 2 bolts.
NOTICE: *
Do not touch the cone part of the speaker.
* When installing the speaker to the instrument panel, be careful that the wires do not get caught
between the parts.
4. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY LH
(a) Connect the speaker connector.
(b) Temporarily install the speaker by aligning the positioning pins of the speaker with the
instrument panel.
(c) Install the speaker with the 2 bolts.
NOTICE: *
Do not touch the cone part of the speaker.
* When installing the speaker to the instrument panel, be careful that the wires do not get caught
between the parts.
5. INSTALL NO. 2 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY
(a) Attach the 4 clips and claw to install the speaker panel.
6. INSTALL NO. 1 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY
Page 7582
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION: Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC
terminals are touched, the IC may be destroyed by static electricity.)
When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact with the terminals of leads from the IC, etc. of the
replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown on the left.
DISCONNECT CONNECTOR
Page 663
Power Door Lock Switch: Diagrams Unlock Warning Switch
Page 6938
Driver Side J/B - Cowl Side Left
Page 7808
Compressor Clutch Relay: Testing and Inspection
AIR CONDITIONING: MAGNETIC CLUTCH RELAY: ON-VEHICLE INSPECTION
1. INSPECT MAGNETIC CLUTCH RELAY (MG CLT)
(a) Remove the magnetic clutch relay from the engine room relay block.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
* If the result is not as specified, replace the relay.
(c) Install the magnetic clutch relay.
Page 6042
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION: Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC
terminals are touched, the IC may be destroyed by static electricity.)
When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact with the terminals of leads from the IC, etc. of the
replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown on the left.
DISCONNECT CONNECTOR
Page 7604
(2) CONNECTORS
Slightly shake the connector vertically and horizontally.
(3) WIRE HARNESS
Slightly shake the wire harness vertically and horizontally.
HINT The connector joint and fulcrum of the vibration are the major areas that should be checked
thoroughly.
(b) HEAT METHOD:
When a malfunction seems to occur when the area in question is heated.
(1) Heat the component that is the possible cause of the malfunction with a hair dryer or similar
device. Check if the malfunction occurs.
NOTICE: *
Do not heat to more than 60°C (140°F). Exceeding this temperature may damage components.
* Do not apply heat directly to the parts in the ECU.
(c) WATER SPRINKLING METHOD:
When a malfunction seems to occur on a rainy day or in high-humidity.
(1) Sprinkle water onto the vehicle and check if the malfunction occurs.
NOTICE: *
Never sprinkle water directly into the engine compartment. Indirectly change the temperature and
humidity by spraying water onto the front of the radiator.
* Never apply water directly onto the electronic components.
HINT If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU
or connections. Look for evidence of corrosion or short circuits. Proceed with caution during water
tests.
(d) HIGH ELECTRICAL LOAD METHOD:
When a malfunction seems to occur when the electrical load is excessive.
(1) Turn on the heater blower, headlights, rear window defogger and all other electrical loads.
Check if the malfunction reoccurs.
5. DIAGNOSTIC TROUBLE CODE CHART
Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate
section's Diagnostic Trouble Code Chart. Use the chart to determine the trouble area and the
proper inspection procedure. A description of each of the chart's columns is below.
Page 9222
Page 1096
Headlamp Dimmer Switch: Service and Repair Removal
LIGHTING: HEADLIGHT DIMMER SWITCH: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE LOWER NO. 2 STEERING WHEEL COVER See: Restraint Systems/Air Bag
Systems/Air Bag/Service and Repair/Removal and
Replacement/Steering Pad/Removal
3. REMOVE LOWER NO. 3 STEERING WHEEL COVER See: Restraint Systems/Air Bag
Systems/Air Bag/Service and Repair/Removal and
Replacement/Steering Pad/Removal
4. REMOVE STEERING PAD (w/ Steering Pad Switch) See: Restraint Systems/Air Bag
Systems/Air Bag/Service and Repair/Removal and
Replacement/Steering Pad/Removal
5. REMOVE STEERING PAD (w/o Steering Pad Switch) See: Restraint Systems/Air Bag
Systems/Air Bag/Service and Repair/Removal and
Replacement/Steering Pad/Removal
6. REMOVE STEERING WHEEL ASSEMBLY See: Steering and Suspension/Steering/Steering
Column/Service and Repair/Removal and
Replacement/Steering Column Assembly (for Power Tilt and Power Telescopic Steering
Column)/Removal
7. REMOVE LOWER STEERING COLUMN COVER (for Manual Tilt) See: Steering and
Suspension/Steering/Steering Column/Service and
Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Removal
8. REMOVE LOWER STEERING COLUMN COVER (for Manual Tilt and Manual Telescopic
Steering Column) See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering
Column Assembly (for Manual Tilt and Manual Telescopic Steering Column)/Removal
9. REMOVE LOWER STEERING COLUMN COVER (for Power Tilt and Power Telescopic Steering
Column) See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering
Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Removal
10. REMOVE UPPER STEERING COLUMN COVER (for Manual Tilt) See: Steering and
Suspension/Steering/Steering Column/Service and
Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Removal
11. REMOVE UPPER STEERING COLUMN COVER (for Manual Tilt and Manual Telescopic
Steering Column) See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering
Column Assembly (for Manual Tilt and Manual Telescopic Steering Column)/Removal
12. REMOVE UPPER STEERING COLUMN COVER (for Power Tilt and Power Telescopic
Steering Column) See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering
Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Removal
13. REMOVE TILT AND TELESCOPIC MANUAL SWITCH (for Power Tilt and Power Telescopic
Steering Column) See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering
Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Removal
14. REMOVE SPIRAL CABLE SUB-ASSEMBLY See: Restraint Systems/Air Bag
Systems/Clockspring Assembly / Spiral Cable/Service and
Repair/Removal
15. REMOVE WINDSHIELD WIPER SWITCH ASSEMBLY
(a) Disconnect the connectors.
Emissions - MIL ON/Multiple Air Injection DTC's Set
Air Injection Control Valve: All Technical Service Bulletins Emissions - MIL ON/Multiple Air Injection
DTC's Set
T-SB-0350-09
Rev1
October 1, 2009
Air Injection Pump With Water Intrusion: MIL "ON" DTC P04181P0419 and/or P244 #
Service Category Engine/Hybrid System
Section Engine Control
Market USA
Applicability
TSB REVISION NOTICE
May 21, 2010 Rev1:
^ DTCs P0418 and P0419 have been added to the TSB.
^ The Applicable Warranty has been updated in the Warranty Information section. Any previous
printed versions of this service bulletin should be discarded.
Introduction
Some 2010 model year Tundra vehicles built in the Texas plant may exhibit a MIL "ON" condition
with Diagnostic Trouble Code (DTC) P0418, P0419, P2440, P2441, P2442, P2443, P2446, and/or
P2447. This concern may be caused by water intrusion into the air injection pump assembly. Use
the following procedure to address this condition.
Parts Information
Production Change Information
Page 9129
If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness
or connector in that circuit in the past. Check the wire harness and connectors.
B -- SYSTEM NORMAL
A -- TROUBLESHOOTING OF EACH PROBLEM SYMPTOM
The problem is still occurring in a place other than the diagnostic circuit (the DTC displayed first is
either for a past problem or a secondary problem).
4. SYMPTOM SIMULATION
HINT The most difficult case in troubleshooting is when no problem symptoms occur. In such a
case, a thorough problem analysis must be carried out. A simulation of the same or similar
conditions and environment in which the problem occurred in the customer's vehicle should be
carried out. No matter how much skill or experience a technician has, troubleshooting without
confirming the problem symptoms will lead to important repairs being overlooked and mistakes or
delays.
For example:
With a problem that only occurs when the engine is cold or as a result of vibration caused by the
road during driving, the problem can never be determined if the symptoms are being checked on a
stationary vehicle or on a vehicle with a warmed-up engine. Vibration, heat or water penetration
(moisture) is difficult to reproduce. The symptom simulation tests below are effective substitutes for
the conditions and can be applied on a stationary vehicle.
Important points in the symptom simulation test:
In the symptom simulation test, the problem symptoms as well as the problem area or parts must
be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then,
connect the tester and carry out the symptom simulation test, judging whether the circuit being
tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the
problem symptoms table for each system to narrow down the possible causes.
To reproduce DTCs, it is necessary to satisfy the respective DTC detection conditions.
(a) VIBRATION METHOD:
When a malfunction seems to occur as a result of vibration.
(1) PART AND SENSOR
Apply slight vibration with a finger to the part of the sensor suspected to be the cause of the
problem, and check whether or not the malfunction occurs.
NOTICE: Applying strong vibration to relays may open them.
Page 1471
Ignition Switch: Diagnostic Aids
Continuity and Resistance Check
CONTINUITY AND RESISTANCE CHECK
Disconnect the battery terminal or wire so there is no voltage between the check points.
Contact the two leads of an ohmmeter to each of the check points.
Page 3692
^ Figure 17 shows an example of the update procedure for a two-processor ECU.
G. Turn ignition OFF. Then click Next.
H. Confirm the following:
^ Ignition is ON and engine is OFF or "READY" OFF (hybrid vehicles).
^ Hood is open.
^ All accessories are OFF.
^ Battery voltage is above 11.4 volts.
NOTICE
Verify the vehicle is connected to a battery charger before continuing - If battery voltage falls below
11.4 volts, ECU damage may occur.
Page 3139
(3) Check for dirt or mud on the pipe and around the connector before disconnection. Clean if
necessary.
(4) Pinch the connector and disconnect the connector and pipe.
(5) If the connector and the pipe are stuck together, pinch the connector, push and pull the pipe to
disconnect the pipe and pull it out.
NOTICE: Do not use any tools.
(6) Check for dirt or mud on the seal surface of the disconnected pipe. Clean if necessary.
(7) To protect the disconnected pipe and connector from damage and contamination, cover it with a
plastic bag.
(e) Observe these precautions when connecting the fuel tube connector (for Quick Type).
(1) Check that there is no damage or contamination in the connected part of the pipe.
(2) Align the axis of the connector with the axis of the pipe. Push the pipe into the connector until
the connector makes a "click" sound. If the
connection is tight, apply a small amount of fresh spindle oil or gasoline on the tip of the pipe.
(3) After having finished the connection, try to pull apart the pipe and the connector to confirm that
they are securely connected.
Page 395
HINT The wavelength becomes shorter as the engine rpm increases.
(f) WAVEFORM 5:
HINT *
The wavelength becomes shorter as the engine rpm increases.
* The waveforms and amplitudes displayed differ slightly depending on the vehicle.
(g) WAVEFORM 6:
HINT The wavelength becomes shorter as engine rpm increases.
(h) WAVEFORM 7:
Page 7533
2. Install ChaSSiSEAR(TM) on the vehicle and attempt to isolate the source of the noise. Is the
noise loudest near the rear wheel bearing assembly?
^ YES - Go to step 3.
^ NO - This TSB does NOT apply. Continue diagnosis to isolate the source of the noise.
3. Replace the rear wheel bearing caliper bracket and related parts.
Refer to the Technical Information System (TIS) applicable model year Repair Manual:
4. Test drive the vehicle and confirm the noise is eliminated.
5. Re-check rear differential oil level and confirm NO leaks are present.
Engine Controls - ECM Update For Shift Performance
Engine Control Module: Customer Interest Engine Controls - ECM Update For Shift Performance
T-SB-0285-10
October 12, 2010
ECM Calibration: Enhancement to Shifting Performance
Service Category Drivetrain
Section Automatic Transmission/Transaxle
Market USA
Applicability
Introduction
Some vehicles may exhibit the following shifting conditions:
^ Harsh shift on acceleration below 20 mph during the 2-1 downshift.
^ Excessive lock-up operation at freeway speeds about 50 - 60 mph, sometimes referred to as
"busy shifting".
The Engine Control Module/ECM (SAE term: Powertrain Control Module/PCM) calibration has
been revised. Use the following repair procedure to address these conditions.
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Federal Emission Warranty. This warranty is in effect for
96 months or 80,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Page 1376
Impact Sensor: Diagrams Front Airbag Sensor
Page 8284
Removal
SEAT BELT: REAR SEAT OUTER BELT ASSEMBLY (for Double Cab): REMOVAL
HINT *
Use the same procedures for the LH side and RH side.
* The procedures listed below are for the LH side.
1. REMOVE REAR SEAT ASSEMBLY
(a) Remove the rear seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Rear Seat Assembly (for Double
Cab)/Removal.
2. REMOVE REAR DOOR SCUFF PLATE See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Removal
Diode (Front Door Courtesy Light)
Diode: Diagrams Diode (Front Door Courtesy Light)
Page 6969
[A] For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
"Case1" Raise the terminal retainer up to the temporary lock position.
Page 5070
09954-03010
09955-03030
09956-03020
(b) Coat the threads of the nut with hypoid gear oil.
(c) Using SST to hold the companion flange.
SST : 09330-00021
09330-00030
(d) Tighten the nut until the standard preload is reached.
Torque : 451 Nm (4599 kgf-cm, 332 ft-lb for less)
NOTICE: As there is no spacer, tighten the nut a little at a time, being careful not to overtighten it.
(e) Using a torque wrench, measure the preload of the backlash between the drive pinion and ring
gear.
Standard preload (at starting):
(f) If necessary, disassemble and inspect the differential assembly.
20. ADJUST BACKLASH BETWEEN DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE
PINION
(a) Using SST and a dial indicator, measure the ring gear backlash.
SST : 09564-33010
Page 8249
Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to
prevent airbag and seat belt pretensioner activation.
2. REMOVE FRONT SEAT ASSEMBLY
(a) for Manual Seat:
Remove the front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Manual Seat)/Removal.
(b) for Power Seat:
Remove the front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Power Seat)/Removal.
3. REMOVE FRONT DOOR SCUFF PLATE See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Removal
4. REMOVE REAR DOOR SCUFF PLATE See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Removal
5. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP
(a) Partially remove the front door opening trim weatherstrip so that the center lower pillar garnish
and center pillar garnish can be removed See:
Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Removal.
6. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP
(a) Partially remove the rear door opening trim weatherstrip so that the center lower pillar garnish
and center pillar garnish can be removed See:
Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Removal.
7. REMOVE LOWER CENTER PILLAR GARNISH
(a) Detach the 2 claws and remove the cover.
(b) Remove the bolt and seat belt anchor.
Page 2512
ERROR: undefined
OFFENDING COMMAND: f‘~
STACK:
Page 3369
[A] For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
"Case1" Raise the terminal retainer up to the temporary lock position.
Page 8201
1. REMOVE UPPER BACK PANEL GARNISH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining
(For Regular Cab)/Removal
2. REMOVE CHILD RESTRAINT SEAT TETHER ANCHOR BRACKET
(a) Remove the 2 bolts and 2 anchor brackets.
Installation
SEAT BELT: CHILD RESTRAINT SEAT ANCHOR BRACKET (for Regular Cab): INSTALLATION
1. INSTALL CHILD RESTRAINT SEAT TETHER ANCHOR BRACKET
(a) Align the holes with the positioning pins and install the 2 anchor brackets with the 2 bolts.
Torque : 42 Nm (428 kgf-cm, 31 ft-lbf)
2. INSTALL UPPER BACK PANEL GARNISH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining
(For Regular Cab)/Installation
Page 2729
(c) Connect the tailpipe to the center exhaust pipe.
(d) Attach a new clamp to the tailpipe and center exhaust pipe. Then install the bolt to the clamp.
Torque : 32 Nm (326 kgf-cm, 24 ft-lbf)
HINT Install the clamp within the angle range shown in the illustration.
14. INSPECT FOR EXHAUST GAS LEAK See: Exhaust Manifold/Service and Repair/Installation
Page 7190
(a) Install a new gasket to the pressure feed tube.
(b) Install the pressure feed tube with the union bolt.
Torque : 51 Nm (520 kgf-cm, 38 ft-lbf)
3. CONNECT SOLENOID VALVE CONNECTOR
(a) Connect the solenoid valve connector.
4. CONNECT POWER STEERING OIL PRESSURE SENSOR CONNECTOR
(a) Connect the oil pressure sensor connector.
5. CONNECT NO. 1 OIL RESERVOIR TO PUMP HOSE
(a) Connect the hose with the clip.
6. CONNECT HARNESS BRACKET
Page 6924
(2) Disconnect connector B and measure the resistance.
Standard resistance (Fig. 7):
* If the results match the examples above, a short circuit exists between terminal 1 of connector B2
and terminal 1 of connector C.
4. CHECK AND REPLACE ECU
NOTICE: *
The connector should not be disconnected from the ECU. Perform the inspection from the backside
of the connector on the wire harness side.
* When no measuring condition is specified, perform the inspection with the engine stopped and
the ignition switch ON.
* Check that the connectors are fully seated. Check for loose, corroded or broken wires.
(a) First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be
faulty. Temporarily replace the ECU with a
normally functioning one and check if the symptoms occur. If the trouble symptoms disappear,
replace the original ECU.
(1) Measure the resistance between the ECU ground terminal and body ground.
Standard resistance:
Below 1 Ohms
(2) Disconnect the ECU connector. Check the ground terminal on the ECU side and wire harness
side for bending, corrosion or foreign matter.
Lastly, check the contact pressure of the female terminals.
Locations
Door Switch: Locations
DOOR LOCK: KEY REMINDER WARNING SYSTEM: PARTS LOCATION
Page 2535
Refer to the Technical Information System (TIS) applicable model and model year Repair Manual:
2. Verify the vehicle has the proper coolant and oil levels.
3. Clear all DTCs and confirm the condition has been corrected.
Page 4688
Transmission Mode Switch: Diagrams Tow/Haul Pattern Select Switch
Page 9364
6. Remove the cab mount bolts by pulling them through the hole and discard. New bolts will be
used in their place
7. Raise the back of the cab from the pinch welds high enough to remove the No.3 cab mounts
(see Figures 8 and 9).
Page 4938
Removal
A760F AUTOMATIC TRANSMISSION: TRANSMISSION CONTROL CABLE (for Floor Shift Type):
REMOVAL
1. REMOVE FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Removal
2. REMOVE FRONT DOOR SCUFF PLATE LH (for Double Cab, CrewMax) See: Body and
Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Removal
3. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Removal
4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Floor Shift Type)/Removal
5. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding
/ Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
6. REMOVE REAR UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
7. REMOVE REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
8. REMOVE CONSOLE BOX CARPET
9. REMOVE REAR CONSOLE BOX ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal
10. REMOVE FRONT CONSOLE BOX See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal
and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal
11. REMOVE TRANSMISSION CONTROL CABLE ASSEMBLY
Page 6521
Use a volt/ohmmeter with high impedance (10 kohms/V minimum) for troubleshooting of the
electrical circuit.
Disconnection of Male and Female Connectors
DISCONNECTION OF MALE AND FEMALE CONNECTORS
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Finding A Short Circuit
FINDING A SHORT CIRCUIT
Specifications
Ball Joint: Specifications
Ball Joints
FRONT SUSPENSION UPPER ARM ASSEMBLY LH
Using a torque wrench, turn the nut continuously at a rate of 3 to 5 seconds per 1 turn and take the
torque reading on the fifth turn.
Standard turning
torque..........................................................................................................................0.98 to 4.41
N*m (1.0 to 45 kgf*cm, 9 to 39 in.*lbf)
FRONT NO. 1 SUSPENSION ARM LOWER SUB-ASSEMBLY LH
Using a torque wrench, turn the nut continuously at a rate of 3 to 5 seconds per turn and take the
torque reading on the fifth turn.
Standard turning
torque.........................................................................................................................3.0 to 10.0 N*m
(31 to 102 kgf*cm, 27 to 89 in.*lbf)
Page 454
Air Bag Control Module: Diagrams
Page 7154
Tire Pressure Sensor: Service and Repair Disposal
TIRE AND WHEEL: TIRE PRESSURE WARNING VALVE AND TRANSMITTER: DISPOSAL
HINT The tire pressure warning valve is powered by a lithium battery. When disposing of the tire
pressure warning valve and transmitter, remove the battery and dispose of it correctly.
1. DISPOSE OF TIRE PRESSURE WARNING VALVE AND TRANSMITTER
(a) Use the tip of a screwdriver to pry off the back cover.
(b) The battery and base board are exposed. While taking out the battery, cut the 2 terminals that
connect the battery to the base board.
Engine Controls - A/F And O2 Sensor Identification
Oxygen Sensor: Technical Service Bulletins Engine Controls - A/F And O2 Sensor Identification
T-SB-0398-09
December 23, 2009
Engine Bank 1 and Bank 2 A/F and 02 Identification
Service Category Engine/Hybrid System
Section Engine Control
Market USA
Applicability
TSB SUPERSESSION NOTICE
The information contained in this TSB supersedes TSB No. EG034-07.
^ Applicability has been updated to include 2009 - 2010 model year vehicles and 2006 - 2010
model year Highlander HV.
TSB No. EG034-07 is Obsolete and any printed versions should be discarded. Be sure to review
the entire content of this service bulletin before proceeding.
Introduction
This service bulletin provides information on the proper identification of engine bank 1 and engine
bank 2 for correct A/F sensor and oxygen sensor replacement.
This bulletin contains information that identifies engine bank 1 and engine bank 2 on the following
engines: 1AZ-FE, 2AZ-FE, 2AZ-FE (PZEV), 1GR-FE, 2GR-FE, 2JZ-GE, 1MZ-FE, 3MZ-FE,
1UR-FE, 3UR-FE, 2UZ-FE 5VZ-FE and 1ZZ-FE.
^ Bank 1 (B1) refers to the bank that includes cylinder No. 1.
^ Bank 2 (B2) refers to the bank opposite bank 1.
^ Sensor 1 (S1) refers to the sensor that is located before the catalytic converters.
^ Sensor 2 (S2) refers to the sensor that is located after the catalytic converters.
Warranty Information
Page 6983
NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do
not operate the ignition switch, any other switches, or the doors.
(a) If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the
harness and connector.
(b) Connect the cable of the Techstream to the DLC3, turn the ignition switch ON and attempt to
use the tester. If the display indicates that a
communication error has occurred, there is a problem either with the vehicle or with the tester.
HINT *
If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of
the original vehicle.
* If communication is still not possible when the tester is connected to another vehicle, the problem
may be in the tester itself. Consult the Service Department listed in the tester's instruction manual.
How To Proceed With Troubleshooting
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: HOW TO
PROCEED WITH TROUBLESHOOTING
1. OPERATION FLOW
HINT Perform troubleshooting in accordance with the procedures below. The following is an outline
of basic troubleshooting procedures. Confirm the troubleshooting procedures for the circuit you are
working on before beginning troubleshooting.
1. VEHICLE BROUGHT TO WORKSHOP
NEXT -- Continue to next step.
2. CUSTOMER PROBLEM ANALYSIS
(a) Ask the customer about the conditions and environment when the problem occurred.
NEXT -- Continue to next step.
3. INSPECT BATTERY VOLTAGE
Standard voltage:
11 to 14 V
If the voltage is below 11 V, recharge or replace the battery before proceeding.
NEXT -- Continue to next step.
Page 6263
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Page 6207
(a) for AC Power Supply:
Disconnect the clamp.
(b) Remove the 4 screws and bezel.
5. REMOVE REAR POWER OUTLET SOCKET (for Standard)
(a) Detach the claw and remove the power outlet socket.
6. REMOVE REAR POWER OUTLET SOCKET COVER (for Standard)
(a) Detach the 2 claws and remove the power outlet socket cover.
7. REMOVE REAR POWER POINT SOCKET (for AC Power Supply)
(a) Detach the 2 claws and remove the power outlet socket.
Page 5844
* The zero point calibration is performed only once after the system enters test mode.
* Calibration cannot be performed again until the stored data is cleared once.
(2) Check that the buzzer sounds for 3 seconds and DTC C1336 is erased.
(3) Turn the ignition switch OFF.
4. CLEAR ZERO POINT CALIBRATION DATA (WHEN USING SST CHECK WIRE)
(a) Turn the ignition switch to ON.
(b) Using SST, connect and disconnect terminals 12 (TS) and 4 (CG) of the DLC3 4 times or more
within 8 seconds.
SST : 09843-18040
(c) Check that the SLIP indicator light comes on.
(d) Using a check wire, perform the zero point calibration of the deceleration sensor.
5. PERFORM ZERO POINT CALIBRATION OF MASTER CYLINDER PRESSURE SENSOR AND
DECELERATION SENSOR (WHEN
USING SST CHECK WIRE)
NOTICE: *
While obtaining the zero point, do not vibrate the vehicle by tilting, moving or shaking it and keep it
stationary. (Do not start the engine.)
* While obtaining the zero point, do not depress the brake pedal.
* Obtain the zero point on a level surface (with an inclination of 1° or less).
(a) Enter Test Mode.
(1) Turn the ignition switch off.
(2) Check that the shift lever is in parking or neutral and apply the parking brake.
CAUTION: Application of the parking brake is not necessary for entering test mode. However,
apply the parking brake for safety.
(3) Using SST, connect terminals 12 (TS) and 4 (CG) of the DLC3.
SST : 09843-18040
(4) Turn the ignition switch to ON.
NOTICE: Do not start the engine.
(b) Obtain the zero points of the master cylinder pressure sensor and deceleration sensor.
Page 636
(a) Detach the 4 clips.
(b) Disconnect the connector and remove the panel.
11. REMOVE GLASS BREAKAGE SENSOR MICROPHONE
(a) Detach the 2 claws and remove the sensor.
Installation
THEFT DETERRENT: GLASS BREAKAGE SENSOR (for Floor Shift Type): INSTALLATION
1. INSTALL GLASS BREAKAGE SENSOR MICROPHONE
(a) Attach the 2 claws to install the sensor.
2. INSTALL INTEGRATION CONTROL AND PANEL ASSEMBLY
Locations
Solar Sensor: Locations
AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Automatic Air Conditioning System):
PARTS LOCATION
Page 3312
Engine Control Module: Locations
Engine Compartment
Page 1799
1. Test drive the vehicle and confirm there is a harsh shift on acceleration below 20 mph and or
excessive lock-up operation at freeway speeds about 50
- 60 mph.
2. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in
Figure 1. Confirm if the ECM (PCM) calibration has
been updated. If the calibration ID listed is NOT the latest ECM (PCM) calibration - go to step 3.
3. Flash reprogram the ECM (PCM).
NOTE
^ The GR8 Battery Diagnostic Station MUST be used in Power Supply Mode to maintain battery
voltage at 13.5 volts while flash reprogramming the vehicle.
^ For details on how to use the GR8 Battery Diagnostic Station, refer to the GR8 Instruction Manual
located on the Technical Information System (TIS), Diagnostics - Battery.
Follow the procedures outlined in TSB No. T-SB-0064-10, "Techstream ECU Flash
Reprogramming Procedure", and flash the ECM (PCM) with the NEW calibration file update.
4. Start the engine and warm it up to normal operating temperature before test driving.
5. Test drive the vehicle to confirm proper vehicle operation and ECM (PCM) initial learning. Refer
to the Technical Information System (TIS) 2010
Tundra Repair Manual:
Drivetrain - Automatic Transmission/Transaxle - "A760E / A760F Automatic
Transmission/Transaxle: Automatic Transmission System: Initialization"
6. Install the Authorized Modifications Label.
A. Using a permanent marker enter the following information on the label:
^ ECM part number [Refer to the Parts Information section for the CURRENT PART NUMBER]
Page 896
ERROR: undefined
OFFENDING COMMAND: f‘~
STACK:
Center Airbag Sensor Assembly (for Column Shift Type)
Air Bag Control Module: Testing and Inspection Center Airbag Sensor Assembly (for Column Shift
Type)
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Column
Shift Type): ON-VEHICLE INSPECTION
1. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION)
(a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnosis System.
2. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND
AIRBAG HAS NOT DEPLOYED)
(a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnosis System.
3. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND
AIRBAG IS DEPLOYED)
(a) Replace the center airbag sensor.
CAUTION: For removal and installation procedures of the center airbag sensor, be sure to follow
the correct procedure.
HINT The center airbag sensor should be replaced after any of the airbags has deployed, as it has
been subjected to the impact.
Page 342
1. Test drive the vehicle and confirm there is a harsh shift on acceleration below 20 mph and or
excessive lock-up operation at freeway speeds about 50
- 60 mph.
2. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in
Figure 1. Confirm if the ECM (PCM) calibration has
been updated. If the calibration ID listed is NOT the latest ECM (PCM) calibration - go to step 3.
3. Flash reprogram the ECM (PCM).
NOTE
^ The GR8 Battery Diagnostic Station MUST be used in Power Supply Mode to maintain battery
voltage at 13.5 volts while flash reprogramming the vehicle.
^ For details on how to use the GR8 Battery Diagnostic Station, refer to the GR8 Instruction Manual
located on the Technical Information System (TIS), Diagnostics - Battery.
Follow the procedures outlined in TSB No. T-SB-0064-10, "Techstream ECU Flash
Reprogramming Procedure", and flash the ECM (PCM) with the NEW calibration file update.
4. Start the engine and warm it up to normal operating temperature before test driving.
5. Test drive the vehicle to confirm proper vehicle operation and ECM (PCM) initial learning. Refer
to the Technical Information System (TIS) 2010
Tundra Repair Manual:
Drivetrain - Automatic Transmission/Transaxle - "A760E / A760F Automatic
Transmission/Transaxle: Automatic Transmission System: Initialization"
6. Install the Authorized Modifications Label.
A. Using a permanent marker enter the following information on the label:
^ ECM part number [Refer to the Parts Information section for the CURRENT PART NUMBER]
Page 8496
Cab)/Installation
7. INSTALL LUGGAGE COMPARTMENT SIDE COVER SUB-ASSEMBLY RH See: Body and
Frame/Seats/Service and Repair/Removal and
Replacement/Rear Seat Assembly (for Double Cab)/Installation
8. INSTALL LUGGAGE COMPARTMENT SIDE COVER SUB-ASSEMBLY LH See: Body and
Frame/Seats/Service and Repair/Removal and
Replacement/Rear Seat Assembly (for Double Cab)/Installation
Page 1318
Push the secondary locking device or terminal retainer in to the full lock position.
CONNECT CONNECTOR
Voltage Check
VOLTAGE CHECK
Page 1112
Interior Light Switch: Service and Repair Installation
LIGHTING: ROOM LIGHT SWITCH: INSTALLATION
1. INSTALL ROOM LIGHT SWITCH ASSEMBLY
(a) Attach the 2 claws to install the light switch.
2. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Panel,
Gauges and Warning Indicators/Instrument Cluster
/ Carrier/Service and Repair/Combination Meter/Installation
Power Source Control ECU
Power Distribution Module: Diagrams Power Source Control ECU
Page 7858
Evaporator Temperature Sensor / Switch: Testing and Inspection
AIR CONDITIONING: FRONT EVAPORATOR TEMPERATURE SENSOR: INSPECTION
1. INSPECT NO. 1 COOLER THERMISTOR
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NOTICE: *
Even slightly touching the sensor may change the resistance value. Be sure to hold the connector
of the sensor.
* When measuring, the sensor temperature must be almost the same as the ambient temperature.
HINT As the temperature increases, the resistance decreases (see the graph).
(b) If the result is not as specified, replace the sensor.
Page 7644
Push the secondary locking device or terminal retainer in to the full lock position.
CONNECT CONNECTOR
Voltage Check
VOLTAGE CHECK
Page 6405
Rear Door Wire
Rear Sonar Wire
Page 3449
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO POWER STEERING ECU
(CANH, CANL)
OK -- REPLACE POWER STEERING ECU See: Relays and Modules/Relays and Modules Steering and Suspension/Relays and Modules - Steering/Steering Control Module/Service and
Repair/Removal
18. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (CENTER AIRBAG SENSOR)
(a) Disconnect the J46 center airbag sensor connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
Page 3730
Locations
Knock Sensor: Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 3727
Page 675
(a) Using a moulding remover, detach the 2 clips and 5 claws, and remove the armrest base panel.
(b) Disconnect the door control switch connector and power window regulator connector.
2. REMOVE DOOR CONTROL SWITCH ASSEMBLY
(a) Detach the 2 claws and remove the door control switch.
Installation
DOOR LOCK: DOOR CONTROL SWITCH (for Front RH): INSTALLATION
1. INSTALL DOOR CONTROL SWITCH ASSEMBLY
(a) Attach the 2 claws to install the control switch.
2. INSTALL FRONT ARMREST UPPER BASE PANEL RH
(a) Connect the door control switch connector and power window regulator connector.
Page 8409
Page 2198
Tire Pressure Monitor Receiver / Transponder: Service and Repair Installation
TIRE AND WHEEL: TIRE PRESSURE WARNING RECEIVER: INSTALLATION
1. INSTALL TIRE PRESSURE WARNING ANTENNA AND RECEIVER
(a) Install the receiver with the bolt.
Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
(b) Connect the receiver connector.
2. INSTALL ROOF HEADLINING ASSEMBLY
(a) for Regular Cab:
Install the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Installation.
(b) for Double Cab:
Install the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Double Cab)/Installation.
(c) for CrewMax:
Install the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (for CrewMax)/Installation.
Page 4660
Transfer Case Actuator: Diagrams
Page 8629
Remove the front door scuff plate LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal.
(c) for CrewMax:
Remove the front door scuff plate LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal.
3. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Removal
4. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal
5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Floor Shift Type)/Removal
6. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal
7. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding
/ Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
8. REMOVE REAR UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
9. REMOVE REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
10. REMOVE CONSOLE BOX CARPET
11. REMOVE REAR CONSOLE BOX ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal
12. REMOVE FRONT CONSOLE BOX See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal
and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal
13. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and
Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
14. REMOVE CENTER LOWER INSTRUMENT PANEL FINISH PANEL See: Body and
Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
15. REMOVE INTEGRATION CONTROL AND PANEL ASSEMBLY (for Manual Air Conditioning
System) See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and
Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal
16. REMOVE INTEGRATION CONTROL AND PANEL ASSEMBLY (for Automatic Air Conditioning
System) See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and
Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal
17. REMOVE STEREO JACK ADAPTER ASSEMBLY
(a) Detach the 2 claws and remove the adapter.
Installation
Page 3996
6. In some instances where water has entered the system DTCs P2440/P2441/P2442/P2443 may
set.
Refer to TIS 2010 model year Tundra Repair Manual to diagnose and inspect the emission control
valves if necessary:
7. If there is NO liquid found in the air pump assemblies or the DTC is still present after
replacement inspect the air injection system.
Refer to TIS 2010 model year Tundra Repair Manual:
8. Clear the DTC and road test the vehicle to confirm the condition has been corrected.
Page 1555
No further tightening is required once the nut is tightened with the specified torque.
2. INSTALL WHEEL
for Aluminum Wheel - Torque : 131 Nm (1336 kgf-cm, 97 ft-lbf)
for Steel Wheel - Torque : 209 Nm (2131 kgf-cm, 154 ft-lbf)
3. INSPECT TIRE
(a) Inspect the tire See: Maintenance/Wheels and Tires/Testing and Inspection/Component Tests
and General Diagnostics.
4. REGISTRATION OF TRANSMITTER ID
(a) Register the transmitter ID See: Instrument Panel, Gauges and Warning Indicators/Tire
Monitoring System/Testing and
Inspection/Programming and Relearning/Registration.
5. PERFORM INITIALIZATION
(a) Perform initialization See: Instrument Panel, Gauges and Warning Indicators/Tire Monitoring
System/Testing and Inspection/Programming
and Relearning/Initialization.
NOTICE: Be sure to inflate all tires to the proper inflation pressure before initialization.
6. CHECK TIRE PRESSURE AFTER REPAIRS
(a) After repairs, confirm that the actual tire pressures are displayed in the DATA LIST See:
Instrument Panel, Gauges and Warning
Indicators/Tire Monitoring System/Testing and Inspection/Scan Tool Testing and Procedures/Data
List / Active Test.
Page 5796
Hydraulic Fluid Regulator: Locations From 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 4369
Fuel Pressure: Testing and Inspection
1UR-FE FUEL: FUEL SYSTEM: ON-VEHICLE INSPECTION
1. CHECK FUEL PUMP OPERATION AND FOR FUEL LEAK
(a) Connect the Techstream to the DLC3.
(b) Turn the ignition switch to ON.
NOTICE: Do not start the engine.
(c) Turn the Techstream main switch ON.
(d) Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump /
Speed.
(e) Check the fuel pump operation.
(1) Check for pressure in the fuel inlet tube from the fuel line. Check that the sound of fuel flowing
in the fuel tank can be heard.
If there is no sound, check the integration relay, fuel pump, ECM and wiring connector.
(f) Check for fuel leak.
(1) Check that there are no fuel leaks after performing maintenance anywhere on the system.
If there are fuel leaks, repair or replace parts as necessary.
2. CHECK FUEL PRESSURE
(a) Check that the battery voltage is 11 to 14 V.
(b) Perform the "DISCHARGE FUEL SYSTEM PRESSURE" procedures See: Service Precautions.
(c) Disconnect the cable from the negative (-) battery terminal.
(d) Remove the fuel pipe clamp from the fuel tube connector.
(e) Pinch and pull the fuel tube (fuel tube connector) to disconnect it.
CAUTION: *
Always read the precautions See: Service Precautions before disconnecting the fuel tube
connector (quick type).
* The fuel tube may spray fuel as a result of pressure that remains in it. Do not allow fuel to be
sprayed in the engine compartment.
(f) Install SST (pressure gauge) as shown in the illustration.
Page 3515
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO 4WD CONTROL ECU
(CANH, CANL)
OK -- REPLACE 4WD CONTROL ECU
26. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (ECM)
(a) Disconnect the A24 ECM connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
Result
E -- REPAIR OR REPLACE CAN MAIN WIRE CONNECTED TO ECM (CANH, CANL)
D -- REPLACE ECM
Recall 11V185000 - TPMS Non-Compliance
Tire Pressure Module: All Technical Service Bulletins Recall 11V185000 - TPMS Non-Compliance
VEHICLE MAKE/MODEL: MODEL YEAR(S) Toyota/FJ Cruiser 2011
Toyota/Tundra 2009-2011
MANUFACTURER: Gulf States Toyota, Inc.
MFR'S REPORT DATE: March 16, 2011
NHTSA CAMPAIGN ID NUMBER: 11V185000
NHTSA ACTION NUMBER: N/A
COMPONENT: Tires: Pressure Monitoring and Regulating Systems
POTENTIAL NUMBER OF UNITS AFFECTED: 1,489
SUMMARY: Gulf States Toyota is recalling certain model year 2011 FJ Cruiser and model year
2009-2011 Tundra vehicles for failing to comply with the requirements of Federal Motor Vehicle
Safety Standard No. 138, "Tire Pressure Monitoring Systems." The TPMS on some vehicles may
not have been properly calibrated and as a result the low tire pressure warning lamp may not
illuminate should the inflation pressure in one or more of the vehicle's tires fall below the threshold
for when the low tire pressure warning lamp should illuminate.
CONSEQUENCE: Drivers will not receive a warning from the tire pressuring monitor that one or
more tires are underinflated increasing the risk that a vehicle will be driven with one or more
underinflated tires and increasing the risk of a tire failure that may lead to a crash.
REMEDY: Dealers will recalibrate the tire pressure monitoring system in accordance with the
regulation free of charge. The safety recall is expected to begin during April 2011. Owners may
contact Gulf State Toyota Customer Assistance Center toll free at 1-800-444-1074 Monday through
Thursday, 8:30 AM to 5:00 PM, or Friday 8:30 AM to 4:00 PM Central Standard Time.
NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle
Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov.
Page 1719
Standard steering axis inclination (unloaded vehicle):
for CrewMax of standard deck
Page 6802
4. SYMPTOM CONFIRMATION AND DTC (INCLUDING FREEZE FRAME DATA) CHECK
(a) Visually check the wire harnesses, connectors and fuses for open and short circuits.
(b) Warm up the engine to the normal operating temperature.
(c) Confirm the problem symptoms and conditions, and check for DTCs.
B -- Go to step 6 A -- Continue to next step.
5. DTC CHART
(a) Check the results obtained in the DTC check. Then find the output DTC in the DTC chart. Look
at the "Trouble Area" column for a list of
potentially malfunctioning circuits and / or parts.
NEXT -- Go to step 7
6. PROBLEM SYMPTOMS TABLE
(a) Check the results obtained in the symptom confirmation. Then find the problem symptoms in
the problem symptoms table. Look at the
"Suspected Area" column for a list of potentially malfunctioning circuits and / or parts.
NEXT -- Continue to next step.
7. CIRCUIT INSPECTION OR PARTS INSPECTION
(a) Confirm the malfunctioning circuit or part.
NEXT -- Continue to next step.
8. ADJUST, REPAIR OR REPLACE
(a) Adjust, repair or replace the malfunctioning circuit or parts.
NEXT -- Continue to next step.
9. CONFIRMATION TEST
(a) After the adjustment, repairs or replacement, confirm that the malfunction no longer exists. If the
malfunction does not reoccur, perform a
confirmation test under the same conditions and in the same environment as when the malfunction
occurred the first time.
NEXT -- END
2. CUSTOMER PROBLEM ANALYSIS
HINT *
In troubleshooting, confirm that the problem symptoms have been accurately identified.
Preconceptions should be discarded in order to make an accurate judgment. To clearly understand
what the problem symptoms are, it is extremely important to ask the customer about the problem
and the conditions at the time the malfunction occurred.
* Gather as much information as possible for reference. Past problems that seem unrelated may
also help in some cases.
* The following 5 questions are important points in the problem analysis:
Page 6350
Establish conditions in which voltage is present at the check point.
Example:
- [A] - Ignition SW on
- [B] - Ignition SW and SW1 on
- [C] - Ignition SW, SW1 and Relay on (SW2 off)
Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or component terminal.
This check can be done with a test light instead of a voltmeter.
Electronic Circuit Inspection Procedure
Page 8190
Seat Occupant Classification Module - Air Bag: Service and Repair Installation
SUPPLEMENTAL RESTRAINT SYSTEM: OCCUPANT CLASSIFICATION ECU: INSTALLATION
1. INSTALL OCCUPANT CLASSIFICATION ECU
(a) Check that the ignition switch is OFF.
(b) Check that the cable is disconnected from the battery negative (-) terminal.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
(c) Attach the claw and install the occupant classification ECU to the seat.
NOTICE: *
If the ECU has been dropped, or there are any cracks, dents or other defects in the case, bracket
or connector, replace it with a new one.
* When installing the ECU, be careful that the SRS wiring does not interfere with other parts and
that it is not pinched between other parts.
(d) Check that there is no looseness in the installation parts of the ECU.
2. INSTALL FRONT SEAT ASSEMBLY RH
(a) Install the front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Manual
Seat)/Installation.
Page 6372
Page 4137
Page 3540
2. CHECK FOR OPEN IN CAN BUS WIRE (CENTER AIRBAG SENSOR BRANCH WIRE)
(a) Disconnect the J46 center airbag sensor connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE CENTER AIRBAG SENSOR BRANCH WIRE OR CONNECTOR
(CANH, CANL) OK -- Continue to next step.
3. CHECK HARNESS AND CONNECTOR (CENTER AIRBAG SENSOR - BATTERY AND BODY
GROUND)
(a) Reconnect the cable to the negative (-) battery terminal before measuring the resistances of the
main wire and the branch wire.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(c) Measure the voltage according to the value(s) in the table below.
Standard voltage:
Page 4919
6. INSTALL COLUMN SHIFT SHIFT LOCK RELEASE LINK
(a) Install the spring and shift lock release link to the shift lever plate.
7. INSTALL SHIFT LEVER PLATE SUB-ASSEMBLY
(a) Install the shift lever plate to the column shift control shift lever retainer with the 3 bolts.
Torque : 2.3 Nm (23 kgf-cm, 20 in-lbf)
(b) Secure the harness with 4 new wire guides and the wire harness clamp as shown in the
illustration.
Page 6818
Page 5762
28. REMOVE REAR WHEEL RH
29. DISCONNECT REAR DISC BRAKE CYLINDER ASSEMBLY RH
HINT Use the same procedures described for the LH side.
30. REMOVE REAR DISC RH
HINT Use the same procedures described for the LH side.
31. REMOVE PARKING BRAKE SHOE RETURN SPRING RH
HINT Use the same procedures described for the LH side.
32. REMOVE NO. 1 PARKING BRAKE SHOE ASSEMBLY RH
HINT Use the same procedures described for the LH side.
33. REMOVE NO. 2 PARKING BRAKE SHOE ASSEMBLY RH
HINT Use the same procedures described for the LH side.
34. REMOVE PARKING BRAKE SHOE LEVER RH
HINT Use the same procedures described for the LH side.
35. REMOVE NO. 2 PARKING BRAKE CABLE ASSEMBLY
(a) Disconnect the No. 2 parking brake cable from the 2 clamps (labeled A).
(b) Remove the 5 bolts (labeled B) and disconnect the No. 2 parking brake cable from the
intermediate lever (labeled C).
NOTICE: Do not bend and twist the parking brake cable.
(c) Remove the bolt (labeled D) and clamp.
Components
Evaporative Emission Control Canister: Service and Repair Components
1UR-FE EMISSION CONTROL: CANISTER: COMPONENTS
Page 1715
Standard caster inclination (unloaded vehicle):
for CrewMax of standard deck
Page 3076
"Case2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 7023
for Double Cab of Long Deck
for CrewMax of standard deck
Page 6155
Establish conditions in which voltage is present at the check point.
Example:
- [A] - Ignition SW on
- [B] - Ignition SW and SW1 on
- [C] - Ignition SW, SW1 and Relay on (SW2 off)
Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or component terminal.
This check can be done with a test light instead of a voltmeter.
Electronic Circuit Inspection Procedure
Diagrams
Steering Angle Sensor: Diagrams
Page 1153
Camshaft Position Sensor: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT POSITION SENSOR: REMOVAL
1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Removal
2. REMOVE CAMSHAFT POSITION SENSOR
(a) Disconnect the sensor connector.
(b) Remove the bolt and sensor.
Diagrams
Variable Valve Timing Actuator Position Sensor: Diagrams
Page 8160
Air Bag Control Module: Locations Airbag System
SUPPLEMENTAL RESTRAINT SYSTEM: AIRBAG SYSTEM: PARTS LOCATION
Page 1879
(b) Remove the oil filter drain plug.
(c) Install the pipe to the oil filter cap.
HINT Use a container to catch the draining oil.
NOTICE: If the O-ring is removed with the drain plug, install the O-ring together with the pipe.
(d) Check that oil is drained from the oil filter. Then disconnect the pipe and remove the O-ring, as
shown in the illustration.
(e) Using SST, remove the oil filter cap.
SST : 09228-06501
NOTICE: Do not remove the oil filter bracket clip.
Page 3459
(a) Disconnect the J28 combination meter ECU connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(c) Measure the voltage according to the value(s) in the table below.
Standard voltage:
NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- REPLACE COMBINATION METER ASSEMBLY
ECM Communication Stop Mode
CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: ECM Communication Stop Mode ECM Communication Stop Mode
DESCRIPTION
WIRING DIAGRAM
Page 7475
Tire Pressure Module: Locations
TIRE AND WHEEL: TIRE PRESSURE WARNING SYSTEM: PARTS LOCATION
Page 6789
"Case1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (/\ Mark) and pull the terminal retainer
up to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Page 1776
Assenmacher Specialty Tools 1-800-525-2943
Locations
Tilt Wheel Switch: Locations
STEERING COLUMN: POWER TILT AND POWER TELESCOPIC STEERING COLUMN
SYSTEM: PARTS LOCATION
Page 6959
Locations
Tire Pressure Sensor: Locations
TIRE AND WHEEL: TIRE PRESSURE WARNING SYSTEM: PARTS LOCATION
Page 3567
16. CHECK OUTER MIRROR CONTROL ECU
HINT For vehicles with a front power seat control system (w/ Seat Memory) only.
(a) Disconnect the N7 and N8 ECU connectors.
(b) Measure the resistance according to the value(s) in the table below.
17. CHECK MULTIPLEX TILT AND TELESCOPIC ECU
HINT For vehicles with a front power seat control system (w/ Seat Memory) only.
(a) Disconnect the J47 ECU connector.
(b) Measure the resistance according to the value(s) in the table below.
Page 1154
Camshaft Position Sensor: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT POSITION SENSOR: INSTALLATION
1. INSTALL CAMSHAFT POSITION SENSOR
(a) Install the sensor with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(b) Connect the sensor connector.
2. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Installation
Page 6558
Relay Box: Electrical Diagrams
Engine Room R/B And Engine Room J/B Inner Circuit
Page 6972
"Case2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 1639
(c) for CrewMax:
(1) Remove the power window regulator master switch See: Service and Repair/Power Window
Master Switch/Removal.
(2) Reconnect the switch connector.
(3) Measure the voltage according to the value(s) in the table below.
Standard voltage:
Page 5040
* Align the holes for the straight pin in the differential case and pinion shaft.
* Apply hypoid gear oil to each sliding surface and rotating part.
(c) Using a dial indicator, measure the side gear backlash while holding one pinion gear toward the
differential case.
Standard backlash:
0.05 to 0.20 mm (0.00197 to 0.00788 in.)
(c) If the backlash is not within the specified value, replace the side gear thrust washer with an
appropriate thickness.
HINT Refer to the following table to select thrust washers which will ensure that the backlash is
within the specified value.
Washer thickness:
(d) Using a pin punch and hammer, tap the straight pin through the holes in the differential case
and pinion shaft.
(e) Using a chisel and hammer, stake the outside of the differential case pin hole.
4. INSTALL REAR DIFFERENTIAL CASE BEARING
(a) Using SST and a press, press in the 2 bearings.
SST : 09710-30050
SST : 09950-60010
09951-00480
SST : 09950-70010
09951-07150
Page 8414
Seat Position Sensor: Service and Repair Installation
SUPPLEMENTAL RESTRAINT SYSTEM: SEAT POSITION SENSOR: INSTALLATION
1. INSTALL SEAT POSITION SENSOR
(a) Check that the ignition switch is OFF.
(b) Check that the cable is disconnected from the battery negative (-) terminal.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
NOTICE: Some systems need to be initialized after the cable is reconnected See: Testing and
Inspection/Programming and Relearning
(c) Using a feeler gauge 1.0 mm (0.0393 in.), install the seat position sensor.
NOTICE: *
If the seat position sensor has been dropped, or there are any cracks, dents or other defects in the
case or connector, replace the seat position sensor with a new one.
* When installing the seat position sensor, be careful that the SRS wiring does not interfere with
other parts and that it is not pinched between other parts.
HINT Be sure that the clearance between the seat position sensor and the seat rail is within 0.6 to
1.4 mm (0.0236 to 0.0551 in.).
(d) Using a T30 "TORX" socket wrench, install the seat position sensor with the screw.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
(e) Make sure that the clearance between the seat position sensor and the seat rail is within 0.6 to
1.4 mm (0.0236 to 0.0551 in.).
(f) Check that there is no looseness in the installation parts of the seat position sensor.
(g) Connect the connector.
(h) Install the seat slide position sensor protector to the seat position sensor.
Page 7544
* The procedures listed below are for the LH side.
1. REMOVE FRONT WHEEL
2. DISCONNECT FRONT DISC BRAKE CALIPER ASSEMBLY LH See: Wheel Hub/Service and
Repair/Removal and Replacement/Removal
3. REMOVE FRONT DISC See: Brakes and Traction Control/Disc Brake System/Service and
Repair/Removal and Replacement/Front
Brake/Removal
4. REMOVE FRONT AXLE LH HUB BOLT
(a) Using SST and a screwdriver or equivalent to hold the axle hub, remove the front axle hub bolt.
SST : 09650-17011
NOTICE: Do not damage the threads of the hub bolts.
5. INSTALL FRONT AXLE LH HUB BOLT
(a) Temporarily install a washer and hub nut to a new hub bolt as shown in the illustration.
NOTICE: Install hub nuts to prevent damage to the hub bolts.
(b) Using a screwdriver or equivalent to hold the hub, turn the hub nut until the bottom surface of
the hub bolt head touches the axle hub.
(c) Remove the washer and hub nut.
NOTICE: Do not damage the threads of the hub bolts.
6. INSTALL FRONT DISC See: Brakes and Traction Control/Disc Brake System/Service and
Repair/Removal and Replacement/Front
Brake/Installation
7. CONNECT FRONT DISC BRAKE CALIPER ASSEMBLY LH See: Wheel Hub/Service and
Repair/Removal and Replacement/Installation
8. INSTALL FRONT WHEEL
for Aluminum Wheel - Torque : 131 Nm (1336 kgf-cm, 97 ft-lbf)
for Steel Wheel - Torque : 209 Nm (2131 kgf-cm, 154 ft-lbf)
Page 5434
2. REMOVE PROPELLER SHAFT ASSEMBLY (for 2 Joint Type) See: Drive/Propeller Shafts,
Bearings and Joints/Drive/Propeller Shaft/Service
and Repair/Removal and Replacement/Propeller Shaft Assembly/Removal
3. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for 3 Joint Type) See:
Drive/Propeller Shafts, Bearings and
Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Propeller Shaft
Assembly/Removal
4. REMOVE REAR OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY See: Service and
Repair/Overhaul/Disassembly
5. REMOVE TRANSFER CASE REAR OIL SEAL
(a) Using SST, tap out the oil seal.
SST : 09308-00010
NOTICE: Do not damage the oil-seal-fitted surface of the rear extension housing.
6. INSTALL TRANSFER CASE REAR OIL SEAL
(a) Apply transfer oil to the spline area of the output shaft.
(b) Using SST and a hammer, tap in the oil seal until its surface is flush with the housing upper
surface.
SST : 09316-60011
09316-00011
7. INSTALL REAR OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY See: Service and
Repair/Overhaul/Reassembly
8. INSTALL PROPELLER SHAFT ASSEMBLY (for 2 Joint Type) See: Drive/Propeller Shafts,
Bearings and Joints/Drive/Propeller Shaft/Service
and Repair/Removal and Replacement/Propeller Shaft Assembly/Installation
9. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for 3 Joint Type) See:
Drive/Propeller Shafts, Bearings and
Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Propeller Shaft
Assembly/Installation
10. ADD TRANSFER OIL See: Fluid - Transfer Case/Service and Repair
11. CHECK TRANSFER OIL See: Fluid - Transfer Case/Testing and Inspection
12. CHECK FOR TRANSFER OIL LEAK
Page 3917
(a) Apply a light coat of engine oil to the O-ring.
(b) Install a new O-ring to the oil control valve.
(c) Install the oil control valve with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(d) Connect the oil control valve connector.
5. INSTALL AIR CLEANER HOSE ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Installation
6. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Installation
Page 3222
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Page 2235
2. Install ChaSSiSEAR(TM) on the vehicle and attempt to isolate the source of the noise. Is the
noise loudest near the rear wheel bearing assembly?
^ YES - Go to step 3.
^ NO - This TSB does NOT apply. Continue diagnosis to isolate the source of the noise.
3. Replace the rear wheel bearing caliper bracket and related parts.
Refer to the Technical Information System (TIS) applicable model year Repair Manual:
4. Test drive the vehicle and confirm the noise is eliminated.
5. Re-check rear differential oil level and confirm NO leaks are present.
Page 4193
Page 6588
Use a volt/ohmmeter with high impedance (10 kohms/V minimum) for troubleshooting of the
electrical circuit.
Disconnection of Male and Female Connectors
DISCONNECTION OF MALE AND FEMALE CONNECTORS
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Finding A Short Circuit
FINDING A SHORT CIRCUIT
Page 6396
Page 5971
If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness
or connector in that circuit in the past. Check the wire harness and connectors.
B -- SYSTEM NORMAL
A -- TROUBLESHOOTING OF EACH PROBLEM SYMPTOM
The problem is still occurring in a place other than the diagnostic circuit (the DTC displayed first is
either for a past problem or a secondary problem).
4. SYMPTOM SIMULATION
HINT The most difficult case in troubleshooting is when no problem symptoms occur. In such a
case, a thorough problem analysis must be carried out. A simulation of the same or similar
conditions and environment in which the problem occurred in the customer's vehicle should be
carried out. No matter how much skill or experience a technician has, troubleshooting without
confirming the problem symptoms will lead to important repairs being overlooked and mistakes or
delays.
For example:
With a problem that only occurs when the engine is cold or as a result of vibration caused by the
road during driving, the problem can never be determined if the symptoms are being checked on a
stationary vehicle or on a vehicle with a warmed-up engine. Vibration, heat or water penetration
(moisture) is difficult to reproduce. The symptom simulation tests below are effective substitutes for
the conditions and can be applied on a stationary vehicle.
Important points in the symptom simulation test:
In the symptom simulation test, the problem symptoms as well as the problem area or parts must
be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then,
connect the tester and carry out the symptom simulation test, judging whether the circuit being
tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the
problem symptoms table for each system to narrow down the possible causes.
To reproduce DTCs, it is necessary to satisfy the respective DTC detection conditions.
(a) VIBRATION METHOD:
When a malfunction seems to occur as a result of vibration.
(1) PART AND SENSOR
Apply slight vibration with a finger to the part of the sensor suspected to be the cause of the
problem, and check whether or not the malfunction occurs.
NOTICE: Applying strong vibration to relays may open them.
Page 6018
Torque : 43 Nm (438 kgf-cm, 32 ft-lbf)
(b) Install the harness bracket to the generator with the bolt.
Torque : 31 Nm (316 kgf-cm, 23 ft-lbf)
(c) Connect the generator connector.
(d) Connect the generator wire with the nut.
Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)
(e) Install the terminal cap.
2. CONNECT OIL COOLER TUBE SUB-ASSEMBLY (w/ Trailer Towing System) See: Engine,
Cooling and Exhaust/Engine/Service and
Repair/Removal and Replacement/Engine Assembly/Installation
3. CONNECT VANE PUMP ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Engine
Lubrication/Oil Pump/Service and Repair/Removal
and Replacement/Installation
4. CONNECT SOLENOID VALVE CONNECTOR See: Steering and Suspension/Steering/Power
Steering/Power Steering Pump/Service and
Repair/Removal and Replacement/Installation
5. CONNECT POWER STEERING OIL PRESSURE SWITCH CONNECTOR See: Steering and
Suspension/Steering/Power Steering/Power
Steering Pump/Service and Repair/Removal and Replacement/Installation
6. INSTALL FRONT FENDER APRON SEAL RH See: Engine, Cooling and Exhaust/Exhaust
System/Exhaust Manifold/Service and
Repair/Installation
7. INSTALL AIR CLEANER ASSEMBLY See: Powertrain Management/Ignition System/Ignition
Coil/Service and Repair/Installation
8. INSTALL FAN AND GENERATOR V BELT
(a) Install the fan and generator V belt See: Engine, Cooling and Exhaust/Engine/Drive Belts,
Mounts, Brackets and Accessories/Drive
Belt/Service and Repair/Installation.
9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Page 4433
(2) If the result is not as specified, replace the integration relay.
3. INSTALL INTEGRATION RELAY See: Ignition System/Ignition Relay/Testing and Inspection
Page 3409
Components
Tire Pressure Warning Reset Switch: Service and Repair Components
TIRE AND WHEEL: TIRE PRESSURE WARNING RESET SWITCH: COMPONENTS
Page 7002
Relay Box: Electrical Diagrams
Engine Room R/B And Engine Room J/B Inner Circuit
Page 9205
NOTICE: w/ Jam Protection Function:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected
See: Windows and Glass/Windows/Testing and Inspection/Programming and
Relearning/Initialization
2. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH
(a) Using a screwdriver, detach the 4 claws and remove the inside handle bezel.
HINT Tape the screwdriver tip before use.
3. REMOVE FRONT UPPER ARMREST BASE PANEL LH
(a) Using a screwdriver, detach the 2 clips and front upper armrest base panel.
HINT Tape the screwdriver tip before use.
(b) Disconnect the connectors.
4. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY
(a) Remove the 3 screws and power window regulator master switch.
5. REMOVE FRONT LOWER DOOR FRAME BRACKET GARNISH LH
(a) Detach the 3 clips and remove the front lower door frame bracket garnish.
Recall 11V185000 - TPMS Non-Compliance
Tire Pressure Module: Recalls Recall 11V185000 - TPMS Non-Compliance
VEHICLE MAKE/MODEL: MODEL YEAR(S) Toyota/FJ Cruiser 2011
Toyota/Tundra 2009-2011
MANUFACTURER: Gulf States Toyota, Inc.
MFR'S REPORT DATE: March 16, 2011
NHTSA CAMPAIGN ID NUMBER: 11V185000
NHTSA ACTION NUMBER: N/A
COMPONENT: Tires: Pressure Monitoring and Regulating Systems
POTENTIAL NUMBER OF UNITS AFFECTED: 1,489
SUMMARY: Gulf States Toyota is recalling certain model year 2011 FJ Cruiser and model year
2009-2011 Tundra vehicles for failing to comply with the requirements of Federal Motor Vehicle
Safety Standard No. 138, "Tire Pressure Monitoring Systems." The TPMS on some vehicles may
not have been properly calibrated and as a result the low tire pressure warning lamp may not
illuminate should the inflation pressure in one or more of the vehicle's tires fall below the threshold
for when the low tire pressure warning lamp should illuminate.
CONSEQUENCE: Drivers will not receive a warning from the tire pressuring monitor that one or
more tires are underinflated increasing the risk that a vehicle will be driven with one or more
underinflated tires and increasing the risk of a tire failure that may lead to a crash.
REMEDY: Dealers will recalibrate the tire pressure monitoring system in accordance with the
regulation free of charge. The safety recall is expected to begin during April 2011. Owners may
contact Gulf State Toyota Customer Assistance Center toll free at 1-800-444-1074 Monday through
Thursday, 8:30 AM to 5:00 PM, or Friday 8:30 AM to 4:00 PM Central Standard Time.
NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle
Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov.
Page 5291
(g) Using needle-nose pliers, install new snap rings into the grooves of the yoke.
2. INSPECT FRONT PROPELLER SHAFT UNIVERSAL JOINT SPIDER BEARING See: Testing
and Inspection/Component Tests and General
Diagnostics/Front Propeller Shaft Assembly
3. INSPECT FRONT PROPELLER SHAFT ASSEMBLY
HINT When replacing the spider bearing, make sure that the grease fitting assembly hole is facing
in the direction shown in the illustration.
Disassembly
PROPELLER SHAFT: PROPELLER SHAFT ASSEMBLY (for 4WD): DISASSEMBLY
1. REMOVE REAR PROPELLER SHAFT UNIVERSAL JOINT SPIDER BEARING (for 3 Joint
Type)
(a) Place matchmarks on the propeller shaft yoke and universal joint yoke.
(b) Remove the grease fitting from the spider bearing.
Page 4036
Required Tools & Equipment
Repair Procedure
1. Using TIS Techstream check if DTC P0418, P0419, P2440, P2441, P2442, P2443, P2446
and/or P2447 are present.
2. Using Techstream perform the manual Air Injection Test (options 1 and 2) to verify if the signal
from the air injection control driver is reaching the
air pumps.
^ The pumps should be heard turning on at this point and there should be battery voltage on pin 2
of the pumps during this test.
^ If there is NO voltage refer to the Repair Manual for air injection control driver diagnosis.
Refer to the Technical Information System (TIS) 2010 model year Tundra Repair Manual:
3. If during the test voltage is present at the pump and the pump is NOT running or the Air
Pressure (gauge) value did NOT increase from 0 to 1 psi on
TIS Techstream with the pump running remove the air pump assemblies for inspection.
Refer to TIS 2010 model year Tundra Repair Manual:
4. With the pumps removed from the vehicle verify if there is liquid or evidence that liquid entered
the pumps.
^ YES - If there is liquid evidence go to step 5.
^ NO - If there is NO evidence of liquid go to step 7.
5. If liquid is present replace the affected pump assembly.
Refer to TIS 2010 model year Tundra Repair Manual:
Page 7899
Solar Sensor: Service and Repair Installation
AIR CONDITIONING: SOLAR SENSOR (for Automatic Air Conditioning System): INSTALLATION
1. INSTALL AUTOMATIC LIGHT CONTROL SENSOR (SOLAR SENSOR)
(a) Connect the connector.
(b) Attach the 2 claws to install the sensor.
2. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY
(a) for Column Shift Type:
Install the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column
Shift Type)/Installation.
(b) for Floor Shift Type:
Install the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation.
Page 3235
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: ELECTRONIC
CIRCUIT INSPECTION PROCEDURE
1. BASIC INSPECTION
(a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS
(1) Unless otherwise stated, all resistance measurements should be made at an ambient
temperature of 20°C (68°F). Resistance measurements
may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been
running. Measurements should be made after the engine has cooled down.
(b) HANDLING CONNECTORS
(1) When disconnecting a connector, first squeeze the mating halves tightly together to release the
lock, and then press the lock claw and
separate the connector.
(2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly
and separate it.
(3) Before connecting a connector, check that there are no deformed, damaged, loose or missing
terminals.
(4) When connecting a connector, press firmly until it locks with a "click" sound.
(5) If checking a connector with a TOYOTA electrical tester, check the connector from the backside
(harness side) using a mini test lead.
NOTICE: *
As a waterproof connector cannot be checked from the backside, check it by connecting a
sub-harness.
* Do not damage the terminals by moving the inserted tester needle.
(c) CHECKING CONNECTORS
(1) Checking when a connector is connected: Squeeze the connectors together to confirm that they
are fully connected and locked.
(2) Checking when a connector is disconnected: Check by pulling the wire harness lightly from the
backside of the connector. Look for
unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for
corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or
deformed terminals.
(3) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a
female terminal, and check for ample tension
Page 6262
Fuse Block: Diagnostic Aids
Continuity and Resistance Check
CONTINUITY AND RESISTANCE CHECK
Disconnect the battery terminal or wire so there is no voltage between the check points.
Contact the two leads of an ohmmeter to each of the check points.
Page 3647
Page 6687
Page 9302
Specifications
Camshaft Gear/Sprocket: Specifications
CAMSHAFT TIMING GEAR
LH
Using a wrench to hold the hexagonal portion of the No. 3 camshaft, tighten the camshaft timing
gear with the bolt.
Torque..................................................................................................................................................
.................................100 Nm (1020 kgf-cm, 74 ft-lbf)
Using a wrench to hold the hexagonal portion of the No. 4 camshaft, tighten the camshaft timing
exhaust gear with the bolt.
Torque..................................................................................................................................................
.................................100 Nm (1020 kgf-cm, 74 ft-lbf)
RH
Using a wrench to hold the hexagonal portion of the No. 1 camshaft, tighten the camshaft timing
gear with the bolt.
Torque..................................................................................................................................................
.................................100 Nm (1020 kgf-cm, 74 ft-lbf)
Using a wrench to hold the hexagonal portion of the No. 2 camshaft, tighten the camshaft timing
exhaust gear with the bolt.
Torque..................................................................................................................................................
.................................100 Nm (1020 kgf-cm, 74 ft-lbf)
Page 4307
NOTE
Only Toyota Certified Technicians and above may access calibration files.
2. Connect the GR8 Battery Diagnostic Station.
A. Connect the GR8 Battery Diagnostic Station to the vehicle and turn it ON.
B. Select Power Supply Mode by following the screen flow below.
NOTICE
^ ECU damage may occur if the correct battery charger and mode setting are NOT used.
Page 4652
Actuator: Service and Repair Installation
DIFFERENTIAL: AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR (for 4WD):
INSTALLATION
1. INSTALL AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR
(a) Remove any old FIPG material and be careful not to drop oil on the contact surfaces of the
differential tube and actuator.
(b) Clean the contact surfaces with any residual FIPG material using gasoline or alcohol.
(c) Apply seal packing to the differential tube as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
HINT Install the actuator within 10 minutes of applying seal packing.
(d) Clean the threads of the 4 bolts and retainer bolt holes with toluene or trichloroethylene.
(e) Install the actuator onto the differential tube.
(f) Apply adhesive to 2 to 3 threads of each bolt end.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
(g) Install the 4 bolts.
Torque : 21 Nm (210 kgf-cm, 15 ft-lbf)
(h) Connect the actuator hose.
(i) Connect the actuator connector.
2. INSTALL NO. 1 ENGINE UNDER COVER See: Engine, Cooling and Exhaust/Engine/Drive
Belts, Mounts, Brackets and Accessories/Drive
Belt/Service and Repair/Installation
3. INSPECT AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR
(a) Inspect the automatic disconnecting differential actuator See: Transmission and
Drivetrain/Transfer Case/Testing and Inspection/Component
Tests and General Diagnostics/Touch Select 2-4 and High-Low System.
Page 5993
(g) Hold the switch in position and tighten the bolt.
Torque : 13 Nm (130 kgf-cm, 9 ft-lbf)
(h) Using a screwdriver, bend the tabs of the lock washer.
(i) Install the transmission control shaft lever RH with the spring washer and nut.
Torque : 16 Nm (160 kgf-cm, 12 ft-lbf)
(j) Connect the switch connector.
2. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY
(a) Connect the cable with the nut.
Torque : 14 Nm (143 kgf-cm, 10 ft-lbf)
NOTICE: When connecting the cable to the transmission control shaft lever, make sure the L
bracket of the cable faces the inside of the vehicle.
3. ADJUST SHIFT LEVER POSITION (for Column Shift Type) See: Transmission and
Drivetrain/Automatic Transmission/Transaxle/Shifter
A/T/Adjustments/SHIFT LEVER ASSEMBLY (for Column Shift Type)
4. ADJUST SHIFT LEVER POSITION (for Floor Shift Type) See: Transmission and
Drivetrain/Automatic Transmission/Transaxle/Shifter
A/T/Adjustments/SHIFT LEVER ASSEMBLY (for Floor Shift Type)
Components
Condenser HVAC: Service and Repair Components
AIR CONDITIONING: CONDENSER: COMPONENTS
Page 7015
Auxiliary Power Outlet Switch: Service and Repair Installation
OTHER SYSTEM: INVERTER MAIN SWITCH (for CrewMax): INSTALLATION
1. INSTALL INVERTER MAIN SWITCH
(a) Attach the 2 claws to install the main switch.
2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Floor Shift Type)/Installation
3. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation
4. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Installation
5. INSTALL FRONT DOOR SCUFF PLATE LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining
(For Double Cab)/Installation
Page 6297
J/B No.4 - Instrument Panel Center
Page 7868
(c) Install the 6 screws and attach the 4 claws.
(d) Install the packing.
3. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY
(a) Install the heater radiator unit.
(b) Attach the 3 claws to install the heater clamp.
(c) Install the plate with the 3 screws.
Locations
Tire Pressure Monitor Receiver / Transponder: Locations
TIRE AND WHEEL: TIRE PRESSURE WARNING SYSTEM: PARTS LOCATION
Page 1396
Door/Service and Repair/Front Door (for Double Cab)/Disassembly
4. REMOVE FRONT LOWER DOOR FRAME BRACKET GARNISH LH (for Front Side) See: Body
and Frame/Doors, Hood and
Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly
5. REMOVE COURTESY LIGHT ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood
and Trunk/Doors/Front Door/Service and
Repair/Front Door (for Double Cab)/Disassembly
6. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Disassembly
7. REMOVE FRONT SIDE AIRBAG SENSOR
(a) Disconnect the connector.
(b) Remove the screw and side airbag sensor.
8. REMOVE REAR SEAT ASSEMBLY (for Rear Side)
(a) Remove the rear seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Rear Seat Assembly (for Double
Cab)/Removal.
9. REMOVE REAR DOOR SCUFF PLATE LH (for Rear Side) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and Repair/Roof
Headlining (For Double Cab)/Removal
10. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH (for Rear Side)
11. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY LH (for Rear Side) See: Body and
Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal
12. REMOVE REAR SIDE AIRBAG SENSOR
(a) Remove the bolt and side airbag sensor.
(b) Disconnect the connector.
Installation
SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for CrewMax):
INSTALLATION
1. INSTALL FRONT SIDE AIRBAG SENSOR
(a) Check that the ignition switch is OFF.
Page 5657
Wheel Speed Sensor: Service and Repair Rear Speed Sensor
Components
BRAKE CONTROL: REAR SPEED SENSOR: COMPONENTS
Removal
BRAKE CONTROL: REAR SPEED SENSOR: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
Page 7060
(d) * for 5 leaf spring
Standard steering axis inclination (unloaded vehicle):
for Regular Cab of Standard Deck
Page 7961
HINT When scrapping a vehicle equipped with the SRS or disposing of the curtain shield airbag
assembly, be sure to deploy the airbag first in accordance with the procedure described below. If
any abnormality occurs with the airbag deployment, contact the SERVICE DEPT. of TOYOTA
MOTOR SALES, U.S.A., INC.
CAUTION: *
Never dispose of a curtain shield airbag that has an unactivated airbag.
* The airbag produces an exploding sound when it is deployed, so perform the operation outdoors
and where it will not create a nuisance to nearby residents.
* When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool).
Perform the operation in a place away from electrical noise.
* When deploying the airbag, perform the operation at least 10 m (32.8 ft.) away from the curtain
shield airbag.
* The curtain shield airbag becomes extremely hot when the airbag is deployed, so do not touch it
for at least 30 minutes after deployment.
* Use gloves and safety glasses when handling a curtain shield airbag with a deployed airbag.
* Do not apply water to a curtain shield airbag with a deployed airbag.
* Always wash your hands with water after completing the operation.
* An airbag or pretensioner may be activated by static electricity. To prevent this, be sure to touch a
metal surface with bare hands to discharge static electricity before performing this procedure.
1. DISPOSE OF CURTAIN SHIELD AIRBAG ASSEMBLY (WHEN INSTALLED IN VEHICLE)
HINT Prepare a battery as the power source to deploy the airbag.
(a) Check the function of SST See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
(b) Read the precaution See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
(c) Disconnect the cable from the negative (-) battery terminal.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
(d) Remove the roof headlining (for CrewMax) See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining
(for CrewMax)/Removal
(e) Install SST.
(1) Disconnect the connector from the curtain shield airbag.
NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness.
(2) After connecting SST each other, connect them to the curtain shield airbag.
Page 6692
Page 2002
Remove the blown fuse and disconnect all loads of the fuse.
Connect a test light in place of the fuse.
Establish conditions in which the test light comes on.
Example:
- [A] - Ignition SW on
- [B] - Ignition SW and SW1 on
- [C] - Ignition SW, SW1 and Relay on (Connect the Relay) and SW2 off (or Disconnect SW2)
Disconnect and reconnect the connectors while watching the test light.
Page 329
^ Calibration ID(s) [Refer to the Calibration Identification Chart for the NEW CALIBRATION ID]
^ Dealer Code
^ Repair Date
^ Change Authority [This TSB number]
B. Affix the Authorized Modifications Label to the vehicle at the location shown in Figure 1. The
Authorized Modifications Label is available
through the MDC P/N 00451-00001-LBL.
Page 6474
Push the secondary locking device or terminal retainer in to the full lock position.
CONNECT CONNECTOR
Voltage Check
VOLTAGE CHECK
Page 6650
Removal
OTHER SYSTEM: POWER OUTLET SOCKET (for CrewMax Column Shift Type): REMOVAL
1. REMOVE CENTER SEATBACK PANEL See: Body and Frame/Seats/Service and
Repair/Overhaul/Front Seat Assembly (for Center
Seat)/Disassembly
2. REMOVE NO. 2 CONSOLE BOX REGISTER ASSEMBLY See: Body and Frame/Seats/Service
and Repair/Overhaul/Front Seat Assembly (for
Center Seat)/Disassembly
3. REMOVE NO. 1 CONSOLE BOX REGISTER ASSEMBLY See: Body and Frame/Seats/Service
and Repair/Overhaul/Front Seat Assembly (for
Center Seat)/Disassembly
4. REMOVE NO. 2 SEATBACK LOCK CONTROL BEZEL
Page 2147
Tire Pressure Monitor Receiver / Transponder: Service and Repair Removal
TIRE AND WHEEL: TIRE PRESSURE WARNING RECEIVER: REMOVAL
1. REMOVE ROOF HEADLINING ASSEMBLY
(a) for Regular Cab:
Remove the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Removal.
(b) for Double Cab:
Remove the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Double Cab)/Removal.
(c) for CrewMax:
Remove the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (for CrewMax)/Removal.
2. REMOVE TIRE PRESSURE WARNING ANTENNA AND RECEIVER
(a) Disconnect the receiver connector.
(b) Remove the bolt and receiver.
Page 6479
(1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be
checked by conducting a voltage check.
With each connector still connected, measure the voltage between the body ground and these
terminals (in this order): 1) terminal 1 of connector A; 2) terminal 1 of connector B; and 3) terminal
1 of connector C.
Standard voltage (Fig. 4):
* If the results match the examples above, an open circuit exists in the wire harness between
terminal 1 of connector B and terminal 1 of connector C.
3. CHECK FOR SHORT CIRCUIT
(a) If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance
check with the body ground (below).
(b) Check the resistance with the body ground.
(1) Disconnect connectors A and C and measure the resistance.
Standard resistance (Fig. 6):
HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally.
If your results match the examples above, a short circuit exists between terminal 1 of connector A
and terminal 1 of connector C.
Page 9225
Disassembly
ENGINE HOOD / DOOR: FRONT DOOR (for Regular Cab): DISASSEMBLY
FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH
HINT A bolt without a torque specification is shown in the standard bolt chart See:
Specifications/Mechanical Specifications/Standard Bolt - Specified Torque For Standard Bolts
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt
Page 723
Removal
SEAT: FRONT POWER SEAT LUMBAR SWITCH (for Manual Seat): REMOVAL
1. REMOVE FRONT SEAT ASSEMBLY LH
(a) Remove the front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Manual
Seat)/Removal.
2. REMOVE VERTICAL ADJUSTING HANDLE LH (for 8 Way Seat) See: Body and
Frame/Seats/Service and Repair/Overhaul/Front Seat
Assembly (for Manual Seat)/Disassembly
3. REMOVE VERTICAL SEAT ADJUSTER KNOB LH (for 8 Way Seat) See: Body and
Frame/Seats/Service and Repair/Overhaul/Front Seat
Assembly (for Manual Seat)/Disassembly
4. REMOVE RECLINING ADJUSTER RELEASE HANDLE LH See: Body and
Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly
(for Manual Seat)/Disassembly
5. REMOVE FRONT SEAT CUSHION SHIELD LH See: Body and Frame/Seats/Service and
Repair/Overhaul/Front Seat Assembly (for Manual
Seat)/Disassembly
6. REMOVE FRONT POWER SEAT LUMBAR SWITCH LH
(a) Remove the 2 screws and switch.
Installation
Page 7324
2. INSTALL FRONT NO. 2 LOWER ARM LH
(a) Using SST and a press, press in a new bush.
SST : 09710-26011
09710-05081
NOTICE: Press the bush while making sure the bush positioning protrusions are perpendicular to
the lower arm, as shown in the illustration.
3. INSTALL FRONT NO. 1 LOWER ARM BUSH LH
(a) Using SST and a press, press in a new bush.
SST : 09223-00010
SST : 09612-30012
4. INSTALL FRONT LOWER BALL JOINT ATTACHMENT LH
(a) Install the attachment with the nut and a new cotter pin.
Torque : 167 Nm (1703 kgf-cm, 123 ft-lbf)
NOTICE:
Page 4323
(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(2) If the result is not as specified, replace the MAF meter.
Air Fuel Ratio Sensor
Oxygen Sensor: Service and Repair Air Fuel Ratio Sensor
Components
1UR-FE ENGINE CONTROL SYSTEM: AIR FUEL RATIO SENSOR: COMPONENTS
Page 8833
Locations
Fuse Block: Locations
Engine Compartment
Page 8189
Seat Occupant Classification Module - Air Bag: Service and Repair Removal
SUPPLEMENTAL RESTRAINT SYSTEM: OCCUPANT CLASSIFICATION ECU: REMOVAL
1. REMOVE FRONT SEAT ASSEMBLY RH
(a) Remove the front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Manual
Seat)/Removal.
2. REMOVE OCCUPANT CLASSIFICATION ECU
(a) Disconnect the connector.
(b) Detach the claw and remove the ECU from the seat.
Page 1315
"Case2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 5572
Acceleration/Deceleration Sensor: Service and Repair Removal
BRAKE CONTROL: YAW RATE AND DECELERATION SENSOR: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to disable the SRS system.
2. REMOVE CENTER FRONT SEAT ASSEMBLY (for Center Seat) See: Body and
Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Center Seat)/Removal
3. REMOVE CONSOLE BOX ASSEMBLY (for Separate Seat Type)
(a) Remove the console box See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and
Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal.
4. REMOVE YAW RATE SENSOR
(a) Remove the 2 nuts (labeled A) and sensor.
(b) Disconnect the sensor connector (labeled B), and then detach the clamp (labeled C) from the
sensor bracket.
Page 3292
NOTE
Only Toyota Certified Technicians and above may access calibration files.
2. Connect the GR8 Battery Diagnostic Station.
A. Connect the GR8 Battery Diagnostic Station to the vehicle and turn it ON.
B. Select Power Supply Mode by following the screen flow below.
NOTICE
^ ECU damage may occur if the correct battery charger and mode setting are NOT used.
Page 4363
Fuel Pressure Regulator: Service and Repair Installation
1UR-FE FUEL: FUEL PRESSURE REGULATOR: INSTALLATION
1. INSTALL FUEL PRESSURE REGULATOR ASSEMBLY
(a) Apply a light coat of gasoline or spindle oil to a new O-ring, and install it to the pressure
regulator.
NOTICE: *
Make sure that there are no scratches or foreign matter in or around the insertion hole of the
delivery pipe.
* When inserting the pressure regulator, be careful not to damage the O-ring.
(b) While turning the pressure regulator left and right, install it to the delivery pipe.
(c) Install the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(d) Connect the vacuum sensing hose to the pressure regulator.
(e) Connect the No. 2 fuel tube to the pressure regulator See: Service Precautions.
2. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
3. INSTALL AIR CLEANER HOSE ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Installation
Recall 10V017000: Accelerator Pedal Sticking
Accelerator Pedal Position Sensor: All Technical Service Bulletins Recall 10V017000: Accelerator
Pedal Sticking
VEHICLE MAKE/MODEL: MODEL YEAR(S): Toyota/Avalon 2005-2010 Toyota/Camry 2007-2010
Toyota/Corolla 2009-2010 Toyota/Corolla Matrix 2009-2010 Toyota/Highlander 2010 Toyota/ RAV4
2009-2010 Toyota/Sequoia 2008-2010 Toyota/Tundra 2007-2010 MANUFACTURER: Toyota
Motor North America, Inc.
MFR'S REPORT DATE: January 21, 2010
NHTSA CAMPAIGN ID NUMBER: 10V017000
NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Accelerator Assembly:
Pedal/Linkage
POTENTIAL NUMBER OF UNITS AFFECTED: ?
SUMMARY: Toyota is recalling certain model year 2005-2010 Avalon, model year 2007-2010
Camry, model year 2009-2010 Corolla, Corolla Matrix, RAV4, model year 2010 Highlander, model
year 2008-2010 Sequoia, and model year 2007-2010 Tundra. due to the manner in which the
friction lever interacts with the sliding surface of the accelerator pedal inside the pedal sensor
assembly, the sliding surface of the lever may become smooth during vehicle operation. In this
condition, if condensation occurs on the surface, as may occur from heater operation (without A/C)
when the pedal assembly is cold, the friction when the accelerator pedal is operated may increase,
which may result in the accelerator pedal becoming harder to depress, slower to return, or, in the
worst case, mechanically stuck in a partially depressed position.
CONSEQUENCE: The accelerator pedal may become hard to depress, slow to return to idle, or, in
the worst case, mechanically stuck in a partially depressed position, increasing the risk of a crash.
REMEDY: Toyota has not yet provided a remedy plan or an owner notification schedule. Owners
may contact Toyota at 1-800-331-4331.
NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle
Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov.
Page 9108
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION: Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC
terminals are touched, the IC may be destroyed by static electricity.)
When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact with the terminals of leads from the IC, etc. of the
replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown on the left.
DISCONNECT CONNECTOR
Page 1454
Seat Position Sensor: Testing and Inspection
SUPPLEMENTAL RESTRAINT SYSTEM: SEAT POSITION SENSOR: ON-VEHICLE
INSPECTION
1. CHECK SEAT POSITION SENSOR (VEHICLE NOT INVOLVED IN COLLISION)
(a) Perform a diagnostic system check See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
2. CHECK SEAT POSITION SENSOR (VEHICLE INVOLVED IN COLLISION)
(a) Perform a diagnostic system check See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
(b) Even if the airbag was not deployed, check if there is any damage to the seat position sensor. If
there are any defects as mentioned below,
replace the seat position sensor with a new one:
* Cracks, dents or chips on the sensor housing.
* Cracks or other damage to the connector.
CAUTION: For removal and installation procedures of the seat position sensor, be sure to follow
the correct procedure.
Page 1846
C. Choose desired ECU group(s) in the Health Check dialog box.
D. Click Next.
E. Click Continue to view Health Check results.
F. Available calibration updates are indicated by a link in the Cal. Update? column. Click the link to
access the appropriate service bulletin on TIS.
NOTE
^ Note any DTCs stored in Systems that will be flash reprogrammed.
^ Clicking the link will automatically launch TIS and perform a calibration search.
G. Log in to TIS. (If already logged in skip this step.)
H. To review the TSB and access the calibration file click the service bulletin link in the Document
Title column of the Calibration Search Result
portlet.
Page 6760
AJ9-JI2
Page 3957
Required Tools & Equipment
Repair Procedure
1. Using TIS Techstream check if DTC P0418, P0419, P2440, P2441, P2442, P2443, P2446
and/or P2447 are present.
2. Using Techstream perform the manual Air Injection Test (options 1 and 2) to verify if the signal
from the air injection control driver is reaching the
air pumps.
^ The pumps should be heard turning on at this point and there should be battery voltage on pin 2
of the pumps during this test.
^ If there is NO voltage refer to the Repair Manual for air injection control driver diagnosis.
Refer to the Technical Information System (TIS) 2010 model year Tundra Repair Manual:
3. If during the test voltage is present at the pump and the pump is NOT running or the Air
Pressure (gauge) value did NOT increase from 0 to 1 psi on
TIS Techstream with the pump running remove the air pump assemblies for inspection.
Refer to TIS 2010 model year Tundra Repair Manual:
4. With the pumps removed from the vehicle verify if there is liquid or evidence that liquid entered
the pumps.
^ YES - If there is liquid evidence go to step 5.
^ NO - If there is NO evidence of liquid go to step 7.
5. If liquid is present replace the affected pump assembly.
Refer to TIS 2010 model year Tundra Repair Manual:
Page 5152
SST : 09502-12010
SST : 09316-60011
09316-00041
Standard oil seal depth:
5.6 to 6.6 mm (0.221 to 0.260 in.)
(b) Coat the lip of the oil seal with MP grease.
20. INSTALL FRONT DRIVE PINION COMPANION FLANGE FRONT SUB-ASSEMBLY See:
Differential Carrier/Service and
Repair/Overhaul/Front Differential Carrier Assembly/Reassembly
21. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD See: Differential Carrier/Service and
Repair/Overhaul/Front Differential Carrier
Assembly/Reassembly
22. INSPECT TOTAL PRELOAD See: Differential Carrier/Service and Repair/Overhaul/Front
Differential Carrier Assembly/Reassembly
23. STAKE FRONT DRIVE PINION COMPANION FLANGE FRONT NUT See: Differential
Carrier/Service and Repair/Overhaul/Front
Differential Carrier Assembly/Reassembly
24. INSTALL DIFFERENTIAL SIDE GEAR INTER SHAFT SUB-ASSEMBLY See: Differential
Carrier/Service and Repair/Overhaul/Front
Differential Carrier Assembly/Reassembly
25. INSTALL FRONT DIFFERENTIAL TUBE ASSEMBLY See: Differential Carrier/Service and
Repair/Overhaul/Front Differential Carrier
Assembly/Reassembly
26. INSTALL FRONT DIFFERENTIAL CARRIER ASSEMBLY
(a) Install the front differential carrier See: Differential Carrier/Service and Repair/Removal and
Replacement/Front Differential Carrier
Assembly/Installation.
27. ADD DIFFERENTIAL OIL See: Fluid - Differential/Service and Repair
Page 6734
Fuse Block: Connector Views
Engine Room R/B, J/B - Engine Compartment Left
Page 4912
Shifter A/T: Overhaul
Disassembly
A760F AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY (for Column Shift Type):
DISASSEMBLY
1. REMOVE COLUMN SHIFT SHIFTING BELLCRANK ASSEMBLY
(a) Remove the bolt and shifting bellcrank from the column shift control shift lever retainer.
2. REMOVE COLUMN SHIFT LEVER COMPRESSION SPRING
(a) Remove the bolt and spring from the column shift control shift lever retainer.
3. REMOVE SHIFT LEVER PLATE SUB-ASSEMBLY
(a) Disconnect the transmission control switch connector clamp from the column shift.
(b) Detach the wire harness clamp and cut off the 4 wire guides.
(c) Remove the 3 bolts.
Page 6559
Engine Room R/B And Engine Room J/B Inner Circuit
Page 7281
Use the same procedures described for the LH side.
7. DISCONNECT PRESSURE FEED TUBE ASSEMBLY
(a) Using a union nut wrench, disconnect the pressure feed tube (return tube side) from the power
steering gear.
(b) Using a union nut wrench, disconnect the pressure feed tube (pressure feed tube side) from the
power steering gear.
(c) Remove the 2 bolts and disconnect the pressure feed tube clamp.
8. REMOVE POWER STEERING GEAR ASSEMBLY
(a) Remove the 2 bolts, 2 nuts and power steering gear.
NOTICE: Because the nut has its own stopper, do not turn the nut. Loosen the bolt with the nut
fixed.
Installation
Diagrams
Steering Mounted Controls Transmitter: Diagrams
Components
Acceleration/Deceleration Sensor: Service and Repair Components
BRAKE CONTROL: YAW RATE AND DECELERATION SENSOR: COMPONENTS
Page 1280
Camshaft Position Sensor: Locations Ignition System
1UR-FE IGNITION: IGNITION SYSTEM: PARTS LOCATION
Locations
Main Relay (Computer/Fuel System): Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 5765
Parking Brake Cable: Service and Repair Installation
PARKING BRAKE: PARKING BRAKE CABLE: INSTALLATION
1. INSTALL NO. 2 CABLE SUPPORT BRACKET
(a) Install the bracket with the 2 bolts.
Torque : 19 Nm (194 kgf-cm, 14 ft-lbf)
2. INSTALL PARKING BRAKE INTERMEDIATE LEVER SUB-ASSEMBLY
(a) Apply MP grease to the moving parts of the intermediate lever.
(b) Apply MP grease to the areas where the cables contact the intermediate lever.
(c) Install the intermediate lever to the bracket with the clip, washer and pin.
(d) Install the intermediate lever with bracket with the 2 bolts.
Torque : 19 Nm (194 kgf-cm, 14 ft-lbf)
3. INSTALL NO. 3 PARKING BRAKE CABLE ASSEMBLY
(a) Install the No. 3 parking brake cable to the rear axle carrier with the bolt.
Page 4453
Accelerator Pedal Position Sensor: Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 2273
Parts Information
Required Tools & Equipment
Additional TIS Techstream units may be ordered by calling Approved Dealer Equipment (ADE).
TSB Overview
1. Confirm that DTC P0012 and/or P0022 is stored in the ECM.
2. Diagnose the Oil Control Valves (OCVs) for proper operation.
3. If the OCVs operate correctly replace both intake VVTi gear assemblies following the Repair
Manual.
Diagnostic Procedure
1. Using TIS Techstream confirm that DTC P0012 and/or P0022 is stored in the ECM.
2. Remove the affected Oil Control Valve (OCV) and inspect for debris in the valve or evidence that
the valve is stuck.
3. Check valve operation by applying positive (+) battery voltage to terminal 1 and negative (-)
battery voltage to terminal 2. Valve should move
quickly when voltage is applied. If NOT valve should be replaced.
4. Reinstall the OCVs warm up the engine to over 167°F (75°C) and perform an Active Test using
Tech stream.
Powertrain / Engine and ECT / Active Test / Control the WT System (Bank 1) or (Bank 2)
5. If there is NO debris and the OCV moves with battery voltage and Active Test functions Replace both intake VVTi gears following the repair
procedure below.
Repair Procedure
1. Replace both intake VVTi gears.
Page 6950
J/B No.3 Inner Circuit
J/B No.4 Inner Circuit
J/B No.5 Inner Circuit
Removal and Replacement
Steering Gear: Removal and Replacement
Components
POWER STEERING: STEERING GEAR: COMPONENTS
Page 6163
4. SYMPTOM CONFIRMATION AND DTC (INCLUDING FREEZE FRAME DATA) CHECK
(a) Visually check the wire harnesses, connectors and fuses for open and short circuits.
(b) Warm up the engine to the normal operating temperature.
(c) Confirm the problem symptoms and conditions, and check for DTCs.
B -- Go to step 6 A -- Continue to next step.
5. DTC CHART
(a) Check the results obtained in the DTC check. Then find the output DTC in the DTC chart. Look
at the "Trouble Area" column for a list of
potentially malfunctioning circuits and / or parts.
NEXT -- Go to step 7
6. PROBLEM SYMPTOMS TABLE
(a) Check the results obtained in the symptom confirmation. Then find the problem symptoms in
the problem symptoms table. Look at the
"Suspected Area" column for a list of potentially malfunctioning circuits and / or parts.
NEXT -- Continue to next step.
7. CIRCUIT INSPECTION OR PARTS INSPECTION
(a) Confirm the malfunctioning circuit or part.
NEXT -- Continue to next step.
8. ADJUST, REPAIR OR REPLACE
(a) Adjust, repair or replace the malfunctioning circuit or parts.
NEXT -- Continue to next step.
9. CONFIRMATION TEST
(a) After the adjustment, repairs or replacement, confirm that the malfunction no longer exists. If the
malfunction does not reoccur, perform a
confirmation test under the same conditions and in the same environment as when the malfunction
occurred the first time.
NEXT -- END
2. CUSTOMER PROBLEM ANALYSIS
HINT *
In troubleshooting, confirm that the problem symptoms have been accurately identified.
Preconceptions should be discarded in order to make an accurate judgment. To clearly understand
what the problem symptoms are, it is extremely important to ask the customer about the problem
and the conditions at the time the malfunction occurred.
* Gather as much information as possible for reference. Past problems that seem unrelated may
also help in some cases.
* The following 5 questions are important points in the problem analysis:
Page 6500
Junction Connector (CAN No.2) - Lower Finish Panel
Page 7459
Tire Pressure Warning Reset Switch: Service and Repair Removal
TIRE AND WHEEL: TIRE PRESSURE WARNING RESET SWITCH: REMOVAL
1. REMOVE FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Removal
2. REMOVE FRONT DOOR SCUFF PLATE LH (for Double Cab, for CrewMax) See: Body and
Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal
3. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Removal
4. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal
5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Removal
6. REMOVE TIRE PRESSURE WARNING RESET SWITCH
(a) Disconnect the switch connector.
(b) Detach the 2 claws and remove the reset switch.
Specifications
Connecting Rod: Specifications
PISTON AND CONNECTING ROD
The connecting rod cap bolts are tightened in 2 progressive steps.
Step 1
Install and alternately tighten the bolts of the connecting rod cap in several steps.
Torque..................................................................................................................................................
.....................................40 Nm (408 kgf-cm, 30 ft-lbf)
Step 2
Mark the front side of each connecting rod cap bolt with paint.
Tighten the cap bolts another 90° as shown in the illustration in the order in step 1.
Check that the painted marks are now at a 90° angle to the front.
CONNECTING ROD SIDE CLEARANCE, OUT-OF-ROUND, & DIAMETER
Page 940
(c) Install the 6 screws and attach the 4 claws.
(d) Install the packing.
3. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY
(a) Install the heater radiator unit.
(b) Attach the 3 claws to install the heater clamp.
(c) Install the plate with the 3 screws.
Page 2013
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: ELECTRONIC
CIRCUIT INSPECTION PROCEDURE
1. BASIC INSPECTION
(a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS
(1) Unless otherwise stated, all resistance measurements should be made at an ambient
temperature of 20°C (68°F). Resistance measurements
may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been
running. Measurements should be made after the engine has cooled down.
(b) HANDLING CONNECTORS
(1) When disconnecting a connector, first squeeze the mating halves tightly together to release the
lock, and then press the lock claw and
separate the connector.
(2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly
and separate it.
(3) Before connecting a connector, check that there are no deformed, damaged, loose or missing
terminals.
(4) When connecting a connector, press firmly until it locks with a "click" sound.
(5) If checking a connector with a TOYOTA electrical tester, check the connector from the backside
(harness side) using a mini test lead.
NOTICE: *
As a waterproof connector cannot be checked from the backside, check it by connecting a
sub-harness.
* Do not damage the terminals by moving the inserted tester needle.
(c) CHECKING CONNECTORS
(1) Checking when a connector is connected: Squeeze the connectors together to confirm that they
are fully connected and locked.
(2) Checking when a connector is disconnected: Check by pulling the wire harness lightly from the
backside of the connector. Look for
unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for
corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or
deformed terminals.
(3) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a
female terminal, and check for ample tension
Locations
Engine Temperature Sensor: Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 6492
Engine Room R/B, J/B - Engine Compartment Left
Page 8256
9. REMOVE FRONT SEAT OUTER BELT ASSEMBLY
(a) Using a screwdriver, detach the 2 claws and open the seat belt anchor cover as shown in the
illustration.
HINT Tape the screwdriver tip before use.
(b) Remove the bolt and disconnect the seat belt's shoulder anchor.
(c) Disconnect the pretensioner connector as shown in the illustration.
(d) Remove the 2 bolts and seat belt.
Installation
SEAT BELT: FRONT SEAT OUTER BELT ASSEMBLY (for Regular Cab): INSTALLATION
HINT *
Use the same procedures for the LH side and RH side.
* The procedures listed below are for the LH side.
1. INSTALL FRONT SEAT OUTER BELT ASSEMBLY
Page 4512
Crankshaft Position Sensor: Locations Ignition System
1UR-FE IGNITION: IGNITION SYSTEM: PARTS LOCATION
Page 8803
Repair/Front Door (for CrewMax)/Reassembly
8. INSTALL FRONT LOWER DOOR FRAME BRACKET GARNISH LH See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for CrewMax)/Reassembly
9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Page 9076
If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness
or connector in that circuit in the past. Check the wire harness and connectors.
B -- SYSTEM NORMAL
A -- TROUBLESHOOTING OF EACH PROBLEM SYMPTOM
The problem is still occurring in a place other than the diagnostic circuit (the DTC displayed first is
either for a past problem or a secondary problem).
4. SYMPTOM SIMULATION
HINT The most difficult case in troubleshooting is when no problem symptoms occur. In such a
case, a thorough problem analysis must be carried out. A simulation of the same or similar
conditions and environment in which the problem occurred in the customer's vehicle should be
carried out. No matter how much skill or experience a technician has, troubleshooting without
confirming the problem symptoms will lead to important repairs being overlooked and mistakes or
delays.
For example:
With a problem that only occurs when the engine is cold or as a result of vibration caused by the
road during driving, the problem can never be determined if the symptoms are being checked on a
stationary vehicle or on a vehicle with a warmed-up engine. Vibration, heat or water penetration
(moisture) is difficult to reproduce. The symptom simulation tests below are effective substitutes for
the conditions and can be applied on a stationary vehicle.
Important points in the symptom simulation test:
In the symptom simulation test, the problem symptoms as well as the problem area or parts must
be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then,
connect the tester and carry out the symptom simulation test, judging whether the circuit being
tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the
problem symptoms table for each system to narrow down the possible causes.
To reproduce DTCs, it is necessary to satisfy the respective DTC detection conditions.
(a) VIBRATION METHOD:
When a malfunction seems to occur as a result of vibration.
(1) PART AND SENSOR
Apply slight vibration with a finger to the part of the sensor suspected to be the cause of the
problem, and check whether or not the malfunction occurs.
NOTICE: Applying strong vibration to relays may open them.
Page 8761
Remote Switch: Testing and Inspection
AUDIO / VISUAL: STEERING PAD SWITCH: INSPECTION
1. INSPECT STEERING PAD SWITCH ASSEMBLY
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the steering pad switch assembly.
Page 4783
Mongoose MFC Software and Driver MUST be installed before Mongoose MFC selection will be
available.
See TIS - Diagnostics - Scantool page for additional information.
^ If using TIS Techstream select TIS Techstream VIM (this is the default).
4. Click OK.
Operation Procedure
1. Verify the vehicle's applicability for recalibration and locate desired calibration file.
A. Connect Techstream and establish a vehicle connection.
B. Click the Health Check button on the System Select tab.
Page 4133
Page 392
Page 930
Evaporator Temperature Sensor / Switch: Testing and Inspection
AIR CONDITIONING: FRONT EVAPORATOR TEMPERATURE SENSOR: INSPECTION
1. INSPECT NO. 1 COOLER THERMISTOR
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NOTICE: *
Even slightly touching the sensor may change the resistance value. Be sure to hold the connector
of the sensor.
* When measuring, the sensor temperature must be almost the same as the ambient temperature.
HINT As the temperature increases, the resistance decreases (see the graph).
(b) If the result is not as specified, replace the sensor.
Page 4013
(b) Remove the 2 bolts.
(c) Remove the 3 bolts, air switching valve and gasket.
NOTICE: Be careful not to damage the installation surface of the gaskets.
Installation
1UR-FE EMISSION CONTROL: AIR SWITCHING VALVE (for Bank 1): INSTALLATION
1. INSTALL AIR SWITCHING VALVE ASSEMBLY
(a) Install a new gasket and the air switching valve with the 3 bolts.
Torque : 24 Nm (245 kgf-cm, 18 ft-lbf)
NOTICE: Make sure the gasket's claws are not caught between the air switching valve and No. 4
air tube.
(b) Install the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(c) Connect the wire harness clamp bracket with the bolt.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
2. CONNECT NO. 2 AIR HOSE
(a) Align the paint mark with the projection and connect the No. 2 air hose.
Page 6883
Power Distribution Module: Diagrams Voltage Inverter
Diagrams
Seat Belt Tensioner: Diagrams
Page 566
Page 249
Power Distribution Relay: Diagrams
Page 5769
Torque : 19 Nm (194 kgf-cm, 14 ft-lbf)
(b) Install the No. 1 parking brake cable to the inside of the vehicle with the 2 bolts (labeled B).
Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)
(c) Connect the clamp (labeled C) to the No. 1 parking brake cable.
(d) Install the clamp with the nut (labeled D).
Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)
(e) Install the No. 1 parking brake cable and cable retainer with the bolt (labeled E).
Torque : 13 Nm (127 kgf-cm, 9 ft-lbf)
(f) Temporarily install the adjustment nut and lock nut (labeled F).
NOTICE: Do not bend and twist the parking brake cable.
HINT The nuts will be tightened to a torque specification in the "ADJUST PARKING BRAKE
PEDAL TRAVEL" procedure.
26. INSTALL NO. 1 PARKING BRAKE CABLE ASSEMBLY (for 3700 mm [12 ft. 1.7 in.] Wheelbase
Type)
(a) Install the No. 1 cable support bracket with the 3 bolts (labeled A).
Torque : 19 Nm (194 kgf-cm, 14 ft-lbf)
(b) Install the No. 1 parking brake cable to the inside of the vehicle with the 2 bolts (labeled B).
Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)
(c) Connect the 2 clamps (labeled C) to the No. 1 parking brake cable.
(d) Install the 2 clamps with the 2 nuts (labeled D).
Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)
Page 4324
Air Flow Meter/Sensor: Testing and Inspection On-Vehicle Inspection
1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: ON-VEHICLE INSPECTION
1. CHECK MASS AIR FLOW METER
(a) Check the mass air flow value.
(1) Connect the Techstream to the DLC3.
(2) Turn the ignition switch to ON.
(3) Turn the Techstream main switch ON.
(4) Enter the following menus: Powertrain / Engine / Data List / All Data / MAF.
(5) Blow air into the MAF meter, and check that the MAF value fluctuates.
(6) If the result is not as specified, check the MAF meter See: Inspection, or wiring and ECM See:
Computers and Control Systems/Testing
and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0102.
Page 2254
Wheel Fastener: Service and Repair Rear Axle Hub Bolt
Components
AXLE: REAR AXLE HUB BOLT: COMPONENTS
Replacement
AXLE: REAR AXLE HUB BOLT: REPLACEMENT
HINT *
Use the same procedures for the LH side and RH side.
Audio and Visual System
Remote Switch: Locations Audio and Visual System
AUDIO / VISUAL: AUDIO AND VISUAL SYSTEM: PARTS LOCATION
Locations
Actuator: Locations
JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION
Page 495
EFI Relay
Fuel Pump Relay: Testing and Inspection EFI Relay
1UR-FE ENGINE CONTROL SYSTEM: EFI RELAY: ON-VEHICLE INSPECTION
1. REMOVE INTEGRATION RELAY See: Relays and Modules - Ignition System/Ignition
Relay/Testing and Inspection
2. INSPECT INTEGRATION RELAY (EFI)
NOTICE: *
Some relays are built into the integration relay. The integration relay cannot be disassembled. If
there is a malfunction in the circuit of the integration relay, replace the integration relay.
* The internal circuit of the integration relay is as shown in the illustration below. Inspect the
integration relay using the following procedures.
(a) Measure the resistance of the EFI No. 1 fuse.
(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(2) If the result is not as specified, replace the EFI No. 1 fuse.
(b) Measure the resistance of the EFI relay.
(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
Page 4898
Shifter A/T: Adjustments SHIFT LEVER ASSEMBLY (for Floor Shift Type)
A760F AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY (for Floor Shift Type):
ADJUSTMENT
1. INSPECT SHIFT LEVER POSITION
(a) When moving the shift lever from N to other positions, check that the lever can be moved
smoothly and accurately to each position and that the
position indicator comes on in accordance with the shift lever position.
If the indicator and shift lever position do not match, carry out the following adjustment procedures.
2. ADJUST SHIFT LEVER POSITION
(a) Move the shift lever to N.
(b) Fold back the transmission control cable adjust case cover. Then while sliding the slider toward
the cable end side, press out the lock piece
from the back side to release the lock.
(c) Check that the spring of the adjust case is applying enough tension to the shift control cable.
Then press in the lock piece to set the lock.
NOTICE: *
Use your hand to push in the lock piece. Do not use any tools.
* Securely push in the lock piece so that the protrusion of the slider is above the lock piece.
(d) Return the cover of the adjust case to its original position.
(e) Inspect the shift lever operation after the adjustment.
Page 9306
properly. Make sure to thoroughly wipe off the double-sided tape.
3. After cleaning the installation area of the body with degreasing agent, attach the name plate to
the position shown in the illustration.
HINT: 1. The working environment should be 20 degrees C when installing the name plate. If the
working environment is below 20 degrees C, heat the
installation area of the body to 20 to 30 degrees C and then install the name plate.
Page 3066
Page 7170
Front Steering Knuckle: Service and Repair Removal
AXLE: STEERING KNUCKLE: REMOVAL
HINT *
Use the same procedures for the LH side and RH side.
* The procedures listed below are for the LH side.
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE FRONT AXLE HUB SUB-ASSEMBLY LH
(a) Remove the front axle hub See: Suspension/Wheel Hub/Service and Repair/Removal and
Replacement/Removal.
3. DISCONNECT FRONT SPEED SENSOR LH
(a) Remove the clip and bolt.
(b) Disconnect the speed sensor from the steering knuckle.
4. DISCONNECT TIE ROD END SUB-ASSEMBLY LH
(a) Remove the cotter pin and nut.
(b) Using SST, disconnect the tie rod end LH from the steering knuckle.
SST : 09610-20012
NOTICE: *
Do not damage the front disc brake dust cover.
* Do not damage the ball joint dust cover.
* Do not damage the steering knuckle.
5. DISCONNECT FRONT LOWER BALL JOINT ATTACHMENT LH See: Suspension/Control
Arm/Service and Repair/Removal and
Replacement/Front Lower Suspension Arm/Removal
6. REMOVE STEERING KNUCKLE LH
(a) Support the front suspension lower arm LH with a jack.
(b) Remove the clip and the nut.
Page 2576
ERROR: undefined
OFFENDING COMMAND: f‘~
STACK:
Airbag Cut-OFF Switch
Air Bag Deactivation Switch: Service and Repair Airbag Cut-OFF Switch
Components
SUPPLEMENTAL RESTRAINT SYSTEM: AIRBAG CUT-OFF SWITCH: COMPONENTS
Removal
SUPPLEMENTAL RESTRAINT SYSTEM: AIRBAG CUT-OFF SWITCH: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY
(a) Remove the lower No. 2 instrument panel airbag assembly See: Restraint Systems/Air Bag
Systems/Air Bag/Service and Repair/Removal
and Replacement/Front Passenger Side Knee Airbag Assembly/Removal.
3. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and
Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument
Panel Safety Pad (for Column Shift Type)/Removal
4. REMOVE AIRBAG CUT-OFF SWITCH
(a) Detach the 2 claws to remove the switch.
Installation
SUPPLEMENTAL RESTRAINT SYSTEM: AIRBAG CUT-OFF SWITCH: INSTALLATION
1. INSTALL AIRBAG CUT-OFF SWITCH
(a) Attach the 2 claws to install the switch.
2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY See: Body and
Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Column Shift Type)/Installation
3. INSTALL LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY
(a) Install the lower No. 2 instrument panel airbag assembly See: Restraint Systems/Air Bag
Systems/Air Bag/Service and Repair/Removal and
Replacement/Front Passenger Side Knee Airbag Assembly/Installation.
4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Locations
Throttle Position Sensor: Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Locations
Switch: Locations
JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION
Page 7692
3. CONNECT AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY
(a) Remove the attached vinyl tape from the pipe and the connecting part of the cooler condenser.
(b) Sufficiently apply compressor oil to a new O-ring and the fitting surface of the pipe joint.
Compressor oil:
ND-OIL 8 or equivalent
(c) Install the O-ring on the air conditioning tube and accessory.
(d) Connect the air conditioning tube and accessory on the cooler condenser with the 2 bolts.
Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)
NOTICE: *
When tightening the bolt, do not allow any tools to contact the pipe.
* When tightening the bolt, hold a part of the pipe near the connector.
4. CONNECT DISCHARGE HOSE
(a) Remove the attached vinyl tape from the hose and the connecting part of the cooler condenser.
(b) Sufficiently apply compressor oil to a new O-ring and the fitting surface of the hose joint.
Compressor oil:
ND-OIL 8 or equivalent
(c) Install the O-ring on the discharge hose.
Page 1402
Door/Service and Repair/Front Door (for Double Cab)/Disassembly
4. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH (for Front Side) See: Body
and Frame/Doors, Hood and
Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly
5. REMOVE COURTESY LIGHT ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood
and Trunk/Doors/Front Door/Service and
Repair/Front Door (for Double Cab)/Disassembly
6. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Disassembly
7. REMOVE FRONT SIDE AIRBAG SENSOR
(a) Disconnect the connector.
(b) Remove the screw and side airbag sensor.
8. REMOVE REAR SEAT ASSEMBLY (for Rear Side)
(a) Remove the rear seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Rear Seat Assembly (for Double
Cab)/Removal.
9. REMOVE REAR DOOR SCUFF PLATE LH (for Rear Side) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and Repair/Roof
Headlining (For Double Cab)/Removal
10. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH (for Rear Side)
11. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY LH (for Rear Side) See: Body and
Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal
12. REMOVE REAR SIDE AIRBAG SENSOR
(a) Remove the bolt and side airbag sensor.
(b) Disconnect the connector.
Installation
SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Double Cab):
INSTALLATION
1. INSTALL FRONT SIDE AIRBAG SENSOR
(a) Check that the ignition switch is OFF.
(b) Check that the cable is disconnected from the battery negative (-) terminal.
CAUTION:
Page 6877
Accessory Relay: Diagrams
Page 8235
Removal
SEAT BELT: FRONT SEAT INNER BELT ASSEMBLY (for Center Seat): REMOVAL
1. REMOVE FRONT SEAT ASSEMBLY LH
(a) for Power Seat:
Remove the front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Power Seat)/Removal.
(b) for Manual Seat:
Remove the front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Manual
Page 6613
6. PROBLEM SYMPTOMS TABLE
When a "Normal" code is output during a DTC check but the problem is still occurring, use the
Problem Symptoms Table. The suspected areas (circuits or parts) for each problem symptom are
in the table. The suspected areas are listed in order of probability. A description of each of the
chart's columns is below.
HINT In some cases, the problem is not detected by the diagnostic system even though a problem
symptom is present. It is possible that the problem is occurring outside the detection range of the
diagnostic system, or that the problem is occurring in a completely different system.
7. CIRCUIT INSPECTION
A description of the main areas of each circuit inspection is below.
Page 4582
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Page 5740
NOTICE: Use the formula to calculate special torque values for situations where a union nut
wrench is combined with a torque wrench See: Service Precautions
3. INSTALL BRAKE TUBE
(a) Using a union nut wrench, connect the 2 brake tubes to the brake master cylinder.
Torque : 20 Nm (199 kgf-cm, 14 ft-lbf)
NOTICE: Use the formula to calculate special torque values for situations where a union nut
wrench is combined with a torque wrench See: Service Precautions
(b) Using a union nut wrench, connect the 2 brake tubes to the VSC actuator.
Torque : 20 Nm (199 kgf-cm, 14 ft-lbf)
NOTICE: Use the formula to calculate special torque values for situations where a union nut
wrench is combined with a torque wrench See: Service Precautions
4. CONNECT VSC ACTUATOR CONNECTOR
(a) Connect the VSC actuator connector.
5. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
6. BLEED BRAKE SYSTEM See: Brake Bleeding/Service and Repair/Bleeding
Audio System - Satellite Radio Inop. Until Key Is Cycled
Radio Receiver: Customer Interest Audio System - Satellite Radio Inop. Until Key Is Cycled
T-SB-0271-09
Rev1
August 11, 2009
XM Satellite Radio Inoperative Until Ignition Key Is Cycled
Service Category
Audio/Visual/Telematics
Section Audio/Video
Market USA
Applicability
March 30, 2010 Rev1:
TSB REVISION NOTICE
^ Applicability has been updated to include additional 2010 - 2011 model year Toyota vehicles.
Any previous printed versions of this service bulletin should be discarded.
Introduction
Some vehicles equipped with a PPO/DIO accessory XM Satellite Radio Receiver (P/N
86180-0W030 or 86180-0W031) may exhibit one or more of the following conditions:
^ XM Satellite Radio becomes non-operational or locked while in use.
^ Sound output becomes sporadic or non-existent.
When either of these conditions occur cycling the ignition from "ON"-"OFF"-"ON" restores normal
operation.
Improved XM Satellite Radio Receiver exchange units are available to correct this condition.
NOTE
Page 6507
J/B No.6 Assembly Inner Circuit
Locations
Integrated Accessory Switch Assembly: Locations
METER: METER / GAUGE SYSTEM: PARTS LOCATION
Page 887
Oil Pressure Sender: Service and Repair Installation
1UR-FE LUBRICATION: OIL PRESSURE SWITCH: INSTALLATION
1. INSTALL OIL PRESSURE SENDER GAUGE ASSEMBLY
(a) Apply adhesive to 2 or 3 threads of the oil pressure sender gauge.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
(b) Install the oil pressure sender gauge.
Torque : 15 Nm (153 kgf-cm, 11 ft-lbf)
NOTICE: Do not start the engine within 1 hour after installation.
(c) Connect the sender gauge connector.
2. INSPECT ENGINE OIL LEVEL See: Engine, Cooling and Exhaust/Engine/Engine
Lubrication/Testing and Inspection
3. INSPECT FOR OIL LEAK See: Engine, Cooling and Exhaust/Engine/Engine Lubrication/Engine
Oil/Service and Repair/Replacement
4. INSTALL NO. 1 ENGINE UNDER COVER See: Engine, Cooling and Exhaust/Engine/Engine
Lubrication/Engine Oil/Service and
Repair/Replacement
Page 7401
Wheel Bearing: Tools and Equipment
Wheel Bearing Nut Socket
AST tool# TOY 185
For R and R of wheel bearing nut located on inboard side of wheel hub. Applicable: Newer Toyota
trucks and SUV's (2wd only).
- Made in USA
Contact AST for pricing.
Assenmacher Specialty Tools 1-800-525-2943
Page 8928
Integrated Accessory Switch Assembly: Diagrams
Page 3081
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: ELECTRONIC
CIRCUIT INSPECTION PROCEDURE
1. BASIC INSPECTION
(a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS
(1) Unless otherwise stated, all resistance measurements should be made at an ambient
temperature of 20°C (68°F). Resistance measurements
may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been
running. Measurements should be made after the engine has cooled down.
(b) HANDLING CONNECTORS
(1) When disconnecting a connector, first squeeze the mating halves tightly together to release the
lock, and then press the lock claw and
separate the connector.
(2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly
and separate it.
(3) Before connecting a connector, check that there are no deformed, damaged, loose or missing
terminals.
(4) When connecting a connector, press firmly until it locks with a "click" sound.
(5) If checking a connector with a TOYOTA electrical tester, check the connector from the backside
(harness side) using a mini test lead.
NOTICE: *
As a waterproof connector cannot be checked from the backside, check it by connecting a
sub-harness.
* Do not damage the terminals by moving the inserted tester needle.
(c) CHECKING CONNECTORS
(1) Checking when a connector is connected: Squeeze the connectors together to confirm that they
are fully connected and locked.
(2) Checking when a connector is disconnected: Check by pulling the wire harness lightly from the
backside of the connector. Look for
unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for
corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or
deformed terminals.
(3) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a
female terminal, and check for ample tension
Components
Cabin Temperature Sensor / Switch: Service and Repair Components
AIR CONDITIONING: ROOM TEMPERATURE SENSOR (for Automatic Air Conditioning System):
COMPONENTS
Locations
Shift Interlock Control Module: Locations
Instrument Panel (Floor Shift)
Instrument Panel (Column Shift)
Page 5991
Page 9275
Hood Shock / Support: Service and Repair Removal
ENGINE HOOD / DOOR: HOOD SUPPORT: REMOVAL
1. REMOVE HOOD SUPPORT ASSEMBLY LH
(a) Using a screwdriver, remove the hood support assembly while releasing the 2 clips.
HINT Tape the screwdriver tip before use.
CAUTION: Remove the hood support while supporting the hood by hand.
2. REMOVE NO. 1 HOOD SUPPORT BOLT
(a) Remove the hood support bolt.
CAUTION: Remove the hood support bolt while supporting the hood by hand.
Page 4539
Knock Sensor: Testing and Inspection
1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: INSPECTION
1. INSPECT KNOCK SENSOR
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) If the result is not as specified, replace the knock sensor.
Locations
Lock Cylinder Switch: Locations
THEFT DETERRENT: THEFT DETERRENT SYSTEM: PARTS LOCATION
Page 1335
Ignition Switch: Testing and Inspection
1UR-FE STARTING: IGNITION SWITCH: INSPECTION
1. INSPECT IGNITION SWITCH ASSEMBLY
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) If the result is not as specified, replace the ignition switch assembly.
Inspection
Air Flow Meter/Sensor: Testing and Inspection Inspection
1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: INSPECTION
1. INSPECT MASS AIR FLOW METER
(a) Check the output voltage.
(1) Apply battery voltage across terminals 1 (+B) and 2 (E2G).
NOTICE: While using the battery during inspection, do not bring the positive and negative tester
probes too close to each other as a short circuit may occur.
(2) Using a voltmeter, connect the positive (+) tester probe to terminal 3 (VG), and negative (-)
tester probe to terminal 2 (E2G).
(3) Blow air into the MAF meter, and check that the voltage fluctuates.
If the result is not as specified, replace the MAF meter.
(b) Perform a visual check for any foreign matter on the platinum hot wire (heater) of the mass air
flow meter shown in the illustration.
OK:
There is no foreign material.
(c) If the result is not as specified, replace the mass air flow meter.
(d) Check the IAT sensor.
Engine Controls - Techstream(R) ECU Re-Flash
Procedure
PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls Techstream(R) ECU Re-Flash Procedure
T-SB-0064-10
February 4, 2010
Techstream ECU Flash Reprogramming Procedure
Service Category Engine/Hybrid System
Section Engine Control
Market USA
Applicability
TSB SUPERSESSION NOTICE
The information contained in this TSB supersedes TSB No. SS002-07.
^ Applicability has been updated to include 2009 - 2011 model year Toyota vehicles.
^ A new section, Techstream Preparation, has been added.
^ Techstream Lite has been added as an option in Required Tools & Materials.
^ Process Overview and Operation Procedure sections have been updated.
TSB No. SS002-07 is Obsolete and any printed versions should be discarded. Be sure to review
the entire content of this service bulletin before proceeding.
Introduction
Flash reprogramming allows the ECU software to be updated without replacing the ECU. Flash
calibration updates for specific vehicle models/ECUs are released as field-fix procedures described
in individual service bulletins. This bulletin details the Techstream ECU flash reprogramming
process and outlines use of the Technical Information System (TIS) and the Calibration Update
Wizard (CUW). Flash calibration updates can only be applied to the vehicle/ECU combination for
which they are intended. ECUs have internal security that will not allow them to be programmed
with another ECU's information.
ECU
Electronic Control Unit (ECU) is a Toyota term used to describe integrated computerized devices
responsible for managing the operation of a system or subsystem. For the purposes of this bulletin,
the term "ECU" is used as a generic label for the following SAE J1930 standard references:
^ Powertrain Control Module (PCM)
Service and Repair
Vehicle Lifting: Service and Repair
INTRODUCTION: REPAIR INSTRUCTION: VEHICLE LIFT AND SUPPORT LOCATIONS
1. NOTICE ABOUT VEHICLE CONDITION WHEN JACKING UP VEHICLE
(a) The vehicle must be unloaded before jacking up / lifting up the vehicle. Never jack up / lift up a
heavily loaded vehicle.
(b) When removing heavy parts such as the engine and transmission, the center of gravity of the
vehicle may shift. To stabilize the vehicle, place a
balance weight in a location where it will not roll or shift, or use a mission jack to hold the jacking
support.
2. NOTICE FOR USING 4 POST LIFT
(a) Follow the safety procedures outlined in the lift's instruction manual.
(b) Use precautionary measures to prevent the free wheel beam from damaging tires or wheels.
(c) Use wheel chocks to secure the vehicle.
3. NOTICE FOR USING JACK AND SAFETY STAND
(a) Work on a level surface. Use wheel chocks at all times.
(b) Use safety stands with rubber attachments as shown in the illustration.
(c) Set the jack and safety stands to the specified locations of the vehicle accurately.
(d) When jacking up the vehicle, first release the parking brake and move the shift lever to N.
(e) When jacking up the entire vehicle:
(1) When jacking up the front wheels first, make sure wheel chocks are behind the rear wheels.
(2) When jacking up the rear wheels first, make sure wheel chocks are in front of the front wheels.
(f) When jacking up only the front or rear wheels of the vehicle:
(1) Before jacking up the front wheels, place wheel chocks on both sides of the rear wheels.
(2) Before jacking up the rear wheels, place wheel chocks on both sides of the front wheels.
(g) When lowering a vehicle that only has its front or rear wheels jacked up:
(1) Before lowering the front wheels, make sure wheel chocks are in front of the rear wheels.
(2) Before lowering the rear wheels, make sure wheel chocks are behind the front wheels.
Testing and Inspection
Wiring Harness: Testing and Inspection
A760F AUTOMATIC TRANSMISSION: TRANSMISSION WIRE: INSPECTION
1. INSPECT TRANSMISSION WIRE (ATF TEMPERATURE SENSOR)
(a) Measure the resistance according to the value(s) in the table below.
HINT If the resistance is out of the specified range at any of the ATF temperatures shown in the
table below, the driveability of the vehicle may decrease.
Standard Resistance:
(b) If the result is not as specified, replace the transmission wire.
Page 4841
(b) When using the Techstream:
Disconnect the Techstream from the DLC3.
(c) w/ Trailer Towing System (with transmission oil thermostat):
(1) Push in the shaft with a screwdriver and remove the pin.
NOTICE: Make sure the shaft of the thermostat is protruding from the hole in the cap.
(d) Inspect for automatic transmission fluid leaks.
Page 1302
Page 2003
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION: Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC
terminals are touched, the IC may be destroyed by static electricity.)
When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact with the terminals of leads from the IC, etc. of the
replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown on the left.
DISCONNECT CONNECTOR
Locations
Accessory Relay: Locations
Instrument Panel (Floor Shift)
Instrument Panel (Column Shift)
Page 5927
Yaw Rate Sensor: Diagrams
Locations
Tire Pressure Warning Reset Switch: Locations
TIRE AND WHEEL: TIRE PRESSURE WARNING SYSTEM: PARTS LOCATION
Page 4003
Required Tools & Equipment
Repair Procedure
1. Using TIS Techstream check if DTC P0418, P0419, P2440, P2441, P2442, P2443, P2446
and/or P2447 are present.
2. Using Techstream perform the manual Air Injection Test (options 1 and 2) to verify if the signal
from the air injection control driver is reaching the
air pumps.
^ The pumps should be heard turning on at this point and there should be battery voltage on pin 2
of the pumps during this test.
^ If there is NO voltage refer to the Repair Manual for air injection control driver diagnosis.
Refer to the Technical Information System (TIS) 2010 model year Tundra Repair Manual:
3. If during the test voltage is present at the pump and the pump is NOT running or the Air
Pressure (gauge) value did NOT increase from 0 to 1 psi on
TIS Techstream with the pump running remove the air pump assemblies for inspection.
Refer to TIS 2010 model year Tundra Repair Manual:
4. With the pumps removed from the vehicle verify if there is liquid or evidence that liquid entered
the pumps.
^ YES - If there is liquid evidence go to step 5.
^ NO - If there is NO evidence of liquid go to step 7.
5. If liquid is present replace the affected pump assembly.
Refer to TIS 2010 model year Tundra Repair Manual:
Page 7525
Required Tools & Equipment
Repair Procedure Overview
^ Confirm noise is coming from the rear of the vehicle and changes with vehicle speed.
^ Install ChaSSiSEAR(TM) (or equivalent) and isolate the noise to the rear wheel bearing.
^ Remove the rear axle shaft assembly.
^ Install new rear wheel bearing brake caliper bracket and seals.
^ Reinstall rear axle shaft assembly and confirm the noise is no longer present.
Repair Procedure
1. Test drive the vehicle and confirm the customer complaint.
Does the noise increase and decrease with vehicle speed?
^ YES - Go to step 2.
^ NO - This TSB does NOT apply. Refer to the Repair Manual for further diagnosis.
Page 3283
2. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in
Figure 1. Confirm if the ECM (PCM) calibration has
been updated. If the calibration ID listed is NOT the latest ECM (PCM) calibration - go to step 3.
3. Flash reprogram the ECM (PCM).
NOTE
^ The GR8 Battery Diagnostic Station MUST be used in Power Supply Mode to maintain battery
voltage at 13.5 volts while flash reprogramming the vehicle.
^ For details on how to use the GR8 Battery Diagnostic Station, refer to the located on the
Technical Information System (TIS), Diagnostics - Battery
Follow the procedures outlined in TSB No. T-SB-0064-10, "Techstream ECU Flash
Reprogramming Procedure1⁄4 and flash the ECM (PCM) with the NEW calibration file update.
4. Install the Authorized Modifications Label.
A. Using a permanent marker enter the following information on the label:
^ ECM part number [Refer to the Parts Information section for the CURRENT PART NUMBER]
^ Calibration ID(s) [Refer to the Calibration Identification Chart for the NEW CALIBRATION ID]
^ Dealer Code
^ Repair Date
^ Change Authority [This TSB number]
B. Affix the Authorized Modifications Label to the vehicle at the location shown in Figure 1. The
Authorized Modifications Label is available
through the MDC P/N 00451-00001-LBL.
5. Test drive the vehicle to confirm proper vehicle operation.
Page 8829
NOTICE: Do not touch the cone part of the speaker.
7. REMOVE FRONT NO. 2 SPEAKER ASSEMBLY RH
(a) Remove the 2 bolts.
(b) Remove the speaker and disconnect the connector.
NOTICE: Do not touch the cone part of the speaker.
8. REMOVE NO. 3 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY
(a) Using a screwdriver, detach the 6 clips and 2 claws.
HINT Tape the screwdriver tip before use.
(b) Remove the speaker panel.
9. REMOVE FRONT NO. 4 SPEAKER ASSEMBLY (for 12 Speakers)
(a) Remove the 2 bolts.
(b) Remove the speaker and disconnect the connector.
A/T - World Standard Automatic Transmission Fluid
Fluid - A/T: Technical Service Bulletins A/T - World Standard Automatic Transmission Fluid
T-SB-0006-11
January 6, 2011
World Standard Automatic Transmission Fluid
Service Category Drivetrain
Section Automatic Transmission/Transaxle
Market USA
Applicability
TSB SUPERSESSION NOTICE
The information contained in this TSB supersedes TSB No. TC010-07.
Applicability has been updated to include 2009 - 2011 model year Toyota vehicles.
TSB No. TC010-07 is Obsolete and any printed versions should be discarded. Be sure to review
the entire content of this service bulletin before proceeding.
Introduction
World Standard (WS) Automatic Transmission Fluid (ATF) was introduced to reduce maintenance
costs and increase the mileage between scheduled maintenance checks. Here are some important
tips when working with ATF-WS in Toyota vehicles requiring its use.
Warranty Information
Page 362
Then click Next.
F. Verify correct current calibration and new calibration information. Then click Next.
NOTE
^ The total number of calibration IDs in the calibration file corresponds to the number of
reprogrammable processors in the ECU.
^ Each calibration file may contain up to three separate calibrations.
Page 5706
* Low pedal or spongy pedal.
* Brake pedal is depressed firmly but braking is insufficient.
(c) Check and adjust brake fluid level in reservoir See: Brake Fluid/Testing and Inspection.
2. BLEED BRAKE SYSTEM
(a) Bleed brake master cylinder
HINT If the master cylinder has been disassembled or if the reservoir becomes empty, bleed air
from the master cylinder.
(1) Remove the brake master cylinder reservoir filler cap assembly.
(2) Add brake fluid into the reservoir between MAX and MIN level on the brake fluid reservoir.
Brake fluid:
SAE J1703 or FMVSS No. 116 DOT3
(3) Using a union nut wrench, disconnect the 2 brake lines from the master cylinder.
(4) Slowly depress and hold the brake pedal.
(5) Block the outer holes with your fingers, and release the pedal.
(6) Repeat the 2 previous steps 3 or 4 times.
(7) Using a union nut wrench, connect the 2 brake lines to the master cylinder.
without union nut wrench - Torque : 20 Nm (199 kgf-cm, 14 ft-lbf)
with union nut wrench - Torque : 18 Nm (185 kgf-cm, 13 ft-lbf)
* Use a torque wrench with a fulcrum length of 300 mm (11.8 in.).
* This torque value is effective when union nut wrench is parallel to the torque wrench.
(b) Bleed brake line
(1) Connect a vinyl tube to the bleeder plug of the front disc brake cylinder RH.
(2) Depress the brake pedal several times, and then loosen the bleeder plug with the pedal
depressed.*1
(3) When fluid stops coming out, tighten the bleeder plug, and then release the brake pedal.*2
(4) Repeat *1 and *2 until all the air in the brake fluid is completely bled out and the new brake fluid
comes out.
(5) Tighten the bleeder plug completely.
Torque : 11 Nm (110 kgf-cm, 8 ft-lbf)
(6) Replace the brake fluid from the front disc brake cylinder LH using the same procedure as for
RH.
(7) Connect a vinyl tube to the bleeder plug of the rear disc brake cylinder RH.
Page 46
(a) Attach the 8 claws and 2 clips to install the scuff plate.
5. INSTALL BACK PANEL TRIM RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for
CrewMax)/Installation
Page 2719
(a) Install the 4 No. 1 converter protector stays.
(b) Install the 2 No. 1 monolithic converter protectors with the 4 bolts and 4 nuts.
Torque : 11 Nm (107 kgf-cm, 8 ft-lbf)
HINT Install the monolithic converter protector within the angle range specified in the illustration.
3. INSTALL MONOLITHIC CONVERTER PROTECTOR (for Bank 2)
(a) Install the 2 No. 1 converter protector stays and 2 No. 2 converter protector stays.
(b) Install the 2 monolithic converter protectors with the 4 bolts and 4 nuts.
Torque : 11 Nm (107 kgf-cm, 8 ft-lbf)
HINT Install the monolithic converter protector within the angle range specified in the illustration.
4. INSTALL NO. 1 MONOLITHIC CONVERTER PROTECTOR (for Bank 2)
(a) Install the 4 No. 1 converter protector stays.
(b) Install the 2 No. 1 monolithic converter protectors with the 4 bolts and 4 nuts.
Torque : 11 Nm (107 kgf-cm, 8 ft-lbf)
HINT
Power Source Control ECU
Power Distribution Module: Diagrams Power Source Control ECU
Page 6673
Diode: Diagrams Diode (Starting)
Locations
Entertainment System Control Module: Locations
Instrument Panel (Floor Shift)
Instrument Panel (Column Shift)
Page 3457
Operating the ignition switch, any switches or any doors triggers related ECU and sensor
communication with the CAN, which causes resistance variation.
PROCEDURE
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
(a) Disconnect the cable from the negative (-) battery terminal before measuring the resistances of
the main wire and the branch wire.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
NEXT -- Continue to next step.
2. CHECK FOR OPEN IN CAN BUS WIRE (CENTER AIRBAG SENSOR BRANCH WIRE)
(a) Disconnect the J46 center airbag sensor connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE CENTER AIRBAG SENSOR BRANCH WIRE OR CONNECTOR
(CANH, CANL) OK -- Continue to next step.
3. CHECK HARNESS AND CONNECTOR (CENTER AIRBAG SENSOR - BATTERY AND BODY
GROUND)
(a) Reconnect the cable to the negative (-) battery terminal before measuring the resistances of the
main wire and the branch wire.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
Locations
Main Relay (Computer/Fuel System): Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 6743
J/B No.6 Assembly - Instrument Panel Center
Page 2218
Tire Pressure Warning Reset Switch: Service and Repair Installation
TIRE AND WHEEL: TIRE PRESSURE WARNING RESET SWITCH: INSTALLATION
1. INSTALL TIRE PRESSURE WARNING RESET SWITCH
(a) Attach the 2 claws to install the reset switch.
(b) Connect the switch connector.
2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Installation
3. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
4. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Installation
5. INSTALL FRONT DOOR SCUFF PLATE LH (for Double Cab, for CrewMax) See: Body and
Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation
6. INSTALL FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Installation
Page 8838
NOTICE: Do not touch the cone part of the speaker.
Installation
AUDIO / VISUAL: INSTRUMENT PANEL SPEAKER (for Double Cab): INSTALLATION
1. INSTALL FRONT NO. 4 SPEAKER ASSEMBLY (for 10 Speakers)
(a) Connect the connector.
(b) Temporarily install the speaker by aligning the positioning pins of the speaker with the
instrument panel.
(c) Install the speaker with the 2 bolts.
NOTICE: *
Do not touch the cone part of the speaker.
* When installing the speaker to the instrument panel, be careful that the wires do not get caught
between the parts.
2. INSTALL NO. 3 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY
(a) Attach the 6 clips and 2 claws to install the speaker panel.
3. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY RH
(a) Connect the speaker connector.
Page 2185
Tire Pressure Module: Diagrams
Page 1685
for Regular Cab of Long Deck
for Double Cab of Standard Deck
Page 1853
Then click Start.
I. Do NOT disturb the vehicle during flash reprogramming.
NOTE
^ ECU flash reprogramming may take anywhere from 3 - 30 minutes per calibration file.
^ Reprogramming time will vary depending on model and ECU communication protocol. Vehicles
using CAN communication protocol will reprogram much faster (2 - 7 minutes).
NOTE
^ If vehicle requires only ONE calibration update, then proceed to step N in this bulletin.
^ If vehicle requires a SECOND calibration update, then continue as follows:
^ For serial communication vehicles, go to step J.
^ For CAN communication vehicles, go to step L.
Page 2630
HINT The direction of hose clamp is indicated in the illustration.
5. CONNECT NO. 8 WATER BY-PASS HOSE
(a) Connect the water by-pass hose.
HINT The direction of hose clamp is indicated in the illustration.
6. INSTALL NO. 1 WATER BY-PASS HOSE
(a) Install the water by-pass hose.
HINT The direction of hose clamp is indicated in the illustration.
7. INSTALL WATER BY-PASS PIPE (w/ Oil Cooler)
(a) Connect the 4 water hoses.
HINT Connect each hose so that the direction of each hose clamp is as indicated in the illustration.
(b) Install the water by-pass hose with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
Diagram Information and Instructions
Trailer Lamps: Diagram Information and Instructions
Wiring Color Codes
Abbreviations Used Within Diagrams
Abbreviations Used Within Diagrams
Page 4913
(d) Remove the shift lever plate from the column shift control shift lever retainer.
4. REMOVE COLUMN SHIFT SHIFT LOCK RELEASE LINK
(a) Remove the shift lock release link and spring from the shift lever plate.
5. REMOVE COLUMN SHIFT SHIFT LEVER SUB-ASSEMBLY
(a) Remove the shift lever and 2 lever selecting bushes from the column shift control shift lever
retainer.
(b) Using a thin-bladed screwdriver, release the connector housing retainer.
Restraints - Seat Belt Extenders
Seat Belt Extension: Technical Service Bulletins Restraints - Seat Belt Extenders
T-SB-0053-09
Rev1
January 27, 2009
Seat Belt Extenders
Service Category Vehicle Interior
Section Seat Belt
Market USA
Applicability
November 5,2009 Rev1:
TSB REVISION NOTICE
Applicability has been updated to include additional 2010 models. Any previous printed versions of
this service bulletin should be discarded.
Introduction
Toyota customers who find it necessary to increase the length of their seat belts may obtain Seat
Belt Extenders at no cost through their local Toyota dealer.
^ The extender is available in 6-inch, 9-inch, 12-inch, 15-inch, and 18-inch lengths.
^ The extender is available only in black.
^ Owners are informed of the Seat Belt Extender availability through the Toyota Owner's Manual
included in each vehicle.
Page 2087
Driver Side J/B - Cowl Side Left
Engine Control System - SFI System
Camshaft Position Sensor: Locations Engine Control System - SFI System
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 9249
Page 5277
4. TIGHTEN PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for 3 Joint Type)
(a) With the vehicle empty and all 4 tires supported by a lift, or with the vehicle suspension in the
full rebound position, adjust the center bearing
so that dimension A (the distance from the front surface of the center bearing housing to the back
surface of the intermediate shaft) is as shown in the chart below.
HINT Measure dimension A (the distance from the front surface of the center bearing housing to
the back surface of the intermediate shaft) at 3 places and make adjustments so that the measured
dimensions are equal.
Standard dimension A:
(b) Check that the center line of the bracket is at right angles to the shaft axial direction.
(c) Tighten the 2 mounting bolts.
Torque : 40 Nm (410 kgf-cm, 30 ft-lbf)
5. INSPECT PROPELLER SHAFT JOINT ANGLE (for 3 Joint Type)
NOTICE: *
Perform the inspection on a level surface.
* Perform the inspection with the vehicle empty.
* Perform the inspection with all wheels on the ground.
(a) Measure the No. 1 joint angle.
(1) Using SST, measure and record the angle of the intermediate shaft (C).
SST : 09370-50010
Service and Repair
Air Bag(s) Arming and Disarming: Service and Repair
Air Bag(s) Arming and Disarming
Before starting work, wait at least 90 seconds after the ignition switch is turned OFF and after the
cable of the negative (-) battery terminal is disconnected. (SRS parts are equipped with a backup
power source. If work is started within 90 seconds of turning the ignition switch OFF and
disconnecting the cable from the negative (-) battery terminal, SRS parts may deploy.)
Page 5272
(a) Remove the 2 bolts and insulator bracket.
2. REMOVE TRANSFER HEAT INSULATOR
(a) Remove the 3 bolts and heat insulator.
3. REMOVE PROPELLER SHAFT ASSEMBLY (for 2 Joint Type)
(a) Place matchmarks on the propeller shaft flange and differential flange.
(b) Remove the 4 nuts and 4 bolts, and disconnect the propeller shaft from differential side.
(c) Place matchmarks on the propeller shaft flange and transfer flange.
(d) Remove the 4 nuts and propeller shaft.
4. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for 3 Joint Type)
Recall 10V091000: Front Driveshaft Replacement
Drive/Propeller Shaft: All Technical Service Bulletins Recall 10V091000: Front Driveshaft
Replacement
VEHICLE MAKE/MODEL: MODEL YEAR(S): Toyota/Tundra 2010 MANUFACTURER: Toyota
Motor North America, Inc.
MFR'S REPORT DATE: March 09, 2010
NHTSA CAMPAIGN ID NUMBER: 10V091000
NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Axle Assembly: Axle Shaft
POTENTIAL NUMBER OF UNITS AFFECTED: 2
SUMMARY: Toyota is recalling certain model year 2010 Tundra vehicles with four wheel drive,
there is a possibility that an improper weld exists at the union of the propeller shaft and yoke. Due
to this improper weld, this joint may separate and the separated shaft may come into contact with
the road surface.
CONSEQUENCE: This may result in a loss of vehicle control increasing the risk of a crash.
REMEDY: Dealers will replace the front propeller shaft free of charge. The safety recall is expected
to begin during March 2010. Owners may contact Toyota at 1-800-331-4331.
NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle
Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov.
Drivetrain - Front End Grinding Noise In 4WD
Differential Mount: Customer Interest Drivetrain - Front End Grinding Noise In 4WD
T-SB-0338-09
Rev1
September 16, 2009
Grinding Noise When in 4WD
Service Category Drivetrain
Section Axle/Differential
Market USA
Applicability
March 10, 2010 Rev1:
^ Applicability has been updated to include 2008 - 2010 model year Sequoia vehicles.
^ Production Change Information has been added.
Any previous printed versions of this service bulletin should be discarded.
Introduction
Some 2008 - 2010 model year Sequoia and 2007 - 2010 model year Tundra vehicles may exhibit a
grinding noise from the front of the vehicle while in 4WD. An updated differential support bolt is
available to address this condition. Follow the repair procedure in this bulletin to inspect and
replace the differential support bolt.
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for
36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Page 8693
Integrated Accessory Switch Assembly: Service and Repair Removal
METER: DRIVE MONITOR SWITCH: REMOVAL
1. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Panel,
Gauges and Warning Indicators/Instrument Cluster
/ Carrier/Service and Repair/Combination Meter/Removal
2. REMOVE DRIVE MONITOR SWITCH
(a) Detach the 2 claws and remove the monitor switch.
Page 398
HINT The wavelength becomes shorter as the engine rpm increases.
(n) WAVEFORM 13:
HINT The waveform varies depending on the CAN communication signal.
(o) WAVEFORM 14:
HINT The waveform varies depending on the CAN communication signal.
(p) WAVEFORM 15:
HINT The wavelength becomes shorter as the engine rpm increases.
Page 4526
(4) Remove the 2 bolts and disconnect the water by-pass pipe.
(5) Remove the 4 bolts and 4 ignition coils.
4. REMOVE SPARK PLUG
(a) Using a 16 mm plug wrench, remove the 8 spark plugs.
Specifications
Timing Cover: Specifications
TIMING CHAIN COVER SUB-ASSEMBLY
Temporarily install the 26 bolts and nut.
Standard Bolt:
Tighten the 3 bolts in several steps in the sequence shown in the illustration.
Torque..................................................................................................................................................
.....................................47 Nm (479 kgf-cm, 35 ft-lbf)
Temporarily install the fan bracket with the 5 bolts.
Standard Bolt:
Temporarily install the belt tensioner with the bolt and 6 mm hexagon bolt.
Tighten the 8 bolts labeled 4 to 11 in several steps in the sequence shown in the illustration.
Page 5684
HINT Due to the inverse screw structure, if the stop light switch is turned clockwise, the stop light
switch moves in the direction to be pulled out.
(e) Connect the stop light switch connector.
(f) Check the protrusion of the rod.
Standard protrusion of the rod:
1.5 to 2.5 mm (0.0591 to 0.0984 in.)
3. CHECK PEDAL FREE PLAY
(a) Stop the engine and depress the brake pedal several times until there is no more vacuum left in
the booster.
(b) Push in the brake pedal until the beginning of the resistance is felt. Measure the distance as
shown in the illustration.
Standard pedal free play:
1.0 to 6.0 mm (0.0394 to 0.236 in.)
4. CHECK PEDAL RESERVE DISTANCE
(a) Release the parking brake pedal.
(b) With the engine running, depress the brake pedal and measure the pedal reserve distance as
shown in the illustration.
Standard pedal reserve distance from asphalt sheet at 490 N (50 kgf, 110.2 lbf):
More than 104 mm (4.09 in.)
(c) If incorrect, troubleshoot the brake system See: Testing and Inspection.
Page 2094
Junction Connector (CAN No.2) - Lower Finish Panel
Page 3725
Engine Control Module: Pinout Values and Diagnostic Parameters
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: TERMINALS OF ECM
1. CHECK ECM
(a) Measure the voltage according to the value(s) in the table below.
HINT The standard voltage between each pair of ECM terminals is shown in the table below. The
appropriate conditions for checking each pair of terminals are also indicated. The result of checks
should be compared with the standard voltage for that pair of terminals, displayed in the Specified
Condition column. The illustration above can be used as a reference to identify the ECM terminal
locations.
Page 71
Double Cab)/Removal
5. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH
6. REMOVE REAR DOOR SCUFF PLATE RH
(a) Remove the front door scuff plate See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Removal.
HINT The procedures listed below are for the LH side.
7. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY RH See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Double Cab)/Removal
8. REMOVE DOOR CONTROL RECEIVER
(a) Disconnect the door control receiver connector.
(b) Remove the bolt and receiver.
Installation
DOOR LOCK: DOOR CONTROL RECEIVER (for Double Cab): INSTALLATION
1. INSTALL DOOR CONTROL RECEIVER
(a) Install the receiver with the bolt.
(b) Connect the door control receiver connector.
2. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY RH
3. INSTALL REAR DOOR SCUFF PLATE RH
(a) Install rear door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double
Cab)/Installation.
HINT The procedures listed below are for the LH side.
4. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH
5. INSTALL REAR SEAT ASSEMBLY See: Body and Frame/Seats/Service and Repair/Removal
and Replacement/Rear Seat Assembly (for
Double Cab)/Installation
6. INSTALL SEAT FLOOR BOX See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Rear Seat Assembly (for Double
Locations
Transmission Position Switch/Sensor: Locations
A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS
LOCATION
Page 1845
Mongoose MFC Software and Driver MUST be installed before Mongoose MFC selection will be
available.
See TIS - Diagnostics - Scantool page for additional information.
^ If using TIS Techstream select TIS Techstream VIM (this is the default).
4. Click OK.
Operation Procedure
1. Verify the vehicle's applicability for recalibration and locate desired calibration file.
A. Connect Techstream and establish a vehicle connection.
B. Click the Health Check button on the System Select tab.
Page 8042
Clockspring Assembly / Spiral Cable: Diagrams Spiral Cable, Steering Pad Switch
Page 4755
When using Techstream Lite, select Generic J2534 Interface. Then click Next.
E. Confirm the following:
^ PC is connected to VIM.
^ VIM is connected to DLC3 connector.
^ Ignition is ON and engine is OFF or "READY" OFF (hybrid vehicles).
Page 5970
* In the DTC check, it is very important to determine whether the problem indicated by the DTC is
either: 1) still occurring; or 2) occurred in the past but has since returned to normal. In addition, the
DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs
should be checked before and after confirmation of symptoms (i.e., whether or not problem
symptoms exist) to determine current system conditions, as shown in the flowchart below.
* Never skip the DTC check. Failing to check DTCs may, depending on the case, result in
unnecessary troubleshooting for systems operating normally or lead to repairs not related to the
problem. Follow the procedures listed in the flowchart in the correct order.
* The following flowchart shows how to proceed with troubleshooting using the DTC check.
Directions from the flowchart will indicate how to proceed either to DTC troubleshooting or to the
troubleshooting of each problem symptom.
1. DTC CHECK
NEXT -- Continue to next step.
2. MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR MEMORY
NEXT -- Continue to next step.
3. SYMPTOM CONFIRMATION
B -- Go to step 5 A -- Continue to next step.
4. SIMULATION TEST USING SYMPTOM SIMULATION METHODS
NEXT -- Continue to next step.
5. DTC CHECK
B -- TROUBLESHOOTING OF PROBLEM INDICATED BY DTC A -- Continue to next step.
6. SYMPTOM CONFIRMATION
Page 3498
Standard resistance:
NG -- CHECK FOR SHORT IN CAN BUS WIRES (AIR CONDITIONING AMPLIFIER) OK -Continue to next step.
20. CHECK FOR SHORT IN CAN BUS WIRES (NO. 2 JUNCTION CONNECTOR - BUS BUFFER
ECU)
NOTICE: For vehicles without a bus buffer ECU, go to "CHECK FOR SHORT IN CAN BUS WIRES
(NO. 2 JUNCTION CONNECTOR - 4WD CONTROL ECU)".
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- CHECK FOR SHORT IN CAN BUS WIRES (BUS BUFFER ECU) OK -- Continue to next
step.
21. CHECK FOR SHORT IN CAN BUS WIRES (NO. 2 JUNCTION CONNECTOR - 4WD
CONTROL ECU)
NOTICE: For vehicles without 4WD, go to "CHECK FOR SHORT IN CAN BUS WIRES (NO. 2
JUNCTION CONNECTOR - ECM)".
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- CHECK FOR SHORT IN CAN BUS WIRES (4WD CONTROL ECU) OK -- Continue to next
step.
22. CHECK FOR SHORT IN CAN BUS WIRES (NO. 2 JUNCTION CONNECTOR - ECM)
(a) Measure the resistance according to the value(s) in the table below.
Page 9246
Page 2813
NG -- REPLACE RELAY OK -- Continue to next step.
3. CHECK HARNESS AND CONNECTOR (ECM - BODY GROUND)
(a) Disconnect the ECM connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR OK -- Continue to next step.
4. INSPECT ECM (IGSW VOLTAGE)
(a) Disconnect the ECM connectors.
(b) Turn the ignition switch to ON.
(c) Measure the voltage according to the value(s) in the table below.
Page 6503
Driver Side J/B Inner Circuit
Up to 11/2009
Hose/Line HVAC: Service and Repair Up to 11/2009
AIR CONDITIONING: REFRIGERANT LINE: COMPONENTS
Page 8349
Impact Sensor: Service and Repair Side Airbag Sensor (for CrewMax)
Components
SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for CrewMax):
COMPONENTS
Page 8392
Seat Belt Buckle Switch: Diagrams
Page 7588
Push the terminal retainer down to the temporary lock position.
Page 7758
Removal
AIR CONDITIONING: AIR CONDITIONING UNIT: REMOVAL
1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM See: Service and Repair
2. DRAIN ENGINE COOLANT
(a) for 1GR-FE:
Climate Control Seat System
Seat Heater Switch: Locations Climate Control Seat System
SEAT: CLIMATE CONTROL SEAT SYSTEM: PARTS LOCATION
Double Cab
Power Mirror Control Module: Locations Double Cab
Body
Page 6092
5. INSPECT PARK/NEUTRAL POSITION SWITCH ASSEMBLY
(a) Inspect the switch See: Testing and Inspection/Initial Inspection and Diagnostic Overview.
Airbag System
Seat Occupant Sensor: Locations Airbag System
SUPPLEMENTAL RESTRAINT SYSTEM: AIRBAG SYSTEM: PARTS LOCATION
Engine - Oil Filter Cap Assembly Precaution
Oil Filter Housing: Technical Service Bulletins Engine - Oil Filter Cap Assembly Precaution
T-SB-01 04-09
April 10, 2009
Oil Filter Cap Assembly Precautions
Service Category Engine/Hybrid System
Section Lubrication
Market USA
Applicability
TSB SUPERSESSION NOTICE
The information contained in this TSB supersedes TSB No. T-SB-0332-08.
^ Applicability has been updated to include 2009 - 2010 model year Highlander, 2010 model year
Camry, Corolla, Matrix, Sequoia, Tundra, and 2009 model year Venza vehicles.
^ The SST table has been updated with an illustration.
^ The Notice in the Repair Procedure has been updated with a Figure and torque specification
ranges to clarify SST usage.
TSB No. T-SB-0332-08 is Obsolete and any printed versions should be discarded. Be sure to
review the entire content of this service bulletin before proceeding.
Introduction
To prevent damage to the oil filter cap assembly this procedure must be closely followed during oil
filter replacement to avoid immediate and future oil filter serviceability concerns.
The following engines are equipped with a plastic oil filter cap assembly:
^ 1UR-FE (Tundra Sequoia)
^ 3UR-FE (Tundra Sequoia Land Cruiser)
^ 2ZR-FE (Corolla Matrix)
Page 299
J/B No.4 - Instrument Panel Center
Page 8299
5. Dealer places copy of the completed worksheet in the customer's records.
Front Door Courtesy Switch
Door Switch: Diagrams Front Door Courtesy Switch
Page 8679
ERROR: undefined
OFFENDING COMMAND: f‘~
STACK:
Page 6332
Symbols Used Within Diagrams
Symbols Used Within Diagrams
Engine - Snow Ingestion Into Air Cleaner Box
Air Cleaner Housing: Customer Interest Engine - Snow Ingestion Into Air Cleaner Box
T-SB-0396-09
December 8, 2009
Snow Entry Into Air Cleaner Box
Service Category Engine/Hybrid System
Section Intake/Exhaust
Market USA
Applicability
Introduction
Some Sequoia and Tundra vehicles operated in areas with significant snow volume may
experience snow accumulation in the air cleaner box which can cause the lid to fracture. The air
cleaner lid and fender liner have been revised to reduce accumulation.
Parts Information
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for
36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Production Change Information
Page 8347
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE BATTERY
(a) Disconnect the cable from the positive (+) battery terminal.
(b) Loosen the nut, move the stay off the battery, and remove the battery.
3. REMOVE FRONT AIRBAG SENSOR
(a) Remove the nut and front airbag sensor from the body.
(b) Disconnect the connector.
Installation
SUPPLEMENTAL RESTRAINT SYSTEM: FRONT AIRBAG SENSOR: INSTALLATION
1. INSTALL FRONT AIRBAG SENSOR
(a) Check that the ignition switch is OFF.
(b) Check that the cable is disconnected from the battery negative (-) terminal.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
(c) Connect the connector.
(d) Install the front airbag sensor with the nut.
Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)
Page 7028
*: for 5 leaf spring
Standard Camber Inclination
for Regular Cab of Standard Deck
Page 4493
(3) When applying a vacuum to port F, check that air is sucked into port E.
If the result is not as specified, replace the vacuum switching valve assembly.
(e) Connect the vacuum switching valve connector.
3. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Installation
Page 1820
^ Figure 17 shows an example of the update procedure for a two-processor ECU.
G. Turn ignition OFF. Then click Next.
H. Confirm the following:
^ Ignition is ON and engine is OFF or "READY" OFF (hybrid vehicles).
^ Hood is open.
^ All accessories are OFF.
^ Battery voltage is above 11.4 volts.
NOTICE
Verify the vehicle is connected to a battery charger before continuing - If battery voltage falls below
11.4 volts, ECU damage may occur.
Locations
Ignition Switch: Locations
1UR-FE STARTING: STARTING SYSTEM: PARTS LOCATION
Page 4420
Fuel Pump Control Unit: Locations Double Cab
Body
Page 2722
Exhaust Pipe: Service and Repair Exhaust Pipe (for Regular Cab Standard Deck)
Components
1UR-FE EXHAUST: EXHAUST PIPE (for Regular Cab Standard Deck): COMPONENTS
Page 4607
(2) CONNECTORS
Slightly shake the connector vertically and horizontally.
(3) WIRE HARNESS
Slightly shake the wire harness vertically and horizontally.
HINT The connector joint and fulcrum of the vibration are the major areas that should be checked
thoroughly.
(b) HEAT METHOD:
When a malfunction seems to occur when the area in question is heated.
(1) Heat the component that is the possible cause of the malfunction with a hair dryer or similar
device. Check if the malfunction occurs.
NOTICE: *
Do not heat to more than 60°C (140°F). Exceeding this temperature may damage components.
* Do not apply heat directly to the parts in the ECU.
(c) WATER SPRINKLING METHOD:
When a malfunction seems to occur on a rainy day or in high-humidity.
(1) Sprinkle water onto the vehicle and check if the malfunction occurs.
NOTICE: *
Never sprinkle water directly into the engine compartment. Indirectly change the temperature and
humidity by spraying water onto the front of the radiator.
* Never apply water directly onto the electronic components.
HINT If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU
or connections. Look for evidence of corrosion or short circuits. Proceed with caution during water
tests.
(d) HIGH ELECTRICAL LOAD METHOD:
When a malfunction seems to occur when the electrical load is excessive.
(1) Turn on the heater blower, headlights, rear window defogger and all other electrical loads.
Check if the malfunction reoccurs.
5. DIAGNOSTIC TROUBLE CODE CHART
Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate
section's Diagnostic Trouble Code Chart. Use the chart to determine the trouble area and the
proper inspection procedure. A description of each of the chart's columns is below.
Page 700
Power Seat Switch: Locations Front Power Seat Control System (w/o Memory)
SEAT: FRONT POWER SEAT CONTROL SYSTEM (w/o Memory): PARTS LOCATION
Page 8517
Page 7332
Front Steering Knuckle: Service and Repair Removal
AXLE: STEERING KNUCKLE: REMOVAL
HINT *
Use the same procedures for the LH side and RH side.
* The procedures listed below are for the LH side.
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE FRONT AXLE HUB SUB-ASSEMBLY LH
(a) Remove the front axle hub See: Wheel Hub/Service and Repair/Removal and
Replacement/Removal.
3. DISCONNECT FRONT SPEED SENSOR LH
(a) Remove the clip and bolt.
(b) Disconnect the speed sensor from the steering knuckle.
4. DISCONNECT TIE ROD END SUB-ASSEMBLY LH
(a) Remove the cotter pin and nut.
(b) Using SST, disconnect the tie rod end LH from the steering knuckle.
SST : 09610-20012
NOTICE: *
Do not damage the front disc brake dust cover.
* Do not damage the ball joint dust cover.
* Do not damage the steering knuckle.
5. DISCONNECT FRONT LOWER BALL JOINT ATTACHMENT LH See: Control Arm/Service and
Repair/Removal and Replacement/Front
Lower Suspension Arm/Removal
6. REMOVE STEERING KNUCKLE LH
(a) Support the front suspension lower arm LH with a jack.
(b) Remove the clip and the nut.
Page 3585
Main Relay (Computer/Fuel System): Testing and Inspection
1UR-FE ENGINE CONTROL SYSTEM: CIRCUIT OPENING RELAY: ON-VEHICLE INSPECTION
1. REMOVE CIRCUIT OPENING RELAY (C/OPN)
(a) Remove the circuit opening relay from the engine room relay block.
2. INSPECT CIRCUIT OPENING RELAY
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) If the result is not as specified, replace the circuit opening relay.
3. INSTALL CIRCUIT OPENING RELAY
(a) Install the circuit opening relay to the engine room relay block.
Page 6902
Page 8096
Page 9114
Push the terminal retainer down to the temporary lock position.
Components
Crankshaft Position Sensor: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: CRANKSHAFT POSITION SENSOR: COMPONENTS
Page 2053
Page 6609
Page 7913
Air Bag: Diagrams Front Passenger Side Squib Circuit
Page 4594
Establish conditions in which voltage is present at the check point.
Example:
- [A] - Ignition SW on
- [B] - Ignition SW and SW1 on
- [C] - Ignition SW, SW1 and Relay on (SW2 off)
Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or component terminal.
This check can be done with a test light instead of a voltmeter.
Electronic Circuit Inspection Procedure
Page 6830
Locations
Cargo Lamp Switch: Locations
LIGHTING: LIGHTING SYSTEM: PARTS LOCATION
Page 1291
Crankshaft Position Sensor: Diagrams
Page 32
Central Control Module: Service and Repair Installation
AUDIO / VISUAL: MULTI-MEDIA INTERFACE ECU: INSTALLATION
1. INSTALL MULTI-DISPLAY CONTROLLER BRACKET A
(a) Install the multi-display controller bracket A with the 2 bolts.
Torque : 2.0 Nm (20 kgf-cm, 17 in-lbf)
2. INSTALL MULTI-MEDIA INTERFACE ECU
(a) Connect the connector.
(b) Install the multi-media interface ECU with the nut.
Torque : 8.0 Nm (81 kgf-cm, 70 in-lbf)
3. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY
(a) for Column Shift Type:
Install the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column
Shift Type)/Installation.
(b) for Floor Shift Type:
Install the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation.
4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Page 809
Page 6160
(2) Disconnect connector B and measure the resistance.
Standard resistance (Fig. 7):
* If the results match the examples above, a short circuit exists between terminal 1 of connector B2
and terminal 1 of connector C.
4. CHECK AND REPLACE ECU
NOTICE: *
The connector should not be disconnected from the ECU. Perform the inspection from the backside
of the connector on the wire harness side.
* When no measuring condition is specified, perform the inspection with the engine stopped and
the ignition switch ON.
* Check that the connectors are fully seated. Check for loose, corroded or broken wires.
(a) First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be
faulty. Temporarily replace the ECU with a
normally functioning one and check if the symptoms occur. If the trouble symptoms disappear,
replace the original ECU.
(1) Measure the resistance between the ECU ground terminal and body ground.
Standard resistance:
Below 1 Ohms
(2) Disconnect the ECU connector. Check the ground terminal on the ECU side and wire harness
side for bending, corrosion or foreign matter.
Lastly, check the contact pressure of the female terminals.
Page 3911
Variable Valve Timing Actuator: Testing and Inspection On-Vehicle Inspection
1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT OIL CONTROL VALVE: ON-VEHICLE
INSPECTION
1. INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
(a) Connect the Techstream to the DLC3.
(b) Start the engine and turn the tester ON.
(c) Warm up the engine.
(d) Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the VVT Linear
(Bank 1) or Control the VVT Linear (Bank
2) or Control the VVT System (Bank 1) or Control the VVT System (Bank 2) or Control the VVT
Exhaust Linear (Bank 1) or Control the VVT Exhaust Linear (Bank 2).
(e) Check the engine speed while operating the Oil Control Valve (OCV) using the tester.
OK:
(f) If the result is not as specified, check the oil control valve, wiring and camshaft timing gear.
HINT *
Control the VVT Linear (Bank 1): Command to activate exhaust and intake side oil control valves of
bank 1 (Control range: Between -128 to 127%).
* Control the VVT Linear (Bank 2): Command to activate exhaust and intake side oil control valves
of bank 2 (Control range: Between -128 to 127%).
* Control VVT System (Bank 1): Command to activate oil control valve of bank 1 (Control range:
ON/OFF).
* Control VVT System (Bank 2): Command to activate oil control valve of bank 2 (Control range:
ON/OFF).
* Control the VVT Exhaust Linear (Bank 1): Command to activate exhaust side oil control valve of
bank 1 (Control range: Between -128 to 127%).
* Control the VVT Exhaust Linear (Bank 2): Command to activate exhaust side oil control valve of
bank 2 (Control range: Between -128 to 127%).
Page 6819
Page 9137
Connectors Part 1
Page 6951
J/B No.6 Assembly Inner Circuit
Page 6293
Driver Side J/B - Cowl Side Left
Specifications
Harmonic Balancer - Crankshaft Pulley: Specifications
CRANKSHAFT PULLEY
Torque..................................................................................................................................................
...............................300 Nm (3059 kgf-cm, 221 ft-lbf)
Page 5196
SST : 09950-00020
Reassembly
DRIVE SHAFT: FRONT DRIVE SHAFT ASSEMBLY (for 4WD): REASSEMBLY
NOTICE: Do not allow brake fluid, front differential oil, gasoline, or battery fluid to contact the drive
shaft boots, as they may damage the boots.
1. INSTALL DUST SEAL
(a) Using SST and a press, press in a new dust seal to the outboard joint shaft.
SST : 09950-00020
NOTICE: Be careful not to damage the dust seal.
2. INSTALL FRONT DRIVE SHAFT DUST COVER LH
(a) Using SST, a steel plate and press, press in a new dust cover.
SST : 09316-20011
NOTICE: Be careful not to damage the dust cover.
3. INSTALL OUTBOARD JOINT BOOT
(a) Place 2 new boot clamps on the boot.
Page 2892
Accelerator Pedal Position Sensor: Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 6176
Locations: The locations of components, connectors, ground points, and splices referred to within
these diagrams can be found at Vehicle Locations. See: Locations
Page 8774
Speaker: Diagrams
Center Speaker
Front Door Speaker
Page 7583
DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector.
Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
Page 6387
Page 263
Page 5612
Steering Angle Sensor: Locations From 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 2330
Refer to the Technical Information System (TIS) applicable model and model year Repair Manual:
2. Verify the vehicle has the proper coolant and oil levels.
3. Clear all DTCs and confirm the condition has been corrected.
Page 757
Sunroof / Moonroof Switch: Service and Repair Installation
SLIDING ROOF: SLIDING ROOF SWITCH ASSEMBLY (for CrewMax): INSTALLATION
1. INSTALL SLIDING ROOF SWITCH
(a) Attach the 4 claws to install the sliding roof switch.
(b) Install the lighting housing (upper side) with the 7 screws.
(c) Attach the clamp.
(d) Connect the 2 connectors.
2. INSTALL ROOF CONSOLE BOX ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining
(for CrewMax)/Installation
Page 7847
Cab)/Installation.
(b) for Double Cab:
Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Installation.
(c) for CrewMax:
Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for CrewMax)/Installation.
Service and Repair
Air Bag(s) Arming and Disarming: Service and Repair
Air Bag(s) Arming and Disarming
Before starting work, wait at least 90 seconds after the ignition switch is turned OFF and after the
cable of the negative (-) battery terminal is disconnected. (SRS parts are equipped with a backup
power source. If work is started within 90 seconds of turning the ignition switch OFF and
disconnecting the cable from the negative (-) battery terminal, SRS parts may deploy.)
Page 673
2. INSTALL FRONT ARMREST UPPER BASE PANEL LH
(a) Connect the power window regulator master switch connector.
(b) Attach the 2 clips and 5 claws to install the armrest base panel.
Recall 10V017000: Accelerator Pedal Sticking
Accelerator Pedal Position Sensor: Recalls Recall 10V017000: Accelerator Pedal Sticking
VEHICLE MAKE/MODEL: MODEL YEAR(S): Toyota/Avalon 2005-2010 Toyota/Camry 2007-2010
Toyota/Corolla 2009-2010 Toyota/Corolla Matrix 2009-2010 Toyota/Highlander 2010 Toyota/ RAV4
2009-2010 Toyota/Sequoia 2008-2010 Toyota/Tundra 2007-2010 MANUFACTURER: Toyota
Motor North America, Inc.
MFR'S REPORT DATE: January 21, 2010
NHTSA CAMPAIGN ID NUMBER: 10V017000
NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Accelerator Assembly:
Pedal/Linkage
POTENTIAL NUMBER OF UNITS AFFECTED: ?
SUMMARY: Toyota is recalling certain model year 2005-2010 Avalon, model year 2007-2010
Camry, model year 2009-2010 Corolla, Corolla Matrix, RAV4, model year 2010 Highlander, model
year 2008-2010 Sequoia, and model year 2007-2010 Tundra. due to the manner in which the
friction lever interacts with the sliding surface of the accelerator pedal inside the pedal sensor
assembly, the sliding surface of the lever may become smooth during vehicle operation. In this
condition, if condensation occurs on the surface, as may occur from heater operation (without A/C)
when the pedal assembly is cold, the friction when the accelerator pedal is operated may increase,
which may result in the accelerator pedal becoming harder to depress, slower to return, or, in the
worst case, mechanically stuck in a partially depressed position.
CONSEQUENCE: The accelerator pedal may become hard to depress, slow to return to idle, or, in
the worst case, mechanically stuck in a partially depressed position, increasing the risk of a crash.
REMEDY: Toyota has not yet provided a remedy plan or an owner notification schedule. Owners
may contact Toyota at 1-800-331-4331.
NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle
Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov.
Page 6091
(g) Hold the switch in position and tighten the bolt.
Torque : 13 Nm (130 kgf-cm, 9 ft-lbf)
(h) Using a screwdriver, bend the tabs of the lock washer.
(i) Install the transmission control shaft lever RH with the spring washer and nut.
Torque : 16 Nm (160 kgf-cm, 12 ft-lbf)
(j) Connect the switch connector.
2. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY
(a) Connect the cable with the nut.
Torque : 14 Nm (143 kgf-cm, 10 ft-lbf)
NOTICE: When connecting the cable to the transmission control shaft lever, make sure the L
bracket of the cable faces the inside of the vehicle.
3. ADJUST SHIFT LEVER POSITION (for Column Shift Type) See: Transmission and
Drivetrain/Automatic Transmission/Transaxle/Shifter
A/T/Adjustments/SHIFT LEVER ASSEMBLY (for Column Shift Type)
4. ADJUST SHIFT LEVER POSITION (for Floor Shift Type) See: Transmission and
Drivetrain/Automatic Transmission/Transaxle/Shifter
A/T/Adjustments/SHIFT LEVER ASSEMBLY (for Floor Shift Type)
Diagrams
Alternator: Diagrams
Up to 11/2009
Wheel Speed Sensor: Locations Up to 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 4756
Then click Next.
F. Verify correct current calibration and new calibration information. Then click Next.
NOTE
^ The total number of calibration IDs in the calibration file corresponds to the number of
reprogrammable processors in the ECU.
^ Each calibration file may contain up to three separate calibrations.
Locations
Temperature Sensor/Switch: Locations
JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION
Components
Transmission Speed Sensor: Service and Repair Components
A760F AUTOMATIC TRANSMISSION: SPEED SENSOR: COMPONENTS
Page 6477
when inserting and after full engagement.
NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal.
(d) REPAIR METHOD OF CONNECTOR TERMINAL
(1) If there is any foreign matter on the terminal, clean the contact point using an air gun or cloth.
Never rub the contact point using sandpaper
as the plating may come off.
(2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is
gold-plated (gold color), use a gold-plated female
terminal; if it is silver-plated (silver color), use a silver-plated female terminal.
(3) Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock
into the housing, the housing may have to be
replaced.
(e) HANDLING OF WIRE HARNESS
(1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be
restored in the same way.
(2) Never twist, pull or slacken the wire harness more than necessary.
(3) The wire harness should never come into contact with a high temperature part, or rotating,
moving, vibrating or sharp-edged parts. Avoid
contact with panel edges, screw tips and other sharp items.
(4) When installing parts, never pinch the wire harness.
(5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with
vinyl tape.
2. CHECK FOR OPEN CIRCUIT
Page 8335
Impact Sensor: Testing and Inspection Center Airbag Sensor Assembly (for Floor Shift Type)
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift
Type): ON-VEHICLE INSPECTION
1. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION)
(a) Perform a diagnostic system check See: Air Bag Systems/Testing and Inspection/Initial
Inspection and Diagnostic Overview/Diagnosis
System.
2. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND
AIRBAG HAS NOT DEPLOYED)
(a) Perform a diagnostic system check See: Air Bag Systems/Testing and Inspection/Initial
Inspection and Diagnostic Overview/Diagnosis
System.
3. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND
AIRBAG IS DEPLOYED)
(a) Replace the center airbag sensor.
CAUTION: For removal and installation procedures of the center airbag sensor, be sure to follow
the correct procedure.
HINT The center airbag sensor should be replaced after any of the airbags has deployed, as it has
been subjected to the impact.
Page 8312
Locations
Accessory Relay: Locations
Instrument Panel (Floor Shift)
Instrument Panel (Column Shift)
Page 5280
Angle of intermediate shaft (C) - Angle of propeller shaft (D)
Measured Value (Reference):
HINT *
Using the following chart, check if the calculated No. 2 joint angle is within the specified value.
* The tolerance is +/-0°60' (1.00°).
Standard No. 2 joint angle:
Page 2911
Camshaft Position Sensor: Diagrams
Page 1561
Tire Pressure Warning Reset Switch: Testing and Inspection
TIRE AND WHEEL: TIRE PRESSURE WARNING RESET SWITCH: INSPECTION
1. CHECK TIRE PRESSURE WARNING RESET SWITCH
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the switch.
Page 9148
Body Control Module: Diagrams
Page 2865
(2) If the result is not as specified, replace the integration relay.
3. INSTALL INTEGRATION RELAY See: Relays and Modules - Ignition System/Ignition
Relay/Testing and Inspection
Page 6783
Use a volt/ohmmeter with high impedance (10 kohms/V minimum) for troubleshooting of the
electrical circuit.
Disconnection of Male and Female Connectors
DISCONNECTION OF MALE AND FEMALE CONNECTORS
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Finding A Short Circuit
FINDING A SHORT CIRCUIT
Diagrams
Navigation Display: Diagrams
Page 4454
Accelerator Pedal Position Sensor: Diagrams
Page 9241
(b) Disconnect the connector.
6. REMOVE REAR DOOR ARMREST COVER LH
7. REMOVE REAR DOOR TRIM BOARD SUB-ASSEMBLY LH
(a) Remove the 2 screws.
(b) Using a clip remover, remove the clip.
(c) for Standard:
(1) Detach the 10 clips and remove the trim board.
(d) for 12 Speakers:
(1) Detach the 10 clips and remove the trim board. Then disconnect the connector.
(e) Disconnect the 2 cables from the inside handle.
(f) Remove the inside handle.
Reassembly
ENGINE HOOD / DOOR: REAR DOOR (for CrewMax): REASSEMBLY
Page 3517
INSPECTION PROCEDURE
HINT Operating the ignition switch, any switches or any doors triggers related ECU and sensor
communication with the CAN, which causes resistance variation.
PROCEDURE
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
(a) Disconnect the cable from the negative (-) battery terminal before measuring the resistances of
the main wire and the branch wire.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
NEXT -- Continue to next step.
2. CHECK FOR SHORT TO GND IN CAN BUS WIRE (DLC3 BRANCH WIRE)
(a) Disconnect the J86 No. 1 junction connector connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO DLC3 (CANH, CANL) OK -Continue to next step.
3. CONNECT CONNECTOR
Page 139
Control Module HVAC: Diagrams A/C Amplifier
Page 4390
Fuel Pump Relay: Testing and Inspection Fuel Pump Relay
1UR-FE ENGINE CONTROL SYSTEM: FUEL PUMP RELAY: ON-VEHICLE INSPECTION
1. REMOVE FUEL PUMP RELAY (F/PMP)
(a) Remove the fuel pump relay from the engine room relay block.
2. INSPECT FUEL PUMP RELAY
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) If the result is not as specified, replace the fuel pump relay.
3. INSTALL FUEL PUMP RELAY
(a) Install the fuel pump relay to the engine room relay block.
Page 5707
(8) Depress the brake pedal several times, and then loosen the bleeder plug with the pedal
depressed.*1
(9) When fluid stops coming out, tighten the bleeder plug, and then release the brake pedal.*2
(10)Repeat *1 and *2 until all the air in the brake fluid is completely bled out and the new brake
fluid comes out.
(11)Tighten the bleeder plug completely.
Torque : 11 Nm (110 kgf-cm, 8 ft-lbf)
(12)Replace the brake fluid from the rear disc brake cylinder LH using the same procedure as for
RH.
(c) Bleed VSC actuator assembly
NOTICE: After bleeding the air from the brake system, if the height or feel of the brake pedal
cannot be obtained, perform air bleeding of the brake actuator with the Techstream by following the
procedure below.
(1) Depress the brake pedal more than 20 times with the engine off.
(2) Connect the Techstream to the DLC3, and turn the ignition switch on.
NOTICE: Do not start the engine.
(3) Select AIR BLEEDING on the Techstream.
HINT Refer to the Techstream operator's manual for further details.
(4) Bleed the air out of the suction line.
NOTICE: *
Perform the bleeding at the right front wheel and right rear wheel.
* Bleed the air by following the steps displayed on the Techstream.
(5) 1. Connect a vinyl tube to the bleeder plug at the right front wheel or the right rear wheel.
2. Loosen the bleeder plug.
3. Operate the brake actuator to bleed the air using the Techstream.
HINT This operation stops automatically after 4 seconds.
NOTICE: Release the brake pedal at this time.
(6) 4. Check if the operation has stopped by referring to the Techstream display.
5. Temporarily tighten the bleeder plug.
6. Repeat the 4 previous steps until all in the fluid is completely bled out.
7. Tighten the bleeder plug.
Torque : 11 Nm (110 kgf-cm, 8 ft-lbf)
(7) 8. Repeat all of the above procedures for the other wheel to bleed the air out of the suction line.
(8) Bleed the air out of the pressure reduction line.
NOTICE: *
Perform the bleeding at the 4 wheels.
* Bleed the air by following the steps displayed on the Techstream.
(9) 1. Connect a vinyl tube to one of the bleeder plugs.
Center Airbag Sensor Assembly (for Column Shift Type)
Air Bag Control Module: Testing and Inspection Center Airbag Sensor Assembly (for Column Shift
Type)
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Column
Shift Type): ON-VEHICLE INSPECTION
1. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION)
(a) Perform a diagnostic system check See: Air Bag Systems/Testing and Inspection/Initial
Inspection and Diagnostic Overview/Diagnosis
System.
2. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND
AIRBAG HAS NOT DEPLOYED)
(a) Perform a diagnostic system check See: Air Bag Systems/Testing and Inspection/Initial
Inspection and Diagnostic Overview/Diagnosis
System.
3. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND
AIRBAG IS DEPLOYED)
(a) Replace the center airbag sensor.
CAUTION: For removal and installation procedures of the center airbag sensor, be sure to follow
the correct procedure.
HINT The center airbag sensor should be replaced after any of the airbags has deployed, as it has
been subjected to the impact.
Page 2217
Tire Pressure Warning Reset Switch: Service and Repair Removal
TIRE AND WHEEL: TIRE PRESSURE WARNING RESET SWITCH: REMOVAL
1. REMOVE FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Removal
2. REMOVE FRONT DOOR SCUFF PLATE LH (for Double Cab, for CrewMax) See: Body and
Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal
3. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Removal
4. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal
5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Removal
6. REMOVE TIRE PRESSURE WARNING RESET SWITCH
(a) Disconnect the switch connector.
(b) Detach the 2 claws and remove the reset switch.
Page 4937
Locations
Integrated Accessory Switch Assembly: Locations
METER: METER / GAUGE SYSTEM: PARTS LOCATION
Up to 11/2009
Steering Angle Sensor: Locations Up to 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 462
Air Bag Control Module: Service and Repair Center Airbag Sensor Assembly (for Floor Shift Type)
Components
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift
Type): COMPONENTS
Page 902
Ambient Temperature Sensor / Switch HVAC: Locations Air Conditioning System (for Manual Air
Conditioning System)
AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Manual Air Conditioning System):
PARTS LOCATION
Page 3226
DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector.
Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
Page 8579
HINT The type of claw on the top and bottom of the sensor are different. Observe the claws
carefully before removing the sensor.
14. REMOVE NO. 2 ULTRASONIC SENSOR RETAINER
(a) Detach the 2 claws and remove the sensor retainer from the rear bumper.
Installation
PARK ASSIST / MONITORING: ULTRASONIC SENSOR (for Rear Side): INSTALLATION
1. INSTALL NO. 1 ULTRASONIC SENSOR RETAINER
(a) Align the keyhole and protrusion as shown in the illustration.
(b) Install the sensor retainer to the rear bumper.
NOTICE: Do not damage the bumper with the protrusion when installing the retainer.
2. INSTALL NO. 1 ULTRASONIC SENSOR
(a) Attach the 2 claws to install the ultrasonic sensor.
Removal and Replacement
Differential Carrier: Removal and Replacement
Components
DIFFERENTIAL: DIFFERENTIAL CARRIER ASSEMBLY (for 1GR-FE, 1UR-FE): COMPONENTS
Components
Camshaft Position Sensor: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT POSITION SENSOR: COMPONENTS
Page 7865
(a) Disconnect the connector.
(b) Remove the 3 screws and damper servo.
14. REMOVE COOLING UNIT DAMPER SERVO SUB-ASSEMBLY (for Automatic Air Conditioning
System)
(a) Disconnect the connector.
(b) Remove the 3 screws and damper servo.
15. REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY
(a) Remove the 3 screws and plate.
(b) Detach the 3 claws and remove the heater clamp.
(c) Remove the heater radiator unit.
16. REMOVE NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY
Page 4081
NOTICE: Be careful not to damage the installation surface of the gaskets.
Page 8352
Door/Service and Repair/Front Door (for Double Cab)/Disassembly
4. REMOVE FRONT LOWER DOOR FRAME BRACKET GARNISH LH (for Front Side) See: Body
and Frame/Doors, Hood and
Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly
5. REMOVE COURTESY LIGHT ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood
and Trunk/Doors/Front Door/Service and
Repair/Front Door (for Double Cab)/Disassembly
6. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Disassembly
7. REMOVE FRONT SIDE AIRBAG SENSOR
(a) Disconnect the connector.
(b) Remove the screw and side airbag sensor.
8. REMOVE REAR SEAT ASSEMBLY (for Rear Side)
(a) Remove the rear seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Rear Seat Assembly (for Double
Cab)/Removal.
9. REMOVE REAR DOOR SCUFF PLATE LH (for Rear Side) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and Repair/Roof
Headlining (For Double Cab)/Removal
10. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH (for Rear Side)
11. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY LH (for Rear Side) See: Body and
Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal
12. REMOVE REAR SIDE AIRBAG SENSOR
(a) Remove the bolt and side airbag sensor.
(b) Disconnect the connector.
Installation
SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for CrewMax):
INSTALLATION
1. INSTALL FRONT SIDE AIRBAG SENSOR
(a) Check that the ignition switch is OFF.
Page 2017
(2) Disconnect connector B and measure the resistance.
Standard resistance (Fig. 7):
* If the results match the examples above, a short circuit exists between terminal 1 of connector B2
and terminal 1 of connector C.
4. CHECK AND REPLACE ECU
NOTICE: *
The connector should not be disconnected from the ECU. Perform the inspection from the backside
of the connector on the wire harness side.
* When no measuring condition is specified, perform the inspection with the engine stopped and
the ignition switch ON.
* Check that the connectors are fully seated. Check for loose, corroded or broken wires.
(a) First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be
faulty. Temporarily replace the ECU with a
normally functioning one and check if the symptoms occur. If the trouble symptoms disappear,
replace the original ECU.
(1) Measure the resistance between the ECU ground terminal and body ground.
Standard resistance:
Below 1 Ohms
(2) Disconnect the ECU connector. Check the ground terminal on the ECU side and wire harness
side for bending, corrosion or foreign matter.
Lastly, check the contact pressure of the female terminals.
Locations
Seat Position Sensor: Locations
SUPPLEMENTAL RESTRAINT SYSTEM: AIRBAG SYSTEM: PARTS LOCATION
Page 3150
(4) Remove the 2 bolts and disconnect the water by-pass pipe.
(5) Remove the 4 bolts and 4 ignition coils.
4. REMOVE SPARK PLUG
(a) Using a 16 mm plug wrench, remove the 8 spark plugs.
Page 7565
Ambient Temperature Sensor / Switch HVAC: Service and Repair Installation
AIR CONDITIONING: AMBIENT TEMPERATURE SENSOR: INSTALLATION
1. INSTALL AMBIENT TEMPERATURE SENSOR
(a) Attach the clamp to install the ambient temperature sensor.
(b) Connect the connector.
Engine - Snow Ingestion Into Air Cleaner Box
Air Cleaner Housing: Customer Interest Engine - Snow Ingestion Into Air Cleaner Box
T-SB-0396-09
December 8, 2009
Snow Entry Into Air Cleaner Box
Service Category Engine/Hybrid System
Section Intake/Exhaust
Market USA
Applicability
Introduction
Some Sequoia and Tundra vehicles operated in areas with significant snow volume may
experience snow accumulation in the air cleaner box which can cause the lid to fracture. The air
cleaner lid and fender liner have been revised to reduce accumulation.
Parts Information
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for
36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Production Change Information
Page 5098
This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown.
Page 7982
pretensioner activation.
2. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY
HINT *
Refer to the procedures up to "REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY"
(for Column Shift Type) See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column
Shift Type)/Removal
* Refer to the procedures up to "REMOVE INSTRUMENT PANEL SAFETY PAD
SUB-ASSEMBLY" (for Floor Shift Type) See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Floor Shift Type)/Removal
3. REMOVE NO. 4 INSTRUMENT PANEL REGISTER ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Overhaul/Instrument Panel Safety Pad (for Column Shift
Type)/Disassembly
4. REMOVE NO. 1 HEATER TO REGISTER DUCT WITH NO. 2 HEATER TO REGISTER DUCT
See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Overhaul/Instrument Panel Safety Pad (for
Column Shift Type)/Disassembly
5. REMOVE SIDE NO. 2 DEFROSTER NOZZLE DUCT See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service
and Repair/Overhaul/Instrument Panel Safety Pad (for Column Shift Type)/Disassembly
6. REMOVE FRONT PASSENGER AIRBAG ASSEMBLY
(a) Disconnect the 2 connectors and remove the instrument panel wire from the front passenger
airbag.
NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness.
(b) Remove the 2 screws.
(c) Detach the 5 hooks (A).
(d) Detach the 5 hooks (B) and remove the front passenger airbag from the instrument panel.
Installation
SUPPLEMENTAL RESTRAINT SYSTEM: FRONT PASSENGER AIRBAG ASSEMBLY:
INSTALLATION
Page 7791
Refrigerant Oil: Fluid Type Specifications
COMPRESSOR OIL
Type......................................................................................................................................................
..............................................ND-OIL 8 or equivalent
Page 705
Power Seat Switch: Diagrams Front Power Seat Switch
Page 6684
Engine Room R/B, J/B - Engine Compartment Left
Page 3492
NEXT -- Continue to next step.
7. CHECK FOR SHORT IN CAN BUS WIRES (NO. 1 JUNCTION CONNECTOR - COMBINATION
METER ECU)
(a) Disconnect the J84 No. 1 junction connector connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- CHECK FOR SHORT IN CAN BUS WIRES (COMBINATION METER ECU) OK -- Continue
to next step.
8. CHECK FOR SHORT IN CAN BUS WIRES (NO. 1 JUNCTION CONNECTOR - MAIN BODY
ECU)
(a) Disconnect the J96 No. 1 junction connector connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- CHECK FOR SHORT IN CAN BUS WIRES (MAIN BODY ECU) OK -- Continue to next step.
9. CHECK FOR SHORT IN CAN BUS WIRES (NO. 1 JUNCTION CONNECTOR - SKID
CONTROL ECU WITH ACTUATOR)
(a) Disconnect the A46 No. 1 junction connector connector.
Page 671
Removal
DOOR LOCK: DOOR CONTROL SWITCH (for Front LH): REMOVAL
1. REMOVE FRONT ARMREST UPPER BASE PANEL LH
(a) Using a moulding remover, detach the 2 clips and 5 claws, and remove the armrest base panel.
Page 941
4. INSTALL COOLING UNIT DAMPER SERVO SUB-ASSEMBLY (for Automatic Air Conditioning
System)
(a) Install the damper servo with the 3 screws, as shown in the illustration.
(b) Connect the connector.
5. INSTALL BLOWER DAMPER SERVO SUB-ASSEMBLY
(a) Install the damper servo with the 3 screws.
(b) Connect the connector.
6. INSTALL BLOWER CASE SUB-ASSEMBLY
(a) Attach the 3 claws to install the case.
(b) Install the 3 screws.
Page 9122
(2) Disconnect connector B and measure the resistance.
Standard resistance (Fig. 7):
* If the results match the examples above, a short circuit exists between terminal 1 of connector B2
and terminal 1 of connector C.
4. CHECK AND REPLACE ECU
NOTICE: *
The connector should not be disconnected from the ECU. Perform the inspection from the backside
of the connector on the wire harness side.
* When no measuring condition is specified, perform the inspection with the engine stopped and
the ignition switch ON.
* Check that the connectors are fully seated. Check for loose, corroded or broken wires.
(a) First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be
faulty. Temporarily replace the ECU with a
normally functioning one and check if the symptoms occur. If the trouble symptoms disappear,
replace the original ECU.
(1) Measure the resistance between the ECU ground terminal and body ground.
Standard resistance:
Below 1 Ohms
(2) Disconnect the ECU connector. Check the ground terminal on the ECU side and wire harness
side for bending, corrosion or foreign matter.
Lastly, check the contact pressure of the female terminals.
Page 8845
(a) Attach the 4 clips and claw to install the speaker panel.
4. INSTALL NO. 1 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY
(a) Attach the 4 clips and claw to install the speaker panel.
5. INSTALL FRONT PILLAR GARNISH RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Installation
6. INSTALL FRONT PILLAR GARNISH LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Installation
7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Components
AUDIO / VISUAL: REAR DOOR SPEAKER (for CrewMax): COMPONENTS
Page 3246
If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness
or connector in that circuit in the past. Check the wire harness and connectors.
B -- SYSTEM NORMAL
A -- TROUBLESHOOTING OF EACH PROBLEM SYMPTOM
The problem is still occurring in a place other than the diagnostic circuit (the DTC displayed first is
either for a past problem or a secondary problem).
4. SYMPTOM SIMULATION
HINT The most difficult case in troubleshooting is when no problem symptoms occur. In such a
case, a thorough problem analysis must be carried out. A simulation of the same or similar
conditions and environment in which the problem occurred in the customer's vehicle should be
carried out. No matter how much skill or experience a technician has, troubleshooting without
confirming the problem symptoms will lead to important repairs being overlooked and mistakes or
delays.
For example:
With a problem that only occurs when the engine is cold or as a result of vibration caused by the
road during driving, the problem can never be determined if the symptoms are being checked on a
stationary vehicle or on a vehicle with a warmed-up engine. Vibration, heat or water penetration
(moisture) is difficult to reproduce. The symptom simulation tests below are effective substitutes for
the conditions and can be applied on a stationary vehicle.
Important points in the symptom simulation test:
In the symptom simulation test, the problem symptoms as well as the problem area or parts must
be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then,
connect the tester and carry out the symptom simulation test, judging whether the circuit being
tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the
problem symptoms table for each system to narrow down the possible causes.
To reproduce DTCs, it is necessary to satisfy the respective DTC detection conditions.
(a) VIBRATION METHOD:
When a malfunction seems to occur as a result of vibration.
(1) PART AND SENSOR
Apply slight vibration with a finger to the part of the sensor suspected to be the cause of the
problem, and check whether or not the malfunction occurs.
NOTICE: Applying strong vibration to relays may open them.
Page 8184
Seat Occupant Classification Module - Air Bag: Locations Seat Belt Warning System
SEAT BELT: SEAT BELT WARNING SYSTEM: PARTS LOCATION
Page 1625
Power Window Switch: Locations Power Window Control System (w/o Jam Protection Function)
WINDSHIELD / WINDOWGLASS: POWER WINDOW CONTROL SYSTEM (w/o Jam Protection
Function): PARTS LOCATION
Specifications
Camshaft Gear/Sprocket: Specifications
CAMSHAFT TIMING GEAR
LH
Using a wrench to hold the hexagonal portion of the No. 3 camshaft, tighten the camshaft timing
gear with the bolt.
Torque..................................................................................................................................................
.................................100 Nm (1020 kgf-cm, 74 ft-lbf)
Using a wrench to hold the hexagonal portion of the No. 4 camshaft, tighten the camshaft timing
exhaust gear with the bolt.
Torque..................................................................................................................................................
.................................100 Nm (1020 kgf-cm, 74 ft-lbf)
RH
Using a wrench to hold the hexagonal portion of the No. 1 camshaft, tighten the camshaft timing
gear with the bolt.
Torque..................................................................................................................................................
.................................100 Nm (1020 kgf-cm, 74 ft-lbf)
Using a wrench to hold the hexagonal portion of the No. 2 camshaft, tighten the camshaft timing
exhaust gear with the bolt.
Torque..................................................................................................................................................
.................................100 Nm (1020 kgf-cm, 74 ft-lbf)
ACC Cut Relay
Power Distribution Relay: Testing and Inspection ACC Cut Relay
1UR-FE STARTING: ACC CUT RELAY: ON-VEHICLE INSPECTION
1. REMOVE ACC CUT RELAY
(a) Remove the clip.
(b) Detach the 2 clips and remove the cowl side trim board RH.
(c) Remove the relay.
2. INSPECT ACC CUT RELAY
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) If the result is not as specified, replace the relay.
3. INSTALL ACC CUT RELAY
(a) Install the relay.
(b) Attach the 2 clips to install the cowl side trim board RH.
(c) Install the clip.
Page 3417
(a) Disconnect the J37 integration control and panel assembly connector.
(b) Disconnect the J19 air conditioning amplifier assembly connector.
(c) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR OK -- Continue to next step.
2. CHECK HARNESS AND CONNECTOR (INTEGRATION CONTROL AND PANEL - BATTERY
AND BODY GROUND)
(a) Disconnect the J37 integration control and panel assembly connector.
(b) Measure the resistance and voltage according to the value(s) in the table below.
Standard Resistance:
Standard Voltage:
NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR OK -- Continue to next step.
3. CHECK INTEGRATION CONTROL AND PANEL ASSEMBLY (OPERATION)
(a) Temporarily replace the integration control and panel assembly with a new or normally
functioning one.
Page 1943
(a) Hook the engine under cover to the vehicle body as shown in the illustration.
(b) Install the 3 screws and 5 bolts.
for bolt - Torque : 29 Nm (296 kgf-cm, 21 ft-lbf)
for screw - Torque : 3.0 Nm (31 kgf-cm, 27 in-lbf)
Page 3296
Then click Next.
F. Verify correct current calibration and new calibration information. Then click Next.
NOTE
^ The total number of calibration IDs in the calibration file corresponds to the number of
reprogrammable processors in the ECU.
^ Each calibration file may contain up to three separate calibrations.
Locations
Oxygen Sensor Relay: Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Locations
Four Wheel Drive Selector Switch: Locations
JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION
Page 4092
EGR Valve: Service and Repair Installation
1UR-FE EMISSION CONTROL: EGR VALVE: INSTALLATION
1. INSTALL EGR VALVE BRACKET
(a) Install the EGR valve bracket with the 3 bolts.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
2. INSTALL NO. 3 EGR PIPE SUB-ASSEMBLY
(a) Install a new gasket and the No. 3 EGR pipe with the 2 nuts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
3. INSTALL EGR INLET
(a) Install a new gasket and the EGR inlet with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
NOTICE: Make sure the gasket's claws are not caught between the EGR inlet and EGR valve.
4. INSTALL EGR VALVE ASSEMBLY
(a) Install a new gasket to the intake manifold.
(b) Install a new gasket to the No. 2 EGR pipe.
Page 3947
6. In some instances where water has entered the system DTCs P2440/P2441/P2442/P2443 may
set.
Refer to TIS 2010 model year Tundra Repair Manual to diagnose and inspect the emission control
valves if necessary:
7. If there is NO liquid found in the air pump assemblies or the DTC is still present after
replacement inspect the air injection system.
Refer to TIS 2010 model year Tundra Repair Manual:
8. Clear the DTC and road test the vehicle to confirm the condition has been corrected.
Page 363
^ Figure 17 shows an example of the update procedure for a two-processor ECU.
G. Turn ignition OFF. Then click Next.
H. Confirm the following:
^ Ignition is ON and engine is OFF or "READY" OFF (hybrid vehicles).
^ Hood is open.
^ All accessories are OFF.
^ Battery voltage is above 11.4 volts.
NOTICE
Verify the vehicle is connected to a battery charger before continuing - If battery voltage falls below
11.4 volts, ECU damage may occur.
Page 2206
Tire Pressure Sensor: Service and Repair Installation
TIRE AND WHEEL: TIRE PRESSURE WARNING VALVE AND TRANSMITTER: INSTALLATION
1. INSTALL TIRE PRESSURE WARNING VALVE AND TRANSMITTER
(a) Insert the tire pressure warning valve into the valve installation hole from the inside of the rim so
that the print surface can be seen.
NOTICE: *
Check that there is no visible deformation, damage or other abnormalities on the tire pressure
warning valve and transmitter.
* Check that there is no foreign matter on the inner grommet and around the rim hole.
* If the tire pressure warning valve and transmitter is installed in the reverse direction, it may be
damaged or fail to transmit signals when running at a high speed.
* If installing a new tire pressure warning valve and transmitter, write down the transmitter ID before
installation.
* The transmitter ID registration must be performed for all tire pressure warning valve and
transmitters, regardless of the number of tire pressure warning valve and transmitters replaced. If
all of the tire pressure warning valve and transmitters do not need to be replaced, check the DATA
LIST and write down the transmitter IDs of the tire pressure warning valve and transmitters that do
not need to be replaced before performing the transmitter ID registration See: Testing and
Inspection/Programming and Relearning/Registration
* It is necessary to perform initialization See: Testing and Inspection/Programming and
Relearning/Initialization after registration See: Testing and Inspection/Programming and
Relearning/Registration of the transmitter IDs into the tire pressure warning ECU after the tire
pressure warning valve and transmitter has been replaced.
(b) If reusing the tire pressure warning valve and transmitter:
Install a new grommet.
HINT A new tire pressure warning valve and transmitter is supplied with a grommet.
(c) Install the washer on the tire pressure warning valve from the rim side and tighten the nut.
Page 1651
2. INSTALL FRONT UPPER ARMREST BASE PANEL LH
(a) Connect the master switch connector.
(b) Attach the 2 clips and 5 claws to install the front upper armrest base panel.
Page 6555
J/B No.5 - Instrument Panel Center
Page 7633
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Page 3340
(b) Install the connector holder block cover.
4. INSTALL AIR CLEANER ASSEMBLY See: Ignition System/Ignition Coil/Service and
Repair/Installation
5. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Installation
Page 6382
Instrumental Panel Wire
Page 2807
NOTE
On some models, DTCs may set as a result of reprogramming. If DTCs are present, clear codes
and run the Health Check again. Troubleshoot any remaining Current, Pending, or History codes.
Permanent codes will not be cleared using Techstream. Permanent codes do not illuminate the MIL
and do not require troubleshooting. They will clear during normal driving once the Universal Trip
Drive Pattern is performed.
4. Attach the Authorized Modifications Label.
A. Using a permanent marker or ball point pen complete the Authorized Modifications Label and
attach to the vehicle. The Authorized
Modifications Label is available through the MDC P/N 00451-00001-LBL.
B. Attach the label under the hood in the location determined by the specific TSB or Campaign.
NOTE
Wait 60 - 90 seconds for ink to set before handling.
Page 201
* In the DTC check, it is very important to determine whether the problem indicated by the DTC is
either: 1) still occurring; or 2) occurred in the past but has since returned to normal. In addition, the
DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs
should be checked before and after confirmation of symptoms (i.e., whether or not problem
symptoms exist) to determine current system conditions, as shown in the flowchart below.
* Never skip the DTC check. Failing to check DTCs may, depending on the case, result in
unnecessary troubleshooting for systems operating normally or lead to repairs not related to the
problem. Follow the procedures listed in the flowchart in the correct order.
* The following flowchart shows how to proceed with troubleshooting using the DTC check.
Directions from the flowchart will indicate how to proceed either to DTC troubleshooting or to the
troubleshooting of each problem symptom.
1. DTC CHECK
NEXT -- Continue to next step.
2. MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR MEMORY
NEXT -- Continue to next step.
3. SYMPTOM CONFIRMATION
B -- Go to step 5 A -- Continue to next step.
4. SIMULATION TEST USING SYMPTOM SIMULATION METHODS
NEXT -- Continue to next step.
5. DTC CHECK
B -- TROUBLESHOOTING OF PROBLEM INDICATED BY DTC A -- Continue to next step.
6. SYMPTOM CONFIRMATION
Transmission Control Switch
Transmission Mode Switch: Diagrams Transmission Control Switch
Page 503
Steering Control Module: Diagrams
Page 5960
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: ELECTRONIC
CIRCUIT INSPECTION PROCEDURE
1. BASIC INSPECTION
(a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS
(1) Unless otherwise stated, all resistance measurements should be made at an ambient
temperature of 20°C (68°F). Resistance measurements
may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been
running. Measurements should be made after the engine has cooled down.
(b) HANDLING CONNECTORS
(1) When disconnecting a connector, first squeeze the mating halves tightly together to release the
lock, and then press the lock claw and
separate the connector.
(2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly
and separate it.
(3) Before connecting a connector, check that there are no deformed, damaged, loose or missing
terminals.
(4) When connecting a connector, press firmly until it locks with a "click" sound.
(5) If checking a connector with a TOYOTA electrical tester, check the connector from the backside
(harness side) using a mini test lead.
NOTICE: *
As a waterproof connector cannot be checked from the backside, check it by connecting a
sub-harness.
* Do not damage the terminals by moving the inserted tester needle.
(c) CHECKING CONNECTORS
(1) Checking when a connector is connected: Squeeze the connectors together to confirm that they
are fully connected and locked.
(2) Checking when a connector is disconnected: Check by pulling the wire harness lightly from the
backside of the connector. Look for
unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for
corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or
deformed terminals.
(3) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a
female terminal, and check for ample tension
Page 5746
Removal
BRAKE: BRAKE MASTER CYLINDER: REMOVAL
NOTICE: Release the vacuum from the booster by depressing the brake pedal several times. Then
remove the brake master cylinder sub-assembly from the brake booster assembly.
1. DRAIN BRAKE FLUID
NOTICE: Immediately wash off any brake fluid that comes into contact with any painted surfaces.
2. DISCONNECT BRAKE FLUID LEVEL WARNING SWITCH CONNECTOR
(a) Disconnect the brake fluid level warning switch connector.
3. DISCONNECT FRONT NO. 1 BRAKE TUBE
(a) Using a union nut wrench, disconnect the brake tube (labeled A) from the brake master
cylinder.
4. DISCONNECT REAR NO. 1 BRAKE TUBE
Page 8271
6. REMOVE REAR SEAT REAR CUSHION MOULDING RH See: Body and Frame/Seats/Service
and Repair/Overhaul/Rear Seat Assembly (for
Crewmax LH Side)/Disassembly
7. REMOVE REAR SEAT INNER BELT ASSEMBLY
(a) Remove the belt.
8. REMOVE REAR NO. 1 SEAT INNER BELT ASSEMBLY LH
(a) Remove the bolt and seat belt.
HINT The rear center seat outer belt's anchor is fixed with the same bolt as the rear No. 1 seat
inner belt. Therefore, it becomes disconnected when the bolt is removed.
Installation
SEAT BELT: REAR SEAT INNER BELT ASSEMBLY (for CrewMax): INSTALLATION
1. INSTALL REAR NO. 1 SEAT INNER BELT ASSEMBLY LH
(a) Install the belt with the bolt.
Torque : 42 Nm (428 kgf-cm, 31 ft-lbf)
HINT The rear center seat outer belt's anchor is fixed with the same bolt as the rear No. 1 seat
inner belt. Therefore, connect it when installing the rear No. 1 seat inner belt.
2. INSTALL REAR SEAT INNER BELT ASSEMBLY
Page 2442
Oil Pressure Sender: Service and Repair Installation
1UR-FE LUBRICATION: OIL PRESSURE SWITCH: INSTALLATION
1. INSTALL OIL PRESSURE SENDER GAUGE ASSEMBLY
(a) Apply adhesive to 2 or 3 threads of the oil pressure sender gauge.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
(b) Install the oil pressure sender gauge.
Torque : 15 Nm (153 kgf-cm, 11 ft-lbf)
NOTICE: Do not start the engine within 1 hour after installation.
(c) Connect the sender gauge connector.
2. INSPECT ENGINE OIL LEVEL See: Testing and Inspection
3. INSPECT FOR OIL LEAK See: Engine Oil/Service and Repair/Replacement
4. INSTALL NO. 1 ENGINE UNDER COVER See: Engine Oil/Service and Repair/Replacement
Page 5894
Traction Control Switch: Diagrams
Page 1409
Removal
SUPPLEMENTAL RESTRAINT SYSTEM: FRONT AIRBAG SENSOR: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE BATTERY
(a) Disconnect the cable from the positive (+) battery terminal.
Components
Central Control Module: Service and Repair Components
AUDIO / VISUAL: MULTI-MEDIA INTERFACE ECU: COMPONENTS
Page 8266
(a) Remove the bolt and disconnect the outer belt.
2. REMOVE REAR SEAT ASSEMBLY
(a) Remove the rear seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Rear Seat Assembly (for Double
Cab)/Removal.
3. REMOVE REAR SEAT BELT RETRACTOR COVER
(a) Detach the 2 claws and 2 clips, and remove the cover.
4. REMOVE CENTER REAR SEAT OUTER BELT ASSEMBLY
(a) Remove the 4 bolts and outer belt.
5. REMOVE SEAT BELT BRACKET
Page 3333
(q) WAVEFORM 16:
HINT The wavelength changes when the air injection control driver detects malfunctions in the air
injection system See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated
Procedures/P Code Charts/P0412
(r) WAVEFORM 17:
HINT The wavelength becomes shorter as engine rpm increases.
(s) WAVEFORM 18:
Page 638
11. INSTALL FRONT DOOR SCUFF PLATE LH
(a) for Regular Cab:
Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular Cab)/Installation.
(b) for Double Cab:
Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Installation.
(c) for CrewMax:
Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for CrewMax)/Installation.
Page 4129
Page 8933
Integrated Accessory Switch Assembly: Service and Repair Installation
METER: DRIVE MONITOR SWITCH: INSTALLATION
1. INSTALL DRIVE MONITOR SWITCH
(a) Attach the 2 claws to install the monitor switch.
2. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Panel,
Gauges and Warning Indicators/Instrument Cluster
/ Carrier/Service and Repair/Combination Meter/Installation
Page 2762
4. Attach the Authorized Vehicle Modification Label.
Modifications to ECU calibrations MUST be recorded and properly displayed on the vehicle using
the Authorized Modification Label.
Techstream Preparation
Selecting the TIS Techstream VIM or the Mongoose MFC VIM.
Techstream software requires a VIM selection before you can use the Mongoose MFC VIM.
If using TIS Techstream no changes are needed.
Perform the following:
1. Select Setup from the Techstream Main Menu screen.
2. Select VIM Select from the Setup drop down menu.
3. Select the correct Interface Setup from the drop down list.
^ If using Techstream Lite select Mongoose MFC.
NOTE
Page 4565
Crankshaft Position Sensor: Locations Ignition System
1UR-FE IGNITION: IGNITION SYSTEM: PARTS LOCATION
Page 6764
PJ1-QK1
Page 6147
DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector.
Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
Page 68
(a) Attach the 8 claws and 2 clips to install the scuff plate.
5. INSTALL BACK PANEL TRIM RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for
CrewMax)/Installation
Page 6736
Engine Room R/B, J/B - Engine Compartment Left
Page 552
Control Module: Service and Repair Removal
JF1A TRANSFER: 4WD CONTROL ECU: REMOVAL
1. REMOVE FRONT DOOR SCUFF PLATE RH (for Regular Cab)
(a) Remove the front door scuff plate RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Removal.
HINT Use the same procedures described for the LH side.
2. REMOVE FRONT DOOR SCUFF PLATE RH (for Double Cab, for CrewMax)
(a) Remove the front door scuff plate RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Removal.
HINT Use the same procedures described for the LH side.
3. REMOVE COWL SIDE TRIM BOARD RH
(a) Remove the cowl side trim board RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Removal.
HINT Use the same procedures described for the LH side.
4. REMOVE INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal
5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and
Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument
Panel Safety Pad (for Column Shift Type)/Removal
6. REMOVE 4WD CONTROL ECU
(a) Disconnect the 2 ECU connectors.
(b) Remove the bolt and ECU.
Page 630
Shock Sensor: Diagrams
Page 3550
(c) Measure the voltage according to the value(s) in the table below.
Standard voltage:
NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- REPLACE SKID CONTROL ECU WITH ACTUATOR See: Brakes and Traction
Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock
Brakes/Service and Repair/Removal and Replacement/Removal
Steering Angle Sensor Communication Stop Mode
CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: Steering Angle Sensor
Communication Stop Mode - Steering Angle Sensor Communication Stop Mode
DESCRIPTION
WIRING DIAGRAM
Page 6786
DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector.
Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
Components
Spark Plug: Service and Repair Components
1UR-FE IGNITION: IGNITION COIL AND SPARK PLUG: COMPONENTS
Page 9024
General Information
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: GENERAL
INFORMATION
* A large number of ECU controlled systems are used in the TOYOTA TUNDRA. In general, ECU
controlled systems are considered to be very intricate, requiring a high level of technical knowledge
to troubleshoot. However, most problem checking procedures only involve inspecting the ECU
controlled system's circuits one by one. An adequate understanding of the system and a basic
knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and
necessary repairs.
1. TROUBLESHOOTING PROCEDURES
* The troubleshooting procedures consist of diagnosis procedures for when a DTC is stored and
diagnosis procedures for when no DTC is stored. The basic idea is explained in the following table.
* Vehicle systems are complex and use many ECUs that are difficult to inspect independently.
Therefore, a process of elimination is used, where components that can be inspected individually
are inspected, and if no problems are found in these components, the related ECU is identified as
the problem and replaced.
* It is extremely important to ask the customer about the environment and the conditions present
when the problem occurred (Customer Problem Analysis). This makes it possible to simulate the
conditions and confirm the symptom. If the symptom cannot be confirmed or the DTC does not
recur, the malfunctioning part may not be identified using the troubleshooting procedure, and the
ECU for the related system may be replaced even though it is not defective. If this happens, the
original problem will not be solved.
* In order to prevent endless expansion of troubleshooting procedures, the troubleshooting
procedures are written with the assumption that multiple malfunctions do not occur simultaneously
for a single problem symptom.
* To identify the malfunctioning part, troubleshooting procedures narrow down the target by
separating components, ECUs and wire harnesses during the inspection. If the wire harness is
identified as the cause of the problem, it is necessary to inspect not only the connections to
components and ECUs but also all of the wire harness connectors between the component and the
ECU.
DIAGNOSTIC TESTER
2. DESCRIPTION
System data and the Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector
3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the Techstream* to
check for a malfunction and perform repairs.
HINT *: Techstream is the name for the diagnostic tester in North America.
3. DATA LINK CONNECTOR 3 (DLC3)
(a) The vehicle's ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of
the DLC3 complies with SAE J1962 and
matches the ISO 15765-4 format.
Page 2582
(f) Install SST (pressure gauge) as shown in the illustration.
SST : 09268-31012
90467-13001
95336-08070
09268-41500
09268-41120
SST : 09268-45014
09268-41200
09268-41220
(g) Wipe off any gasoline.
(h) Reconnect the cable to the negative (-) battery terminal.
(i) Operate the fuel pump.
(1) Connect the Techstream to the DLC3.
(2) Turn the ignition switch to ON.
NOTICE: Do not start the engine.
(3) Turn the Techstream main switch ON.
(4) Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump /
Speed.
(j) Measure the fuel pressure.
Standard fuel pressure:
281 to 287 kPa (2.87 to 2.93 kgf/cm2, 41 to 42 psi)
(k) If the pressure is higher than the specification, replace the fuel pressure regulator.
If the pressure is lower than the specification, check the fuel hoses and connections, fuel pump,
fuel filter and fuel pressure regulator assembly.
(l) Start the engine.
Page 8625
Remove the front door scuff plate LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Removal.
(c) for CrewMax:
Remove the front door scuff plate LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Removal.
3. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Removal
4. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal
5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Removal
6. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column
Shift Type)/Removal
7. REMOVE CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service
and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Removal
8. REMOVE FRONT ASH RECEPTACLE BOX SUB-ASSEMBLY
9. REMOVE LOWER INSTRUMENT CLUSTER FINISH PANEL See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column
Shift Type)/Removal
10. REMOVE INSTRUMENT PANEL CUP HOLDER ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column
Shift Type)/Removal
11. REMOVE INTEGRATION CONTROL AND PANEL ASSEMBLY (for Manual Air Conditioning
System) See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and
Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal
12. REMOVE INTEGRATION CONTROL AND PANEL ASSEMBLY (for Automatic Air Conditioning
System) See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and
Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal
13. REMOVE STEREO JACK ADAPTER ASSEMBLY
(a) Detach the 2 claws and remove the stereo jack adapter.
Installation
AUDIO / VISUAL: STEREO JACK ADAPTER ASSEMBLY (for Column Shift Type):
INSTALLATION
1. INSTALL STEREO JACK ADAPTER ASSEMBLY
Page 5402
Fluid - Transfer Case: Fluid Type Specifications
Transfer Oil
Type .....................................................................................................................................................
....................................... Gear oil API GL-4 or GL-5 Recommended viscosity ...................................
................................................................................................................................................ SAE
75W-90
Engine Controls - ECM Update For Shift Performance
Engine Control Module: All Technical Service Bulletins Engine Controls - ECM Update For Shift
Performance
T-SB-0285-10
October 12, 2010
ECM Calibration: Enhancement to Shifting Performance
Service Category Drivetrain
Section Automatic Transmission/Transaxle
Market USA
Applicability
Introduction
Some vehicles may exhibit the following shifting conditions:
^ Harsh shift on acceleration below 20 mph during the 2-1 downshift.
^ Excessive lock-up operation at freeway speeds about 50 - 60 mph, sometimes referred to as
"busy shifting".
The Engine Control Module/ECM (SAE term: Powertrain Control Module/PCM) calibration has
been revised. Use the following repair procedure to address these conditions.
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Federal Emission Warranty. This warranty is in effect for
96 months or 80,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Page 2961
Oxygen Sensor: Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 2614
Spark Plug: Service and Repair Removal
1UR-FE IGNITION: IGNITION COIL AND SPARK PLUG: REMOVAL
1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Service and Repair/Removal and
Replacement/Engine Assembly/Removal
2. REMOVE AIR CLEANER ASSEMBLY
(a) Disconnect the MAF meter connector and clamp.
(b) Disconnect the ventilation hose and vacuum hose.
(c) Loosen the hose clamp.
(d) Remove the 2 bolts and air cleaner.
3. REMOVE IGNITION COIL ASSEMBLY
(a) for Bank 1:
(1) Disconnect the 3 wire harness clamps.
(2) Disconnect the 4 ignition coil connectors.
(3) Remove the 4 bolts and 4 ignition coils.
(b) for Bank 2:
(1) Disconnect the 2 wire harness clamps.
(2) Disconnect the 4 ignition coil connectors.
(3) Disconnect the engine wire harness clamp.
Locations
Temperature Sensor/Switch: Locations
JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION
Page 4180
Page 3237
(a) For an open circuit in the wire harness in Fig. 1, check the resistance or voltage, as described
below.
(b) Check the resistance.
(1) Disconnect connectors A and C and measure the resistance between them.
Standard resistance (Fig. 2):
HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally.
If the results match the examples above, an open circuit exists between terminal 1 of connector A
and terminal 1 of connector C.
(2) Disconnect connector B and measure the resistance between the connectors.
Standard resistance (Fig. 3):
* If the results match the examples above, an open circuit exists between terminal 1 of connector
B2 and terminal 1 of connector C.
(c) Check the voltage.
Page 2409
(c) Install the oil cooler with the 5 nuts.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
3. INSTALL OIL FILTER BRACKET
(a) Apply a light coat of engine oil to 2 new O-rings.
(b) Install the 2 O-rings to the timing chain cover.
(c) Install the oil filter bracket with the 2 nuts and 2 bolts.
Torque : 35 Nm (357 kgf-cm, 26 ft-lbf)
4. INSTALL NO. 1 OIL COOLER BRACKET
(a) Connect the ground wire to the cylinder block.
(b) Install the oil cooler bracket with the 2 nuts.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
5. INSTALL WATER BY-PASS PIPE See: Water Pump/Service and Repair/Installation
6. CONNECT COOLER COMPRESSOR ASSEMBLY See: Oil Pump/Service and Repair/Removal
and Replacement/Installation
7. INSTALL OIL PRESSURE SENDER GAUGE ASSEMBLY See: Oil Pressure Sender/Service
and Repair/Installation
8. INSTALL OIL FILTER ELEMENT See: Engine Oil/Service and Repair/Replacement
Page 8659
Page 9206
6. REMOVE FRONT NO. 3 SPEAKER ASSEMBLY (for 12 Speakers) See: Accessories and
Optional Equipment/Radio, Stereo, and Compact
Disc/Speaker/Service and Repair/Front Door Speaker (for Double Cab)/Removal
7. REMOVE COURTESY LIGHT ASSEMBLY
(a) Detach the claw and remove the courtesy light from the door trim board.
(b) Disconnect the connector.
8. REMOVE FRONT DOOR ARMREST COVER LH
9. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH
(a) Remove the 2 screws.
(b) Remove the clip.
(c) Detach the 9 clips and remove the trim board cover. Then disconnect the connector.
(d) Disconnect the 2 cables from the inside handle.
Page 8401
Seat Occupant Sensor: Locations Occupant Classification System
SUPPLEMENTAL RESTRAINT SYSTEM: OCCUPANT CLASSIFICATION SYSTEM: PARTS
LOCATION
Page 6119
(b) Hang the plunger of the magnet starter switch onto the drive lever from the upper side.
(c) Install the magnet starter switch with the 2 nuts.
Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
(d) Connect the lead wire to the magnet starter switch and connect it with the nut.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
Disassembly
1UR-FE STARTING: STARTER (for 2.0 kW Type): DISASSEMBLY
1. REMOVE MAGNET STARTER SWITCH ASSEMBLY
(a) Remove the nut, and disconnect the lead wire from the magnet starter switch.
(b) Remove the 2 nuts and magnet starter switch.
2. REMOVE STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY
(a) Using a T30 "TORX" socket wrench, remove the 2 bolts.
(b) Pull out the yoke and starter commutator end frame assembly together with the armature.
Components
Interior Light Switch: Service and Repair Components
LIGHTING: ROOM LIGHT SWITCH: COMPONENTS
Components
Transmission Speed Sensor: Service and Repair Components
A760F AUTOMATIC TRANSMISSION: SPEED SENSOR: COMPONENTS
Page 1680
*: for 5 leaf spring
Standard Wheel Angle
for Regular Cab of Standard Deck
Page 2465
(j) Connect the purge VSV connector.
(k) Connect the purge line hose to the purge VSV.
(l) Connect the vacuum switching valve connector (for ACIS).
(m)Connect the No. 1 ventilation hose.
(n) Connect the No. 4 water by-pass hose.
(o) Connect the throttle body connector.
11. INSTALL VENTILATION HOSE ASSEMBLY
(a) Install the ventilation hose with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(b) Connect the ventilation hose to the ventilation pipe of the cylinder head cover LH and RH.
12. INSTALL AIR TUBE SUB-ASSEMBLY LH See: Cooling System/Thermostat/Service and
Repair/Installation
13. INSTALL COWL TOP OUTER PANEL SUB-ASSEMBLY
(a) Install the outer panel with the 7 bolts.
Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
(b) Connect the washer hose.
(c) Connect the 2 wire harness clamps.
14. INSTALL FRONT WIPER MOTOR AND LINK ASSEMBLY
Page 7499
No further tightening is required once the nut is tightened with the specified torque.
2. INSTALL WHEEL
for Aluminum Wheel - Torque : 131 Nm (1336 kgf-cm, 97 ft-lbf)
for Steel Wheel - Torque : 209 Nm (2131 kgf-cm, 154 ft-lbf)
3. INSPECT TIRE
(a) Inspect the tire See: Testing and Inspection/Component Tests and General Diagnostics.
4. REGISTRATION OF TRANSMITTER ID
(a) Register the transmitter ID See: Testing and Inspection/Programming and
Relearning/Registration.
5. PERFORM INITIALIZATION
(a) Perform initialization See: Testing and Inspection/Programming and Relearning/Initialization.
NOTICE: Be sure to inflate all tires to the proper inflation pressure before initialization.
6. CHECK TIRE PRESSURE AFTER REPAIRS
(a) After repairs, confirm that the actual tire pressures are displayed in the DATA LIST See: Testing
and Inspection/Scan Tool Testing and
Procedures/Data List / Active Test.
Page 8669
"Case2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 3847
5. REMOVE PROPELLER SHAFT HEAT INSULATOR (for 4WD) See: Transmission and
Drivetrain/Drive/Propeller Shafts, Bearings and
Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Front Propeller Shaft
Assembly/Removal
6. REMOVE FRONT NO. 2 EXHAUST PIPE ASSEMBLY (for 4WD)
(a) Disconnect the heated oxygen sensor connector.
(b) Disconnect the air fuel ratio sensor connector.
(c) Disconnect the front No. 2 exhaust pipe from the exhaust pipe support.
(d) Remove the 3 nuts, front No. 2 exhaust pipe and gasket from the exhaust manifold LH.
7. REMOVE AIR FUEL RATIO SENSOR (for Bank 1 Sensor 1)
(a) for 2WD:
Disconnect the air fuel ratio sensor connector.
(b) Using SST, remove the sensor.
SST : 09224-00010
Installation
1UR-FE ENGINE CONTROL SYSTEM: AIR FUEL RATIO SENSOR: INSTALLATION
1. INSTALL AIR FUEL RATIO SENSOR (for Bank 1 Sensor 1)
(a) Install the sensor to the exhaust pipe by hand.
(b) Using SST, tighten the sensor.
SST : 09224-00010
Page 5763
(d) Remove the bolt and No. 2 parking brake cable from the rear axle carrier.
36. REMOVE PARKING BRAKE INTERMEDIATE LEVER SUB-ASSEMBLY
(a) Remove the 2 bolts and intermediate lever with bracket.
(b) Remove the clip, washer, pin and intermediate lever from the bracket.
37. REMOVE NO. 2 CABLE SUPPORT BRACKET
(a) Remove the 2 bolts and bracket.
Page 2628
(a) Remove the 3 bolts and water inlet housing.
(b) Remove the gasket from the water pump.
10. REMOVE WATER PUMP PULLEY
(a) Using SST, hold the water pump pulley.
SST : 09960-10010
09962-01000
09963-01000
(b) Remove the 4 bolts and water pump pulley.
11. REMOVE WATER PUMP ASSEMBLY
(a) Remove the 8 bolts, water pump and gasket.
Page 1391
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE BATTERY
(a) Disconnect the cable from the positive (+) battery terminal.
(b) Loosen the nut, move the stay off the battery, and remove the battery.
3. REMOVE FRONT AIRBAG SENSOR
(a) Remove the nut and front airbag sensor from the body.
(b) Disconnect the connector.
Installation
SUPPLEMENTAL RESTRAINT SYSTEM: FRONT AIRBAG SENSOR: INSTALLATION
1. INSTALL FRONT AIRBAG SENSOR
(a) Check that the ignition switch is OFF.
(b) Check that the cable is disconnected from the battery negative (-) terminal.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
(c) Connect the connector.
(d) Install the front airbag sensor with the nut.
Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)
Page 1690
for Double Cab of Long Deck
Page 3773
Air Flow Meter/Sensor: Diagrams
Components
Radiator: Service and Repair Components
1UR-FE COOLING: RADIATOR: COMPONENTS
Page 1811
^ Engine Control Module (ECM)
^ Transmission Control Module (TCM)
^ Or any other Toyota specific control unit
Warranty Information
Parts Information
Required Tools & Equipment
NOTE
Additional SSTs may be ordered by calling 1-800-933-8335.
Process Overview
Techstream ECU flash reprogramming is a 4-step process:
1. Verify the vehicle's applicability for recalibration and locate desired calibration file by performing
the Techstream Health Check function.
NOTE
Techstream will automatically search TIS for the appropriate service bulletin using the current
Calibration ID from the vehicle. Calibration file links can be found embedded in the corresponding
service bulletin.
2. Connect the GR8 Battery Diagnostic Station using "Power Supply Mode" only.
The GR8 Battery Diagnostic Station includes a Power Supply Mode to help maintain battery
voltage at 13.5 volts during ECU reprogramming.
ECU damage may occur if the correct battery charger mode setting is NOT used.
3. Locate appropriate calibration ID and reprogram the vehicle ECU with Techstream.
Techstream uses the Calibration Update Wizard (CUW) application to open calibration files and
facilitate the ECU flash reprogramming process.
Page 6398
Page 7835
Ambient Temperature Sensor / Switch HVAC: Service and Repair Removal
AIR CONDITIONING: AMBIENT TEMPERATURE SENSOR: REMOVAL
1. REMOVE AMBIENT TEMPERATURE SENSOR
(a) Disconnect the connector.
(b) Using a screwdriver, detach the clamp and remove the ambient temperature sensor.
HINT Tape the screwdriver tip before use.
Page 4142
Page 7862
(a) Remove the filter.
6. REMOVE NO. 2 AIR DUCT SUB-ASSEMBLY
(a) Remove the screw and duct.
7. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY
(a) Remove the 2 screws and amplifier.
8. REMOVE BLOWER WITH FAN MOTOR SUB-ASSEMBLY
(a) Remove the 3 screws and motor.
9. REMOVE AIR DUCT
(a) Remove the 2 screws and duct.
Locations
Power Distribution Module: Locations
Instrument Panel (Floor Shift)
Instrument Panel (Column Shift)
Name Plate
Body Emblem: Service and Repair Name Plate
EXTERIOR: NAME PLATE: COMPONENTS
Engine - Snow Ingestion Into Air Cleaner Box
Air Cleaner Housing: All Technical Service Bulletins Engine - Snow Ingestion Into Air Cleaner Box
T-SB-0396-09
December 8, 2009
Snow Entry Into Air Cleaner Box
Service Category Engine/Hybrid System
Section Intake/Exhaust
Market USA
Applicability
Introduction
Some Sequoia and Tundra vehicles operated in areas with significant snow volume may
experience snow accumulation in the air cleaner box which can cause the lid to fracture. The air
cleaner lid and fender liner have been revised to reduce accumulation.
Parts Information
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for
36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Production Change Information
Page 6209
(a) for AC Power Supply:
Connect the clamp.
(b) Install the bezel with the 4 screws.
5. INSTALL NO. 2 CONSOLE BOX REGISTER ASSEMBLY See: Body and Frame/Seats/Service
and Repair/Overhaul/Front Seat Assembly (for
Center Seat)/Reassembly
6. INSTALL NO. 1 CONSOLE BOX REGISTER ASSEMBLY See: Body and Frame/Seats/Service
and Repair/Overhaul/Front Seat Assembly (for
Center Seat)/Reassembly
7. INSTALL CENTER SEATBACK PANEL See: Body and Frame/Seats/Service and
Repair/Overhaul/Front Seat Assembly (for Center
Seat)/Reassembly
Components
OTHER SYSTEM: POWER OUTLET SOCKET (for CrewMax Floor Shift Type): COMPONENTS
Removal and Replacement
Parking Brake Pedal: Removal and Replacement
Components
PARKING BRAKE: PARKING BRAKE PEDAL: COMPONENTS
Removal
PARKING BRAKE: PARKING BRAKE PEDAL: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to disable the SRS system.
2. RELEASE PARKING BRAKE PEDAL
3. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal
4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Removal
5. REMOVE LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY See: Restraint
Systems/Air Bag Systems/Air Bag/Service and
Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Removal
6. DISCONNECT NO. 1 PARKING BRAKE CABLE ASSEMBLY
(a) Remove the lock nut and adjustment nut.
Page 6835
Page 1694
for Double Cab of Long Deck
Locations
Relay Box: Locations
Engine Compartment
Page 713
Reclining switch
(b) If the result is not as specified, replace the switch.
3. INSPECT LEG SUPPORT ADJUSTMENT SWITCH (w/ Leg Support Adjustment Switch)
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the switch.
Page 811
Steering Angle Sensor: Service and Repair Installation
BRAKE CONTROL: STEERING ANGLE SENSOR: INSTALLATION
1. INSTALL STEERING ANGLE SENSOR See: Restraint Systems/Air Bag Systems/Clockspring
Assembly / Spiral Cable/Service and
Repair/Installation
2. INSTALL SPIRAL CABLE SUB-ASSEMBLY See: Restraint Systems/Air Bag
Systems/Clockspring Assembly / Spiral Cable/Service and
Repair/Installation
3. INSTALL UPPER STEERING COLUMN COVER See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Removal and
Replacement/Steering Column Assembly (for Manual Tilt)/Installation
4. INSTALL LOWER STEERING COLUMN COVER See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Removal and
Replacement/Steering Column Assembly (for Manual Tilt)/Installation
5. ADJUST SPIRAL CABLE See: Restraint Systems/Air Bag Systems/Clockspring Assembly /
Spiral Cable/Service and Repair/Installation
6. INSTALL STEERING WHEEL ASSEMBLY See: Steering and Suspension/Steering/Steering
Column/Service and Repair/Removal and
Replacement/Steering Column Assembly (for Manual Tilt)/Installation
7. INSTALL STEERING PAD See: Restraint Systems/Air Bag Systems/Air Bag/Service and
Repair/Removal and Replacement/Steering
Pad/Installation
8. INSTALL LOWER NO. 3 STEERING WHEEL COVER See: Restraint Systems/Air Bag
Systems/Air Bag/Service and Repair/Removal and
Replacement/Steering Pad/Installation
9. INSTALL LOWER NO. 2 STEERING WHEEL COVER See: Restraint Systems/Air Bag
Systems/Air Bag/Service and Repair/Removal and
Replacement/Steering Pad/Installation
10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
11. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
Diagrams
Variable Valve Timing Actuator Position Sensor: Diagrams
Page 4189
Front Speed Sensor
Wheel Speed Sensor: Service and Repair Front Speed Sensor
Components
BRAKE CONTROL: FRONT SPEED SENSOR: COMPONENTS
Removal
BRAKE CONTROL: FRONT SPEED SENSOR: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to disable the SRS system.
2. REMOVE FRONT WHEEL
3. REMOVE FRONT SKID CONTROL SENSOR WIRE LH
(a) Disconnect the connector (labeled A) from the front speed sensor.
(b) Detach the 3 clips (labeled B) and remove the clamp bolt (labeled C).
(c) Disconnect the connector (labeled D).
Page 5974
Ignition Switch: Connector Views
Air Fuel Ratio Sensor
Oxygen Sensor: Diagrams Air Fuel Ratio Sensor
Page 3671
1. Test drive the vehicle and confirm there is a harsh shift on acceleration below 20 mph and or
excessive lock-up operation at freeway speeds about 50
- 60 mph.
2. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in
Figure 1. Confirm if the ECM (PCM) calibration has
been updated. If the calibration ID listed is NOT the latest ECM (PCM) calibration - go to step 3.
3. Flash reprogram the ECM (PCM).
NOTE
^ The GR8 Battery Diagnostic Station MUST be used in Power Supply Mode to maintain battery
voltage at 13.5 volts while flash reprogramming the vehicle.
^ For details on how to use the GR8 Battery Diagnostic Station, refer to the GR8 Instruction Manual
located on the Technical Information System (TIS), Diagnostics - Battery.
Follow the procedures outlined in TSB No. T-SB-0064-10, "Techstream ECU Flash
Reprogramming Procedure", and flash the ECM (PCM) with the NEW calibration file update.
4. Start the engine and warm it up to normal operating temperature before test driving.
5. Test drive the vehicle to confirm proper vehicle operation and ECM (PCM) initial learning. Refer
to the Technical Information System (TIS) 2010
Tundra Repair Manual:
Drivetrain - Automatic Transmission/Transaxle - "A760E / A760F Automatic
Transmission/Transaxle: Automatic Transmission System: Initialization"
6. Install the Authorized Modifications Label.
A. Using a permanent marker enter the following information on the label:
^ ECM part number [Refer to the Parts Information section for the CURRENT PART NUMBER]
Page 7162
Tire Pressure Warning Reset Switch: Service and Repair Removal
TIRE AND WHEEL: TIRE PRESSURE WARNING RESET SWITCH: REMOVAL
1. REMOVE FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Removal
2. REMOVE FRONT DOOR SCUFF PLATE LH (for Double Cab, for CrewMax) See: Body and
Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal
3. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Removal
4. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal
5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Removal
6. REMOVE TIRE PRESSURE WARNING RESET SWITCH
(a) Disconnect the switch connector.
(b) Detach the 2 claws and remove the reset switch.
Up to 11/2009
Electronic Brake Control Module: Locations Up to 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 3461
Result
E -- REPAIR OR REPLACE HARNESS OR CONNECTOR
D -- REPLACE ECM See: Engine Control Module/Service and Repair/Removal
C -- REPLACE ECM See: Engine Control Module/Service and Repair/Removal
B -- REPLACE ECM See: Engine Control Module/Service and Repair/Removal
A -- REPLACE ECM
Power Steering ECU Communication Stop Mode
CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: Power Steering ECU
Communication Stop Mode - Power Steering ECU Communication Stop Mode
DESCRIPTION
WIRING DIAGRAM
INSPECTION PROCEDURE
HINT
Skid Control Sensor Wire
Wheel Speed Sensor: Diagrams Skid Control Sensor Wire
Page 7861
Evaporator Temperature Sensor / Switch: Service and Repair Disassembly
AIR CONDITIONING: FRONT EVAPORATOR TEMPERATURE SENSOR: DISASSEMBLY
1. REMOVE AIR CONDITIONING UNIT
(a) Remove the air conditioning unit See: Housing Assembly HVAC/Service and Repair/Removal
and Replacement/Removal.
2. REMOVE LOWER DEFROSTER NOZZLE ASSEMBLY
(a) Detach the 4 claws and remove the nozzle.
3. REMOVE NO. 3 AIR DUCT SUB-ASSEMBLY
(a) Detach the 4 claws and remove the duct.
4. REMOVE AIR FILTER COVER PLATE
(a) Detach the 2 clips and remove the plate.
5. REMOVE CLEAN AIR FILTER
Page 5728
* The procedures listed below are for the LH side.
1. REMOVE REAR WHEEL
2. DRAIN BRAKE FLUID
NOTICE: Wash off brake fluid immediately if it comes in contact with any painted surface.
3. REMOVE REAR BRAKE FLEXIBLE HOSE
(a) Disconnect the brake tube from the flexible hose with a union nut wrench while holding the
flexible hose with a wrench.
NOTICE: *
Do not bend or damage the brake tube.
* Do not allow any foreign matter such as dirt and dust to enter the brake tube from the connecting
point.
(b) Remove the clip.
(c) Remove the union bolt and gasket, and then remove the flexible hose from the disc brake
cylinder.
Installation
BRAKE: REAR BRAKE FLEXIBLE HOSE: INSTALLATION
HINT *
Use the same procedures for the LH side and RH side.
* The procedures listed below are for the LH side.
1. INSTALL REAR BRAKE FLEXIBLE HOSE
(a) Install the flexible hose and a new gasket to the disc brake cylinder with the union bolt.
Torque : 30 Nm (306 kgf-cm, 22 ft-lbf)
HINT Install the flexible hose lock securely in the lock hole in the cylinder.
(b) Set the flexible hose to the connecting point with the brake tube, and then attach a new clip.
(c) Using a union nut wrench, connect the flexible hose to the brake tube while holding the flexible
hose with a wrench.
Page 8729
Additional SSTs may be ordered by calling 1-800-933-8335.
Repair Procedure
1. Verify the condition in the Introduction.
2. Perform diagnostic troubleshooting to confirm the problem is related to the condition described in
this TSB.
Refer to the Technical Information System (TIS), Accessory - Accessory Diagnostic Guide "2004-2011 All Vehicles XM Satellite Radio Tuner 86180-0W030 Troubleshooting Guide"
3. Order a replacement XM Satellite Radio Receiver through the Pioneer exchange program.
For information regarding the satellite radio warranty, refer to TIS, Reference Information Warranty Policy & Procedures -"Policy 4.28: Satellite Radio Warranty"
Heated Oxygen Sensor
Oxygen Sensor: Testing and Inspection Heated Oxygen Sensor
1UR-FE ENGINE CONTROL SYSTEM: HEATED OXYGEN SENSOR: ON-VEHICLE
INSPECTION
1. CHECK HEATED OXYGEN SENSOR
(a) Disconnect the heated oxygen sensor connector.
(b) Measure the heater resistance according to the value(s) in the table below.
Standard Resistance:
(c) If the result is not as specified, replace the heated oxygen sensor.
(d) Connect the heated oxygen sensor connector.
Page 4279
Then click Next.
F. Verify correct current calibration and new calibration information. Then click Next.
NOTE
^ The total number of calibration IDs in the calibration file corresponds to the number of
reprogrammable processors in the ECU.
^ Each calibration file may contain up to three separate calibrations.
Page 5778
Installation
PARKING BRAKE: PARKING BRAKE PEDAL: INSTALLATION
1. INSTALL PARKING BRAKE CONTROL PEDAL ASSEMBLY
(a) Install the control pedal to the body with the 3 nuts.
Torque : 13 Nm (127 kgf-cm, 9 ft-lbf)
(b) Attach the wire harness clamp to the control pedal.
Page 7195
(b) Using SST and a press, press in the oil seal.
SST : 09950-60010
09951-00280
SST : 09950-70010
09951-07100
NOTICE: Make sure that the oil seal is installed facing in the correct direction as shown in the
illustration.
2. INSTALL VANE PUMP SHAFT SUB-ASSEMBLY WITH PULLEY
(a) Coat the inside surface of the bushing in the vane pump front housing with power steering fluid.
(b) Gradually insert the vane pump shaft sub-assembly with pulley.
NOTICE: *
Do not damage the lip of the oil seal in the front housing.
* Wrap protective tape around the spline of the vane pump shaft with vane pump shaft
sub-assembly with pulley in order to prevent damage to the oil seal.
3. INSTALL VANE PUMP FRONT SIDE PLATE
(a) Coat a new O-ring with power steering fluid and install it into the front housing.
(b) Coat a new O-ring with power steering fluid and install it onto the front side plate.
Fuel System - Fuel Sending Unit Upper Cover
Replacement
Fuel Gauge Sender: Technical Service Bulletins Fuel System - Fuel Sending Unit Upper Cover
Replacement
T-SB-0399-09
December 23, 2009
Fuel Sending Unit Upper Cover Installation
Service Category Engine/Hybrid System
Section Fuel System
Market USA
Applicability
Introduction
A Fuel Sending Unit Upper Cover has been developed as a separate service part for 2007-2010
MY Tundra vehicles to allow for individual replacement. This bulletin supplements the Repair
Manual by providing the installation procedures and part number details for this component.
Vehicles produced after the production change below utilize this replaceable Fuel Sending Unit
Upper Cover.
Production Change Information
This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown.
Page 6649
(a) Attach the claw to install the power outlet socket.
3. INSTALL LOWER INSTRUMENT CLUSTER FINISH PANEL See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column
Shift Type)/Installation
4. INSTALL FRONT ASH RECEPTACLE BOX SUB-ASSEMBLY
5. INSTALL CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service
and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
6. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Installation
7. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
8. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Installation
9. INSTALL FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Installation
10. INSTALL FRONT DOOR SCUFF PLATE LH (for Double Cab)
Components
OTHER SYSTEM: POWER OUTLET SOCKET (for CrewMax Column Shift Type): COMPONENTS
Page 8265
Removal
SEAT BELT: REAR CENTER SEAT OUTER BELT ASSEMBLY (for Double Cab): REMOVAL
1. DISCONNECT CENTER REAR SEAT OUTER BELT ASSEMBLY
Page 9004
Page 2800
load while reprogramming.
^ Confirm the hood is open and ensure under hood temperature does NOT exceed 158°F (70°C).
^ Confirm cable connections between the vehicle and Techstream are secure.
^ Do NOT disconnect or turn off Techstream or vehicle ignition during reprogramming.
^ Set parking brake.
^ Complete ALL flash calibration updates provided for each ECU.
^ If the battery's state of charge or capacity are in question, test with SST. No. 00002-8150-KIT
"Digital Battery Analyze," and follow TSB No. PG001-06, "Battery Maintenance for In-Stock
Vehicles & Pre-Delivery" or the appropriate "Maintenance for HV & Auxiliary Batteries" service
bulletin.
^ The GR8 Battery Diagnostic Station MUST be used in Power Supply Mode to maintain battery
voltage at 13.5 volts while flash reprogramming the vehicle. For details on how to use the GR8
Battery Diagnostic Station, refer to the GR8 Instruction Manual located on TIS, Diagnostics - Tools
& Equipment - Battery Diagnostics.
3C. Click Next to start the calibration update process.
D. When using TIS Techstream select Techstream VIM as the desired programming device. Then
click Next.
Page 9313
(3) Attach the 2 clips to install the moulding.
HINT Press the moulding firmly to install it.
Diagrams
Tilt Wheel Motor: Diagrams
Page 8639
(a) Attach the clip and 2 claws to install the bracket.
(b) Install the 4 bolts.
HINT Install the bolts in the order shown in the illustration.
2. INSTALL ROOF HEADLINING ASSEMBLY (for CrewMax)
(a) Install the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (for
CrewMax)/Installation.
3. INSTALL TELEVISION DISPLAY ASSEMBLY
(a) Attach the 2 clips and 2 claws to install the television display.
(b) Install the 4 bolts.
HINT Install the bolts in the order shown in the illustration.
4. INSTALL ROOM NO. 1 LIGHT ASSEMBLY
Page 269
DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector.
Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
Page 4973
Transmission Speed Sensor: Diagrams
Page 924
Compressor Speed Sensor: Locations Air Conditioning System (for Manual Air Conditioning
System)
AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Manual Air Conditioning System):
PARTS LOCATION
Page 6773
Multiple Junction Connector: Locations Wire and Wire In Seat [Separate Seat]
PZ1-ZU1
PZ1-ZU1
Page 7872
(a) Install the motor with the 3 screws.
11. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY
(a) Install the amplifier with the 2 screws.
12. INSTALL NO. 2 AIR DUCT SUB-ASSEMBLY
(a) install the duct with the screw.
13. INSTALL CLEAN AIR FILTER
(a) Install the filter as shown in the illustration.
14. INSTALL AIR FILTER COVER PLATE
(a) Attach the 2 clips to install the plate.
Components
Parking Assist Control Module: Service and Repair Components
PARK ASSIST / MONITORING: CLEARANCE WARNING ECU: COMPONENTS
Page 5297
09957-04010
09958-04011
SST : 09955-04100
NOTICE: Pull out the spider bearing until the SST claws contact the flange yoke.
(k) Clamp the protruding universal joint spider bearing in a vise.
(l) Using a brass bar and hammer, tap the flange yoke to remove the universal joint spider bearing.
HINT Use the same removal procedure for the universal joint spider bearing on the opposite side.
(m)Remove the spider from the flange yoke.
Reassembly
PROPELLER SHAFT: PROPELLER SHAFT ASSEMBLY (for 4WD): REASSEMBLY
1. INSTALL REAR PROPELLER SHAFT UNIVERSAL JOINT SPIDER BEARING
HINT Use the same installation procedure for both the front and rear propeller shaft universal joint
spider bearings.
(a) Apply MP grease to a new spider and 4 new bearings.
NOTICE: Be careful not to apply too much grease.
(b) Measure dimension A between the snap ring grooves.
(c) Install the 4 spider bearings to the spider journal portions, and then measure dimension B of the
universal joint.
Page 4029
6. In some instances where water has entered the system DTCs P2440/P2441/P2442/P2443 may
set.
Refer to TIS 2010 model year Tundra Repair Manual to diagnose and inspect the emission control
valves if necessary:
7. If there is NO liquid found in the air pump assemblies or the DTC is still present after
replacement inspect the air injection system.
Refer to TIS 2010 model year Tundra Repair Manual:
8. Clear the DTC and road test the vehicle to confirm the condition has been corrected.
Emissions - MIL ON/Multiple Air Injection DTC's Set
Air Injection Check Valve: All Technical Service Bulletins Emissions - MIL ON/Multiple Air Injection
DTC's Set
T-SB-0350-09
Rev1
October 1, 2009
Air Injection Pump With Water Intrusion: MIL "ON" DTC P04181P0419 and/or P244 #
Service Category Engine/Hybrid System
Section Engine Control
Market USA
Applicability
TSB REVISION NOTICE
May 21, 2010 Rev1:
^ DTCs P0418 and P0419 have been added to the TSB.
^ The Applicable Warranty has been updated in the Warranty Information section. Any previous
printed versions of this service bulletin should be discarded.
Introduction
Some 2010 model year Tundra vehicles built in the Texas plant may exhibit a MIL "ON" condition
with Diagnostic Trouble Code (DTC) P0418, P0419, P2440, P2441, P2442, P2443, P2446, and/or
P2447. This concern may be caused by water intrusion into the air injection pump assembly. Use
the following procedure to address this condition.
Parts Information
Production Change Information
Page 8941
Parking Assist Distance Sensor: Diagrams
Page 3639
Power Steering Pressure Switch: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: POWER STEERING OIL PRESSURE SWITCH:
INSTALLATION
1. INSTALL POWER STEERING OIL PRESSURE SWITCH
(a) Install a new O-ring to the power steering oil pressure switch.
(b) Apply a light coat of engine oil to the O-ring of the power steering oil pressure switch.
NOTICE: *
When reusing the power steering oil pressure switch, inspect the O-ring.
* If the O-ring has scratches or cuts, replace the power steering oil pressure switch.
(c) Using SST, install the power steering oil pressure switch.
SST : 09922-10010
without SST - Torque : 21 Nm (210 kgf-cm, 15 ft-lbf)
with SST - Torque : 15 Nm (148 kgf-cm, 11 ft-lbf)
HINT *
Use a torque wrench with a fulcrum length of 30 cm (11.8 in.). When using a torque wrench with a
fulcrum length that is not 30 cm (11.8 in.), calculate the torque specification for the torque wrench
and SST based on the "without SST" torque specification See: Service Precautions
* Make sure SST and the torque wrench are connected in a straight line.
(d) Connect the oil pressure switch connector.
2. INSTALL FAN AND GENERATOR V BELT
(a) Install the fan and generator V belt See: Engine, Cooling and Exhaust/Engine/Drive Belts,
Mounts, Brackets and Accessories/Drive
Belt/Service and Repair/Installation.
3. ADD POWER STEERING FLUID
4. BLEED POWER STEERING FLUID See: Steering and Suspension/Steering/Testing and
Inspection/Component Tests and General
Diagnostics/Power Steering System/On-Vehicle Inspection
5. INSPECT FOR POWER STEERING FLUID LEAK
6. CHECK FLUID LEVEL See: Steering and Suspension/Steering/Testing and
Inspection/Component Tests and General Diagnostics/Power
Steering System/On-Vehicle Inspection
7. INSTALL FRONT FENDER APRON SEAL RH See: Engine, Cooling and Exhaust/Exhaust
System/Exhaust Manifold/Service and
Repair/Installation
8. INSTALL FRONT WHEEL See: Steering and Suspension/Suspension/Suspension Strut / Shock
Absorber/Service and Repair/Removal and
Replacement/Front Shock Absorber/Installation
Page 1328
3. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE
HINT The diagnostic system in the TOYOTA TUNDRA has various functions.
* The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU
memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a
previous malfunction's DTC can be checked by a technician during troubleshooting.
* Another function is the Input Signal Check, which checks if the signals from various switches are
sent to the ECU correctly.
* By using these functions, the problem areas can be narrowed down and troubleshooting is more
effective. Diagnostic functions are incorporated in the following systems in the TOYOTA TUNDRA.
Diagrams
Keyless Entry Receiver: Diagrams
Page 6035
Page 6482
NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do
not operate the ignition switch, any other switches, or the doors.
(a) If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the
harness and connector.
(b) Connect the cable of the Techstream to the DLC3, turn the ignition switch ON and attempt to
use the tester. If the display indicates that a
communication error has occurred, there is a problem either with the vehicle or with the tester.
HINT *
If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of
the original vehicle.
* If communication is still not possible when the tester is connected to another vehicle, the problem
may be in the tester itself. Consult the Service Department listed in the tester's instruction manual.
How To Proceed With Troubleshooting
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: HOW TO
PROCEED WITH TROUBLESHOOTING
1. OPERATION FLOW
HINT Perform troubleshooting in accordance with the procedures below. The following is an outline
of basic troubleshooting procedures. Confirm the troubleshooting procedures for the circuit you are
working on before beginning troubleshooting.
1. VEHICLE BROUGHT TO WORKSHOP
NEXT -- Continue to next step.
2. CUSTOMER PROBLEM ANALYSIS
(a) Ask the customer about the conditions and environment when the problem occurred.
NEXT -- Continue to next step.
3. INSPECT BATTERY VOLTAGE
Standard voltage:
11 to 14 V
If the voltage is below 11 V, recharge or replace the battery before proceeding.
NEXT -- Continue to next step.
Page 4394
8110 - 10-Pc. Line Disconnect Set
Page 4948
(c) Replace the ATF in the torque converter clutch.
(1) If the ATF is discolored and/or has a foul odor, stir the ATF in the torque converter clutch
thoroughly and drain the ATF with the torque
converter facing upward.
(d) Prevent deformation of the torque converter clutch and damage to the oil pump gear.
(1) When any marks due to interference are found on the end of a bolt for the torque converter
clutch and on the bottom of the bolt hole,
replace the bolt and torque converter clutch.
(2) Make sure all of the bolts are the same length.
(3) Make sure no spring washers are missing.
2. INSPECT DRIVE PLATE
(a) Check the drive plate for damage.
(b) Set up a dial indicator and measure the runout of the 6 portions around the torque converter
clutch contact surfaces.
Maximum runout:
0.30 mm (0.0118 in.)
(c) If the runout is more than the maximum, or the drive plate is damaged, replace the drive plate
See: Engine, Cooling and
Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Installation.
Page 1763
Spark Plug: Service and Repair Installation
1UR-FE IGNITION: IGNITION COIL AND SPARK PLUG: INSTALLATION
1. INSTALL SPARK PLUG
(a) Using a 16 mm plug wrench, install the 8 spark plugs.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
2. INSTALL IGNITION COIL ASSEMBLY
(a) for Bank 1:
(1) Install the 4 ignition coils with the 4 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(2) Connect the 4 ignition coil connectors.
(3) Connect the 3 wire harness clamps.
(b) for Bank 2:
(1) Install the 4 ignition coils with the 4 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(2) Connect the 4 ignition coil connectors and 2 wire harness clamps.
(3) Connect the water by-pass pipe with the 2 bolts.
Torque : 18 Nm (184 kgf-cm, 13 ft-lbf)
Page 4125
Page 2499
Oil Pressure Sender: Testing and Inspection
1UR-FE LUBRICATION: OIL PRESSURE SWITCH: ON-VEHICLE INSPECTION
1. INSPECT OIL PRESSURE SENDER GAUGE ASSEMBLY
(a) Disconnect the sender gauge connector.
(b) Apply battery positive (+) voltage to the sender gauge terminal through a test LED.
(c) Check that the LED does not illuminate when the engine is stopped.
(d) Check that the LED flashes when the engine is running. The number of flashes varies with
engine speed.
If the operation is not as specified, replace the oil pressure sender gauge assembly.
Recall 10V091000: Front Driveshaft Replacement
Drive/Propeller Shaft: All Technical Service Bulletins Recall 10V091000: Front Driveshaft
Replacement
VEHICLE MAKE/MODEL: MODEL YEAR(S): Toyota/Tundra 2010 MANUFACTURER: Toyota
Motor North America, Inc.
MFR'S REPORT DATE: March 09, 2010
NHTSA CAMPAIGN ID NUMBER: 10V091000
NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Axle Assembly: Axle Shaft
POTENTIAL NUMBER OF UNITS AFFECTED: 2
SUMMARY: Toyota is recalling certain model year 2010 Tundra vehicles with four wheel drive,
there is a possibility that an improper weld exists at the union of the propeller shaft and yoke. Due
to this improper weld, this joint may separate and the separated shaft may come into contact with
the road surface.
CONSEQUENCE: This may result in a loss of vehicle control increasing the risk of a crash.
REMEDY: Dealers will replace the front propeller shaft free of charge. The safety recall is expected
to begin during March 2010. Owners may contact Toyota at 1-800-331-4331.
NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle
Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov.
Page 7969
Tire size:
Must exceed the following dimensions
Width 185 mm (7.28 in.)
Inner diameter 360 mm (1.18 ft.)
CAUTION: *
Make sure that the wire harnesses are tight. If there is slack in the wire harnesses, the front seat
side airbag may become loose due to the shock when the airbag is deployed.
* Always tie down the front seat side airbag with the airbag deployment direction facing inside the
tire.
NOTICE: As the tires may be damaged by the airbag deployment, use a tire that you are planning
to throw away.
(d) Install SST.
(1) Connect SST connector to the front seat airbag connector.
SST : 09082-00820
(e) Place the tires.
(1) Place at least 2 tires under the tire which the front seat side airbag is tied to.
(2) Place at least 2 tires over the tire which the front seat side airbag is tied to. The top tire should
have the disc wheel installed.
NOTICE: *
Do not place SST connector under the tire because it could be damaged.
* As the disc wheel may be damaged by the airbag deployment, use a disc wheel that you are
planning to throw away.
* As the tires may be damaged by the airbag deployment, use a tire that you are planning to throw
away.
(3) Tie the tires together with 2 wire harnesses.
Page 9029
* In the DTC check, it is very important to determine whether the problem indicated by the DTC is
either: 1) still occurring; or 2) occurred in the past but has since returned to normal. In addition, the
DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs
should be checked before and after confirmation of symptoms (i.e., whether or not problem
symptoms exist) to determine current system conditions, as shown in the flowchart below.
* Never skip the DTC check. Failing to check DTCs may, depending on the case, result in
unnecessary troubleshooting for systems operating normally or lead to repairs not related to the
problem. Follow the procedures listed in the flowchart in the correct order.
* The following flowchart shows how to proceed with troubleshooting using the DTC check.
Directions from the flowchart will indicate how to proceed either to DTC troubleshooting or to the
troubleshooting of each problem symptom.
1. DTC CHECK
NEXT -- Continue to next step.
2. MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR MEMORY
NEXT -- Continue to next step.
3. SYMPTOM CONFIRMATION
B -- Go to step 5 A -- Continue to next step.
4. SIMULATION TEST USING SYMPTOM SIMULATION METHODS
NEXT -- Continue to next step.
5. DTC CHECK
B -- TROUBLESHOOTING OF PROBLEM INDICATED BY DTC A -- Continue to next step.
6. SYMPTOM CONFIRMATION
Locations
Trailer Towing Relay: Locations
Engine Room R/B, J/B - Engine Compartment Left
Page 6682
Engine Room R/B, J/B - Engine Compartment Left
Components
Tire Pressure Sensor: Service and Repair Components
TIRE AND WHEEL: TIRE PRESSURE WARNING VALVE AND TRANSMITTER: COMPONENTS
Page 6948
Driver Side J/B Inner Circuit
Page 95
Sunroof / Moonroof Module: Diagrams
Specifications
Compression Check: Specifications
COMPRESSION
Page 8107
9. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH (for Rear Side)
10. INSTALL REAR DOOR SCUFF PLATE LH (for Rear Side) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and Repair/Roof
Headlining (For Double Cab)/Installation
11. INSTALL REAR SEAT ASSEMBLY (for Rear Side)
(a) Install the rear seat assembly See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Rear Seat Assembly (for Double
Cab)/Installation.
12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
13. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
Components
SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Regular Cab):
COMPONENTS
Page 23
(a) Disconnect the connectors.
(b) Remove the 2 nuts and junction block.
(c) Remove the nut and ECU.
Components
Actuator: Service and Repair Components
DIFFERENTIAL: AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR (for 4WD):
COMPONENTS
Components
Tire Pressure Monitor Receiver / Transponder: Service and Repair Components
TIRE AND WHEEL: TIRE PRESSURE WARNING RECEIVER: COMPONENTS
Page 6544
If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness
or connector in that circuit in the past. Check the wire harness and connectors.
B -- SYSTEM NORMAL
A -- TROUBLESHOOTING OF EACH PROBLEM SYMPTOM
The problem is still occurring in a place other than the diagnostic circuit (the DTC displayed first is
either for a past problem or a secondary problem).
4. SYMPTOM SIMULATION
HINT The most difficult case in troubleshooting is when no problem symptoms occur. In such a
case, a thorough problem analysis must be carried out. A simulation of the same or similar
conditions and environment in which the problem occurred in the customer's vehicle should be
carried out. No matter how much skill or experience a technician has, troubleshooting without
confirming the problem symptoms will lead to important repairs being overlooked and mistakes or
delays.
For example:
With a problem that only occurs when the engine is cold or as a result of vibration caused by the
road during driving, the problem can never be determined if the symptoms are being checked on a
stationary vehicle or on a vehicle with a warmed-up engine. Vibration, heat or water penetration
(moisture) is difficult to reproduce. The symptom simulation tests below are effective substitutes for
the conditions and can be applied on a stationary vehicle.
Important points in the symptom simulation test:
In the symptom simulation test, the problem symptoms as well as the problem area or parts must
be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then,
connect the tester and carry out the symptom simulation test, judging whether the circuit being
tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the
problem symptoms table for each system to narrow down the possible causes.
To reproduce DTCs, it is necessary to satisfy the respective DTC detection conditions.
(a) VIBRATION METHOD:
When a malfunction seems to occur as a result of vibration.
(1) PART AND SENSOR
Apply slight vibration with a finger to the part of the sensor suspected to be the cause of the
problem, and check whether or not the malfunction occurs.
NOTICE: Applying strong vibration to relays may open them.
Page 6057
General Information
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: GENERAL
INFORMATION
* A large number of ECU controlled systems are used in the TOYOTA TUNDRA. In general, ECU
controlled systems are considered to be very intricate, requiring a high level of technical knowledge
to troubleshoot. However, most problem checking procedures only involve inspecting the ECU
controlled system's circuits one by one. An adequate understanding of the system and a basic
knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and
necessary repairs.
1. TROUBLESHOOTING PROCEDURES
* The troubleshooting procedures consist of diagnosis procedures for when a DTC is stored and
diagnosis procedures for when no DTC is stored. The basic idea is explained in the following table.
* Vehicle systems are complex and use many ECUs that are difficult to inspect independently.
Therefore, a process of elimination is used, where components that can be inspected individually
are inspected, and if no problems are found in these components, the related ECU is identified as
the problem and replaced.
* It is extremely important to ask the customer about the environment and the conditions present
when the problem occurred (Customer Problem Analysis). This makes it possible to simulate the
conditions and confirm the symptom. If the symptom cannot be confirmed or the DTC does not
recur, the malfunctioning part may not be identified using the troubleshooting procedure, and the
ECU for the related system may be replaced even though it is not defective. If this happens, the
original problem will not be solved.
* In order to prevent endless expansion of troubleshooting procedures, the troubleshooting
procedures are written with the assumption that multiple malfunctions do not occur simultaneously
for a single problem symptom.
* To identify the malfunctioning part, troubleshooting procedures narrow down the target by
separating components, ECUs and wire harnesses during the inspection. If the wire harness is
identified as the cause of the problem, it is necessary to inspect not only the connections to
components and ECUs but also all of the wire harness connectors between the component and the
ECU.
DIAGNOSTIC TESTER
2. DESCRIPTION
System data and the Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector
3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the Techstream* to
check for a malfunction and perform repairs.
HINT *: Techstream is the name for the diagnostic tester in North America.
3. DATA LINK CONNECTOR 3 (DLC3)
(a) The vehicle's ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of
the DLC3 complies with SAE J1962 and
matches the ISO 15765-4 format.
Engine - Snow Ingestion Into Air Cleaner Box
Air Cleaner Housing: All Technical Service Bulletins Engine - Snow Ingestion Into Air Cleaner Box
T-SB-0396-09
December 8, 2009
Snow Entry Into Air Cleaner Box
Service Category Engine/Hybrid System
Section Intake/Exhaust
Market USA
Applicability
Introduction
Some Sequoia and Tundra vehicles operated in areas with significant snow volume may
experience snow accumulation in the air cleaner box which can cause the lid to fracture. The air
cleaner lid and fender liner have been revised to reduce accumulation.
Parts Information
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for
36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Production Change Information
Page 7128
Power Steering Pressure Switch: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: POWER STEERING OIL PRESSURE SWITCH:
REMOVAL
1. REMOVE FAN AND GENERATOR V BELT
(a) Remove the fan and generator V belt See: Engine, Cooling and Exhaust/Engine/Drive Belts,
Mounts, Brackets and Accessories/Drive
Belt/Service and Repair/Removal.
2. REMOVE FRONT WHEEL
3. REMOVE FRONT FENDER APRON SEAL RH See: Engine, Cooling and Exhaust/Exhaust
System/Exhaust Manifold/Service and
Repair/Removal
4. DRAIN POWER STEERING FLUID
5. REMOVE POWER STEERING OIL PRESSURE SWITCH
(a) Disconnect the power steering oil pressure switch connector.
(b) Remove the power steering oil pressure switch.
(c) Remove the O-ring.
Page 3412
HINT *
o: DTC is memorized.
* *1: Only during failure status.
Fail-Safe Chart
CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: FAIL-SAFE CHART
1. FAIL-SAFE FUNCTION
(a) When communication fails in any of the main wires (communication lines) due to a short circuit
or other causes, the fail-safe function, which is
specified for each system, operates to prevent the system from malfunctioning.
(b) The table below shows the effects on each system when communication is impossible. For
further details, refer to each system.
Page 8140
Seat Occupant Sensor: Locations Occupant Classification System
SUPPLEMENTAL RESTRAINT SYSTEM: OCCUPANT CLASSIFICATION SYSTEM: PARTS
LOCATION
Page 8172
Removal
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift
Type): REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal
3. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding
/ Trim/Dashboard / Instrument
Engine Immobiliser System
Alarm Module: Locations Engine Immobiliser System
ENGINE IMMOBILISER: ENGINE IMMOBILISER SYSTEM: PARTS LOCATION
Page 415
(2) If the result is not as specified, replace the integration relay.
3. INSTALL INTEGRATION RELAY See: Relays and Modules - Ignition System/Ignition
Relay/Testing and Inspection
Page 4621
Knock Sensor: Testing and Inspection
1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: INSPECTION
1. INSPECT KNOCK SENSOR
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) If the result is not as specified, replace the knock sensor.
Page 2091
J/B No.4 - Instrument Panel Center
Page 8668
"Case1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (/\ Mark) and pull the terminal retainer
up to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Locations
Engine Temperature Sensor: Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 2806
M. Turn ignition OFF for a minimum of 10 seconds. Then click Next.
N. Turn ignition to the ON position. Then click Next.
0. Confirm all calibrations were updated as specified in the service bulletin. Then click Finish.
Page 8291
Page 6462
Relay Box: Diagnostic Aids
Continuity and Resistance Check
CONTINUITY AND RESISTANCE CHECK
Disconnect the battery terminal or wire so there is no voltage between the check points.
Contact the two leads of an ohmmeter to each of the check points.
Capacity Specifications
Fluid - A/T: Capacity Specifications
Automatic Transmission Fluid Capacities:
With tow package:
2WD .....................................................................................................................................................
.......................................................... 12.3 qt (11.6L) 4WD .................................................................
.............................................................................................................................................. 11.9 qt
(11.3L)
Without tow package:
2WD .....................................................................................................................................................
.......................................................... 11.7 qt (11.7L) 4WD .................................................................
.............................................................................................................................................. 11.4 qt
(10.8L)
Page 3408
HINT *
o: DTC is memorized.
* *1: Only during failure status.
Diagrams
Steering Angle Sensor: Diagrams
Page 6454
Instrument Panel (Floor Shift)
Instrument Panel (Column Shift)
Page 3724
(e) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- REPAIR OR REPLACE ENGINE ROOM RELAY BLOCK
Page 1164
Crankshaft Position Sensor: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: CRANKSHAFT POSITION SENSOR: INSTALLATION
1. INSTALL CRANKSHAFT POSITION SENSOR
(a) Install the sensor with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(b) Connect the sensor connector.
2. INSTALL CRANKSHAFT POSITION SENSOR PROTECTOR
(a) Install the sensor protector with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
Page 2348
(a) Apply a light coat of engine oil to the O-ring.
(b) Install a new O-ring to the oil control valve.
(c) Install the oil control valve with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(d) Connect the oil control valve connector.
5. INSTALL AIR CLEANER HOSE ASSEMBLY See: Service and Repair/Removal and
Replacement/Engine Assembly/Installation
6. INSTALL V-BANK COVER SUB-ASSEMBLY See: Service and Repair/Removal and
Replacement/Engine Assembly/Installation
Locations
Collision Avoidance System Switch: Locations
PARK ASSIST / MONITORING: INTUITIVE PARKING ASSIST SYSTEM: PARTS LOCATION
Page 4265
Parts Information
Required Tools & Equipment
Repair Procedure
1. Confirm the condition matches the Introduction.
Page 3741
Engine Control Module: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: ECM: REMOVAL
1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Removal
2. REMOVE AIR CLEANER ASSEMBLY See: Ignition System/Ignition Coil/Service and
Repair/Removal
3. DISCONNECT CONNECTOR HOLDER BLOCK
(a) Remove the connector holder block cover.
(b) Remove the 3 bolts and move the connector holder block so that the ECM can be removed in
the next step.
4. REMOVE ECM
(a) Disconnect the wire harness clamp.
(b) Raise the 2 levers while pushing the locks on the 2 levers shown in the illustration.
NOTICE: Make sure that the lock lever is raised 90° as shown in the illustration before
disconnecting the connectors. Failure to do this may cause the connectors to break.
(c) Disconnect the 2 connectors.
(d) Remove the 4 bolts and ECM.
5. REMOVE GASKET
(a) Peel off the rubber part of the gasket.
Page 4737
^ Calibration ID(s) [Refer to the Calibration Identification Chart for the NEW CALIBRATION ID]
^ Dealer Code
^ Repair Date
^ Change Authority [This TSB number]
B. Affix the Authorized Modifications Label to the vehicle at the location shown in Figure 1. The
Authorized Modifications Label is available
through the MDC P/N 00451-00001-LBL.
Page 7988
(b) Disconnect the 2 clamps.
(c) Remove the 2 nuts and the front seat side airbag assembly.
CAUTION: *
The nuts must not be reused.
* Make sure that the seat frame assembly is not deformed. If it is, replace it with a new one.
Installation
SUPPLEMENTAL RESTRAINT SYSTEM: FRONT SEAT SIDE AIRBAG ASSEMBLY (except Fold
Down Seat Type): INSTALLATION
CAUTION: Wear protective gloves. Sharp areas on the seat frame and adjuster may injure your
hands.
HINT Use the same procedures for the LH side and RH side.
1. INSTALL FRONT SEAT SIDE AIRBAG ASSEMBLY
CAUTION: *
The nuts must not be reused.
* Make sure that the seat frame assembly is not deformed. If it is, replace it with a new one.
(a) Install the front seat side airbag assembly with 2 new nuts.
Torque : 5.5 Nm (56 kgf-cm, 49 in-lbf)
(b) Connect the 2 clamps.
(c) Connect the 3 wire harness clamps to under the seat.
Page 8098
Removal
SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for CrewMax): REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Disassembly
3. REMOVE FRONT UPPER ARMREST BASE PANEL LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Page 1635
Standard Resistance:
(2) If the result is not as specified, replace the power window regulator switch assembly.
(b) Check that the LED illuminates.
(1) Apply battery voltage to the power window regulator switch and check that the LED illuminates.
OK:
(2) If the result is not as specified, replace the power window regulator switch assembly.
Page 1485
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: ELECTRONIC
CIRCUIT INSPECTION PROCEDURE
1. BASIC INSPECTION
(a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS
(1) Unless otherwise stated, all resistance measurements should be made at an ambient
temperature of 20°C (68°F). Resistance measurements
may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been
running. Measurements should be made after the engine has cooled down.
(b) HANDLING CONNECTORS
(1) When disconnecting a connector, first squeeze the mating halves tightly together to release the
lock, and then press the lock claw and
separate the connector.
(2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly
and separate it.
(3) Before connecting a connector, check that there are no deformed, damaged, loose or missing
terminals.
(4) When connecting a connector, press firmly until it locks with a "click" sound.
(5) If checking a connector with a TOYOTA electrical tester, check the connector from the backside
(harness side) using a mini test lead.
NOTICE: *
As a waterproof connector cannot be checked from the backside, check it by connecting a
sub-harness.
* Do not damage the terminals by moving the inserted tester needle.
(c) CHECKING CONNECTORS
(1) Checking when a connector is connected: Squeeze the connectors together to confirm that they
are fully connected and locked.
(2) Checking when a connector is disconnected: Check by pulling the wire harness lightly from the
backside of the connector. Look for
unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for
corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or
deformed terminals.
(3) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a
female terminal, and check for ample tension
Drivetrian - Rear End Howling/Growling Noises
Wheel Bearing: All Technical Service Bulletins Drivetrian - Rear End Howling/Growling Noises
T-SB-0151-10
June11, 2010
Rear Axle Bearing Abnormal Noise
Service Category Drivetrain
Section Axle/Differential
Market USA
Applicability
Introduction
Some 2007 - 2010 model year Tundra vehicles may exhibit a howling or growling noise from the
rear of the vehicle that increases with vehicle speed. Changes have been made to the rear axle
bearing to correct this condition. Follow the procedure in the bulletin to address customer concerns.
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60
months or 60,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Parts Information
Page 6909
Remove the blown fuse and disconnect all loads of the fuse.
Connect a test light in place of the fuse.
Establish conditions in which the test light comes on.
Example:
- [A] - Ignition SW on
- [B] - Ignition SW and SW1 on
- [C] - Ignition SW, SW1 and Relay on (Connect the Relay) and SW2 off (or Disconnect SW2)
Disconnect and reconnect the connectors while watching the test light.
Page 6964
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Page 6908
Use a volt/ohmmeter with high impedance (10 kohms/V minimum) for troubleshooting of the
electrical circuit.
Disconnection of Male and Female Connectors
DISCONNECTION OF MALE AND FEMALE CONNECTORS
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Finding A Short Circuit
FINDING A SHORT CIRCUIT
Page 8273
(a) Connect the seat belt with the bolt.
Torque : 42 Nm (428 kgf-cm, 31 ft-lbf)
NOTICE: Do not overlap the anchor part of the seat belt and protruding parts of the vehicle body.
7. INSTALL REAR NO. 1 SEAT INNER BELT ASSEMBLY RH
(a) Install the belt with the bolt.
Torque : 42 Nm (428 kgf-cm, 31 ft-lbf)
8. INSTALL REAR SEAT ASSEMBLY RH See: Body and Frame/Seats/Service and
Repair/Removal and Replacement/Rear Seat Assembly (for
Crewmax RH Side)/Installation
Components
SEAT BELT: REAR SEAT INNER BELT ASSEMBLY (for Double Cab): COMPONENTS
Locations
Engine Temperature Sensor: Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 3677
Parts Information
Required Tools & Equipment
Repair Procedure
1. Confirm the condition matches the Introduction.
Page 6758
Multiple Junction Connector: Locations Wire and Wire In Instrument Panel [Column Shift]
AJ1-QK1
Page 5840
Acceleration/Deceleration Sensor: Locations From 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 8841
Page 428
Fuel Pump Control Unit: Service and Repair Installation
1UR-FE FUEL: FUEL PUMP ECU: INSTALLATION
1. INSTALL FUEL PUMP ECU
(a) Install the fuel pump ECU with the 2 bolts.
Torque : 20 Nm (199 kgf-cm, 14 ft-lbf)
NOTICE: Do not use the fuel pump ECU if it has been subjected to physical shocks such as being
dropped, etc.
(b) Connect the 2 fuel pump ECU connectors.
Page 639
Ultrasonic Sensor: Service and Repair Glass Breakage Sensor (for Column Shift Type)
Components
THEFT DETERRENT: GLASS BREAKAGE SENSOR (for Column Shift Type): COMPONENTS
Removal
THEFT DETERRENT: GLASS BREAKAGE SENSOR (for Column Shift Type): REMOVAL
1. REMOVE FRONT DOOR SCUFF PLATE LH
Page 3484
Standard resistance:
NG -- REPAIR OR REPLACE CAN BRANCH WIRE OR CONNECTOR (STEERING ANGLE
SENSOR)
OK -- REPLACE STEERING ANGLE SENSOR
8. CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (BUS BUFFER ECU)
NOTICE: For vehicles without a bus buffer ECU, go to "CHECK FOR OPEN IN ONE SIDE OF CAN
BRANCH WIRE (CENTER AIRBAG SENSOR)".
(a) Disconnect the J59 bus buffer ECU connector.
(b) Reconnect the cable to the negative (-) battery terminal.
(c) Select "CAN Bus Check" on the Techstream.
Result
B -- CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (CENTER AIRBAG SENSOR) A
-- Continue to next step.
9. CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (BUS BUFFER ECU BRANCH
WIRE)
(a) Measure the resistance according to the value(s) in the table below.
Page 1965
2. Loosen the bleeder plug.
3. Using the Techstream, operate the brake actuator, completely depress the brake pedal and hold
it there.
HINT The operation stops automatically after 4 seconds. When performing this procedure
continuously, set an interval of at least 20 seconds.
NOTICE: *
During this procedure, the pedal will feel heavy, but completely depress it so that the brake fluid
comes out of the bleeder plug.
* Depress and hold the brake pedal. Do not depress and release the pedal repeatedly.
(10)4. Tighten the bleeder plug, and then release the brake pedal.
5. Repeat the 3 previous steps until all air in the fluid is completely bled out.
6. Tighten the bleeder plug.
Torque : 11 Nm (110 kgf-cm, 8 ft-lbf)
(11)7. Repeat all of the above procedures for the other wheels to bleed the air out of the pressure
reduction line.
(12)Clear the DTCs See: Brakes and Traction Control/Antilock Brakes / Traction Control
Systems/Testing and Inspection/Reading and
Clearing Diagnostic Trouble Codes.
(13)Inspect for brake fluid leak.
(14)Check and adjust brake fluid level in reservoir See: Fluids/Brake Fluid/Testing and Inspection.
(15)If any DTC is set, perform the troubleshooting for the DTC
(16)Check the DTC See: Brakes and Traction Control/Antilock Brakes / Traction Control
Systems/Testing and Inspection/Reading and
Clearing Diagnostic Trouble Codes.
Page 8092
(e) Connect the holder (with connectors).
(f) Check that the waterproof sheet is properly set.
2. INSTALL FRONT CONSOLE BOX See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal
and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation
3. INSTALL REAR CONSOLE BOX ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation
4. INSTALL CONSOLE BOX CARPET
5. INSTALL REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
6. INSTALL UPPER CONSOLE REAR PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
7. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding
/ Trim/Dashboard / Instrument Panel/Service
and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
8. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation
9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
10. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
Components
SUPPLEMENTAL RESTRAINT SYSTEM: FRONT AIRBAG SENSOR: COMPONENTS
Components
Tire Pressure Sensor: Service and Repair Components
TIRE AND WHEEL: TIRE PRESSURE WARNING VALVE AND TRANSMITTER: COMPONENTS
Page 1199
A/F and 02 Sensor Identification
Locations
Entertainment System Control Module: Locations
Instrument Panel (Floor Shift)
Instrument Panel (Column Shift)
Page 609
Replacement/Rear Bumper (for Resin Type Bumper)/Installation
7. INSTALL REAR BUMPER PLATE RH (for Steel Type Bumper) See: Body and
Frame/Bumper/Rear Bumper/Service and Repair/Removal and
Replacement/Rear Bumper (for Steel Type Bumper)/Installation
8. INSTALL REAR BUMPER PLATE LH (for Steel Type Bumper) See: Body and
Frame/Bumper/Rear Bumper/Service and Repair/Removal and
Replacement/Rear Bumper (for Steel Type Bumper)/Installation
9. INSTALL REAR BUMPER PAD SUB-ASSEMBLY (for Steel Type Bumper) See: Body and
Frame/Bumper/Rear Bumper/Service and
Repair/Removal and Replacement/Rear Bumper (for Steel Type Bumper)/Installation
10. INSTALL LICENSE PLATE LIGHT ASSEMBLY RH (for Steel Type Bumper) See: Body and
Frame/Bumper/Rear Bumper/Service and
Repair/Removal and Replacement/Rear Bumper (for Resin Type Bumper)/Installation
11. INSTALL LICENSE PLATE LIGHT ASSEMBLY RH (for Resin Type Bumper) See: Body and
Frame/Bumper/Rear Bumper/Service and
Repair/Removal and Replacement/Rear Bumper (for Resin Type Bumper)/Installation
12. INSTALL LICENSE PLATE LIGHT ASSEMBLY LH (for Steel Type Bumper) See: Body and
Frame/Bumper/Rear Bumper/Service and
Repair/Removal and Replacement/Rear Bumper (for Steel Type Bumper)/Installation
13. INSTALL LICENSE PLATE LIGHT ASSEMBLY LH (for Resin Type Bumper) See: Body and
Frame/Bumper/Rear Bumper/Service and
Repair/Removal and Replacement/Rear Bumper (for Resin Type Bumper)/Installation
14. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Page 5448
Four Wheel Drive Selector Switch: Service and Repair Installation
JF1A TRANSFER: 4WD CONTROL SWITCH: INSTALLATION
1. INSTALL 4WD CONTROL SWITCH
(a) Attach the 3 claws to install the switch.
2. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Panel,
Gauges and Warning Indicators/Instrument Cluster
/ Carrier/Service and Repair/Combination Meter/Installation
Removal and Replacement
Control Arm: Removal and Replacement
Components
SUSPENSION: FRONT UPPER SUSPENSION ARM: COMPONENTS
Removal
SUSPENSION: FRONT UPPER SUSPENSION ARM: REMOVAL
HINT *
Use the same procedures for the RH side and LH side.
* The procedures listed below are for the LH side.
Page 8580
3. INSTALL NO. 2 ULTRASONIC SENSOR RETAINER
(a) Align the keyhole and protrusion as shown in the illustration.
(b) Install the sensor retainer to the rear bumper.
NOTICE: Do not damage the bumper with the protrusion when installing the retainer.
4. INSTALL NO. 2 ULTRASONIC SENSOR
(a) Attach the 2 claws to install the ultrasonic sensor.
5. INSTALL REAR BUMPER BAR (for Steel Type Bumper) See: Body and Frame/Bumper/Front
Bumper/Service and Repair/Removal and
Replacement/Front Bumper (for Steel Type Bumper)/Installation
6. INSTALL REAR BUMPER COVER (for Resin Type Bumper) See: Body and
Frame/Bumper/Rear Bumper/Service and Repair/Removal and
Page 3070
Remove the blown fuse and disconnect all loads of the fuse.
Connect a test light in place of the fuse.
Establish conditions in which the test light comes on.
Example:
- [A] - Ignition SW on
- [B] - Ignition SW and SW1 on
- [C] - Ignition SW, SW1 and Relay on (Connect the Relay) and SW2 off (or Disconnect SW2)
Disconnect and reconnect the connectors while watching the test light.
Page 3720
(a) Remove the AM2 fuse, IG2 MAIN fuse, EFI NO. 1 fuse and IGN fuse from the engine room
relay block.
(b) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
NG -- CHECK FOR SHORT IN ALL HARNESSES AND CONNECTORS CONNECTED TO FUSE
AND REPLACE FUSE OK -- Continue to next step.
2. INSPECT RELAY (IG2, EFI)
(a) Remove the integration relay from the engine room relay block.
(b) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
Page 67
2. REMOVE REAR DOOR SCUFF PLATE RH
(a) Detach the 8 claws and 2 clips, and remove the scuff plate.
3. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP RH
4. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY RH See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (for CrewMax)/Removal
5. REMOVE DOOR CONTROL RECEIVER
(a) Disconnect the door control receiver connector.
(b) Remove the bolt and receiver.
Installation
DOOR LOCK: DOOR CONTROL RECEIVER (for CrewMax): INSTALLATION
1. INSTALL DOOR CONTROL RECEIVER
(a) Install the receiver with the bolt.
(b) Connect the door control receiver connector.
2. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY RH See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (for CrewMax)/Installation
3. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP RH
4. INSTALL REAR DOOR SCUFF PLATE RH
Locations
Gear Sensor/Switch: Locations
JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION
Page 641
(a) Detach the 4 clips.
(b) Disconnect the connector and remove the panel.
11. REMOVE GLASS BREAKAGE SENSOR MICROPHONE
(a) Detach the 2 claws and remove the sensor.
Installation
THEFT DETERRENT: GLASS BREAKAGE SENSOR (for Column Shift Type): INSTALLATION
1. INSTALL GLASS BREAKAGE SENSOR MICROPHONE
(a) Attach the 2 claws to install the sensor.
2. INSTALL INTEGRATION CONTROL AND PANEL ASSEMBLY
Page 4837
Fluid - A/T: Service and Repair
A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION FLUID: ADJUSTMENT
NOTICE: *
This transmission requires Toyota Genuine ATF WS.
* After servicing the transmission, you must follow the ATF adjustment procedure.
* Maintain the vehicle in a horizontal position while adjusting the fluid level.
1. PRELIMINARY PROCEDURES
(a) w/ Trailer Towing System (with transmission oil thermostat):
(1) Using compressed air, etc., blow dust off the thermostat cap to clean it.
(2) Using a screwdriver, push in the shaft of the thermostat.
HINT *
Distance pushed: 5.5 to 7.0 mm (0.217 to 0.276 in.)
* Push the shaft until the screwdriver contacts the step inside the cap.
(3) With the shaft of the thermostat pressed, push a pin into a hole in the side of the thermostat
cap. Insert the pin until it passes through the
hole in the other side of the thermostat cap to fix the shaft in place.
HINT Pin diameter: 1.0 to 1.8 mm (0.0394 to 0.0709 in.)
2. BEFORE FILLING TRANSMISSION
* When you have replaced the entire transmission, transmission pan, drain plug, valve body and/or
torque converter, proceed to the "Transmission Fill" procedures.
Components
Four Wheel Drive Selector Switch: Service and Repair Components
JF1A TRANSFER: 4WD CONTROL SWITCH: COMPONENTS
Page 1132
Accelerator Pedal Position Sensor: Diagrams
Page 1366
5. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System
Page 3946
Required Tools & Equipment
Repair Procedure
1. Using TIS Techstream check if DTC P0418, P0419, P2440, P2441, P2442, P2443, P2446
and/or P2447 are present.
2. Using Techstream perform the manual Air Injection Test (options 1 and 2) to verify if the signal
from the air injection control driver is reaching the
air pumps.
^ The pumps should be heard turning on at this point and there should be battery voltage on pin 2
of the pumps during this test.
^ If there is NO voltage refer to the Repair Manual for air injection control driver diagnosis.
Refer to the Technical Information System (TIS) 2010 model year Tundra Repair Manual:
3. If during the test voltage is present at the pump and the pump is NOT running or the Air
Pressure (gauge) value did NOT increase from 0 to 1 psi on
TIS Techstream with the pump running remove the air pump assemblies for inspection.
Refer to TIS 2010 model year Tundra Repair Manual:
4. With the pumps removed from the vehicle verify if there is liquid or evidence that liquid entered
the pumps.
^ YES - If there is liquid evidence go to step 5.
^ NO - If there is NO evidence of liquid go to step 7.
5. If liquid is present replace the affected pump assembly.
Refer to TIS 2010 model year Tundra Repair Manual:
Page 3500
OK -- REPLACE BUS BUFFER ECU
25. CHECK FOR SHORT IN CAN BUS WIRES (4WD CONTROL ECU)
(a) Disconnect the A25 4WD control ECU connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO 4WD CONTROL ECU
(CANH, CANL)
OK -- REPLACE 4WD CONTROL ECU
26. CHECK FOR SHORT IN CAN BUS WIRES (ECM)
(a) Disconnect the A24 ECM connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
Result
E -- REPAIR OR REPLACE CAN MAIN WIRE CONNECTED TO ECM (CANH, CANL)
D -- REPLACE ECM See: Engine Control Module/Service and Repair/Removal
C -- REPLACE ECM See: Engine Control Module/Service and Repair/Removal
Page 8033
5. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System
Page 9021
(a) For an open circuit in the wire harness in Fig. 1, check the resistance or voltage, as described
below.
(b) Check the resistance.
(1) Disconnect connectors A and C and measure the resistance between them.
Standard resistance (Fig. 2):
HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally.
If the results match the examples above, an open circuit exists between terminal 1 of connector A
and terminal 1 of connector C.
(2) Disconnect connector B and measure the resistance between the connectors.
Standard resistance (Fig. 3):
* If the results match the examples above, an open circuit exists between terminal 1 of connector
B2 and terminal 1 of connector C.
(c) Check the voltage.
Page 1902
Coolant: Fluid Type Specifications
Coolant Type
Use either of the following:
"Toyota Super Long Life Coolant"
Similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, and non-borate
coolant with long-life hybrid organic acid technology.
Do not use plain water alone.
Page 9210
ERROR: undefined
OFFENDING COMMAND: f‘~
STACK:
Testing and Inspection
Interior Light Switch: Testing and Inspection
LIGHTING: ROOM LIGHT SWITCH: INSPECTION
1. INSPECT ROOM LIGHT SWITCH ASSEMBLY
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the switch.
(c) Inspect the switch illumination.
(1) Connect the battery's positive (+) lead to terminal 1 (ILL+) and the negative (-) lead to terminal 4
(ILL-).
(2) Check that the light comes on.
OK:
Light illuminates.
(3) If the result is not as specified, replace doom light switch.
Page 4192
Page 6104
Minimum length:
9.0 mm (0.354 in.)
(b) If the length is less than the minimum, replace the starter brush holder assembly.
(c) Inspect the load of the brush spring.
(1) Take a pull scale reading immediately after the brush spring separates from the brush.
Standard spring load:
16 to 20 N (1.7 to 2 kgf, 3.6 to 4.5 lbf)
Minimum spring load:
6.7 N (0.7 kgf, 1.5 lbf)
(2) If the load is less than the minimum, replace the starter brush holder assembly.
5. INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY
(a) Check the gear teeth on the planet gears, and the internal gear and pinion gear of the starter
center bearing clutch for wear or damage.
If any of the gears is damaged, replace the gear or starter center bearing clutch sub-assembly.
(b) Hold the starter clutch, rotate the pinion gear clockwise and check that it turns freely. Try to
rotate the pinion gear counterclockwise and check
that it locks.
(c) If the result is not as specified, replace the starter center bearing clutch sub-assembly.
Airbag System
Seat Occupant Classification Module - Air Bag: Locations Airbag System
SUPPLEMENTAL RESTRAINT SYSTEM: AIRBAG SYSTEM: PARTS LOCATION
Page 8883
Central Control Module: Service and Repair Installation
AUDIO / VISUAL: MULTI-MEDIA INTERFACE ECU: INSTALLATION
1. INSTALL MULTI-DISPLAY CONTROLLER BRACKET A
(a) Install the multi-display controller bracket A with the 2 bolts.
Torque : 2.0 Nm (20 kgf-cm, 17 in-lbf)
2. INSTALL MULTI-MEDIA INTERFACE ECU
(a) Connect the connector.
(b) Install the multi-media interface ECU with the nut.
Torque : 8.0 Nm (81 kgf-cm, 70 in-lbf)
3. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY
(a) for Column Shift Type:
Install the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column
Shift Type)/Installation.
(b) for Floor Shift Type:
Install the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation.
4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Page 9219
3. INSTALL COURTESY LIGHT ASSEMBLY
(a) Attach the claw to install the courtesy light.
(b) Connect the connector.
4. INSTALL FRONT NO. 3 SPEAKER ASSEMBLY See: Accessories and Optional
Equipment/Radio, Stereo, and Compact Disc/Speaker/Service
and Repair/Front Door Speaker (for Double Cab)/Installation
5. INSTALL FRONT LOWER DOOR FRAME BRACKET GARNISH LH
(a) Attach the 3 clips to install the front door lower frame bracket garnish.
6. INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY
(a) Install the power window regulator master switch with the 3 screws.
7. INSTALL FRONT UPPER ARMREST BASE PANEL LH
(a) Connect the connectors.
Page 7218
(a) Attach the claw to install the upper steering column cover.
(b) Attach the 4 clips to install the upper steering cover onto the instrument panel cluster finish
panel.
(c) Install the 2 screws.
Torque : 2.0 Nm (20 kgf-cm, 18 in-lbf)
HINT Turn the steering wheel to the right and left as necessary to install the 2 screws.
8. INSPECT SRS WARNING LIGHT
(a) Inspect the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
9. CONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
Page 5987
Neutral Safety Switch: Adjustments
A760F AUTOMATIC TRANSMISSION: PARK / NEUTRAL POSITION SWITCH: ADJUSTMENT
1. ADJUST PARK/NEUTRAL POSITION SWITCH ASSEMBLY
(a) Loosen the bolt of the park/neutral position switch and move the shift lever to N.
(b) Align the groove with the neutral basic line.
(c) Hold the switch in position and tighten the bolt.
Torque : 13 Nm (130 kgf-cm, 9 ft-lbf)
(d) After the adjustment, perform the on-vehicle inspection See: Testing and Inspection/Initial
Inspection and Diagnostic Overview.
Engine Control System - SFI System
Crankshaft Position Sensor: Locations Engine Control System - SFI System
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Components
Variable Valve Timing Actuator Position Sensor: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: VVT SENSOR: COMPONENTS
Page 7987
CAUTION: *
Be sure to read Precaution thoroughly before servicing See: Service Precautions
* If the side airbag was deployed, replace the front seat assembly with a new one.
* Wear protective gloves. Sharp areas on the seat frame and adjuster may injure your hands.
HINT Use the same procedures for the LH side and RH side.
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
NOTICE: Wait for 90 seconds after disconnecting the cable to prevent the airbag and seat belt
pretensioner from deploying See: Service Precautions
2. REMOVE FRONT SEAT ASSEMBLY LH (for Manual Seat)
(a) Remove the front seat assembly LH See: Body and Frame/Seats/Service and Repair/Removal
and Replacement/Front Seat Assembly (for
Manual Seat)/Removal.
3. REMOVE VERTICAL ADJUSTING HANDLE LH (for 8 Way Manual Seat) See: Body and
Frame/Seats/Service and Repair/Overhaul/Front
Seat Assembly (for Manual Seat)/Disassembly
4. REMOVE VERTICAL SEAT ADJUSTER KNOB LH (for 8 Way Manual Seat) See: Body and
Frame/Seats/Service and Repair/Overhaul/Front
Seat Assembly (for Manual Seat)/Disassembly
5. REMOVE RECLINING ADJUSTER RELEASE HANDLE LH (for Manual Seat) See: Body and
Frame/Seats/Service and
Repair/Overhaul/Front Seat Assembly (for Manual Seat)/Disassembly
6. REMOVE FRONT SEAT CUSHION SHIELD LH (for Manual Seat) See: Body and
Frame/Seats/Service and Repair/Overhaul/Front Seat
Assembly (for Manual Seat)/Disassembly
7. REMOVE INNER FRONT SEAT CUSHION SHIELD LH (for Manual Seat) See: Body and
Frame/Seats/Service and Repair/Overhaul/Front
Seat Assembly (for Manual Seat)/Disassembly
8. REMOVE FRONT SEAT HEADREST ASSEMBLY LH (for Manual Seat)
9. REMOVE FRONT SEATBACK COVER WITH PAD LH (for Manual Seat) See: Body and
Frame/Seats/Service and Repair/Overhaul/Front
Seat Assembly (for Manual Seat)/Disassembly
10. REMOVE FRONT SEAT ASSEMBLY LH (for Power Seat)
(a) Remove the front seat assembly LH See: Body and Frame/Seats/Service and Repair/Removal
and Replacement/Front Seat Assembly (for
Power Seat)/Removal.
11. REMOVE SLIDE AND VERTICAL POWER SEAT SWITCH KNOB LH (for Power Seat) See:
Body and Frame/Seats/Service and
Repair/Overhaul/Front Seat Assembly (for Power Seat)/Disassembly
12. REMOVE RECLINING POWER SEAT SWITCH KNOB LH (for Power Seat) See: Body and
Frame/Seats/Service and Repair/Overhaul/Front
Seat Assembly (for Power Seat)/Disassembly
13. REMOVE FRONT SEAT CUSHION SHIELD LH (for Power Seat) See: Body and
Frame/Seats/Service and Repair/Overhaul/Front Seat
Assembly (for Power Seat)/Disassembly
14. REMOVE FRONT SEAT INNER BELT ASSEMBLY LH (for Power Seat) See: Seat Belt
Systems/Seat Belt/Service and Repair/Removal and
Replacement/Front Seat Inner Belt Assembly/Removal
15. REMOVE INNER FRONT SEAT CUSHION SHIELD LH (for Power Seat) See: Body and
Frame/Seats/Service and Repair/Overhaul/Front Seat
Assembly (for Power Seat)/Disassembly
16. REMOVE FRONT SEATBACK COVER WITH PAD LH (for Power Seat) See: Body and
Frame/Seats/Service and Repair/Overhaul/Front Seat
Assembly (for Power Seat)/Disassembly
17. REMOVE FRONT SEAT SIDE AIRBAG ASSEMBLY
(a) Disconnect the 3 wire harness clamps from under the seat.
Page 3444
Standard resistance:
NG -- CHECK FOR SHORT TO B+ IN CAN BUS WIRE (SKID CONTROL ECU WITH ACTUATOR)
OK -- Continue to next step.
10. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (NO. 1 JUNCTION CONNECTOR STEERING ANGLE SENSOR)
(a) Disconnect the J87 No. 1 junction connector connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- CHECK FOR SHORT TO B+ IN CAN BUS WIRE (STEERING ANGLE SENSOR) OK -Continue to next step.
11. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (NO. 1 JUNCTION CONNECTOR - POWER
STEERING ECU)
NOTICE: For vehicles without a power steering ECU, go to "CHECK FOR SHORT TO B+ IN CAN
BUS WIRE (NO. 1 JUNCTION CONNECTOR - CENTER AIRBAG SENSOR)".
(a) Disconnect the J115 No. 1 junction connector connector.
Diagrams
Brake Warning Indicator: Diagrams
Locations
Collision Avoidance Module: Locations
PARK ASSIST / MONITORING: INTUITIVE PARKING ASSIST SYSTEM: PARTS LOCATION
Transmission Control Switch
Transmission Mode Switch: Diagrams Transmission Control Switch
Removal and Replacement
Grille: Removal and Replacement
Components
EXTERIOR: RADIATOR GRILLE: COMPONENTS
Installation
EXTERIOR: RADIATOR GRILLE: INSTALLATION
HINT A bolt without a torque specification is shown in the standard bolt chart See:
Specifications/Mechanical Specifications/Standard Bolt - Specified Torque For Standard Bolts
1. INSTALL LOWER RADIATOR GRILLE BRACKET LH
Page 7334
Front Steering Knuckle: Service and Repair Installation
AXLE: STEERING KNUCKLE: INSTALLATION
HINT *
Use the same procedures for the LH side and RH side.
* The procedures listed below are for the LH side.
1. INSTALL KNUCKLE GREASE RETAINER CAP LH (for 2WD)
(a) Using a brass bar and hammer, tap in a new retainer cap.
NOTICE: *
The retainer cap is a non-reusable part.
* Do not damage the retainer cap.
2. INSTALL STEERING KNUCKLE OIL SEAL LH
(a) Using SST and a press, press in a new oil seal.
SST : 09950-60020
09951-01030
SST : 09950-70010
09951-07100
NOTICE: *
The oil seal is a non-reusable part.
* Do not damage the steering knuckle oil seal.
3. INSTALL STEERING KNUCKLE LH
(a) Install the front suspension upper arm to the steering knuckle with the nut.
Torque : 110 Nm (1,122 kgf-cm, 81 ft-lbf)
(b) Install a new clip.
HINT If the holes for the clip are not aligned, tighten the nut up to another 60.
4. CONNECT FRONT LOWER BALL JOINT ATTACHMENT LH See: Control Arm/Service and
Repair/Removal and Replacement/Front Lower
Suspension Arm/Installation
5. CONNECT TIE ROD END SUB-ASSEMBLY LH See: Steering/Steering Gear/Service and
Repair/Removal and Replacement/Installation
Page 76
6. INSTALL LUGGAGE COMPARTMENT BOX RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof
Headlining (For Regular Cab)/Installation
7. INSTALL LUGGAGE COMPARTMENT BOX LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof
Headlining (For Regular Cab)/Installation
8. INSTALL UPPER BACK PANEL GARNISH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining
(For Regular Cab)/Installation
Page 2020
4. SYMPTOM CONFIRMATION AND DTC (INCLUDING FREEZE FRAME DATA) CHECK
(a) Visually check the wire harnesses, connectors and fuses for open and short circuits.
(b) Warm up the engine to the normal operating temperature.
(c) Confirm the problem symptoms and conditions, and check for DTCs.
B -- Go to step 6 A -- Continue to next step.
5. DTC CHART
(a) Check the results obtained in the DTC check. Then find the output DTC in the DTC chart. Look
at the "Trouble Area" column for a list of
potentially malfunctioning circuits and / or parts.
NEXT -- Go to step 7
6. PROBLEM SYMPTOMS TABLE
(a) Check the results obtained in the symptom confirmation. Then find the problem symptoms in
the problem symptoms table. Look at the
"Suspected Area" column for a list of potentially malfunctioning circuits and / or parts.
NEXT -- Continue to next step.
7. CIRCUIT INSPECTION OR PARTS INSPECTION
(a) Confirm the malfunctioning circuit or part.
NEXT -- Continue to next step.
8. ADJUST, REPAIR OR REPLACE
(a) Adjust, repair or replace the malfunctioning circuit or parts.
NEXT -- Continue to next step.
9. CONFIRMATION TEST
(a) After the adjustment, repairs or replacement, confirm that the malfunction no longer exists. If the
malfunction does not reoccur, perform a
confirmation test under the same conditions and in the same environment as when the malfunction
occurred the first time.
NEXT -- END
2. CUSTOMER PROBLEM ANALYSIS
HINT *
In troubleshooting, confirm that the problem symptoms have been accurately identified.
Preconceptions should be discarded in order to make an accurate judgment. To clearly understand
what the problem symptoms are, it is extremely important to ask the customer about the problem
and the conditions at the time the malfunction occurred.
* Gather as much information as possible for reference. Past problems that seem unrelated may
also help in some cases.
* The following 5 questions are important points in the problem analysis:
Page 4759
J. When Cal 1 has completed the update process turn ignition OFF for a minimum of 10 seconds.
Then click Next.
K. Turn ignition to the ON position. Then click Start.
L. Do NOT disturb the vehicle during flash reprogramming.
Page 6202
(a) Attach the claw to install the power outlet socket.
6. INSTALL CONSOLE BOX BEZEL
(a) Attach the 5 claws to install the console box bezel.
(b) Connect the connector.
7. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding
/ Trim/Dashboard / Instrument Panel/Service
and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
Components
OTHER SYSTEM: POWER OUTLET SOCKET (for Column Shift Type): COMPONENTS
Page 6221
Auxiliary Power Outlet Switch: Service and Repair Removal
OTHER SYSTEM: INVERTER MAIN SWITCH (for CrewMax): REMOVAL
1. REMOVE FRONT DOOR SCUFF PLATE LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining
(For Double Cab)/Removal
2. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for
CrewMax)/Removal
3. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal
4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Floor Shift Type)/Removal
5. REMOVE INVERTER MAIN SWITCH
(a) Detach the 2 claws and remove the main switch.
Page 4714
Four Wheel Drive Selector Switch: Testing and Inspection
JF1A TRANSFER: 4WD CONTROL SWITCH: ON-VEHICLE INSPECTION
1. INSPECT 4WD CONTROL SWITCH
(a) Check the harness and connector (ECU - battery and body ground).
(1) Measure the voltage and resistance according to the value(s) in the table below.
Standard voltage:
(2) If there is a malfunction, inspect the harness or connector. If the harness is malfunctioning,
repair or replace harness or connector. If the
harness or connector is normal, replace the 4WD control ECU See: Relays and Modules Transmission and Drivetrain/Relays and Modules - Transfer Case/Control Module/Service and
Repair/Removal.
Standard resistance:
(3) If there is a malfunction, repair or replace the harness or connector.
(b) Check the harness and connector (switch - ECU).
(1) Disconnect the A25 ECU connector.
(2) Disconnect the L1 switch connector.
(3) Measure the resistance according to the value(s) in the table below.
Page 4179
Page 8226
Prepare a battery to activate the seat belt pretensioner.
(a) Check if SST is functioning properly.
SST : 09082-00700
CAUTION: When activating the seat belt pretensioner, always use the specified SST.
(1) Connect SST's red clip to the battery's positive (+) terminal and the black clip to the battery's
negative (-) terminal.
HINT Do not connect the yellow connector. The yellow connector is used to connect to the seat belt
pretensioner.
(2) Press SST activation switch and check that the LED of SST activation switch illuminates.
CAUTION: If the LED illuminates when the activation switch is not being pressed, SST may be
malfunctioning. Replace SST with a new one.
(b) Disconnect SST from the battery.
(c) Disconnect the pretensioner connector.
(1) Disconnect the cable from the negative (-) battery terminal.
(2) Remove the front door opening trim weatherstrip See: Removal and Replacement/Front Seat
Outer Belt Assembly (for Regular
Cab)/Removal.
(3) Remove the front door scuff plate See: Removal and Replacement/Front Seat Outer Belt
Assembly (for Regular Cab)/Removal.
(4) Remove the lower quarter trim panel See: Removal and Replacement/Front Seat Outer Belt
Assembly (for Regular Cab)/Removal.
Page 7364
(b) Press down on the vehicle several times to stabilize the suspension.
3. TIGHTEN FRONT SHOCK ABSORBER WITH COIL SPRING
(a) Tighten the nut.
Torque : 195 Nm (1988 kgf-cm, 144 ft-lbf)
(b) Tighten the 4 upper nuts in diametrically opposite pairs.
Torque : 45 Nm (459 kgf-cm, 33 ft-lbf)
(c) Check that the first nut that was tightened is at the torque specification.
4. INSTALL FRONT WHEEL
for Aluminum Wheel - Torque : 131 Nm (1336 kgf-cm, 97 ft-lbf)
for Steel Wheel - Torque : 209 Nm (2131 kgf-cm, 154 ft-lbf)
Disposal
SUSPENSION: FRONT SHOCK ABSORBER: DISPOSAL
1. DISPOSE OF FRONT SHOCK ABSORBER ASSEMBLY LH
(a) Fully extend the shock absorber rod.
Page 8953
3. INSTALL NO. 2 ULTRASONIC SENSOR RETAINER
(a) Align the keyhole and protrusion as shown in the illustration.
(b) Install the sensor retainer to the rear bumper.
NOTICE: Do not damage the bumper with the protrusion when installing the retainer.
4. INSTALL NO. 2 ULTRASONIC SENSOR
(a) Attach the 2 claws to install the ultrasonic sensor.
5. INSTALL REAR BUMPER BAR (for Steel Type Bumper) See: Body and Frame/Bumper/Front
Bumper/Service and Repair/Removal and
Replacement/Front Bumper (for Steel Type Bumper)/Installation
6. INSTALL REAR BUMPER COVER (for Resin Type Bumper) See: Body and
Frame/Bumper/Rear Bumper/Service and Repair/Removal and
Page 8492
(a) Attach the 8 claws and 2 clips to install the scuff plate.
5. INSTALL BACK PANEL TRIM RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for
CrewMax)/Installation
Page 7786
* Do not operate the cooler compressor before charging refrigerant as the cooler compressor will
not work properly without any refrigerant, and will overheat.
* Approximately 200 g (7.05 oz.) of refrigerant may need to be charged after bubbles disappear.
The refrigerant amount should be checked by measuring its quantity, and not with the sight glass.
3. WARM UP ENGINE
(a) Warm up the engine at less than 1500 rpm for 1 minute or more after charging the refrigerant.
NOTICE: Be sure to warm up the compressor when turning the A/C switch ON after removing and
installing the cooler refrigerant lines (including the compressor), to prevent damage to the
compressor.
4. CHECK FOR REFRIGERANT GAS LEAK
(a) After recharging the refrigerant gas, check for refrigerant gas leakage using a halogen leak
detector.
(b) Perform the operation under the following conditions:
* The ignition switch is OFF.
* The vehicle is in a place with good air ventilation and without any volatile gases, such as
evaporated gasoline or exhaust gas. The detector is very sensitive to volatile gases.
* Some refrigerant is remaining in the refrigerant system.
* The compressor is off and its pressure is approximately 392 to 588 kPa (4.0 to 6.0 kgf/cm2, 57 to
85 psi).
(c) Using a halogen leak detector, check the refrigerant line for leakage.
(d) If a gas leak is not detected on the drain hose, remove the blower motor control (blower
resistor) from the cooling unit. Insert the halogen leak
detector sensor into the unit and perform the test.
(e) Disconnect the connector and wait for approximately 20 minutes. Bring the halogen leak
detector close to the pressure switch and perform the
test.
Page 3331
HINT The wavelength becomes shorter as the vehicle speed increases.
(k) WAVEFORM 10:
HINT The duty ratio varies depending on the throttle actuator operation.
(l) WAVEFORM 11:
HINT The duty ratio varies depending on the throttle actuator operation.
(m)WAVEFORM 12:
Page 7045
(a) Bounce the vehicle up and down at the corners to stabilize the suspension, and then inspect the
toe-in.
Standard toe-in (unloaded vehicle):
for Regular Cab of Standard Deck
Standard toe-in (unloaded vehicle):
for Regular Cab of Long Deck
Standard toe-in (unloaded vehicle):
for Double Cab of Standard Deck
Page 1418
Page 9376
13. Reinstall the body plugs for the cab mount bolt holes and then the carpet.
14. Test drive vehicle to confirm the condition has improved.
Page 6552
Driver Side J/B - Cowl Side Left
Page 7660
Compressor HVAC: Connector Views
Page 7599
4. SYMPTOM CONFIRMATION AND DTC (INCLUDING FREEZE FRAME DATA) CHECK
(a) Visually check the wire harnesses, connectors and fuses for open and short circuits.
(b) Warm up the engine to the normal operating temperature.
(c) Confirm the problem symptoms and conditions, and check for DTCs.
B -- Go to step 6 A -- Continue to next step.
5. DTC CHART
(a) Check the results obtained in the DTC check. Then find the output DTC in the DTC chart. Look
at the "Trouble Area" column for a list of
potentially malfunctioning circuits and / or parts.
NEXT -- Go to step 7
6. PROBLEM SYMPTOMS TABLE
(a) Check the results obtained in the symptom confirmation. Then find the problem symptoms in
the problem symptoms table. Look at the
"Suspected Area" column for a list of potentially malfunctioning circuits and / or parts.
NEXT -- Continue to next step.
7. CIRCUIT INSPECTION OR PARTS INSPECTION
(a) Confirm the malfunctioning circuit or part.
NEXT -- Continue to next step.
8. ADJUST, REPAIR OR REPLACE
(a) Adjust, repair or replace the malfunctioning circuit or parts.
NEXT -- Continue to next step.
9. CONFIRMATION TEST
(a) After the adjustment, repairs or replacement, confirm that the malfunction no longer exists. If the
malfunction does not reoccur, perform a
confirmation test under the same conditions and in the same environment as when the malfunction
occurred the first time.
NEXT -- END
2. CUSTOMER PROBLEM ANALYSIS
HINT *
In troubleshooting, confirm that the problem symptoms have been accurately identified.
Preconceptions should be discarded in order to make an accurate judgment. To clearly understand
what the problem symptoms are, it is extremely important to ask the customer about the problem
and the conditions at the time the malfunction occurred.
* Gather as much information as possible for reference. Past problems that seem unrelated may
also help in some cases.
* The following 5 questions are important points in the problem analysis:
Page 2893
Accelerator Pedal Position Sensor: Diagrams
Page 3338
(b) Spray gasket remover or equivalent on the remaining tape of the gasket.
NOTICE: When using gasket remover or equivalent, cover the ECM connector with a cloth.
(c) Remove the tape of the gasket without using bladed objects.
Page 6169
6. PROBLEM SYMPTOMS TABLE
When a "Normal" code is output during a DTC check but the problem is still occurring, use the
Problem Symptoms Table. The suspected areas (circuits or parts) for each problem symptom are
in the table. The suspected areas are listed in order of probability. A description of each of the
chart's columns is below.
HINT In some cases, the problem is not detected by the diagnostic system even though a problem
symptom is present. It is possible that the problem is occurring outside the detection range of the
diagnostic system, or that the problem is occurring in a completely different system.
7. CIRCUIT INSPECTION
A description of the main areas of each circuit inspection is below.
Locations
Oxygen Sensor Relay: Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 2958
Page 9138
Connectors Part 2
Page 7629
Page 3561
4. CHECK DLC3
(a) Measure the resistance according to the value(s) in the table below.
5. CHECK SKID CONTROL ECU WITH ACTUATOR
(a) Disconnect the A17 ECU connector.
(b) Measure the resistance according to the value(s) in the table below.
6. CHECK MAIN BODY ECU
Locations
Hazard Warning Switch: Locations
LIGHTING: LIGHTING SYSTEM: PARTS LOCATION
Page 3407
The steering angle sensor is connected to the CAN communication system but CAN
communication DTCs are not output.
(h) CENTER AIRBAG SENSOR
HINT The center airbag sensor is connected to the CAN communication system but CAN
communication DTCs are not output.
(i) POWER STEERING ECU
For vehicles with a power steering ECU only.
HINT The power steering ECU is connected to the CAN communication system but CAN
communication DTCs are not output.
(j) 4WD CONTROL ECU
For vehicles with 4WD only.
HINT The 4WD control ECU is connected to the CAN communication system but CAN
communication DTCs are not output.
(k) BUS BUFFER ECU
For vehicles with a bus buffer ECU only.
HINT The bus buffer ECU is connected to the CAN communication system but CAN
communication DTCs are not output.
(l) FRONT POWER SEAT CONTROL ECU AND SWITCH LH
For vehicles with a front power seat control system (w/ Seat Memory) only.
HINT The front power control seat ECU and switch LH is connected to the CAN communication
system but CAN communication DTCs are not output.
(m)OUTER MIRROR CONTROL ECU
For vehicles with a front power seat control system (w/ Seat Memory) only.
HINT The outer mirror control ECU and switch LH is connected to the CAN communication system
but CAN communication DTCs are not output.
4. DTC COMBINATION TABLE
Components
Cruise Control Switch: Service and Repair Components
CRUISE CONTROL: CRUISE CONTROL MAIN SWITCH: COMPONENTS
Page 7049
Standard wheel angle (unloaded vehicle):
for Double Cab of Standard Deck
Page 9298
Page 145
Control Module HVAC: Service and Repair Installation
AIR CONDITIONING: AIR CONDITIONING AMPLIFIER: INSTALLATION
1. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY
(a) Install the amplifier with the 2 screws.
(b) for Manual Air Conditioning System:
Connect the 2 connectors.
(c) for Automatic Air Conditioning System:
Connect the 3 connectors.
2. INSTALL NO. 2 AIR DUCT SUB-ASSEMBLY
(a) Install the duct with the screw.
3. INSTALL LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY
for Column Shift Type:
Install the lower No. 2 instrument panel airbag assembly See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument
Panel Safety Pad (for Column Shift Type)/Installation.
for Floor Shift Type:
Install the lower No. 2 instrument panel airbag assembly See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument
Panel Safety Pad (for Floor Shift Type)/Installation.
4. INSTALL LOWER INSTRUMENT PANEL
for Column Shift Type:
Page 5289
Do not tap the shaft tube.
HINT Remove the bearing on the opposite side using the same procedure.
(c) Install the 2 removed spider bearing outer races to the spider.
(d) Using SST, push the bearing out of the flange yoke.
SST : 09332-25010
HINT Before installing SST, sufficiently raise the part labeled A. If part A is too low, SST may be
difficult to install.
(e) Clamp the outer bearing race in a vise and tap off the flange yoke with a hammer.
(f) Remove the spider.
HINT Remove the bearing on the opposite side using the same procedure.
Reassembly
PROPELLER SHAFT: FRONT PROPELLER SHAFT ASSEMBLY: REASSEMBLY
1. INSTALL FRONT PROPELLER SHAFT UNIVERSAL JOINT SPIDER BEARING
(a) Apply MP grease to a new spider and bearings.
NOTICE: Be careful not to apply too much grease.
(b) Fit the spider to the yoke.
Page 4278
When using Techstream Lite, select Generic J2534 Interface. Then click Next.
E. Confirm the following:
^ PC is connected to VIM.
^ VIM is connected to DLC3 connector.
^ Ignition is ON and engine is OFF or "READY" OFF (hybrid vehicles).
Page 4585
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION: Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC
terminals are touched, the IC may be destroyed by static electricity.)
When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact with the terminals of leads from the IC, etc. of the
replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown on the left.
DISCONNECT CONNECTOR
Page 3693
Then click Start.
I. Do NOT disturb the vehicle during flash reprogramming.
NOTE
^ ECU flash reprogramming may take anywhere from 3 - 30 minutes per calibration file.
^ Reprogramming time will vary depending on model and ECU communication protocol. Vehicles
using CAN communication protocol will reprogram much faster (2 - 7 minutes).
NOTE
^ If vehicle requires only ONE calibration update, then proceed to step N in this bulletin.
^ If vehicle requires a SECOND calibration update, then continue as follows:
^ For serial communication vehicles, go to step J.
^ For CAN communication vehicles, go to step L.
Page 2534
Parts Information
Required Tools & Equipment
Additional TIS Techstream units may be ordered by calling Approved Dealer Equipment (ADE).
TSB Overview
1. Confirm that DTC P0012 and/or P0022 is stored in the ECM.
2. Diagnose the Oil Control Valves (OCVs) for proper operation.
3. If the OCVs operate correctly replace both intake VVTi gear assemblies following the Repair
Manual.
Diagnostic Procedure
1. Using TIS Techstream confirm that DTC P0012 and/or P0022 is stored in the ECM.
2. Remove the affected Oil Control Valve (OCV) and inspect for debris in the valve or evidence that
the valve is stuck.
3. Check valve operation by applying positive (+) battery voltage to terminal 1 and negative (-)
battery voltage to terminal 2. Valve should move
quickly when voltage is applied. If NOT valve should be replaced.
4. Reinstall the OCVs warm up the engine to over 167°F (75°C) and perform an Active Test using
Tech stream.
Powertrain / Engine and ECT / Active Test / Control the WT System (Bank 1) or (Bank 2)
5. If there is NO debris and the OCV moves with battery voltage and Active Test functions Replace both intake VVTi gears following the repair
procedure below.
Repair Procedure
1. Replace both intake VVTi gears.
Page 3837
Oxygen Sensor: Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Components
Steering Column Control Module: Service and Repair Components
STEERING COLUMN: MULTIPLEX TILT AND TELESCOPIC ECU (for Power Tilt and Power
Telescopic Steering Column): COMPONENTS
Locations
Solar Sensor: Locations
AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Automatic Air Conditioning System):
PARTS LOCATION
Up to 11/2009
Brake Fluid Pressure Sensor/Switch: Locations Up to 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 8350
Page 7647
when inserting and after full engagement.
NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal.
(d) REPAIR METHOD OF CONNECTOR TERMINAL
(1) If there is any foreign matter on the terminal, clean the contact point using an air gun or cloth.
Never rub the contact point using sandpaper
as the plating may come off.
(2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is
gold-plated (gold color), use a gold-plated female
terminal; if it is silver-plated (silver color), use a silver-plated female terminal.
(3) Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock
into the housing, the housing may have to be
replaced.
(e) HANDLING OF WIRE HARNESS
(1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be
restored in the same way.
(2) Never twist, pull or slacken the wire harness more than necessary.
(3) The wire harness should never come into contact with a high temperature part, or rotating,
moving, vibrating or sharp-edged parts. Avoid
contact with panel edges, screw tips and other sharp items.
(4) When installing parts, never pinch the wire harness.
(5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with
vinyl tape.
2. CHECK FOR OPEN CIRCUIT
Page 1512
Neutral Safety Switch: Adjustments
A760F AUTOMATIC TRANSMISSION: PARK / NEUTRAL POSITION SWITCH: ADJUSTMENT
1. ADJUST PARK/NEUTRAL POSITION SWITCH ASSEMBLY
(a) Loosen the bolt of the park/neutral position switch and move the shift lever to N.
(b) Align the groove with the neutral basic line.
(c) Hold the switch in position and tighten the bolt.
Torque : 13 Nm (130 kgf-cm, 9 ft-lbf)
(d) After the adjustment, perform the on-vehicle inspection See: Testing and Inspection/Initial
Inspection and Diagnostic Overview.
Page 8521
Shock Sensor: Diagrams
Page 913
Cabin Temperature Sensor / Switch: Testing and Inspection
AIR CONDITIONING: ROOM TEMPERATURE SENSOR (for Automatic Air Conditioning System):
INSPECTION
1. INSPECT ROOM TEMPERATURE SENSOR
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
HINT As the temperature increases, the resistance decreases (see the graph).
(b) If the result is not as specified, replace the thermistor.
NOTICE: *
Touching the sensor even slightly may change the resistance value. Hold the connector of the
sensor.
* When measuring the resistance, the sensor temperature must be the same as the ambient
temperature.
Page 978
Drivetrian - Rear End Howling/Growling Noises
Wheel Bearing: Customer Interest Drivetrian - Rear End Howling/Growling Noises
T-SB-0151-10
June11, 2010
Rear Axle Bearing Abnormal Noise
Service Category Drivetrain
Section Axle/Differential
Market USA
Applicability
Introduction
Some 2007 - 2010 model year Tundra vehicles may exhibit a howling or growling noise from the
rear of the vehicle that increases with vehicle speed. Changes have been made to the rear axle
bearing to correct this condition. Follow the procedure in the bulletin to address customer concerns.
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60
months or 60,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Parts Information
Page 3787
Camshaft Position Sensor: Diagrams
Page 5913
(c) Disconnect the connector (labeled D).
(d) Remove the connector (labeled D) from the skid control sensor clamp (labeled H).
(e) Remove the 2 bolts (labeled E) and 2 harness clamps (labeled F).
(f) Remove the bolt (labeled G) and skid control sensor clamp (labeled H).
7. REMOVE FRONT SPEED SENSOR RH
(a) Remove the hexagon socket head cap bolt (labeled A) and speed sensor (labeled B) from the
knuckle.
8. REMOVE FRONT SKID CONTROL SENSOR CLAMP RH
(a) Remove the bolt (labeled C) and skid control sensor clamp (labeled D) from the knuckle.
Installation
BRAKE CONTROL: FRONT SPEED SENSOR: INSTALLATION
1. INSTALL FRONT SKID CONTROL SENSOR CLAMP LH
(a) Install the skid control sensor clamp (labeled A) with the bolt (labeled B).
Torque : 13 Nm (127 kgf-cm, 9 ft-lbf)
NOTICE: Install the bracket so that the rotation stopper (labeled C) touches the knuckle.
Up to 11/2009
Braking Sensor/Switch: Locations Up to 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 2818
Procedures
Air Bag: Procedures
Front Passenger Side Knee Airbag Assembly
SUPPLEMENTAL RESTRAINT SYSTEM: FRONT PASSENGER SIDE KNEE AIRBAG
ASSEMBLY: DISPOSAL
HINT When scrapping a vehicle equipped with the SRS or disposing of the lower No. 2 instrument
panel airbag, be sure to deploy the airbag first in accordance with the procedure described below.
If any abnormality occurs with the airbag deployment, contact the service dept. of the distributor.
CAUTION: *
Never dispose of a lower No. 2 instrument panel airbag that has an unactivated airbag.
* The airbag produces an exploding sound when it is deployed, so perform the operation outdoors
and where it will not create a nuisance to nearby residents.
* When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool).
Perform the operation in a place away from electrical noise.
* When deploying the airbag, perform the operation at least 10 m (32.8 ft.) away from the lower No.
2 instrument panel airbag.
* The lower No. 2 instrument panel airbag becomes extremely hot when the airbag is deployed, so
do not touch it for at least 30 minutes after deployment.
* Use gloves and safety glasses when handling a lower No. 2 instrument panel airbag with a
deployed airbag.
* Do not apply water, etc. to a lower No. 2 instrument panel airbag with a deployed airbag.
* Always wash your hands with water after completing the operation.
* An airbag or pretensioner may be activated by static electricity. To prevent this, be sure to touch a
metal surface with bare hands to discharge static electricity before performing this procedure.
1. DISPOSE OF LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY (WHEN INSTALLED
IN VEHICLE)
HINT Prepare a battery as the power source to deploy the airbag.
(a) Check the function of SST See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
(b) Read the precaution See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
(c) Disconnect the cable from the negative (-) battery terminal.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to disable the SRS system.
(d) Remove the lower No. 2 instrument panel airbag See: Removal and Replacement/Front
Passenger Side Knee Airbag Assembly/Removal.
(e) Install SST.
(1) Connect SST connector to the lower No. 2 instrument panel airbag.
SST : 09082-00700
SST : 09082-00780
NOTICE: To avoid damaging SST connector and wire harness, do not lock the secondary lock of
the twin lock.
Components
Engine Oil: Service and Repair Components
1UR-FE LUBRICATION: OIL AND OIL FILTER: COMPONENTS
Page 3068
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Page 997
Parts Information
NOTE
The fuel sending unit lower cover is installed and supplied as part of the fuel tank assembly part
numbers listed in the part information table above.
Warranty Information
Installation Procedure
1. Insert the tip of the fuel sender unit upper cover into the hole on the fuel sender unit lower cover
(2 places).
2. Fasten the tab of the fuel sender unit upper cover to the lip on the fuel sender unit lower cover (1
place).
Page 1503
Page 2583
(m)Measure the fuel pressure.
Standard fuel pressure:
281 to 287 kPa (2.87 to 2.93 kgf/cm2, 41 to 42 psi)
(n) If the pressure is not as specified, check the fuel pump, pressure regulator and/or injectors.
(o) Stop the engine.
(p) Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped.
Standard fuel pressure:
147 kPa (1.5 kgf/cm2, 21 psi) or higher
(q) If the pressure is not as specified, check the fuel pump, pressure regulator and/or injectors.
(r) After checking the fuel pressure, disconnect the cable from the negative (-) battery terminal and
carefully remove SST and the fuel tube
connector to prevent gasoline from spraying.
(s) Reconnect the fuel tube (fuel tube connector).
(t) Check for fuel leak.
(1) Check that there are no fuel leaks after performing maintenance anywhere on the system.
If there are fuel leaks, repair or replace parts as necessary.
Page 6748
Driver Side J/B Inner Circuit
Diagrams
Power Steering Pump: Diagrams
Page 1711
Standard camber inclination (unloaded vehicle):
for CrewMax of standard deck
Page 6517
Page 3557
(a) Disconnect the N12 front power window regulator motor assembly LH connector.
(b) Measure the voltage and resistance according to the value(s) in the table below.
* If the result is not as specified, there may be a malfunction on the wire harness side.
4. CHECK FRONT POWER WINDOW REGULATOR MOTOR ASSEMBLY RH (for Power Window
Control System [w/ Jam Protection
Function])
(a) Disconnect the M11 front power window regulator motor assembly RH connector.
(b) Measure the voltage and resistance according to the value(s) in the table below.
* If the result is not as specified, there may be a malfunction on the wire harness side.
5. CHECK SLIDING ROOF DRIVE GEAR SUB-ASSEMBLY (SLIDING ROOF ECU) (w/ Sliding
Roof System)
(a) Disconnect the W3 sliding roof drive gear sub-assembly connector.
(b) Measure the voltage and resistance according to the value(s) in the table below.
(c) If the result is not as specified, there may be a malfunction on the wire harness side.
6. CHECK AIR CONDITIONING AMPLIFIER ASSEMBLY (A/C ECU)
Page 9081
Trailer Towing Part 3
Page 4141
Page 7425
Tire Pressure Module: Locations
TIRE AND WHEEL: TIRE PRESSURE WARNING SYSTEM: PARTS LOCATION
Page 1334
Ignition Switch: Connector Views
Page 8044
Clockspring Assembly / Spiral Cable: Testing and Inspection
SUPPLEMENTAL RESTRAINT SYSTEM: SPIRAL CABLE: INSPECTION
1. REMOVE SPIRAL CABLE
(a) If there are any defects as mentioned below, replace the spiral cable with a new one:
Scratches, cracks, dents or chips on the connector or the spiral cable.
(b) Check the spiral cable.
(1) Set the spiral cable to the center position See: Service and Repair/Installation.
(2) After setting the spiral cable to the center position, rotate the spiral cable 2.5 times clockwise,
and measure the resistance as shown. Then
rotate the spiral cable 5 times counterclockwise, measure the resistance according to the U4 (uecs)
in the table below.
Standard resistance:
Page 9216
(a) Using a screwdriver, detach the 4 claws and remove the inside handle bezel.
HINT Tape the screwdriver tip before use.
3. REMOVE FRONT UPPER ARMREST BASE PANEL LH
(a) Using a screwdriver, detach the 2 clips and front armrest upper base panel.
HINT Tape the screwdriver tip before use.
(b) Disconnect the connectors.
4. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY
(a) Remove the 3 screws and power window regulator master switch.
5. REMOVE FRONT LOWER DOOR FRAME BRACKET GARNISH LH
(a) Detach the 3 clips and remove the door lower frame bracket garnish.
Diagrams
Fuel Tank Pressure Release Valve: Diagrams
Page 3938
Required Tools & Equipment
Repair Procedure
1. Using TIS Techstream check if DTC P0418, P0419, P2440, P2441, P2442, P2443, P2446
and/or P2447 are present.
2. Using Techstream perform the manual Air Injection Test (options 1 and 2) to verify if the signal
from the air injection control driver is reaching the
air pumps.
^ The pumps should be heard turning on at this point and there should be battery voltage on pin 2
of the pumps during this test.
^ If there is NO voltage refer to the Repair Manual for air injection control driver diagnosis.
Refer to the Technical Information System (TIS) 2010 model year Tundra Repair Manual:
3. If during the test voltage is present at the pump and the pump is NOT running or the Air
Pressure (gauge) value did NOT increase from 0 to 1 psi on
TIS Techstream with the pump running remove the air pump assemblies for inspection.
Refer to TIS 2010 model year Tundra Repair Manual:
4. With the pumps removed from the vehicle verify if there is liquid or evidence that liquid entered
the pumps.
^ YES - If there is liquid evidence go to step 5.
^ NO - If there is NO evidence of liquid go to step 7.
5. If liquid is present replace the affected pump assembly.
Refer to TIS 2010 model year Tundra Repair Manual:
Page 6805
* In the DTC check, it is very important to determine whether the problem indicated by the DTC is
either: 1) still occurring; or 2) occurred in the past but has since returned to normal. In addition, the
DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs
should be checked before and after confirmation of symptoms (i.e., whether or not problem
symptoms exist) to determine current system conditions, as shown in the flowchart below.
* Never skip the DTC check. Failing to check DTCs may, depending on the case, result in
unnecessary troubleshooting for systems operating normally or lead to repairs not related to the
problem. Follow the procedures listed in the flowchart in the correct order.
* The following flowchart shows how to proceed with troubleshooting using the DTC check.
Directions from the flowchart will indicate how to proceed either to DTC troubleshooting or to the
troubleshooting of each problem symptom.
1. DTC CHECK
NEXT -- Continue to next step.
2. MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR MEMORY
NEXT -- Continue to next step.
3. SYMPTOM CONFIRMATION
B -- Go to step 5 A -- Continue to next step.
4. SIMULATION TEST USING SYMPTOM SIMULATION METHODS
NEXT -- Continue to next step.
5. DTC CHECK
B -- TROUBLESHOOTING OF PROBLEM INDICATED BY DTC A -- Continue to next step.
6. SYMPTOM CONFIRMATION
Page 9103
Page 6804
Components
Steering Control Module: Service and Repair Components
POWER STEERING: POWER STEERING ECU (for 1UR-FE): COMPONENTS
Restraints - OCS System Initialization
Seat Occupant Sensor: Technical Service Bulletins Restraints - OCS System Initialization
COLLISION REPAIR INFORMATION FOR THE COLLISION REPAIR PROFESSIONAL
TITLE: SRS OCCUPANT CLASSIFICATION SYSTEM INITIALIZATION
SECTION: ELECTRICAL BULLETIN # 177
MODELS: ALL EQUIPPED TOYOTA LEXUS and SCION MODELS
DATE: MARCH 2010
Models equipped with a Supplemental Restraint System (SRS) Occupant Classification System
(OCS) will enable or disable the passenger front and side airbags based on seat occupancy
passenger weight and seat belt latch engagement.
If an equipped vehicle sustains collision damage or if the front passenger seat or any of the OCS
components are serviced the SRS Malfunction Indicator Light (MIL) may illuminate setting a
Diagnostic Trouble Code (DTC).
NOTE:
It is necessary to diagnose and repair the root cause of a SRS or OCS DTC before initializing the
OCS system. If SRS and OCS DTC's are not cleared the system may not operate properly.
Be sure to check and clear DTC's and perform OCS initialization per repair manual instructions
with a Techstream Special Service Tool (SST) or capable diagnostic tester.
Any of the following conditions could set a DTC illuminate the SRS MIL or cause the PASSENGER
AIRBAG light to indicate incorrectly regardless of occupancy:
^ The OCS Electronic Control Unit (ECU) is replaced
^ Accessories such as a seatback tray are installed on the passenger seat
^ The passenger seat is removed and replaced or reinstalled
^ The vehicle is involved in an accident or collision
Model-specific repair manuals can be accessed through the Technical Information System (TIS)
www.techinfo.toyota.com
Page 7109
9. CHECK TIRE PRESSURE AFTER REPAIRS
(a) After repairs, confirm that the actual tire pressures are displayed in the DATA LIST See: Wheels
and Tires/Tire Monitoring System/Testing
and Inspection/Scan Tool Testing and Procedures/Data List / Active Test.
Page 8942
Page 2768
When using Techstream Lite, select Generic J2534 Interface. Then click Next.
E. Confirm the following:
^ PC is connected to VIM.
^ VIM is connected to DLC3 connector.
^ Ignition is ON and engine is OFF or "READY" OFF (hybrid vehicles).
Page 3618
Removal
1UR-FE ENGINE CONTROL SYSTEM: AIR FUEL RATIO SENSOR: REMOVAL
CAUTION: *
Wear protective gloves when removing the exhaust pipe.
* The exhaust pipe is extremely hot immediately after the engine has stopped.
* Confirm that the exhaust pipe has cooled down before removing it.
1. REMOVE TAILPIPE ASSEMBLY See: Engine, Cooling and Exhaust/Exhaust System/Exhaust
Pipe/Service and Repair/Exhaust Pipe (for
Regular Cab Standard Deck)/Removal
2. REMOVE CENTER EXHAUST PIPE ASSEMBLY See: Engine, Cooling and Exhaust/Exhaust
System/Exhaust Pipe/Service and
Repair/Exhaust Pipe (for Regular Cab Standard Deck)/Removal
3. REMOVE FRONT EXHAUST PIPE ASSEMBLY
(a) Disconnect the heated oxygen sensor connector and 2 clamps.
(b) Disconnect the air fuel ratio sensor connector.
(c) Remove the 3 nuts, front exhaust pipe and gasket from the exhaust manifold RH.
4. REMOVE AIR FUEL RATIO SENSOR (for Bank 2 Sensor 1)
(a) Using SST, remove the sensor.
SST : 09224-00010
Page 8237
4. INSTALL CENTER FRONT SEAT ASSEMBLY
(a) Install the center front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Center
Seat)/Installation.
5. INSTALL FRONT SEAT ASSEMBLY RH
(a) for Power Seat:
Install the front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Power Seat)/Installation.
(b) for Manual Seat:
Install the front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Manual Seat)/Installation.
6. INSTALL FRONT SEAT ASSEMBLY LH
(a) for Power Seat:
Install the front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Power Seat)/Installation.
(b) for Manual Seat:
Install the front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Manual Seat)/Installation.
Components
SEAT BELT: FRONT SEAT OUTER BELT ASSEMBLY (for Center Seat): COMPONENTS
Page 1773
Drive Belt: Service and Repair Removal
1UR-FE ENGINE MECHANICAL: DRIVE BELT: REMOVAL
1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Removal
2. REMOVE NO. 1 ENGINE UNDER COVER See: Fluids/Engine Oil/Service and
Repair/Replacement
3. REMOVE FAN AND GENERATOR V BELT
(a) While turning the belt tensioner counterclockwise, align the service hole for the belt tensioner
and the belt tensioner fixing position, and then
insert a bar of dia 5 mm (0.197 in.) into the service hole to fix the belt tensioner in place.
HINT The pulley bolt for the belt tensioner has a left-hand thread.
(b) Remove the V belt.
Page 3392
Information Bus: Service Precautions
CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: PRECAUTION
1. STEERING SYSTEM HANDLING PRECAUTIONS
(a) Care must be taken when replacing parts. Incorrect replacement could affect the performance
of the steering system and result in hazards when
driving.
2. SRS AIRBAG SYSTEM HANDLING PRECAUTIONS
(a) This vehicle is equipped with an SRS (Supplemental Restraint System) such as the driver
airbag and front passenger airbag. Failure to carry
out service operations in the correct sequence could cause unexpected SRS deployment during
servicing and may lead to a serious accident. Before servicing (including installation/removal,
inspection and replacement of parts), be sure to read the precautionary notice for the supplemental
restraint system See: Restraint Systems/Air Bag Systems/Service Precautions.
3. BUS LINE REPAIR
(a) After repairing the bus line with solder, wrap the repaired part with vinyl tape See:
Diagrams/Diagnostic Aids/How To Troubleshoot ECU
Controlled Systems/Electronic Circuit Inspection Procedure.
NOTICE: *
The CANL bus line and CANH bus line must be installed together.
* When installing the CAN bus lines, twist them together.
* CAN bus lines are likely to be influenced by noise if the bus lines are not twisted together.
* The difference in length between the CANL bus line and CANH bus line should be less than 100
mm (3.94 in.).
* Leave approximately 80 mm (3.15 in.) loose in the twisted wires around the connectors.
(b) Do not use by-pass wiring between the connectors.
NOTICE: The feature of the twisted wire harness will be lost if by-pass wiring is used.
4. CONNECTOR HANDLING
(a) When inserting tester probes into a connector, insert them from the rear of the connector.
Page 6997
J/B No.3 - Instrument Panel Right
Components
Air Flow Meter/Sensor: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: COMPONENTS
Page 7331
Page 7025
for Regular Cab of Long Deck
for Double Cab of Standard Deck
Page 6064
(2) CONNECTORS
Slightly shake the connector vertically and horizontally.
(3) WIRE HARNESS
Slightly shake the wire harness vertically and horizontally.
HINT The connector joint and fulcrum of the vibration are the major areas that should be checked
thoroughly.
(b) HEAT METHOD:
When a malfunction seems to occur when the area in question is heated.
(1) Heat the component that is the possible cause of the malfunction with a hair dryer or similar
device. Check if the malfunction occurs.
NOTICE: *
Do not heat to more than 60°C (140°F). Exceeding this temperature may damage components.
* Do not apply heat directly to the parts in the ECU.
(c) WATER SPRINKLING METHOD:
When a malfunction seems to occur on a rainy day or in high-humidity.
(1) Sprinkle water onto the vehicle and check if the malfunction occurs.
NOTICE: *
Never sprinkle water directly into the engine compartment. Indirectly change the temperature and
humidity by spraying water onto the front of the radiator.
* Never apply water directly onto the electronic components.
HINT If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU
or connections. Look for evidence of corrosion or short circuits. Proceed with caution during water
tests.
(d) HIGH ELECTRICAL LOAD METHOD:
When a malfunction seems to occur when the electrical load is excessive.
(1) Turn on the heater blower, headlights, rear window defogger and all other electrical loads.
Check if the malfunction reoccurs.
5. DIAGNOSTIC TROUBLE CODE CHART
Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate
section's Diagnostic Trouble Code Chart. Use the chart to determine the trouble area and the
proper inspection procedure. A description of each of the chart's columns is below.
Components
Camshaft Position Sensor: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT POSITION SENSOR: COMPONENTS
Page 6077
Page 7214
Service and Repair
Oil Change Reminder Lamp: Service and Repair
Oil Change Reset Procedure
1. Turn the engine switch off with the trip meter A reading shown.
2. While pressing the trip meter reset button, turn the engine switch on.
Without multi-information display
3. Continue to press and hold the button until the trip meter displays 000000.
With multi-information display
3. Continue to press and hold the button until "MAINT REQD RESET MODE COMPLETE" appears
in the display.
Navigation Maintenance Item Setting (If equipped)
When the navigation system is turned on, the "Information" screen displays when it is time to
replace a part or certain components.
1. Push the "INFO" button.
2. Touch "Maintenance"
3. Touch the desired button.
"Delete All": To cancel all conditions which have been input.
"Reset All" : To reset the item which has satisfied a condition.
If "ON" is selected, the system gives maintenance information with the "Information" screen when
the system is turned on.
If "OFF" is selected, the "Information" screen is disabled.
When the vehicle needs to be serviced, the touch screen button color will change to orange.
4. Input the conditions.
Notice of "Date": The next maintenance date can be input.
Notice of "Distance": The driving distance until the next maintenance check can be input.
"Delete": To cancel the date and distance conditions.
"Reset": To reset the date and distance conditions.
5. Touch "OK" The screen returns to the "Maintenance" screen.
Note:
- For scheduled maintenance information, please refer to the Scheduled maintenance guide or
Owners manual supplement.
- Depending on your driving or the road conditions, the system may have a time-lag between the
data which has been input and the actual date and driving distance.
Page 8830
NOTICE: Do not touch the cone part of the speaker.
Installation
AUDIO / VISUAL: INSTRUMENT PANEL SPEAKER (for CrewMax): INSTALLATION
1. INSTALL FRONT NO. 4 SPEAKER ASSEMBLY (for 12 Speakers)
(a) Connect the connector.
(b) Temporarily install the speaker by aligning the positioning pins of the speaker with the
instrument panel.
(c) Install the speaker with the 2 bolts.
NOTICE: *
Do not touch the cone part of the speaker.
* When installing the speaker to the instrument panel, be careful that the wires do not get caught
between the parts.
2. INSTALL NO. 3 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY
(a) Attach the 6 clips and 2 claws to install the speaker panel.
3. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY RH
(a) Connect the speaker connector.
Page 6639
Removal
OTHER SYSTEM: CENTER POWER OUTLET SOCKET (for Column Shift Type): REMOVAL
1. REMOVE FRONT SEAT ASSEMBLY LH (for Manual Seat)
(a) Remove the front seat LH See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Manual
Seat)/Removal.
2. REMOVE FRONT SEAT ASSEMBLY RH (for Manual Seat)
HINT Use the same procedures described for the LH side.
Page 282
(2) Disconnect connector B and measure the resistance.
Standard resistance (Fig. 7):
* If the results match the examples above, a short circuit exists between terminal 1 of connector B2
and terminal 1 of connector C.
4. CHECK AND REPLACE ECU
NOTICE: *
The connector should not be disconnected from the ECU. Perform the inspection from the backside
of the connector on the wire harness side.
* When no measuring condition is specified, perform the inspection with the engine stopped and
the ignition switch ON.
* Check that the connectors are fully seated. Check for loose, corroded or broken wires.
(a) First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be
faulty. Temporarily replace the ECU with a
normally functioning one and check if the symptoms occur. If the trouble symptoms disappear,
replace the original ECU.
(1) Measure the resistance between the ECU ground terminal and body ground.
Standard resistance:
Below 1 Ohms
(2) Disconnect the ECU connector. Check the ground terminal on the ECU side and wire harness
side for bending, corrosion or foreign matter.
Lastly, check the contact pressure of the female terminals.
Components
Oil Pressure Sender: Service and Repair Components
1UR-FE LUBRICATION: OIL PRESSURE SWITCH: COMPONENTS
Page 256
Instrument Panel (Floor Shift)
Instrument Panel (Column Shift)
Page 1136
Air Flow Meter/Sensor: Diagrams
Page 6747
Driver Side J/B Inner Circuit
Page 4132
Page 3814
Locations
Collision Avoidance Module: Locations
PARK ASSIST / MONITORING: INTUITIVE PARKING ASSIST SYSTEM: PARTS LOCATION
Page 7999
4. INSTALL LOWER NO. 2 STEERING WHEEL COVER
(a) w/ Cruise Control:
(1) Attach the 2 claws to install the cover.
(b) w/o Cruise Control:
(1) Attach the 2 claws to install the cover.
5. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
6. INSPECT STEERING PAD
(a) With the steering pad installed on the vehicle, perform a visual check. If there are any defects
as mentioned below, replace the steering pad
with a new one:
Cuts, minute cracks or marked discoloration on the steering pad top surface or in the grooved
portion.
(b) Check that the horn sounds.
If the horn does not sound, inspect the horn system.
7. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
Inspection
Variable Valve Timing Actuator: Testing and Inspection Inspection
1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT OIL CONTROL VALVE: INSPECTION
1. INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) If the result is not as specified, replace the camshaft timing oil control valve assembly.
(c) Connect the battery's positive (+) lead to terminal 1 and the negative (-) lead to terminal 2, and
check the movement of the valve.
OK:
(d) If the result is not as specified, replace the camshaft timing oil control valve assembly. If the
valve cannot return properly because of foreign
matter, a small pressure leak in the advanced direction may occur and a DTC may be output.
Page 3686
C. Choose desired ECU group(s) in the Health Check dialog box.
D. Click Next.
E. Click Continue to view Health Check results.
F. Available calibration updates are indicated by a link in the Cal. Update? column. Click the link to
access the appropriate service bulletin on TIS.
NOTE
^ Note any DTCs stored in Systems that will be flash reprogrammed.
^ Clicking the link will automatically launch TIS and perform a calibration search.
G. Log in to TIS. (If already logged in skip this step.)
H. To review the TSB and access the calibration file click the service bulletin link in the Document
Title column of the Calibration Search Result
portlet.
Page 6811
Engine Room Main Wire
Airbag System
Seat Occupant Classification Module - Air Bag: Locations Airbag System
SUPPLEMENTAL RESTRAINT SYSTEM: AIRBAG SYSTEM: PARTS LOCATION
Locations
Neutral Safety Switch: Locations
1UR-FE STARTING: STARTING SYSTEM: PARTS LOCATION
Page 3861
Power Steering Pressure Switch: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: POWER STEERING OIL PRESSURE SWITCH:
REMOVAL
1. REMOVE FAN AND GENERATOR V BELT
(a) Remove the fan and generator V belt See: Engine, Cooling and Exhaust/Engine/Drive Belts,
Mounts, Brackets and Accessories/Drive
Belt/Service and Repair/Removal.
2. REMOVE FRONT WHEEL
3. REMOVE FRONT FENDER APRON SEAL RH See: Engine, Cooling and Exhaust/Exhaust
System/Exhaust Manifold/Service and
Repair/Removal
4. DRAIN POWER STEERING FLUID
5. REMOVE POWER STEERING OIL PRESSURE SWITCH
(a) Disconnect the power steering oil pressure switch connector.
(b) Remove the power steering oil pressure switch.
(c) Remove the O-ring.
Page 6214
Removal
OTHER SYSTEM: POWER OUTLET SOCKET (for Floor Shift Type): REMOVAL
1. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal
2. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding
/ Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
3. REMOVE REAR UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
4. REMOVE CENTER LOWER INSTRUMENT PANEL FINISH PANEL See: Body and
Frame/Interior Moulding / Trim/Dashboard / Instrument
Page 9086
Connectors Part 4
Locations: The locations of components, connectors, ground points, and splices referred to within
these diagrams can be found at Vehicle Locations. See: Locations
Page 3834
Page 6934
Relay Box: Connector Views
Engine Room R/B, J/B - Engine Compartment Left
Power Steering Oil Pressure Sensor
Power Steering Pressure Switch: Diagrams Power Steering Oil Pressure Sensor
Page 4217
Page 2705
Exhaust Manifold: Service and Repair Removal
1UR-FE EXHAUST: EXHAUST MANIFOLD: REMOVAL
1. REMOVE FRONT FENDER APRON SEAL RH
(a) Remove the 6 clips and fender apron seal.
2. REMOVE FRONT FENDER APRON SEAL REAR RH
(a) Remove the 5 clips and fender apron seal.
3. REMOVE FRONT FENDER APRON SEAL LH
(a) Remove the 6 clips and fender apron seal.
4. REMOVE FRONT FENDER APRON SEAL REAR LH
(a) Remove the 5 clips and fender apron seal.
5. REMOVE INTAKE MANIFOLD ASSEMBLY
(a) Remove the intake manifold See: Engine/Intake Manifold/Service and Repair/Removal.
6. REMOVE GENERATOR ASSEMBLY
(a) Remove the generator See: Starting and Charging/Charging System/Alternator/Service and
Repair/Removal and Replacement/Removal.
7. DISCONNECT COOLER COMPRESSOR ASSEMBLY See: Heating and Air
Conditioning/Compressor HVAC/Service and Repair/Removal
and Replacement/Removal
8. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE
(a) Remove the dipstick.
(b) Remove the bolt and dipstick guide.
(c) Remove the O-ring from dipstick guide.
9. REMOVE EXHAUST PIPE ASSEMBLY
(a) for regular cab standard deck:
Remove the exhaust pipe See: Exhaust Pipe/Service and Repair/Exhaust Pipe (for Regular Cab
Standard Deck)/Removal.
(b) except regular cab standard deck:
Remove the exhaust pipe See: Exhaust Pipe/Service and Repair/Exhaust Pipe (Except Regular
Cab Standard Deck)/Removal.
10. REMOVE FRONT PROPELLER SHAFT ASSEMBLY (for 4WD) See: Transmission and
Drivetrain/Drive/Propeller Shafts, Bearings and
Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Front Propeller Shaft
Assembly/Removal
11. REMOVE FRONT NO. 4 FLOOR HEAT INSULATOR
(a) Remove the 4 nuts and front floor heat insulator.
Service and Repair
Repairs and Inspections Required After a Collision: Service and Repair
Repairs and Inspections Required After a Collision
NOTICE: *
Malfunction symptoms of SRS parts are difficult to confirm. DTCs are the most important source of
information when troubleshooting. During troubleshooting, always confirm DTCs before
disconnecting the cable from the negative (-) battery terminal.
* For minor collisions where SRS parts do not deploy, always inspect the SRS parts.
* Before performing repairs, remove airbag sensors if any kind of impact is likely to occur to an
airbag sensor during repairs.
* Never use SRS parts from another vehicle. When replacing SRS parts, replace them with new
ones.
* Never disassemble or attempt to repair SRS parts.
* If an SRS part has been dropped, or if there are any cracks, dents or other defects in the case,
bracket or connector, replace the SRS part with a new one.
* Use an ohmmeter/voltmeter with high impedance (10 kOhms/V minimum) for troubleshooting the
electrical circuits.
* Information labels are attached to the periphery of SRS parts. Follow the cautions and
instructions on the labels.
* After work on the SRS is completed, perform the SRS warning light check See: Air Bag
Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnosis System
* When the cable is disconnected from the negative (-) battery terminal, the memory settings of
each system will be cleared. Because of this, be sure to write down the settings of each system
before starting work. When work is finished, reset the settings of each system as before. Never use
a backup power supply from outside the vehicle to avoid erasing the memory in a system.
* If the vehicle is equipped with a mobile communication system, refer to the precautions.
HINT In the airbag system, the center airbag sensor, front airbag sensor LH and RH, side airbag
sensor LH and RH, door side airbag sensor LH and RH are collectively referred to as the airbag
sensors.
INSPECTION PROCEDURE FOR VEHICLE INVOLVED IN ACCIDENT
(a) When the airbag has not deployed, confirm the DTCs by checking the SRS warning light. If
there is any malfunction in the SRS airbag system,
perform troubleshooting.
(b) When any of the airbags have deployed, replace the airbag sensors and check the installation
condition.
Page 8085
Removal
SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Double Cab): REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Disassembly
3. REMOVE FRONT ARMREST BASE PANEL UPPER LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Adjustments
Parking Assist Control Module: Adjustments
PARK ASSIST / MONITORING: CLEARANCE WARNING ECU: ADJUSTMENT
1. ADJUST BUZZER VOLUME
(a) Turn the knob on the clearance warning ECU to adjust the volume.
Page 8254
Removal
SEAT BELT: FRONT SEAT OUTER BELT ASSEMBLY (for Regular Cab): REMOVAL
HINT *
Use the same procedures for the LH side and RH side.
* The procedures listed below are for the LH side.
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE FRONT SEAT ASSEMBLY
Initial Inspection and Diagnostic Overview
Neutral Safety Switch: Initial Inspection and Diagnostic Overview
A760F AUTOMATIC TRANSMISSION: PARK / NEUTRAL POSITION SWITCH: ON-VEHICLE
INSPECTION
1. INSPECT PARK/NEUTRAL POSITION SWITCH ASSEMBLY
(a) Apply the parking brake and turn the ignition switch to ON.
(b) Depress the brake pedal and check that the engine starts when the shift lever is in N or P, but
does not start when the shift lever is in other
positions.
(c) Check that the back-up light illuminates and the reverse warning buzzer sounds when the shift
lever is in R, but do not function when the shift
lever is in other positions.
Page 5294
SST : 09955-04100
NOTICE: Pull out the spider bearing until the SST claws contact the propeller shaft yoke.
(l) Clamp the protruding universal joint spider bearing in a vise.
(m)Using a brass bar and hammer, tap the propeller shaft yoke to remove the universal joint spider
bearing.
NOTICE: Do not tap the propeller shaft tube.
HINT Use the same removal procedure for the universal joint spider bearing on the opposite side.
(n) Remove the spider from the propeller shaft.
2. REMOVE NO. 1 CENTER SUPPORT BEARING ASSEMBLY (for 3 Joint Type)
(a) Fix the center support bearing in a vise.
(b) Using a chisel and hammer, loosen the staked part of the lock nut. Then remove the lock nut.
(c) Place matchmarks on the joint yoke and shaft.
(d) Using a brass bar and hammer, tap the end of the intermediate shaft to remove the joint yoke,
washer and center support bearing from the
intermediate shaft.
3. REMOVE REAR PROPELLER SHAFT UNIVERSAL JOINT SPIDER BEARING
HINT Use the same removal procedure for both the front and rear propeller shaft universal joint
spider bearings.
(a) Place matchmarks on the flange yoke and shaft.
Page 2065
"Case2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 938
(a) Remove the packing.
(b) Remove the 6 screws and detach the 4 claws.
(c) Remove the blower case (back side).
(d) Remove the evaporator from the blower case (front side).
17. REMOVE NO. 1 COOLER THERMISTOR
(a) Remove the No. 1 cooler thermistor.
Page 3509
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO MAIN BODY ECU (CANH,
CANL)
OK -- REPLACE MAIN BODY ECU
15. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (SKID CONTROL ECU WITH ACTUATOR)
(a) Disconnect the A17 skid control ECU with actuator connector.
Service and Repair
Cabin Air Filter: Service and Repair
Step 1. Turn the engine switch off.
Step 2. Open the glove box.
Step 3. Remove the tray.
Components
Manifold Pressure/Vacuum Sensor: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: MANIFOLD ABSOLUTE PRESSURE SENSOR:
COMPONENTS
Engine Controls - ECM Update For Shift Performance
Engine Control Module: Customer Interest Engine Controls - ECM Update For Shift Performance
T-SB-0285-10
October 12, 2010
ECM Calibration: Enhancement to Shifting Performance
Service Category Drivetrain
Section Automatic Transmission/Transaxle
Market USA
Applicability
Introduction
Some vehicles may exhibit the following shifting conditions:
^ Harsh shift on acceleration below 20 mph during the 2-1 downshift.
^ Excessive lock-up operation at freeway speeds about 50 - 60 mph, sometimes referred to as
"busy shifting".
The Engine Control Module/ECM (SAE term: Powertrain Control Module/PCM) calibration has
been revised. Use the following repair procedure to address these conditions.
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Federal Emission Warranty. This warranty is in effect for
96 months or 80,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Page 3026
(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(2) If the result is not as specified, replace the MAF meter.
Page 2361
Page 1837
Parts Information
Required Tools & Equipment
Repair Procedure
1. Confirm the condition matches the Introduction.
Page 4631
Spark Plug: Service and Repair Removal
1UR-FE IGNITION: IGNITION COIL AND SPARK PLUG: REMOVAL
1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Removal
2. REMOVE AIR CLEANER ASSEMBLY
(a) Disconnect the MAF meter connector and clamp.
(b) Disconnect the ventilation hose and vacuum hose.
(c) Loosen the hose clamp.
(d) Remove the 2 bolts and air cleaner.
3. REMOVE IGNITION COIL ASSEMBLY
(a) for Bank 1:
(1) Disconnect the 3 wire harness clamps.
(2) Disconnect the 4 ignition coil connectors.
(3) Remove the 4 bolts and 4 ignition coils.
(b) for Bank 2:
(1) Disconnect the 2 wire harness clamps.
(2) Disconnect the 4 ignition coil connectors.
(3) Disconnect the engine wire harness clamp.
Locations
Main Relay (Computer/Fuel System): Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Components
Yaw Rate Sensor: Service and Repair Components
BRAKE CONTROL: YAW RATE AND DECELERATION SENSOR: COMPONENTS
Page 2592
This TSB applies to all Sequoia and Tundra vehicles equipped with lUR-FE (4.6L) 2UZ-FE (4.7L)
and 3UR-FE/FBE (5.7L) engines produced BEFORE the Production Change Effective VINs shown.
Repair Procedure
1. Remove and replace the air cleaner lid.
2. Remove and replace the front right hand (RH) fender liner.
Page 1139
(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(2) If the result is not as specified, replace the MAF meter.
Locations
Actuator: Locations
JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION
Page 3052
Crankshaft Position Sensor: Diagrams
Components
Engine Temperature Sensor: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: ENGINE COOLANT TEMPERATURE SENSOR:
COMPONENTS
Page 3501
B -- REPLACE ECM
A -- REPLACE ECM See: Engine Control Module/Service and Repair/Removal
Short to B+ in CAN Bus Line
CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: Short to B+ in CAN Bus Line - Short
to B+ in CAN Bus Line
DESCRIPTION
There may be a short circuit between the CAN bus line and +B when there is resistance between
terminals 6 (CANH) and 16 (BAT) or terminals 14 (CANL) and 16 (BAT) of the DLC3.
HINT *
*1: w/ Bus Buffer ECU
* *2: w/ 4WD
* *3: w/ Power Steering ECU
WIRING DIAGRAM
Locations
Telescoping Wheel Switch: Locations
STEERING COLUMN: POWER TILT AND POWER TELESCOPIC STEERING COLUMN
SYSTEM: PARTS LOCATION
Removal and Replacement
Auxiliary Step / Running Board: Removal and Replacement
Components
EXTERIOR: SIDE STEP: COMPONENTS
Page 6304
Driver Side J/B Inner Circuit
Page 507
Steering Control Module: Service and Repair Installation
POWER STEERING: POWER STEERING ECU (for 1UR-FE): INSTALLATION
1. INSTALL POWER STEERING ECU ASSEMBLY
(a) Install the power steering ECU with the nut.
Torque : 8.5 Nm (87 kgf-cm, 75 in-lbf)
(b) Connect the power steering ECU connector.
2. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column
Shift Type)/Installation
3. INSTALL LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY See: Restraint
Systems/Air Bag Systems/Air Bag/Service and
Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Installation
4. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Installation
5. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
6. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Installation
7. INSTALL FRONT DOOR SCUFF PLATE LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining
(For Regular Cab)/Installation
Page 5660
Torque : 11 Nm (107 kgf-cm, 8 ft-lbf)
(b) Connect the speed sensor connector (labeled C).
NOTICE: Securely connect the connector.
4. INSTALL REAR WHEEL See: Steering and Suspension/Suspension/Suspension Strut / Shock
Absorber/Service and Repair/Removal and
Replacement/Rear Shock Absorber/Installation
5. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
6. CHECK SPEED SENSOR SIGNAL
(a) Check the speed sensor signal See: Testing and Inspection/Scan Tool Testing and
Procedures/Test Mode Procedure.
Up to 11/2009
Electronic Brake Control Module: Locations Up to 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 1966
Brake Bleeding: Service and Repair Replacement
BRAKE: BRAKE FLUID: REPLACEMENT
NOTICE: *
Perform fluid replacement with the parking brake applied.
* Perform fluid replacement while maintaining the brake fluid level between the MIN/MAX level on
the brake fluid reservoir.
* Do not allow brake fluid to contact the vehicle's paint surfaces. If contact occurs, clean it off
immediately.
* Add fluid to the brake fluid reservoir as necessary so that the fluid does not decrease below the
MIN level.
1. REPLACE BRAKE FLUID
(a) Replace the brake fluid.
(1) Remove the brake master cylinder reservoir filler cap assembly.
(2) Add brake fluid into the reservoir between MAX and MIN level on the brake fluid reservoir.
Brake fluid:
SAE J1703 or FMVSS No. 116 DOT3
(3) Connect a vinyl tube to the bleeder plug of the front disc brake cylinder RH.
(4) Depress the brake pedal several times, and then loosen the bleeder plug with the pedal
depressed.*1
(5) When fluid stops coming out, tighten the bleeder plug, and then release the brake pedal.*2
(6) Repeat *1 and *2 until all the air in the brake fluid is completely bled out and the new brake fluid
comes out.
(7) Tighten the bleeder plug completely.
Torque : 11 Nm (110 kgf-cm, 8 ft-lbf)
(8) Replace the brake fluid from the front disc brake cylinder LH using the same procedure as for
RH.
(9) Connect a vinyl tube to the bleeder plug of the rear disc brake cylinder RH.
(10)Depress the brake pedal several times, and then loosen the bleeder plug with the pedal
depressed.*1
(11)When fluid stops coming out, tighten the bleeder plug, and then release the brake pedal.*2
(12)Repeat *1 and *2 until all the air in the brake fluid is completely bled out and the new brake
fluid comes out.
(13)Tighten the bleeder plug completely.
Torque : 11 Nm (110 kgf-cm, 8 ft-lbf)
(14)Replace the brake fluid from the rear disc brake cylinder LH using the same procedure as for
RH.
(b) Check and bleed brake system.
(1) If the following malfunction symptoms occur, air may have entered the brake fluid line. Perform
the following air bleed procedures.
* Low pedal or spongy pedal.
* Brake pedal is depressed firmly but braking is insufficient.
(c) Inspect for the brake fluid leak.
(d) Check and adjust brake fluid level in reservoir See: Fluids/Brake Fluid/Testing and Inspection.
Page 8574
HINT The type of claw on the top and bottom of the sensor are different. Observe the claws
carefully before removing the sensor.
12. REMOVE NO. 1 ULTRASONIC SENSOR RETAINER
(a) Detach the 2 claws and remove the sensor retainer from the front bumper.
Installation
PARK ASSIST / MONITORING: ULTRASONIC SENSOR (for Front Side): INSTALLATION
1. INSTALL NO. 1 ULTRASONIC SENSOR RETAINER
(a) Align the keyhole and protrusion as shown in the illustration.
(b) Install the sensor retainer to the front bumper.
NOTICE: Do not damage the bumper with the protrusion when installing the retainer.
2. INSTALL NO. 1 ULTRASONIC SENSOR
(a) Attach the 2 claws to install the ultrasonic sensor.
Page 528
9. CHECK TIRE PRESSURE AFTER REPAIRS
(a) After repairs, confirm that the actual tire pressures are displayed in the DATA LIST See:
Instrument Panel, Gauges and Warning
Indicators/Tire Monitoring System/Testing and Inspection/Scan Tool Testing and Procedures/Data
List / Active Test.
Page 1649
Removal
WINDSHIELD / WINDOWGLASS: POWER WINDOW MASTER SWITCH: REMOVAL
1. REMOVE FRONT UPPER ARMREST BASE PANEL LH
(a) Using a screwdriver, detach the 2 clips and 5 claws, and remove the front upper armrest base
panel.
Page 5638
Traction Control Switch: Service and Repair Installation
BRAKE CONTROL: VSC OFF SWITCH: INSTALLATION
1. INSTALL VSC OFF SWITCH
(a) Attach the 2 claws to install the VSC OFF switch into the lower instrument panel finish panel
LH.
(b) Connect the VSC OFF switch connector.
2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Installation
3. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Installation
4. INSTALL FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Installation
5. INSTALL FRONT DOOR SCUFF PLATE LH (for Double Cab, CrewMax) See: Body and
Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Installation
Page 8174
(e) Connect the holder (with connectors).
(f) Check that the waterproof sheet is properly set.
2. INSTALL FRONT CONSOLE BOX See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal
and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation
3. INSTALL REAR CONSOLE BOX ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation
4. INSTALL CONSOLE BOX CARPET
5. INSTALL REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
6. INSTALL UPPER CONSOLE REAR PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
7. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding
/ Trim/Dashboard / Instrument Panel/Service
and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
8. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation
9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
10. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Air Bag Systems/Testing and Inspection/Initial Inspection
and Diagnostic Overview/Diagnosis System.
Recall 10V017000: Accelerator Pedal Sticking
Accelerator Pedal Position Sensor: All Technical Service Bulletins Recall 10V017000: Accelerator
Pedal Sticking
VEHICLE MAKE/MODEL: MODEL YEAR(S): Toyota/Avalon 2005-2010 Toyota/Camry 2007-2010
Toyota/Corolla 2009-2010 Toyota/Corolla Matrix 2009-2010 Toyota/Highlander 2010 Toyota/ RAV4
2009-2010 Toyota/Sequoia 2008-2010 Toyota/Tundra 2007-2010 MANUFACTURER: Toyota
Motor North America, Inc.
MFR'S REPORT DATE: January 21, 2010
NHTSA CAMPAIGN ID NUMBER: 10V017000
NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Accelerator Assembly:
Pedal/Linkage
POTENTIAL NUMBER OF UNITS AFFECTED: ?
SUMMARY: Toyota is recalling certain model year 2005-2010 Avalon, model year 2007-2010
Camry, model year 2009-2010 Corolla, Corolla Matrix, RAV4, model year 2010 Highlander, model
year 2008-2010 Sequoia, and model year 2007-2010 Tundra. due to the manner in which the
friction lever interacts with the sliding surface of the accelerator pedal inside the pedal sensor
assembly, the sliding surface of the lever may become smooth during vehicle operation. In this
condition, if condensation occurs on the surface, as may occur from heater operation (without A/C)
when the pedal assembly is cold, the friction when the accelerator pedal is operated may increase,
which may result in the accelerator pedal becoming harder to depress, slower to return, or, in the
worst case, mechanically stuck in a partially depressed position.
CONSEQUENCE: The accelerator pedal may become hard to depress, slow to return to idle, or, in
the worst case, mechanically stuck in a partially depressed position, increasing the risk of a crash.
REMEDY: Toyota has not yet provided a remedy plan or an owner notification schedule. Owners
may contact Toyota at 1-800-331-4331.
NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle
Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov.
Page 2058
Use a volt/ohmmeter with high impedance (10 kohms/V minimum) for troubleshooting of the
electrical circuit.
Disconnection of Male and Female Connectors
DISCONNECTION OF MALE AND FEMALE CONNECTORS
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Finding A Short Circuit
FINDING A SHORT CIRCUIT
Page 261
Page 9341
2. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH
(a) for Steel Type Bumper:
Remove the front fender splash shield.
(1) Remove the 3 clips and 2 screws and fender splash shield.
(b) for Resin Type Bumper:
Remove the front fender splash shield.
(1) Using a screwdriver, remove the pin hold clip.
(2) Remove the 2 clips, 2 screws and fender splash shield.
Page 4009
Air Injection Control Valve: Testing and Inspection Air Switching Valve (for Bank 2)
1UR-FE EMISSION CONTROL: AIR SWITCHING VALVE (for Bank 2): INSPECTION
1. INSPECT AIR SWITCHING VALVE ASSEMBLY
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) If the result is not as specified, replace the air switching valve.
(c) Check the operation of the air switching valve.
(1) Check that air does not flow from port A to port B.
NOTICE: Make sure the applied pressure is 30 kPa (0.3 kgf/cm2, 4.4 psi) or less.
(2) If the result is not as specified, replace the air switching valve.
(3) Apply battery voltage across terminals 1 and 2.
NOTICE: When applying voltage, do not touch terminals 3, 4 and 5.
Page 6702
Page 4743
2. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in
Figure 1. Confirm if the ECM (PCM) calibration has
been updated. If the calibration ID listed is NOT the latest ECM (PCM) calibration - go to step 3.
3. Flash reprogram the ECM (PCM).
NOTE
^ The GR8 Battery Diagnostic Station MUST be used in Power Supply Mode to maintain battery
voltage at 13.5 volts while flash reprogramming the vehicle.
^ For details on how to use the GR8 Battery Diagnostic Station, refer to the located on the
Technical Information System (TIS), Diagnostics - Battery
Follow the procedures outlined in TSB No. T-SB-0064-10, "Techstream ECU Flash
Reprogramming Procedure1⁄4 and flash the ECM (PCM) with the NEW calibration file update.
4. Install the Authorized Modifications Label.
A. Using a permanent marker enter the following information on the label:
^ ECM part number [Refer to the Parts Information section for the CURRENT PART NUMBER]
^ Calibration ID(s) [Refer to the Calibration Identification Chart for the NEW CALIBRATION ID]
^ Dealer Code
^ Repair Date
^ Change Authority [This TSB number]
B. Affix the Authorized Modifications Label to the vehicle at the location shown in Figure 1. The
Authorized Modifications Label is available
through the MDC P/N 00451-00001-LBL.
5. Test drive the vehicle to confirm proper vehicle operation.
Page 8846
Removal
AUDIO / VISUAL: REAR DOOR SPEAKER (for CrewMax): REMOVAL
HINT *
Use the same procedures for the LH side and RH side.
* The procedures listed below are for the LH side.
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE REAR DOOR FRAME GARNISH LH See: Body and Frame/Doors, Hood and
Trunk/Doors/Rear Door/Service and Repair/Rear
Door (for CrewMax)/Disassembly
3. REMOVE REAR DOOR INSIDE HANDLE BEZEL PLUG LH See: Body and Frame/Doors, Hood
and Trunk/Doors/Rear Door/Service and
Repair/Rear Door (for CrewMax)/Disassembly
Page 866
Engine Temperature Sensor: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: ENGINE COOLANT TEMPERATURE SENSOR:
INSTALLATION
1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR
(a) Install a new gasket to the sensor.
(b) Using a 19 mm ball joint lock nut wrench, install the sensor.
Torque : 20 Nm (200 kgf-cm, 14 ft-lbf)
NOTICE: Use the formula to calculate special torque values for situations where ball joint lock nut
wrench is combined with a torque wrench See: Service Precautions
(c) Connect the sensor connector.
2. ADD ENGINE COOLANT See: Engine, Cooling and Exhaust/Cooling System/Coolant/Service
and Repair
3. INSPECT FOR COOLANT LEAK See: Engine, Cooling and Exhaust/Cooling System/Testing
and Inspection
4. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Installation
5. INSTALL NO. 1 ENGINE UNDER COVER See: Engine, Cooling and Exhaust/Engine/Engine
Lubrication/Engine Oil/Service and
Repair/Replacement
Page 3387
* In the DTC check, it is very important to determine whether the problem indicated by the DTC is
either: 1) still occurring; or 2) occurred in the past but has since returned to normal. In addition, the
DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs
should be checked before and after confirmation of symptoms (i.e., whether or not problem
symptoms exist) to determine current system conditions, as shown in the flowchart below.
* Never skip the DTC check. Failing to check DTCs may, depending on the case, result in
unnecessary troubleshooting for systems operating normally or lead to repairs not related to the
problem. Follow the procedures listed in the flowchart in the correct order.
* The following flowchart shows how to proceed with troubleshooting using the DTC check.
Directions from the flowchart will indicate how to proceed either to DTC troubleshooting or to the
troubleshooting of each problem symptom.
1. DTC CHECK
NEXT -- Continue to next step.
2. MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR MEMORY
NEXT -- Continue to next step.
3. SYMPTOM CONFIRMATION
B -- Go to step 5 A -- Continue to next step.
4. SIMULATION TEST USING SYMPTOM SIMULATION METHODS
NEXT -- Continue to next step.
5. DTC CHECK
B -- TROUBLESHOOTING OF PROBLEM INDICATED BY DTC A -- Continue to next step.
6. SYMPTOM CONFIRMATION
Page 8542
Cellular Phone Microphone: Service and Repair Installation
AUDIO / VISUAL: MICROPHONE AMPLIFIER: INSTALLATION
1. INSTALL MICROPHONE AMPLIFIER ASSEMBLY
(a) Attach the 2 claws and clip to install the microphone.
(b) Connect the connector.
2. INSTALL ROOF CONSOLE BOX ASSEMBLY
(a) Install the roof console box See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double
Cab)/Installation.
3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
CAN Communication System
Body Control Module: Locations CAN Communication System
CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: PARTS LOCATION
Page 4458
Air Flow Meter/Sensor: Diagrams
Page 2507
Page 7712
Control Module HVAC: Locations Air Conditioning System (for Manual Air Conditioning System)
AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Manual Air Conditioning System):
PARTS LOCATION
Page 1077
Hazard Warning Switch: Service and Repair Installation
LIGHTING: HAZARD WARNING SWITCH: INSTALLATION
1. INSTALL HAZARD WARNING SWITCH
(a) Attach the 2 claws to install the switch.
2. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Panel,
Gauges and Warning Indicators/Instrument Cluster
/ Carrier/Service and Repair/Combination Meter/Installation
Page 1212
with SST - Torque : 40 Nm (408 kgf-cm, 30 ft-lbf)
HINT *
Use a torque wrench with a fulcrum length of 30 cm (11.8 in.). When using a torque wrench with a
fulcrum length that is not 30 cm (11.8 in.), calculate the torque specification for the torque wrench
and SST based on the "without SST" torque specification See: Service Precautions
* Make sure SST and the wrench are connected in a straight line.
4. INSTALL PROPELLER SHAFT HEAT INSULATOR (for 4WD) See: Transmission and
Drivetrain/Drive/Propeller Shafts, Bearings and
Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Front Propeller Shaft
Assembly/Installation
5. INSTALL FRONT EXHAUST PIPE ASSEMBLY
(a) Install a new gasket and the front exhaust pipe to the exhaust manifold RH with 3 new nuts.
Torque : 54 Nm (554 kgf-cm, 40 ft-lbf)
(b) Connect the air fuel ratio sensor connector.
(c) Connect the heated oxygen sensor connector and 2 clamps.
6. INSTALL CENTER EXHAUST PIPE ASSEMBLY See: Engine, Cooling and Exhaust/Exhaust
System/Exhaust Pipe/Service and
Repair/Exhaust Pipe (for Regular Cab Standard Deck)/Installation
7. INSTALL TAILPIPE ASSEMBLY See: Engine, Cooling and Exhaust/Exhaust System/Exhaust
Pipe/Service and Repair/Exhaust Pipe (for
Regular Cab Standard Deck)/Installation
8. INSPECT FOR EXHAUST GAS LEAK See: Engine, Cooling and Exhaust/Exhaust
System/Exhaust Manifold/Service and Repair/Installation
Specifications
Firing Order: Specifications
Firing Order
1-8-4-3-6-5-7-2
Page 7290
(c) Coat a new piston ring with power steering fluid.
(d) Install the piston ring onto the power steering rack, and position it with your fingers.
2. INSTALL POWER STEERING CYLINDER TUBE OIL SEAL
(a) Coat a new cylinder tube oil seal lip with power steering fluid.
(b) Using SST and a press, install the cylinder tube oil seal.
SST : 09950-60010
09951-00280
09951-00480
09952-06010
SST : 09950-70010
09951-07360
NOTICE: *
Make sure that the cylinder tube oil seal is installed facing in the correct direction.
* Take care not to reverse the cylinder tube oil seal direction when installing.
3. INSTALL POWER STEERING RACK
Page 4187
Page 6213
(a) for AC Power Supply:
Connect the clamp.
(b) Install the bezel with the 3 screws.
5. INSTALL REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
Components
OTHER SYSTEM: POWER OUTLET SOCKET (for Floor Shift Type): COMPONENTS
Page 3275
Parts Information
Calibration Information
Required Tools & Equipment
Repair Procedure
Power Source Control ECU
Power Distribution Module: Diagrams Power Source Control ECU
Page 4130
Page 4216
Page 1443
Center Airbag Sensor Assembly (for Column Shift Type)
Air Bag Control Module: Service and Repair Center Airbag Sensor Assembly (for Column Shift
Type)
Components
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Column
Shift Type): COMPONENTS
Page 2283
Variable Valve Timing Actuator: Diagrams
Page 9025
NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do
not operate the ignition switch, any other switches, or the doors.
(a) If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the
harness and connector.
(b) Connect the cable of the Techstream to the DLC3, turn the ignition switch ON and attempt to
use the tester. If the display indicates that a
communication error has occurred, there is a problem either with the vehicle or with the tester.
HINT *
If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of
the original vehicle.
* If communication is still not possible when the tester is connected to another vehicle, the problem
may be in the tester itself. Consult the Service Department listed in the tester's instruction manual.
How To Proceed With Troubleshooting
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: HOW TO
PROCEED WITH TROUBLESHOOTING
1. OPERATION FLOW
HINT Perform troubleshooting in accordance with the procedures below. The following is an outline
of basic troubleshooting procedures. Confirm the troubleshooting procedures for the circuit you are
working on before beginning troubleshooting.
1. VEHICLE BROUGHT TO WORKSHOP
NEXT -- Continue to next step.
2. CUSTOMER PROBLEM ANALYSIS
(a) Ask the customer about the conditions and environment when the problem occurred.
NEXT -- Continue to next step.
3. INSPECT BATTERY VOLTAGE
Standard voltage:
11 to 14 V
If the voltage is below 11 V, recharge or replace the battery before proceeding.
NEXT -- Continue to next step.
Page 9218
(e) Remove the inside handle.
Reassembly
ENGINE HOOD / DOOR: FRONT DOOR (for Double Cab): REASSEMBLY
FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH
HINT *
Use the same procedures for the RH side and LH side.
* The procedures listed below are for the LH side.
* A bolt without a torque specification is shown in the standard bolt chart See:
Specifications/Mechanical Specifications/Standard Bolt - Specified Torque For Standard Bolts
1. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH
(a) Connect the 2 cables to the inside handle.
(b) Connect the connector.
(c) Attach the inside handle's knob to the door trim board.
(d) Attach the 9 clips to install the door trim board.
(e) Install the inside handle and door trim board to the door trim panel with the screw.
(f) Install the door trim board to the door panel with the screw.
(g) Install the clip.
2. INSTALL FRONT DOOR ARMREST COVER LH
Page 8970
Remote Switch: Service and Repair Removal
AUDIO / VISUAL: STEERING PAD SWITCH: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE LOWER NO. 2 STEERING WHEEL COVER See: Restraint Systems/Air Bag
Systems/Air Bag/Service and Repair/Removal and
Replacement/Steering Pad/Removal
3. REMOVE LOWER NO. 3 STEERING WHEEL COVER See: Restraint Systems/Air Bag
Systems/Air Bag/Service and Repair/Removal and
Replacement/Steering Pad/Removal
4. REMOVE STEERING PAD See: Restraint Systems/Air Bag Systems/Air Bag/Service and
Repair/Removal and Replacement/Steering
Pad/Removal
5. REMOVE STEERING PAD SWITCH ASSEMBLY
(a) Disconnect the connector.
(b) Remove the 2 screws.
(c) Detach the 4 pins and remove the steering pad switch.
Page 3687
NOTE
Only Toyota Certified Technicians and above may access calibration files.
2. Connect the GR8 Battery Diagnostic Station.
A. Connect the GR8 Battery Diagnostic Station to the vehicle and turn it ON.
B. Select Power Supply Mode by following the screen flow below.
NOTICE
^ ECU damage may occur if the correct battery charger and mode setting are NOT used.
Page 187
Push the terminal retainer down to the temporary lock position.
Page 3858
Power Steering Pressure Switch: Testing and Inspection
1UR-FE ENGINE CONTROL SYSTEM: POWER STEERING OIL PRESSURE SWITCH:
ON-VEHICLE INSPECTION
1. INSPECT POWER STEERING OIL PRESSURE SWITCH
(a) Check the oil pressure switch.
(1) Connect the Techstream to the DLC3.
(2) Turn the ignition switch to ON.
(3) Turn the Techstream main switch on.
(4) Enter the following menus: Powertrain / Engine and ECT / Data List / All Data / Power Steering
pressure.
(5) Start the engine.
(6) Operate the steering wheel while idling, and read the value on the Techstream.
Standard:
(7) If not as specified, check for DTCs See: Testing and Inspection/Reading and Clearing
Diagnostic Trouble Codes/DTC Check / Clear. If
the power steering system inspection results are normal and a DTC is not output, replace the
power steering oil pressure switch.
Inspect the power steering system See: Steering and Suspension/Steering/Testing and
Inspection/Component Tests and General Diagnostics/Power Steering System/On-Vehicle
Inspection. If the power steering system inspection results are normal and a DTC is not output,
replace the power steering oil pressure switch.
Page 944
(a) Install the motor with the 3 screws.
11. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY
(a) Install the amplifier with the 2 screws.
12. INSTALL NO. 2 AIR DUCT SUB-ASSEMBLY
(a) install the duct with the screw.
13. INSTALL CLEAN AIR FILTER
(a) Install the filter as shown in the illustration.
14. INSTALL AIR FILTER COVER PLATE
(a) Attach the 2 clips to install the plate.
Page 7661
Compressor HVAC: Testing and Inspection
AIR CONDITIONING: COMPRESSOR (for 1UR-FE): INSPECTION
1. INSPECT MAGNET CLUTCH ASSEMBLY
(a) Check the magnet clutch operation.
(1) Confirm that the magnet clutch hub and magnet clutch rotor lock when the battery positive lead
is connected to terminal 3 of the magnet
clutch, and the negative lead is connected to the ground wire.
If the operation is not as specified, replace the magnet clutch assembly.
(b) Measure the resistance.
(c) Measure the resistance between terminals 1 and 2.
Standard resistance:
65 to 125 Ohms at 20°C (68°F)
If the resistance is not as specified, replace the cooler compressor assembly.
Components
Manifold Pressure/Vacuum Sensor: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: MANIFOLD ABSOLUTE PRESSURE SENSOR:
COMPONENTS
Recall 11V185000 - TPMS Non-Compliance
Tire Pressure Module: Recalls Recall 11V185000 - TPMS Non-Compliance
VEHICLE MAKE/MODEL: MODEL YEAR(S) Toyota/FJ Cruiser 2011
Toyota/Tundra 2009-2011
MANUFACTURER: Gulf States Toyota, Inc.
MFR'S REPORT DATE: March 16, 2011
NHTSA CAMPAIGN ID NUMBER: 11V185000
NHTSA ACTION NUMBER: N/A
COMPONENT: Tires: Pressure Monitoring and Regulating Systems
POTENTIAL NUMBER OF UNITS AFFECTED: 1,489
SUMMARY: Gulf States Toyota is recalling certain model year 2011 FJ Cruiser and model year
2009-2011 Tundra vehicles for failing to comply with the requirements of Federal Motor Vehicle
Safety Standard No. 138, "Tire Pressure Monitoring Systems." The TPMS on some vehicles may
not have been properly calibrated and as a result the low tire pressure warning lamp may not
illuminate should the inflation pressure in one or more of the vehicle's tires fall below the threshold
for when the low tire pressure warning lamp should illuminate.
CONSEQUENCE: Drivers will not receive a warning from the tire pressuring monitor that one or
more tires are underinflated increasing the risk that a vehicle will be driven with one or more
underinflated tires and increasing the risk of a tire failure that may lead to a crash.
REMEDY: Dealers will recalibrate the tire pressure monitoring system in accordance with the
regulation free of charge. The safety recall is expected to begin during April 2011. Owners may
contact Gulf State Toyota Customer Assistance Center toll free at 1-800-444-1074 Monday through
Thursday, 8:30 AM to 5:00 PM, or Friday 8:30 AM to 4:00 PM Central Standard Time.
NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle
Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov.
Page 5721
Brake Fluid Pressure Sensor/Switch: Locations From 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 2076
NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do
not operate the ignition switch, any other switches, or the doors.
(a) If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the
harness and connector.
(b) Connect the cable of the Techstream to the DLC3, turn the ignition switch ON and attempt to
use the tester. If the display indicates that a
communication error has occurred, there is a problem either with the vehicle or with the tester.
HINT *
If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of
the original vehicle.
* If communication is still not possible when the tester is connected to another vehicle, the problem
may be in the tester itself. Consult the Service Department listed in the tester's instruction manual.
How To Proceed With Troubleshooting
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: HOW TO
PROCEED WITH TROUBLESHOOTING
1. OPERATION FLOW
HINT Perform troubleshooting in accordance with the procedures below. The following is an outline
of basic troubleshooting procedures. Confirm the troubleshooting procedures for the circuit you are
working on before beginning troubleshooting.
1. VEHICLE BROUGHT TO WORKSHOP
NEXT -- Continue to next step.
2. CUSTOMER PROBLEM ANALYSIS
(a) Ask the customer about the conditions and environment when the problem occurred.
NEXT -- Continue to next step.
3. INSPECT BATTERY VOLTAGE
Standard voltage:
11 to 14 V
If the voltage is below 11 V, recharge or replace the battery before proceeding.
NEXT -- Continue to next step.
Page 4175
Page 6855
Multiple Junction Connector: Electrical Diagrams
Junction Connector (CAN LH No.2) Inner Circuit
Components
Tire Pressure Module: Service and Repair Components
TIRE AND WHEEL: TIRE PRESSURE WARNING ECU: COMPONENTS
Page 711
Power Seat Switch: Testing and Inspection Power Seat Switch (w/o Seat Position Memory System)
SEAT: POWER SEAT SWITCH (w/o Seat Position Memory System): INSPECTION
1. INSPECT FRONT POWER SEAT SWITCH LH
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
Slide switch
Front vertical switch
Lifter switch
Page 2781
1. Test drive the vehicle and confirm there is a harsh shift on acceleration below 20 mph and or
excessive lock-up operation at freeway speeds about 50
- 60 mph.
2. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in
Figure 1. Confirm if the ECM (PCM) calibration has
been updated. If the calibration ID listed is NOT the latest ECM (PCM) calibration - go to step 3.
3. Flash reprogram the ECM (PCM).
NOTE
^ The GR8 Battery Diagnostic Station MUST be used in Power Supply Mode to maintain battery
voltage at 13.5 volts while flash reprogramming the vehicle.
^ For details on how to use the GR8 Battery Diagnostic Station, refer to the GR8 Instruction Manual
located on the Technical Information System (TIS), Diagnostics - Battery.
Follow the procedures outlined in TSB No. T-SB-0064-10, "Techstream ECU Flash
Reprogramming Procedure", and flash the ECM (PCM) with the NEW calibration file update.
4. Start the engine and warm it up to normal operating temperature before test driving.
5. Test drive the vehicle to confirm proper vehicle operation and ECM (PCM) initial learning. Refer
to the Technical Information System (TIS) 2010
Tundra Repair Manual:
Drivetrain - Automatic Transmission/Transaxle - "A760E / A760F Automatic
Transmission/Transaxle: Automatic Transmission System: Initialization"
6. Install the Authorized Modifications Label.
A. Using a permanent marker enter the following information on the label:
^ ECM part number [Refer to the Parts Information section for the CURRENT PART NUMBER]
Page 6216
4. INSTALL REAR UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
5. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding
/ Trim/Dashboard / Instrument Panel/Service
and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
6. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation
Page 8708
Page 5137
Fluid - Differential: Fluid Type Specifications
Differential Oil
Type ........................................................................................................................ Toyota Genuine
Differential Gear Oil LT 75W-85 GL-5 or equivalent
Page 185
"Case1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (/\ Mark) and pull the terminal retainer
up to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
A760F Automatic Transmission System
Control Module: Locations A760F Automatic Transmission System
A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS
LOCATION
Page 1998
Testing and Inspection
Variable Induction Control Valve: Testing and Inspection
1UR-FE INTAKE: VACUUM SWITCHING VALVE (for ACIS): ON-VEHICLE INSPECTION
1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Removal
2. INSPECT VACUUM SWITCHING VALVE ASSEMBLY (for ACIS)
(a) Disconnect the vacuum switching valve connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(c) If the result is not as specified, replace the vacuum switching valve assembly.
(d) Check the vacuum switching valve operation.
(1) When applying a vacuum to port E, check that air is sucked into the filter.
(2) Apply voltage across the terminals.
Page 2160
Tire Pressure Sensor: Service and Repair Disposal
TIRE AND WHEEL: TIRE PRESSURE WARNING VALVE AND TRANSMITTER: DISPOSAL
HINT The tire pressure warning valve is powered by a lithium battery. When disposing of the tire
pressure warning valve and transmitter, remove the battery and dispose of it correctly.
1. DISPOSE OF TIRE PRESSURE WARNING VALVE AND TRANSMITTER
(a) Use the tip of a screwdriver to pry off the back cover.
(b) The battery and base board are exposed. While taking out the battery, cut the 2 terminals that
connect the battery to the base board.
Page 2986
Power Steering Pressure Switch: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: POWER STEERING OIL PRESSURE SWITCH:
INSTALLATION
1. INSTALL POWER STEERING OIL PRESSURE SWITCH
(a) Install a new O-ring to the power steering oil pressure switch.
(b) Apply a light coat of engine oil to the O-ring of the power steering oil pressure switch.
NOTICE: *
When reusing the power steering oil pressure switch, inspect the O-ring.
* If the O-ring has scratches or cuts, replace the power steering oil pressure switch.
(c) Using SST, install the power steering oil pressure switch.
SST : 09922-10010
without SST - Torque : 21 Nm (210 kgf-cm, 15 ft-lbf)
with SST - Torque : 15 Nm (148 kgf-cm, 11 ft-lbf)
HINT *
Use a torque wrench with a fulcrum length of 30 cm (11.8 in.). When using a torque wrench with a
fulcrum length that is not 30 cm (11.8 in.), calculate the torque specification for the torque wrench
and SST based on the "without SST" torque specification See: Service Precautions
* Make sure SST and the torque wrench are connected in a straight line.
(d) Connect the oil pressure switch connector.
2. INSTALL FAN AND GENERATOR V BELT
(a) Install the fan and generator V belt See: Engine, Cooling and Exhaust/Engine/Drive Belts,
Mounts, Brackets and Accessories/Drive
Belt/Service and Repair/Installation.
3. ADD POWER STEERING FLUID
4. BLEED POWER STEERING FLUID See: Steering and Suspension/Steering/Testing and
Inspection/Component Tests and General
Diagnostics/Power Steering System/On-Vehicle Inspection
5. INSPECT FOR POWER STEERING FLUID LEAK
6. CHECK FLUID LEVEL See: Steering and Suspension/Steering/Testing and
Inspection/Component Tests and General Diagnostics/Power
Steering System/On-Vehicle Inspection
7. INSTALL FRONT FENDER APRON SEAL RH See: Engine, Cooling and Exhaust/Exhaust
System/Exhaust Manifold/Service and
Repair/Installation
8. INSTALL FRONT WHEEL See: Steering and Suspension/Suspension/Suspension Strut / Shock
Absorber/Service and Repair/Removal and
Replacement/Front Shock Absorber/Installation
Page 3436
Standard resistance:
NG -- CHECK FOR SHORT IN CAN BUS WIRES (AIR CONDITIONING AMPLIFIER) OK -Continue to next step.
20. CHECK FOR SHORT IN CAN BUS WIRES (NO. 2 JUNCTION CONNECTOR - BUS BUFFER
ECU)
NOTICE: For vehicles without a bus buffer ECU, go to "CHECK FOR SHORT IN CAN BUS WIRES
(NO. 2 JUNCTION CONNECTOR - 4WD CONTROL ECU)".
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- CHECK FOR SHORT IN CAN BUS WIRES (BUS BUFFER ECU) OK -- Continue to next
step.
21. CHECK FOR SHORT IN CAN BUS WIRES (NO. 2 JUNCTION CONNECTOR - 4WD
CONTROL ECU)
NOTICE: For vehicles without 4WD, go to "CHECK FOR SHORT IN CAN BUS WIRES (NO. 2
JUNCTION CONNECTOR - ECM)".
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- CHECK FOR SHORT IN CAN BUS WIRES (4WD CONTROL ECU) OK -- Continue to next
step.
22. CHECK FOR SHORT IN CAN BUS WIRES (NO. 2 JUNCTION CONNECTOR - ECM)
(a) Measure the resistance according to the value(s) in the table below.
Page 5283
following procedure.
(a) Adjust the No. 1, No. 2 and No. 3 joint angle.
(1) Support the propeller shaft with a jack.
(2) Remove the 2 center bearing mounting bolts.
(3) Slowly lower the jack, and disconnect the center bearing.
(4) Select an appropriate center support bearing washer thickness from the table below, and obtain
a washer set.
Standard bearing washer thickness:
HINT *
Each set contains 2 washers.
* Using the washer set, perform the adjustment.
* As a reference when selecting a bearing washer, the angle changes as follows for every 1.0 mm
(0.0394 in.) change in bearing washer thickness.
Angle variation for every 1.0 mm (0.0394 in.) change in bearing washer thickness:
No. 1 joint angle 0°04' (0.06°)
No. 2 joint angle 0°07' (0.12°)
No. 3 joint angle 0°04' (0.06°)
7. INSTALL TRANSFER HEAT INSULATOR
(a) Install the heat insulator with the 3 bolts.
Torque : 15 Nm (153 kgf-cm, 11 ft-lbf)
8. INSTALL PROPELLER SHAFT HEAT INSULATOR BRACKET SUB-ASSEMBLY
Page 9087
Trailer Lamps: Testing and Inspection
LIGHTING: LIGHTING SYSTEM: PROBLEM SYMPTOMS TABLE
HINT *
Use the table below to help determine the cause of the problem symptom. The potential causes of
the symptoms are listed in order of probability in the "Suspected Area" column of the table. Check
each symptom by checking the suspected areas in the order they are listed. Replace parts as
necessary.
* Inspect the fuses and relays related to this system before inspecting the suspected areas below.
Page 9208
3. INSTALL COURTESY LIGHT ASSEMBLY
(a) Attach the claw to install the courtesy light.
(b) Connect the connector.
4. INSTALL FRONT NO. 3 SPEAKER ASSEMBLY See: Accessories and Optional
Equipment/Radio, Stereo, and Compact Disc/Speaker/Service
and Repair/Front Door Speaker (for Double Cab)/Installation
5. INSTALL FRONT LOWER DOOR FRAME BRACKET GARNISH LH
(a) Attach the 3 clips to install the front lower door frame bracket garnish.
6. INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY
(a) Install the power window regulator master switch with the 3 screws.
7. INSTALL FRONT UPPER ARMREST BASE PANEL LH
(a) Connect the connectors.
Page 4921
(a) Apply MP grease to the shifting bellcrank as shown in the illustration.
(b) Install the shifting bellcrank with the bolt.
Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)
Disassembly
A760F AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY (for Floor Shift Type):
DISASSEMBLY
1. REMOVE INDICATOR LIGHT WIRE SUB-ASSEMBLY
(a) Using a thin-bladed screwdriver, release the connector housing retainer.
(b) Using a thin-bladed screwdriver, push out terminals 4 (ILL+) and 8 (ILL-) from the rear as
shown in the illustration.
(c) Rotate the indicator light wire counterclockwise to align the wire with the key part of the
transmission floor shift assembly and remove the
wire.
Power Source Control ECU
Power Distribution Module: Diagrams Power Source Control ECU
Page 8985
(a) for Regular Cab:
Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular Cab)/Removal.
(b) for Double Cab:
Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Removal.
(c) for CrewMax:
Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for CrewMax)/Removal.
2. REMOVE COWL SIDE TRIM BOARD LH
(a) for Regular Cab:
Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular Cab)/Removal.
(b) for Double Cab:
Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Removal.
(c) for CrewMax:
Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for CrewMax)/Removal.
3. REMOVE CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service
and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Removal
4. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal
5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Removal
6. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column
Shift Type)/Removal
7. REMOVE FRONT ASH RECEPTACLE BOX SUB-ASSEMBLY
8. REMOVE LOWER INSTRUMENT CLUSTER FINISH PANEL See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column
Shift Type)/Removal
9. REMOVE INSTRUMENT PANEL CUP HOLDER ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column
Shift Type)/Removal
10. REMOVE INTEGRATION CONTROL AND PANEL ASSEMBLY
Page 8986
(a) Detach the 4 clips.
(b) Disconnect the connector and remove the panel.
11. REMOVE GLASS BREAKAGE SENSOR MICROPHONE
(a) Detach the 2 claws and remove the sensor.
Installation
THEFT DETERRENT: GLASS BREAKAGE SENSOR (for Column Shift Type): INSTALLATION
1. INSTALL GLASS BREAKAGE SENSOR MICROPHONE
(a) Attach the 2 claws to install the sensor.
2. INSTALL INTEGRATION CONTROL AND PANEL ASSEMBLY
Page 3238
(1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be
checked by conducting a voltage check.
With each connector still connected, measure the voltage between the body ground and these
terminals (in this order): 1) terminal 1 of connector A; 2) terminal 1 of connector B; and 3) terminal
1 of connector C.
Standard voltage (Fig. 4):
* If the results match the examples above, an open circuit exists in the wire harness between
terminal 1 of connector B and terminal 1 of connector C.
3. CHECK FOR SHORT CIRCUIT
(a) If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance
check with the body ground (below).
(b) Check the resistance with the body ground.
(1) Disconnect connectors A and C and measure the resistance.
Standard resistance (Fig. 6):
HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally.
If your results match the examples above, a short circuit exists between terminal 1 of connector A
and terminal 1 of connector C.
Page 908
Ambient Temperature Sensor / Switch HVAC: Service and Repair Installation
AIR CONDITIONING: AMBIENT TEMPERATURE SENSOR: INSTALLATION
1. INSTALL AMBIENT TEMPERATURE SENSOR
(a) Attach the clamp to install the ambient temperature sensor.
(b) Connect the connector.
Components
Actuator: Service and Repair Components
DIFFERENTIAL: AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR (for 4WD):
COMPONENTS
Page 7104
Tire Pressure Module: Diagrams
Page 4314
J. When Cal 1 has completed the update process turn ignition OFF for a minimum of 10 seconds.
Then click Next.
K. Turn ignition to the ON position. Then click Start.
L. Do NOT disturb the vehicle during flash reprogramming.
Page 7720
(a) for Manual Air Conditioning System:
Disconnect the 2 connectors.
(b) for Automatic Air Conditioning System:
Disconnect the 3 connectors.
(c) Remove the 2 screws and amplifier.
Page 7439
Tire Pressure Monitor Receiver / Transponder: Service and Repair Installation
TIRE AND WHEEL: TIRE PRESSURE WARNING RECEIVER: INSTALLATION
1. INSTALL TIRE PRESSURE WARNING ANTENNA AND RECEIVER
(a) Install the receiver with the bolt.
Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
(b) Connect the receiver connector.
2. INSTALL ROOF HEADLINING ASSEMBLY
(a) for Regular Cab:
Install the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Installation.
(b) for Double Cab:
Install the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Double Cab)/Installation.
(c) for CrewMax:
Install the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (for CrewMax)/Installation.
Page 8391
Page 3364
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Page 4041
Air Injection Pump: Service and Repair Removal
1UR-FE EMISSION CONTROL: AIR PUMP: REMOVAL
1. DISCONNECT FRONT FENDER LINER RH
(a) Remove the 8 clips, disconnect the fender liner.
2. DISCONNECT FRONT FENDER APRON SEAL RH
(a) Using a clip remover, remove the 2 clips and fold back the fender apron seal.
3. REMOVE NO. 2 AIR INJECTION SYSTEM HOSE
(a) Engine Room Side:
(1) Disconnect the 2 clamps.
(2) Disconnect the No. 2 air injection system hose.
(3) Using a clip remover, remove the clamp from the body panel.
(b) Front Fender RH Inside:
(1) Disconnect the clamp.
(2) Disconnect the No. 2 air injection system hose from the air pump.
4. REMOVE NO. 3 AIR INJECTION SYSTEM HOSE
(a) Engine Room Side:
Up to 11/2009
Hydraulic Fluid Regulator: Locations Up to 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Components
Radiator Cooling Fan: Service and Repair Components
1UR-FE COOLING: FAN: COMPONENTS
Specifications
Fuel Pressure: Specifications
FUEL PRESSURE
Page 6066
Ignition Switch: Connector Views
Page 8924
Hood Sensor/Switch (For Alarm): Diagrams
Page 6208
Installation
OTHER SYSTEM: POWER OUTLET SOCKET (for CrewMax Column Shift Type): INSTALLATION
1. INSTALL REAR POWER POINT SOCKET (for AC Power Supply)
(a) Attach the 2 claws to install the power outlet socket.
2. INSTALL REAR POWER OUTLET SOCKET COVER (for Standard)
(a) Attach the 2 claws to install the power outlet socket cover.
3. INSTALL REAR POWER OUTLET SOCKET (for Standard)
(a) Attach the claw to install the power outlet socket.
4. INSTALL NO. 2 SEATBACK LOCK CONTROL BEZEL
Page 397
HINT The wavelength becomes shorter as the vehicle speed increases.
(k) WAVEFORM 10:
HINT The duty ratio varies depending on the throttle actuator operation.
(l) WAVEFORM 11:
HINT The duty ratio varies depending on the throttle actuator operation.
(m)WAVEFORM 12:
Locations
Knock Sensor: Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 6164
3. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE
HINT The diagnostic system in the TOYOTA TUNDRA has various functions.
* The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU
memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a
previous malfunction's DTC can be checked by a technician during troubleshooting.
* Another function is the Input Signal Check, which checks if the signals from various switches are
sent to the ECU correctly.
* By using these functions, the problem areas can be narrowed down and troubleshooting is more
effective. Diagnostic functions are incorporated in the following systems in the TOYOTA TUNDRA.
Engine Immobiliser System
Alarm Module: Locations Engine Immobiliser System
ENGINE IMMOBILISER: ENGINE IMMOBILISER SYSTEM: PARTS LOCATION
Page 8410
Seat Position Sensor: Testing and Inspection
SUPPLEMENTAL RESTRAINT SYSTEM: SEAT POSITION SENSOR: ON-VEHICLE
INSPECTION
1. CHECK SEAT POSITION SENSOR (VEHICLE NOT INVOLVED IN COLLISION)
(a) Perform a diagnostic system check See: Air Bag Systems/Testing and Inspection/Initial
Inspection and Diagnostic Overview/Diagnosis
System.
2. CHECK SEAT POSITION SENSOR (VEHICLE INVOLVED IN COLLISION)
(a) Perform a diagnostic system check See: Air Bag Systems/Testing and Inspection/Initial
Inspection and Diagnostic Overview/Diagnosis
System.
(b) Even if the airbag was not deployed, check if there is any damage to the seat position sensor. If
there are any defects as mentioned below,
replace the seat position sensor with a new one:
* Cracks, dents or chips on the sensor housing.
* Cracks or other damage to the connector.
CAUTION: For removal and installation procedures of the seat position sensor, be sure to follow
the correct procedure.
Page 4027
This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown.
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60
months or 60,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Op Code EG9029 or EG9024: For California specification vehicles sold, registered, and operated
in California, Connecticut, Maine, Massachusetts, New Jersey, Oregon, Pennsylvania, Rhode
Island, Vermont, and Washington, this repair is covered under the California Emission Warranty.
This warranty is in effect for 84 months or 70,000 miles, whichever occurs first, from the vehicle's
in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Page 3835
Engine Bank Identification
Page 1695
for CrewMax of standard deck
Page 5201
(d) Grind the rear axle bearing inner race surface using a grinder, then remove it with a chisel.
3. REMOVE REAR AXLE HUB AND BEARING ASSEMBLY
(a) Temporarily install 4 nuts to the housing bolts.
NOTICE: Do not use any nuts removed from the vehicle, as they may be damaged.
(b) Using a hammer, remove the 4 housing bolts and rear axle hub and bearing.
(c) Remove the nuts.
4. REMOVE BRAKE DRUM OIL DEFLECTOR
(a) Using SST, remove the 5 hub bolts.
SST : 09650-17011
(b) Remove the deflector and deflector gasket from the rear axle shaft.
Reassembly
AXLE: REAR AXLE SHAFT: REASSEMBLY
NOTICE: Do not allow foreign matter, etc. to contact the ABS rotor bearing.
1. INSTALL BRAKE DRUM OIL DEFLECTOR
(a) Install a new deflector gasket and deflector to the rear axle shaft.
Page 1345
Page 6502
Engine Room R/B And Engine Room J/B Inner Circuit
Page 219
(1) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(2) If the result is not as specified, replace the HORN fuse.
(b) Measure the resistance of the horn relay circuit.
(1) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(2) If the result is not as specified, replace the integration relay.
4. INSTALL INTEGRATION RELAY (UNIT E)
(a) Connect the 3 connectors.
(b) Install the integration relay to the engine room relay block.
(c) Install the engine room relay block cover.
5. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
NOTICE: Some systems need to be initialized after the cable is reconnected See: Testing and
Inspection/Programming and Relearning
Page 6691
Fuse Block Location - Under The Instrument Panel
Fuse Location - Under The Instrument Panel
Page 7211
Steering Column Control Module: Diagrams
Page 912
Cabin Temperature Sensor / Switch: Diagrams
Page 4320
Air Flow Meter/Sensor: Diagrams
Locations
Main Relay (Computer/Fuel System): Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 5952
[A] For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
"Case1" Raise the terminal retainer up to the temporary lock position.
Page 7742
(1) Insert the pin into the plate groove.
(2) Attach the claw to install the main plate.
(3) Install the 2 screws.
(c) Set the damper servo so that the cutout part engages with the tooth of the gear, and attach the
claw to install the damper servo.
(d) Install the 4 screws and connect the 2 connectors.
9. INSTALL AIR DUCT
(a) Install the duct with the 2 screws.
10. INSTALL BLOWER WITH FAN MOTOR SUB-ASSEMBLY
Page 8328
Page 6844
Page 6906
Relay Box: Diagnostic Aids
Continuity and Resistance Check
CONTINUITY AND RESISTANCE CHECK
Disconnect the battery terminal or wire so there is no voltage between the check points.
Contact the two leads of an ohmmeter to each of the check points.
Page 1435
Page 934
(a) Remove the filter.
6. REMOVE NO. 2 AIR DUCT SUB-ASSEMBLY
(a) Remove the screw and duct.
7. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY
(a) Remove the 2 screws and amplifier.
8. REMOVE BLOWER WITH FAN MOTOR SUB-ASSEMBLY
(a) Remove the 3 screws and motor.
9. REMOVE AIR DUCT
(a) Remove the 2 screws and duct.
Page 3445
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- CHECK FOR SHORT TO B+ IN CAN BUS WIRE (POWER STEERING ECU) OK -- Continue
to next step.
12. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (NO. 1 JUNCTION CONNECTOR - CENTER
AIRBAG SENSOR)
(a) Disconnect the J83 No. 1 junction connector connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- CHECK FOR SHORT TO B+ IN CAN BUS WIRE (CENTER AIRBAG SENSOR)
Page 8949
Parking Assist Distance Sensor: Service and Repair Ultrasonic Sensor (for Rear Side)
Components
PARK ASSIST / MONITORING: ULTRASONIC SENSOR (for Rear Side): COMPONENTS
Page 183
[A] For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
"Case1" Raise the terminal retainer up to the temporary lock position.
Page 6411
Multiple Junction Connector: Electrical Diagrams
Junction Connector (CAN LH No.2) Inner Circuit
Page 9070
General Information
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: GENERAL
INFORMATION
* A large number of ECU controlled systems are used in the TOYOTA TUNDRA. In general, ECU
controlled systems are considered to be very intricate, requiring a high level of technical knowledge
to troubleshoot. However, most problem checking procedures only involve inspecting the ECU
controlled system's circuits one by one. An adequate understanding of the system and a basic
knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and
necessary repairs.
1. TROUBLESHOOTING PROCEDURES
* The troubleshooting procedures consist of diagnosis procedures for when a DTC is stored and
diagnosis procedures for when no DTC is stored. The basic idea is explained in the following table.
* Vehicle systems are complex and use many ECUs that are difficult to inspect independently.
Therefore, a process of elimination is used, where components that can be inspected individually
are inspected, and if no problems are found in these components, the related ECU is identified as
the problem and replaced.
* It is extremely important to ask the customer about the environment and the conditions present
when the problem occurred (Customer Problem Analysis). This makes it possible to simulate the
conditions and confirm the symptom. If the symptom cannot be confirmed or the DTC does not
recur, the malfunctioning part may not be identified using the troubleshooting procedure, and the
ECU for the related system may be replaced even though it is not defective. If this happens, the
original problem will not be solved.
* In order to prevent endless expansion of troubleshooting procedures, the troubleshooting
procedures are written with the assumption that multiple malfunctions do not occur simultaneously
for a single problem symptom.
* To identify the malfunctioning part, troubleshooting procedures narrow down the target by
separating components, ECUs and wire harnesses during the inspection. If the wire harness is
identified as the cause of the problem, it is necessary to inspect not only the connections to
components and ECUs but also all of the wire harness connectors between the component and the
ECU.
DIAGNOSTIC TESTER
2. DESCRIPTION
System data and the Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector
3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the Techstream* to
check for a malfunction and perform repairs.
HINT *: Techstream is the name for the diagnostic tester in North America.
3. DATA LINK CONNECTOR 3 (DLC3)
(a) The vehicle's ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of
the DLC3 complies with SAE J1962 and
matches the ISO 15765-4 format.
Page 3547
2. CHECK FOR OPEN IN CAN BUS WIRE (MAIN BODY ECU BRANCH WIRE)
(a) Disconnect the J2 main body ECU connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE MAIN BODY ECU BRANCH WIRE OR CONNECTOR (CANH,
CANL) OK -- Continue to next step.
3. CHECK HARNESS AND CONNECTOR (MAIN BODY ECU - BATTERY AND BODY GROUND)
(a) Reconnect the cable to the negative (-) battery terminal before measuring the resistances of the
main wire and the branch wire.
(b) Disconnect the DA, DB and DD main body ECU connectors.
(c) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(d) Measure the voltage according to the value(s) in the table below.
Standard voltage:
Page 6738
Driver Side J/B - Cowl Side Left
Emissions - MIL ON/Multiple Air Injection DTC's Set
Air Injection Bypass Valve: Customer Interest Emissions - MIL ON/Multiple Air Injection DTC's Set
T-SB-0350-09
Rev1
October 1, 2009
Air Injection Pump With Water Intrusion: MIL "ON" DTC P04181P0419 and/or P244 #
Service Category Engine/Hybrid System
Section Engine Control
Market USA
Applicability
TSB REVISION NOTICE
May 21, 2010 Rev1:
^ DTCs P0418 and P0419 have been added to the TSB.
^ The Applicable Warranty has been updated in the Warranty Information section. Any previous
printed versions of this service bulletin should be discarded.
Introduction
Some 2010 model year Tundra vehicles built in the Texas plant may exhibit a MIL "ON" condition
with Diagnostic Trouble Code (DTC) P0418, P0419, P2440, P2441, P2442, P2443, P2446, and/or
P2447. This concern may be caused by water intrusion into the air injection pump assembly. Use
the following procedure to address this condition.
Parts Information
Production Change Information
Page 9277
Hood Shock / Support: Service and Repair Disposal
ENGINE HOOD / DOOR: HOOD SUPPORT: DISPOSAL
HINT *
Use the same procedures for the RH side and LH side.
* The procedures listed below are for the LH side.
1. DISPOSE OF HOOD SUPPORT ASSEMBLY
(a) Horizontally fix the hood support in a vise with the piston-rod pulled out.
(b) Wear safety glasses. Gradually cut a part between A and B shown in the illustration using a
metal saw and gradually release the gas.
CAUTION: Be careful when drilling because shards of metal may fly about. Always use the proper
safety equipment.
NOTICE: The gas is colorless, odorless and nonpoisonous.
Page 3262
1. Test drive the vehicle and confirm there is a harsh shift on acceleration below 20 mph and or
excessive lock-up operation at freeway speeds about 50
- 60 mph.
2. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in
Figure 1. Confirm if the ECM (PCM) calibration has
been updated. If the calibration ID listed is NOT the latest ECM (PCM) calibration - go to step 3.
3. Flash reprogram the ECM (PCM).
NOTE
^ The GR8 Battery Diagnostic Station MUST be used in Power Supply Mode to maintain battery
voltage at 13.5 volts while flash reprogramming the vehicle.
^ For details on how to use the GR8 Battery Diagnostic Station, refer to the GR8 Instruction Manual
located on the Technical Information System (TIS), Diagnostics - Battery.
Follow the procedures outlined in TSB No. T-SB-0064-10, "Techstream ECU Flash
Reprogramming Procedure", and flash the ECM (PCM) with the NEW calibration file update.
4. Start the engine and warm it up to normal operating temperature before test driving.
5. Test drive the vehicle to confirm proper vehicle operation and ECM (PCM) initial learning. Refer
to the Technical Information System (TIS) 2010
Tundra Repair Manual:
Drivetrain - Automatic Transmission/Transaxle - "A760E / A760F Automatic
Transmission/Transaxle: Automatic Transmission System: Initialization"
6. Install the Authorized Modifications Label.
A. Using a permanent marker enter the following information on the label:
^ ECM part number [Refer to the Parts Information section for the CURRENT PART NUMBER]
Page 6040
Use a volt/ohmmeter with high impedance (10 kohms/V minimum) for troubleshooting of the
electrical circuit.
Disconnection of Male and Female Connectors
DISCONNECTION OF MALE AND FEMALE CONNECTORS
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Finding A Short Circuit
FINDING A SHORT CIRCUIT
Page 6336
Engine - Snow Ingestion Into Air Cleaner Box
Front Fender Liner: By Symptom Engine - Snow Ingestion Into Air Cleaner Box
T-SB-0396-09
December 8, 2009
Snow Entry Into Air Cleaner Box
Service Category Engine/Hybrid System
Section Intake/Exhaust
Market USA
Applicability
Introduction
Some Sequoia and Tundra vehicles operated in areas with significant snow volume may
experience snow accumulation in the air cleaner box which can cause the lid to fracture. The air
cleaner lid and fender liner have been revised to reduce accumulation.
Parts Information
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for
36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Production Change Information
Page 4591
Push the terminal retainer down to the temporary lock position.
Locations
Ambient Light Sensor: Locations
LIGHTING: LIGHTING SYSTEM: PARTS LOCATION
Page 2370
(3) Check for dirt or mud on the pipe and around the connector before disconnection. Clean if
necessary.
(4) Pinch the connector and disconnect the connector and pipe.
(5) If the connector and the pipe are stuck together, pinch the connector, push and pull the pipe to
disconnect the pipe and pull it out.
NOTICE: Do not use any tools.
(6) Check for dirt or mud on the seal surface of the disconnected pipe. Clean if necessary.
(7) To protect the disconnected pipe and connector from damage and contamination, cover it with a
plastic bag.
(e) Observe these precautions when connecting the fuel tube connector (for Quick Type).
(1) Check that there is no damage or contamination in the connected part of the pipe.
(2) Align the axis of the connector with the axis of the pipe. Push the pipe into the connector until
the connector makes a "click" sound. If the
connection is tight, apply a small amount of fresh spindle oil or gasoline on the tip of the pipe.
(3) After having finished the connection, try to pull apart the pipe and the connector to confirm that
they are securely connected.
Page 2081
If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness
or connector in that circuit in the past. Check the wire harness and connectors.
B -- SYSTEM NORMAL
A -- TROUBLESHOOTING OF EACH PROBLEM SYMPTOM
The problem is still occurring in a place other than the diagnostic circuit (the DTC displayed first is
either for a past problem or a secondary problem).
4. SYMPTOM SIMULATION
HINT The most difficult case in troubleshooting is when no problem symptoms occur. In such a
case, a thorough problem analysis must be carried out. A simulation of the same or similar
conditions and environment in which the problem occurred in the customer's vehicle should be
carried out. No matter how much skill or experience a technician has, troubleshooting without
confirming the problem symptoms will lead to important repairs being overlooked and mistakes or
delays.
For example:
With a problem that only occurs when the engine is cold or as a result of vibration caused by the
road during driving, the problem can never be determined if the symptoms are being checked on a
stationary vehicle or on a vehicle with a warmed-up engine. Vibration, heat or water penetration
(moisture) is difficult to reproduce. The symptom simulation tests below are effective substitutes for
the conditions and can be applied on a stationary vehicle.
Important points in the symptom simulation test:
In the symptom simulation test, the problem symptoms as well as the problem area or parts must
be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then,
connect the tester and carry out the symptom simulation test, judging whether the circuit being
tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the
problem symptoms table for each system to narrow down the possible causes.
To reproduce DTCs, it is necessary to satisfy the respective DTC detection conditions.
(a) VIBRATION METHOD:
When a malfunction seems to occur as a result of vibration.
(1) PART AND SENSOR
Apply slight vibration with a finger to the part of the sensor suspected to be the cause of the
problem, and check whether or not the malfunction occurs.
NOTICE: Applying strong vibration to relays may open them.
Page 8127
Seat Occupant Classification Module - Air Bag: Testing and Inspection
SUPPLEMENTAL RESTRAINT SYSTEM: OCCUPANT CLASSIFICATION ECU: ON-VEHICLE
INSPECTION
1. CHECK OCCUPANT CLASSIFICATION ECU (VEHICLE NOT INVOLVED IN COLLISION)
(a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnosis System.
2. CHECK OCCUPANT CLASSIFICATION ECU (VEHICLE INVOLVED IN COLLISION AND
AIRBAG HAS NOT DEPLOYED)
(a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnosis System.
3. CHECK OCCUPANT CLASSIFICATION ECU (VEHICLE INVOLVED IN COLLISION AND
AIRBAG IS DEPLOYED)
(a) Replace the ECU.
CAUTION: *
For removal and installation procedures of the occupant classification ECU, be sure to follow the
correct procedure.
* If the airbags have deployed, replace the occupant classification ECU on the side in which the
collision occurred. Replace both if necessary.
Page 1986
Page 7581
Remove the blown fuse and disconnect all loads of the fuse.
Connect a test light in place of the fuse.
Establish conditions in which the test light comes on.
Example:
- [A] - Ignition SW on
- [B] - Ignition SW and SW1 on
- [C] - Ignition SW, SW1 and Relay on (Connect the Relay) and SW2 off (or Disconnect SW2)
Disconnect and reconnect the connectors while watching the test light.
Page 6994
Driver Side J/B - Cowl Side Left
Page 6840
Diagrams
Brake Fluid Level Sensor/Switch: Diagrams
Page 1091
Headlamp Dimmer Switch: Testing and Inspection
LIGHTING: HEADLIGHT DIMMER SWITCH: INSPECTION
1. INSPECT HEADLIGHT DIMMER SWITCH ASSEMBLY
(a) Check the light control switch.
(1) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(2) If the result is not as specified, replace the headlight dimmer switch.
(b) Check the headlight dimmer switch.
(1) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(2) If the result is not as specified, replace the headlight dimmer switch.
HINT Perform the "LOW BEAM" and "HI BEAM" inspection with the light control switch on "HEAD".
(c) Check the turn signal switch.
(1) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(2) If the result is not as specified, replace the headlight dimmer switch.
Page 8375
Locations
Engine Temperature Sensor: Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 287
Page 6720
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: ELECTRONIC
CIRCUIT INSPECTION PROCEDURE
1. BASIC INSPECTION
(a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS
(1) Unless otherwise stated, all resistance measurements should be made at an ambient
temperature of 20°C (68°F). Resistance measurements
may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been
running. Measurements should be made after the engine has cooled down.
(b) HANDLING CONNECTORS
(1) When disconnecting a connector, first squeeze the mating halves tightly together to release the
lock, and then press the lock claw and
separate the connector.
(2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly
and separate it.
(3) Before connecting a connector, check that there are no deformed, damaged, loose or missing
terminals.
(4) When connecting a connector, press firmly until it locks with a "click" sound.
(5) If checking a connector with a TOYOTA electrical tester, check the connector from the backside
(harness side) using a mini test lead.
NOTICE: *
As a waterproof connector cannot be checked from the backside, check it by connecting a
sub-harness.
* Do not damage the terminals by moving the inserted tester needle.
(c) CHECKING CONNECTORS
(1) Checking when a connector is connected: Squeeze the connectors together to confirm that they
are fully connected and locked.
(2) Checking when a connector is disconnected: Check by pulling the wire harness lightly from the
backside of the connector. Look for
unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for
corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or
deformed terminals.
(3) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a
female terminal, and check for ample tension
Page 286
3. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE
HINT The diagnostic system in the TOYOTA TUNDRA has various functions.
* The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU
memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a
previous malfunction's DTC can be checked by a technician during troubleshooting.
* Another function is the Input Signal Check, which checks if the signals from various switches are
sent to the ECU correctly.
* By using these functions, the problem areas can be narrowed down and troubleshooting is more
effective. Diagnostic functions are incorporated in the following systems in the TOYOTA TUNDRA.
Page 4138
Page 6593
"Case2" Open the secondary locking device.
[B] For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray
Gray or White : Black
Page 5072
Standard Drive Pinion Preload Plus:
(b) If necessary, disassemble and inspect the differential.
22. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION
(a) Remove the bearing retainer and differential case.
(b) Coat 3 or 4 teeth at 3 different positions on the ring gear with Prussian blue.
(c) Install the differential case to the differential carrier.
(d) Install the differential cross shaft bearing retainer and front differential front support assembly
LH with the 14 bolts.
for bolt A - Torque : 65 Nm (633 kgf-cm, 48 ft-lbf)
for bolt B - Torque : 155 Nm (1581 kgf-cm, 114 ft-lbf)
(e) Hold the companion flange firmly and rotate the ring gear in both directions.
(f) Remove the differential case, side bearing retainer and differential case.
(g) Inspect the tooth contact pattern.
Page 3474
Page 7671
Compressor washer thickness:
0.1 mm (0.004 in.)
0.3 mm (0.012 in.)
0.5 mm (0.020 in.)
NOTICE: Adjustment should be performed with 3 or fewer magnet clutch washers.
(e) Remove the cooler compressor from the vise.
Page 2052
Page 1838
2. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in
Figure 1. Confirm if the ECM (PCM) calibration has
been updated. If the calibration ID listed is NOT the latest ECM (PCM) calibration - go to step 3.
3. Flash reprogram the ECM (PCM).
NOTE
^ The GR8 Battery Diagnostic Station MUST be used in Power Supply Mode to maintain battery
voltage at 13.5 volts while flash reprogramming the vehicle.
^ For details on how to use the GR8 Battery Diagnostic Station, refer to the located on the
Technical Information System (TIS), Diagnostics - Battery
Follow the procedures outlined in TSB No. T-SB-0064-10, "Techstream ECU Flash
Reprogramming Procedure1⁄4 and flash the ECM (PCM) with the NEW calibration file update.
4. Install the Authorized Modifications Label.
A. Using a permanent marker enter the following information on the label:
^ ECM part number [Refer to the Parts Information section for the CURRENT PART NUMBER]
^ Calibration ID(s) [Refer to the Calibration Identification Chart for the NEW CALIBRATION ID]
^ Dealer Code
^ Repair Date
^ Change Authority [This TSB number]
B. Affix the Authorized Modifications Label to the vehicle at the location shown in Figure 1. The
Authorized Modifications Label is available
through the MDC P/N 00451-00001-LBL.
5. Test drive the vehicle to confirm proper vehicle operation.
Page 73
Keyless Entry Module: Service and Repair Door Control Receiver (for Regular Cab)
Components
DOOR LOCK: DOOR CONTROL RECEIVER (for Regular Cab): COMPONENTS
Page 189
Push the secondary locking device or terminal retainer in to the full lock position.
CONNECT CONNECTOR
Voltage Check
VOLTAGE CHECK
Components
Manifold Pressure/Vacuum Sensor: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: MANIFOLD ABSOLUTE PRESSURE SENSOR:
COMPONENTS
Removal and Replacement
Brake Master Cylinder: Removal and Replacement
Components
BRAKE: BRAKE MASTER CYLINDER: COMPONENTS
Page 4035
This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown.
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60
months or 60,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Op Code EG9029 or EG9024: For California specification vehicles sold, registered, and operated
in California, Connecticut, Maine, Massachusetts, New Jersey, Oregon, Pennsylvania, Rhode
Island, Vermont, and Washington, this repair is covered under the California Emission Warranty.
This warranty is in effect for 84 months or 70,000 miles, whichever occurs first, from the vehicle's
in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Page 6401
Page 5186
(a) Install a new snap ring to the inboard joint shaft.
(b) Coat the spline of the inboard joint shaft assembly with gear oil.
(c) Align the shaft splines and install the drive shaft with a brass bar and hammer.
NOTICE: *
Set the snap ring with the opening side facing downward.
* Be careful not to damage the oil seal.
HINT Whether the inboard joint shaft is in contact with the pinion shaft or not can be confirmed
from the sound or feeling when driving it.
2. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH (for Axle Hub Side)
(a) Install the drive shaft to the steering knuckle.
NOTICE: Be careful not to damage the oil seal, boots and dust seal.
3. CONNECT FRONT LOWER BALL JOINT ATTACHMENT See: Steering and
Suspension/Suspension/Control Arm/Service and
Repair/Removal and Replacement/Front Lower Suspension Arm/Installation
4. INSTALL TIE ROD END SUB-ASSEMBLY See: Steering and Suspension/Steering/Steering
Gear/Service and Repair/Removal and
Replacement/Installation
5. INSTALL AXLE HUB NUT See: Wheel Hub/Service and Repair/Removal and
Replacement/Installation
6. INSTALL FRONT AXLE HUB GREASE CAP See: Wheel Hub/Service and Repair/Removal and
Replacement/Installation
7. INSTALL FRONT SPEED SENSOR LH
(a) Install the front speed sensor See: Brakes and Traction Control/Antilock Brakes / Traction
Control Systems/Wheel Speed Sensor/Service and
Repair/Front Speed Sensor/Installation.
8. INSTALL NO. 1 ENGINE UNDER COVER See: Engine, Cooling and Exhaust/Engine/Drive
Belts, Mounts, Brackets and Accessories/Drive
Belt/Service and Repair/Installation
9. INSTALL FRONT WHEEL
(a) Install the front wheels.
for aluminum wheel - Torque : 131 Nm (1336 kgf-cm, 97 ft-lbf)
for steel wheel - Torque : 209 Nm (2131 kgf-cm, 154 ft-lbf)
10. ADD DIFFERENTIAL OIL See: Differential Assembly/Fluid - Differential/Service and Repair
11. CHECK SPEED SENSOR SIGNAL
(a) Check the speed sensor signal See: Brakes and Traction Control/Antilock Brakes / Traction
Control Systems/Testing and Inspection/Scan
Tool Testing and Procedures/Test Mode Procedure.
12. CHECK FOR DIFFERENTIAL OIL LEAK
13. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
Page 2406
Removal
1UR-FE LUBRICATION: ENGINE OIL COOLER: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. DRAIN ENGINE OIL See: Engine Oil/Service and Repair/Replacement
3. DRAIN ENGINE COOLANT See: Cooling System/Coolant/Service and Repair
4. REMOVE NO. 1 ENGINE UNDER COVER See: Engine Oil/Service and Repair/Replacement
5. REMOVE FAN AND GENERATOR V BELT See: Drive Belts, Mounts, Brackets and
Accessories/Drive Belt/Service and Repair/Removal
6. REMOVE OIL FILTER ELEMENT See: Engine Oil/Service and Repair/Replacement
7. REMOVE OIL PRESSURE SENDER GAUGE ASSEMBLY See: Oil Pressure Sender/Service
and Repair/Removal
8. DISCONNECT COOLER COMPRESSOR ASSEMBLY See: Oil Pump/Service and
Repair/Removal and Replacement/Removal
9. REMOVE WATER BY-PASS PIPE See: Water Pump/Service and Repair/Removal
10. REMOVE NO. 1 OIL COOLER BRACKET
(a) Remove the 2 nuts and bracket.
Locations
Telescoping Wheel Switch: Locations
STEERING COLUMN: POWER TILT AND POWER TELESCOPIC STEERING COLUMN
SYSTEM: PARTS LOCATION
Page 6159
(1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be
checked by conducting a voltage check.
With each connector still connected, measure the voltage between the body ground and these
terminals (in this order): 1) terminal 1 of connector A; 2) terminal 1 of connector B; and 3) terminal
1 of connector C.
Standard voltage (Fig. 4):
* If the results match the examples above, an open circuit exists in the wire harness between
terminal 1 of connector B and terminal 1 of connector C.
3. CHECK FOR SHORT CIRCUIT
(a) If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance
check with the body ground (below).
(b) Check the resistance with the body ground.
(1) Disconnect connectors A and C and measure the resistance.
Standard resistance (Fig. 6):
HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally.
If your results match the examples above, a short circuit exists between terminal 1 of connector A
and terminal 1 of connector C.
Page 1978
Driver Side J/B - Cowl Side Left
Page 7844
Cabin Temperature Sensor / Switch: Service and Repair Removal
AIR CONDITIONING: ROOM TEMPERATURE SENSOR (for Automatic Air Conditioning System):
REMOVAL
1. REMOVE FRONT DOOR SCUFF PLATE LH
(a) for Regular Cab:
Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular Cab)/Removal.
(b) for Double Cab:
Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Removal.
(c) for CrewMax:
Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for CrewMax)/Removal.
2. REMOVE COWL SIDE TRIM BOARD LH
(a) for Regular Cab:
Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular Cab)/Removal.
(b) for Double Cab:
Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Removal.
(c) for CrewMax:
Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for CrewMax)/Removal.
3. REMOVE INSTRUMENT SIDE PANEL LH
(a) for Column Shift Type:
Remove the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Column Shift Type)/Removal.
(b) for Floor Shift Type:
Remove the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Floor Shift Type)/Removal.
4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH
(a) for Column Shift Type:
Remove the instrument panel finish panel See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument
Panel Safety Pad (for Column Shift Type)/Removal.
(b) for Floor Shift Type:
Remove the instrument panel finish panel See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument
Panel Safety Pad (for Floor Shift Type)/Removal.
5. REMOVE ROOM TEMPERATURE SENSOR
Locations
Starter Motor: Locations
1UR-FE STARTING: STARTING SYSTEM: PARTS LOCATION
Locations
Transmission Position Switch/Sensor: Locations
A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS
LOCATION
Page 3808
Engine Temperature Sensor: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: ENGINE COOLANT TEMPERATURE SENSOR:
REMOVAL
1. REMOVE NO. 1 ENGINE UNDER COVER See: Engine, Cooling and Exhaust/Engine/Engine
Lubrication/Engine Oil/Service and
Repair/Replacement
2. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Removal
3. DRAIN ENGINE COOLANT See: Engine, Cooling and Exhaust/Cooling System/Coolant/Service
and Repair
4. REMOVE ENGINE COOLANT TEMPERATURE SENSOR
(a) Disconnect the sensor connector.
(b) Using a 19 mm ball joint lock nut wrench, remove the sensor.
(c) Remove the gasket from the sensor.
Page 8257
(a) Align the vehicle's claws with the seat belt retractor positioning holes.
(b) Install the seat belt with the 2 bolts.
HINT First install bolt A, and then install bolt B.
for bolt A - Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
for bolt B - Torque : 43 Nm (428 kgf-cm, 31 ft-lbf)
(c) Connect the pretensioner connector as shown in the illustration.
(d) Insert the bolt and extension of the anti-rotation device through the quarter trim panel hole into
the vehicle body.
(e) Install the seat belt's shoulder anchor with the bolt.
Torque : 42 Nm (428 kgf-cm, 31 ft-lbf)
(f) Attach the 2 claws to close the seat belt anchor cover.
2. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY
Air Conditioning System (for Automatic Air Conditioning
System)
Ambient Temperature Sensor / Switch HVAC: Locations Air Conditioning System (for Automatic Air
Conditioning System)
AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Automatic Air Conditioning System):
PARTS LOCATION
Component Tests and General Diagnostics
Garage Door Opener Transmitter: Component Tests and General Diagnostics
GARAGE DOOR OPENER: GARAGE DOOR OPENER SYSTEM: ON-VEHICLE INSPECTION
1. INSPECT GARAGE DOOR OPENER
(a) Press each switch and check that the red LED turns on. If one or more of the switches does not
turn on the LED, confirm normal operation of
the fuse and wire harness. If the fuse and wire harness are malfunctioning, replace them. If not,
replace the garage door opener.
2. INSPECT GARAGE DOOR OPENER REGISTRATION AND TRANSMITTING
HINT Use the "HomeLink" tester and a tester transmitter for this test. First erase the customer's
transmitter code, and then register the tester transmitter code.
(a) Check if the tester transmitter code was successfully registered.
HINT If the code cannot be registered, replace the garage door opener.
(b) Press the garage door opener switch that was registered to the tester transmitter. Check if the
"HomeLink" tester's green LED illuminates.
HINT If the green LED does not illuminate, replace the garage door opener.
(c) When the inspection is complete, reregister the customer's transmitter code(s) again.
Page 1602
Four Wheel Drive Selector Switch: Testing and Inspection
JF1A TRANSFER: 4WD CONTROL SWITCH: ON-VEHICLE INSPECTION
1. INSPECT 4WD CONTROL SWITCH
(a) Check the harness and connector (ECU - battery and body ground).
(1) Measure the voltage and resistance according to the value(s) in the table below.
Standard voltage:
(2) If there is a malfunction, inspect the harness or connector. If the harness is malfunctioning,
repair or replace harness or connector. If the
harness or connector is normal, replace the 4WD control ECU See: Powertrain
Management/Transmission Control Systems/Relays and Modules - Transmission and
Drivetrain/Relays and Modules - Transfer Case/Control Module/Service and Repair/Removal.
Standard resistance:
(3) If there is a malfunction, repair or replace the harness or connector.
(b) Check the harness and connector (switch - ECU).
(1) Disconnect the A25 ECU connector.
(2) Disconnect the L1 switch connector.
(3) Measure the resistance according to the value(s) in the table below.
Page 6380
Page 8843
(a) Using a screwdriver, detach the 4 clips and claw.
HINT Tape the screwdriver tip before use.
(b) Remove the speaker panel.
5. REMOVE NO. 2 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY
(a) Using a screwdriver, detach the 4 clips and claw.
HINT Tape the screwdriver tip before use.
(b) Remove the speaker panel.
6. REMOVE FRONT NO. 2 SPEAKER ASSEMBLY LH
(a) Remove the 2 bolts.
(b) Remove the speaker and disconnect the connector.
NOTICE: Do not touch the cone part of the speaker.
7. REMOVE FRONT NO. 2 SPEAKER ASSEMBLY RH
Page 2280
This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown.
Page 7389
Required Tools & Equipment
Repair Procedure Overview
^ Confirm noise is coming from the rear of the vehicle and changes with vehicle speed.
^ Install ChaSSiSEAR(TM) (or equivalent) and isolate the noise to the rear wheel bearing.
^ Remove the rear axle shaft assembly.
^ Install new rear wheel bearing brake caliper bracket and seals.
^ Reinstall rear axle shaft assembly and confirm the noise is no longer present.
Repair Procedure
1. Test drive the vehicle and confirm the customer complaint.
Does the noise increase and decrease with vehicle speed?
^ YES - Go to step 2.
^ NO - This TSB does NOT apply. Refer to the Repair Manual for further diagnosis.
Page 2870
Main Relay (Computer/Fuel System): Testing and Inspection
1UR-FE ENGINE CONTROL SYSTEM: CIRCUIT OPENING RELAY: ON-VEHICLE INSPECTION
1. REMOVE CIRCUIT OPENING RELAY (C/OPN)
(a) Remove the circuit opening relay from the engine room relay block.
2. INSPECT CIRCUIT OPENING RELAY
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) If the result is not as specified, replace the circuit opening relay.
3. INSTALL CIRCUIT OPENING RELAY
(a) Install the circuit opening relay to the engine room relay block.
Page 527
Tire Pressure Module: Service and Repair Installation
TIRE AND WHEEL: TIRE PRESSURE WARNING ECU: INSTALLATION
1. INSTALL TIRE PRESSURE WARNING ECU
(a) Install the ECU with the 2 nuts.
Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
(b) Connect the ECU connector.
2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Installation
3. INSTALL INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
4. INSTALL COWL SIDE TRIM BOARD RH
(a) Install the cowl side trim board RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Installation.
HINT Use the same procedures described for the LH side.
5. INSTALL FRONT DOOR SCUFF PLATE RH (for Double Cab, for CrewMax)
(a) Install the front door scuff plate RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Installation.
HINT Use the same procedures described for the LH side.
6. INSTALL FRONT DOOR SCUFF PLATE RH (for Regular Cab)
(a) Install the front door scuff plate RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Installation.
HINT Use the same procedures described for the LH side.
7. REGISTRATION OF TRANSMITTER ID
(a) Register the transmitter ID See: Instrument Panel, Gauges and Warning Indicators/Tire
Monitoring System/Testing and
Inspection/Programming and Relearning/Registration.
8. PERFORM INITIALIZATION
(a) Perform initialization See: Instrument Panel, Gauges and Warning Indicators/Tire Monitoring
System/Testing and Inspection/Programming
and Relearning/Initialization.
NOTICE: Be sure to inflate all tires to the proper inflation pressure before initialization.
Locations
Transmission Temperature Sensor/Switch: Locations
A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS
LOCATION
Page 1931
Fluid - Transfer Case: Service and Repair
JF1A TRANSFER: TRANSFER OIL: REPLACEMENT
1. DRAIN TRANSFER OIL
(a) Remove the 4 bolts and lower transfer case protector.
(b) Remove the filler plug and gasket.
(c) Remove the drain plug and gasket, and drain the transfer oil.
2. ADD TRANSFER OIL
(a) Install a new gasket and the drain plug.
Torque : 37 Nm (377 kgf-cm, 27 ft-lbf)
(b) Pour oil so that the oil level is between 0 to 5.0 mm (0 to 0.197 in.) from the bottom lip of the
filler plug hole.
NOTICE: *
Pour oil slowly.
* Pour oil a little at a time, waiting several minutes between each addition of oil.
(c) Wait approximately 5 minutes and check that the oil level has not changed.
(d) Install a new gasket and the filler plug.
Torque : 37 Nm (377 kgf-cm, 27 ft-lbf)
(e) Install the lower transfer case protector with the 4 bolts.
Torque : 18 Nm (184 kgf-cm, 13 ft-lbf)
Page 3565
(b) Measure the resistance according to the value(s) in the table below.
12. CHECK POWER STEERING ECU
HINT For vehicles with a power steering ECU only.
(a) Disconnect the J101 ECU connector.
(b) Measure the resistance according to the value(s) in the table below.
13. CHECK 4WD CONTROL ECU
HINT For vehicles with 4WD only.
(a) Disconnect the A25 and A26 ECU connectors.
(b) Measure the resistance according to the value(s) in the table below.
Page 9101
Page 7038
for Double Cab of Long Deck
Page 5435
Seals and Gaskets: Service and Repair Front Oil Seal
Components
JF1A TRANSFER: TRANSFER CASE FRONT OIL SEAL: COMPONENTS
Replacement
JF1A TRANSFER: TRANSFER CASE FRONT OIL SEAL: REPLACEMENT
1. DRAIN TRANSFER OIL See: Fluid - Transfer Case/Service and Repair
Page 6845
Page 792
Parking Brake Warning Switch: Locations From 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 7048
Standard difference:
0 +/-1 mm (0 +/-0.0394 in.) or less
(e) Tighten the tie rod end lock nuts.
Torque : 82 Nm (836 kgf-cm, 60 ft-lbf)
(f) Place the boots on the seats and install the clips.
HINT Make sure that the boots are not twisted.
5. INSPECT WHEEL ANGLE
(a) Turn the steering wheel to the left and right full lock positions, and measure the turning angle.
Standard wheel angle (unloaded vehicle):
for Regular Cab of Standard Deck
Standard wheel angle (unloaded vehicle):
for Regular Cab of Long Deck
Page 854
Page 8457
Alarm Module: Diagrams Glass Breakage Sensor ECU
Page 5444
Standard voltage:
(3) If the voltage is not as specified, replace the 4WD control ECU See: Control Module/Service
and Repair/Removal. If the voltage is
normal, replace the 4WD control switch.
Page 6596
Push the terminal retainer down to the temporary lock position.
Components
Auxiliary Power Outlet Switch: Service and Repair Components
OTHER SYSTEM: INVERTER MAIN SWITCH (for CrewMax): COMPONENTS
Page 8353
(b) Check that the cable is disconnected from the battery negative (-) terminal.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
(c) Install the door airbag sensor with the screw.
Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)
NOTICE: *
If the door airbag sensor has been dropped, or there are any cracks, dents or other defects in the
case, bracket or connector, replace it with a new one.
* When installing the door airbag sensor, be careful that the SRS wiring does not interfere with
other parts and that it is not pinched between other parts.
(d) Check that there is no looseness in the installation parts of the door airbag sensor.
(e) Connect the connector.
2. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Reassembly
3. INSTALL COURTESY LIGHT ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood
and Trunk/Doors/Front Door/Service and
Repair/Front Door (for Double Cab)/Reassembly
4. INSTALL FRONT LOWER DOOR FRAME BRACKET GARNISH LH (for Front Side) See: Body
and Frame/Doors, Hood and
Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly
5. INSTALL FRONT UPPER ARMREST BASE PANEL LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Reassembly
6. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Reassembly
7. INSTALL REAR SIDE AIRBAG SENSOR
(a) Check that the ignition switch is OFF.
(b) Check that the cable is disconnected from the battery negative (-) terminal.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
(c) Install the side airbag sensor with the bolt.
Testing and Inspection
Malfunction Indicator Lamp: Testing and Inspection
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: MIL Circuit - MIL Circuit
DESCRIPTION
The MIL (Malfunction Indicator Lamp) is used to indicate vehicle malfunction detections by the
ECM. When the ignition switch is turned to ON, power is supplied to the MIL circuit, and the ECM
provides the circuit ground which illuminates the MIL.
The MIL operation can be checked visually: When the ignition switch is first turned to ON, the MIL
should be illuminated and should then turn off when the engine is started. If the MIL remains
illuminated or is not illuminated, conduct the following troubleshooting procedure using the
Techstream.
WIRING DIAGRAM
INSPECTION PROCEDURE
PROCEDURE
1. CHECK THAT MIL IS ILLUMINATED
(a) Perform troubleshooting in accordance with the table below.
Result
B -- CHECK THAT MIL IS ILLUMINATED A -- Continue to next step.
2. CHECK WHETHER MIL TURNS OFF
(a) Connect the Techstream to the DLC3.
(b) Turn the ignition switch to ON.
(c) Turn the Techstream on.
Page 1140
Air Flow Meter/Sensor: Testing and Inspection On-Vehicle Inspection
1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: ON-VEHICLE INSPECTION
1. CHECK MASS AIR FLOW METER
(a) Check the mass air flow value.
(1) Connect the Techstream to the DLC3.
(2) Turn the ignition switch to ON.
(3) Turn the Techstream main switch ON.
(4) Enter the following menus: Powertrain / Engine / Data List / All Data / MAF.
(5) Blow air into the MAF meter, and check that the MAF value fluctuates.
(6) If the result is not as specified, check the MAF meter See: Inspection, or wiring and ECM See:
Powertrain Management/Computers and
Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated
Procedures/P Code Charts/P0102.
Page 4595
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: ELECTRONIC
CIRCUIT INSPECTION PROCEDURE
1. BASIC INSPECTION
(a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS
(1) Unless otherwise stated, all resistance measurements should be made at an ambient
temperature of 20°C (68°F). Resistance measurements
may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been
running. Measurements should be made after the engine has cooled down.
(b) HANDLING CONNECTORS
(1) When disconnecting a connector, first squeeze the mating halves tightly together to release the
lock, and then press the lock claw and
separate the connector.
(2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly
and separate it.
(3) Before connecting a connector, check that there are no deformed, damaged, loose or missing
terminals.
(4) When connecting a connector, press firmly until it locks with a "click" sound.
(5) If checking a connector with a TOYOTA electrical tester, check the connector from the backside
(harness side) using a mini test lead.
NOTICE: *
As a waterproof connector cannot be checked from the backside, check it by connecting a
sub-harness.
* Do not damage the terminals by moving the inserted tester needle.
(c) CHECKING CONNECTORS
(1) Checking when a connector is connected: Squeeze the connectors together to confirm that they
are fully connected and locked.
(2) Checking when a connector is disconnected: Check by pulling the wire harness lightly from the
backside of the connector. Look for
unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for
corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or
deformed terminals.
(3) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a
female terminal, and check for ample tension
Page 4700
Transmission Speed Sensor: Service and Repair Removal
A760F AUTOMATIC TRANSMISSION: SPEED SENSOR: REMOVAL
1. REMOVE SPEED SENSOR NT
(a) Disconnect the sensor connector.
(b) Remove the bolt and sensor.
(c) Remove the O-ring from the sensor.
2. REMOVE SPEED SENSOR SP2
(a) Disconnect the sensor connector.
(b) Remove the bolt and sensor.
(c) Remove the O-ring from the sensor.
Page 3386
Page 1644
Tape the screwdriver tip before use.
(b) Remove the regulator switch.
Installation
WINDSHIELD / WINDOWGLASS: BACK POWER WINDOW SWITCH: INSTALLATION
1. INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY
(a) Attach the 2 claws to install the regulator switch.
2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Installation
3. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
4. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for
CrewMax)/Installation
5. INSTALL FRONT DOOR SCUFF PLATE LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining
(for CrewMax)/Installation
Page 6245
Specifications
Brake Pad: Specifications
FRONT BRAKE
PAD LINING THICKNESS
Standard thickness...............................................................................................................................
......................................................11.9 mm (0.469 in.)
Minimum thickness...............................................................................................................................
....................................................1.0 mm (0.0394 in.)
REAR BRAKE
PAD LINING THICKNESS
Standard thickness...............................................................................................................................
......................................................12.0 mm (0.472 in.)
Minimum thickness...............................................................................................................................
....................................................1.0 mm (0.0394 in.)
Page 8089
Impact Sensor: Service and Repair
Components
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift
Type): COMPONENTS
Page 1654
HINT Tape the screwdriver tip before use.
(b) Disconnect the connector.
2. REMOVE REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY
(a) Detach the 2 claws and remove the regulator switch.
Installation
WINDSHIELD / WINDOWGLASS: REAR POWER WINDOW SWITCH: INSTALLATION
HINT *
Use the same procedures for the LH side and RH side.
* The procedures listed below are for the LH side.
1. INSTALL REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY
(a) Attach the 2 claws to install the regulator switch.
2. INSTALL REAR UPPER DOOR ARMREST BASE PANEL LH
(a) Connect the connector.
Page 8491
2. REMOVE REAR DOOR SCUFF PLATE RH
(a) Detach the 8 claws and 2 clips, and remove the scuff plate.
3. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP RH
4. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY RH See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (for CrewMax)/Removal
5. REMOVE DOOR CONTROL RECEIVER
(a) Disconnect the door control receiver connector.
(b) Remove the bolt and receiver.
Installation
DOOR LOCK: DOOR CONTROL RECEIVER (for CrewMax): INSTALLATION
1. INSTALL DOOR CONTROL RECEIVER
(a) Install the receiver with the bolt.
(b) Connect the door control receiver connector.
2. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY RH See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (for CrewMax)/Installation
3. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP RH
4. INSTALL REAR DOOR SCUFF PLATE RH
Page 5568
(1) Keep the vehicle stationary on a level surface for 1 second or more.
HINT *
The zero point calibration is performed only once after the system enters test mode.
* Calibration cannot be performed again until the stored data is cleared once.
(2) Check that the buzzer sounds for 3 seconds and DTC C1336 is erased.
(3) Turn the ignition switch off.
6. PERFORM INITIALIZATION OF STEERING ANGLE SENSOR
NOTICE: Complete the adjustment of the steering wheel and wheel alignment, and then initialize
the steering angle sensor. If the order is reversed, the steering wheel and wheel alignment will
become misaligned.
(a) Check that the steering wheel is in the centered position.
(b) Disconnect the negative battery terminal for more than 2 seconds.
NOTICE: After the ignition switch is turned OFF, the navigation system requires approximately 90
seconds to record various types of memory and settings. As a result, after turning the ignition
switch OFF, wait 90 seconds or more before disconnecting the cable from the negative (-) battery
terminal.
(c) Reconnect the negative battery terminal.
Engine - Controls - Non-Linear Acceleration From A Stop
Engine Control Module: All Technical Service Bulletins Engine - Controls - Non-Linear Acceleration
From A Stop
T-SB-0273-10
September 28, 2010
Non-Linear Acceleration from a Stop
Service Category Engine/Hybrid System
Section Engine Control
Market USA
Applicability
Introduction
Some 2010 model year Tundra vehicles with the 1UR-FE (4.6 L) engine may exhibit non-linear
acceleration from a stop under certain conditions of low engine rpm with high engine load. The
Engine Control Module/ECM (SAE term: Powertrain Control Module/PCM) logic has been revised
to address this condition. Use the following repair procedure to recalibrate the ECM (PCM).
Calibration Information
Warranty Information
Applicable Warranty
^ This repair is covered under the Toyota Federal Emission Warranty. This warranty is in effect for
96 months or 80,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Page 3327
HINT *: The ECM terminal voltage is constant regardless of the output voltage from the sensor.
(b) WAVEFORM 1:
Page 6556
J/B No.6 Assembly - Instrument Panel Center
Page 5563
Acceleration/Deceleration Sensor: Locations From 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 9136
Trailer Towing Part 4
Airbag Cut-OFF Switch
Air Bag Deactivation Switch: Testing and Inspection Airbag Cut-OFF Switch
SUPPLEMENTAL RESTRAINT SYSTEM: AIRBAG CUT-OFF SWITCH: INSPECTION
1. INSPECT AIRBAG CUT-OFF SWITCH
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
Page 2819
Page 749
Seat Memory Switch: Service and Repair Installation
SEAT: SEAT MEMORY SWITCH (w/ Seat Position Memory System): INSTALLATION
1. INSTALL SEAT MEMORY SWITCH
(a) Install the seat memory with the 2 screws.
2. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH See: Body and Frame/Doors,
Hood and Trunk/Doors/Front Door/Service and
Repair/Front Door (for Double Cab)/Reassembly
3. INSTALL FRONT DOOR ARMREST COVER LH
4. INSTALL COURTESY LIGHT ASSEMBLY See: Body and Frame/Doors, Hood and
Trunk/Doors/Front Door/Service and Repair/Front Door
(for Double Cab)/Reassembly
5. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH LH See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Reassembly
6. INSTALL FRONT ARMREST UPPER BASE PANEL LH See: Body and Frame/Doors, Hood and
Trunk/Doors/Front Door/Service and
Repair/Front Door (for Double Cab)/Reassembly
7. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH See: Body and Frame/Doors,
Hood and Trunk/Doors/Front Door/Service and
Repair/Front Door (for Double Cab)/Reassembly
Page 5767
(a) Install the clamp with the bolt (labeled A).
Torque : 19 Nm (194 kgf-cm, 14 ft-lbf)
(b) Install the No. 2 parking brake cable to the rear axle carrier with the bolt.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
(c) Connect the No. 2 parking brake cable to the intermediate lever (labeled B) and install the 5
bolts (labeled C and D).
NOTICE: Do not bend and twist the parking brake cable.
for bolt C - Torque : 19 Nm (194 kgf-cm, 14 ft-lbf)
for bolt D - Torque : 14 Nm (138 kgf-cm, 10 ft-lbf)
(d) Connect the No. 2 parking brake cable to the 2 clamps (labeled E).
14. INSTALL NO. 2 CABLE RETAINER
(a) Install the retainer with the bolt.
Components
Solar Sensor: Service and Repair Components
AIR CONDITIONING: SOLAR SENSOR (for Automatic Air Conditioning System): COMPONENTS
Page 7616
Cabin Temperature Sensor / Switch: Testing and Inspection
AIR CONDITIONING: ROOM TEMPERATURE SENSOR (for Automatic Air Conditioning System):
INSPECTION
1. INSPECT ROOM TEMPERATURE SENSOR
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
HINT As the temperature increases, the resistance decreases (see the graph).
(b) If the result is not as specified, replace the thermistor.
NOTICE: *
Touching the sensor even slightly may change the resistance value. Hold the connector of the
sensor.
* When measuring the resistance, the sensor temperature must be the same as the ambient
temperature.
Page 1312
[A] For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
"Case1" Raise the terminal retainer up to the temporary lock position.
Components
Camshaft Position Sensor: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT POSITION SENSOR: COMPONENTS
Page 6542
Locations
Transmission Temperature Sensor/Switch: Locations
A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS
LOCATION
Page 7942
(f) Place the tires.
NOTICE: Do not place the deployment direction of the curtain shield airbag facing the ground.
(1) Place at least 2 tires under the tire which the curtain shield airbag is tied to.
(2) Place at least 2 tires over the tire which the curtain shield airbag is tied to. The top tire should
have the disc wheel installed.
NOTICE: *
Do not place SST connector under the tire because it could be damaged.
* As the disc wheel may be damaged by the airbag deployment, use a disc wheel that you are
planning to throw away.
* As the tires may be damaged by the airbag deployment, use a tire that you are planning to throw
away.
(3) Tie the tires together with 2 wire harnesses.
NOTICE: Make sure that the wire harnesses are tight. Looseness in the wire harnesses results in
the tires coming free due to the shock when the airbag is deployed.
(g) Install SST.
Page 793
Parking Brake Warning Switch: Diagrams
Page 2726
HINT Install the monolithic converter protector within the angle range specified in the illustration.
2. INSTALL NO. 1 MONOLITHIC CONVERTER PROTECTOR (for Bank 1)
(a) Install the 4 No. 1 converter protector stays.
(b) Install the 2 No. 1 monolithic converter protectors with the 4 bolts and 4 nuts.
Torque : 11 Nm (107 kgf-cm, 8 ft-lbf)
HINT Install the monolithic converter protector within the angle range specified in the illustration.
3. INSTALL MONOLITHIC CONVERTER PROTECTOR (for Bank 2)
(a) Install the 2 No. 1 converter protector stays and 2 No. 2 converter protector stays.
(b) Install the 2 monolithic converter protectors with the 4 bolts and 4 nuts.
Torque : 11 Nm (107 kgf-cm, 8 ft-lbf)
HINT Install the monolithic converter protector within the angle range specified in the illustration.
4. INSTALL NO. 1 MONOLITHIC CONVERTER PROTECTOR (for Bank 2)
(a) Install the 4 No. 1 converter protector stays.
Page 4992
A760F AUTOMATIC TRANSMISSION: VALVE BODY ASSEMBLY: REMOVAL
1. DRAIN AUTOMATIC TRANSMISSION FLUID See: Wiring Harness/Service and Repair/Removal
2. REMOVE AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY See: Wiring
Harness/Service and Repair/Removal
3. REMOVE VALVE BODY OIL STRAINER ASSEMBLY See: Wiring Harness/Service and
Repair/Removal
4. DISCONNECT TRANSMISSION WIRE See: Wiring Harness/Service and Repair/Removal
5. REMOVE TRANSMISSION VALVE BODY ASSEMBLY
(a) Remove the bolt, detent spring cover and detent spring.
(b) Remove the 19 bolts and valve body.
(c) Remove the check ball body and spring.
NOTICE: Do not drop the check ball body and spring.
Installation
A760F AUTOMATIC TRANSMISSION: VALVE BODY ASSEMBLY: INSTALLATION
1. INSTALL TRANSMISSION VALVE BODY ASSEMBLY
(a) Install the spring and check ball body.
(b) Align the hole of the manual valve with the pin of the lever and connect the pin to the manual
valve.
Page 3622
Oxygen Sensor: Service and Repair Heated Oxygen Sensor
Components
1UR-FE ENGINE CONTROL SYSTEM: HEATED OXYGEN SENSOR: COMPONENTS
Removal
1UR-FE ENGINE CONTROL SYSTEM: HEATED OXYGEN SENSOR: REMOVAL
CAUTION: *
The procedures should be performed by at least 2 people.
* Wear protective gloves when removing the exhaust pipe.
* The exhaust pipe is extremely hot immediately after the engine has stopped.
* Confirm that the exhaust pipe has cooled down before removing it.
1. REMOVE PROPELLER SHAFT HEAT INSULATOR (for 4WD) See: Transmission and
Drivetrain/Drive/Propeller Shafts, Bearings and
Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Front Propeller Shaft
Assembly/Removal
2. REMOVE HEATED OXYGEN SENSOR (for Bank 1 Sensor 2)
(a) Disconnect the sensor connector.
(b) Using SST, remove the sensor.
SST : 09224-00010
3. REMOVE HEATED OXYGEN SENSOR (for Bank 2 Sensor 2)
(a) Disconnect the heated oxygen sensor connector and 2 clamps.
Transmission Control Cable (for Column Shift Type)
Shift Cable: Service and Repair Transmission Control Cable (for Column Shift Type)
Components
A760F AUTOMATIC TRANSMISSION: TRANSMISSION CONTROL CABLE (for Column Shift
Type): COMPONENTS
Removal
A760F AUTOMATIC TRANSMISSION: TRANSMISSION CONTROL CABLE (for Column Shift
Type): REMOVAL
Page 5154
1. DRAIN DIFFERENTIAL OIL See: Fluid - Differential/Service and Repair
2. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH
(a) Remove the front drive shaft See: Drive Axles, Bearings and Joints/Axle Shaft
Assembly/Service and Repair/Removal and
Replacement/Front Drive Shaft Assembly/Removal.
3. REMOVE DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL
(a) Using SST, tap out the 2 oil seals.
SST : 09308-10010
4. INSTALL DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL
(a) Apply MP grease to 2 new oil seals.
(b) Using SST and a hammer, tap in the 2 oil seals.
SST : 09550-00032
SST : 09950-70010
09951-07100
NOTICE: Make sure the LH and RH oil seals are installed in the proper locations.
Standard oil seal depth:
5. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH
(a) Install the front drive shaft See: Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service
and Repair/Removal and Replacement/Front
Drive Shaft Assembly/Installation.
6. ADD DIFFERENTIAL OIL See: Fluid - Differential/Service and Repair
Page 3354
Page 1942
(g) Apply a small amount of engine oil to a new drain plug O-ring, and install it to the oil filter cap.
NOTICE: Before installing the O-ring, remove any dirt or foreign matter from the installation surface
of the oil filter cap.
(h) Install the oil filter drain plug.
Torque : 13 Nm (127 kgf-cm, 9 ft-lbf)
NOTICE: Be careful that the O-ring does not get caught between any surrounding parts.
5. ADD ENGINE OIL
(a) Add fresh oil.
Standard Oil Grade (for USA):
Standard Oil Grade (for Canada):
Standard Oil Capacity:
(b) Install the oil filler cap.
6. INSPECT FOR OIL LEAK
(a) Start the engine. Make sure that there are no oil leaks from the area that was worked on.
7. CHECK ENGINE OIL LEVEL See: Engine, Cooling and Exhaust/Engine/Engine
Lubrication/Testing and Inspection
8. INSTALL NO. 1 ENGINE UNDER COVER
Page 6999
J/B No.5 - Instrument Panel Center
Page 8362
Removal
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift
Type): REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal
3. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding
/ Trim/Dashboard / Instrument
Page 2408
(b) Remove the gasket.
Installation
1UR-FE LUBRICATION: ENGINE OIL COOLER: INSTALLATION
1. INSTALL OIL COOLER SPACER
(a) Apply a light coat of engine oil to a new gasket.
(b) Install the gasket to the oil cooler spacer.
(c) Install the oil cooler spacer to the oil filter bracket with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
2. INSTALL OIL COOLER ASSEMBLY
(a) Apply a light coat of engine oil to 2 new O-rings.
(b) Install the 2 O-rings to the oil cooler.
Page 6393
Page 1981
Page 6506
J/B No.3 Inner Circuit
J/B No.4 Inner Circuit
J/B No.5 Inner Circuit
Page 9078
6. PROBLEM SYMPTOMS TABLE
When a "Normal" code is output during a DTC check but the problem is still occurring, use the
Problem Symptoms Table. The suspected areas (circuits or parts) for each problem symptom are
in the table. The suspected areas are listed in order of probability. A description of each of the
chart's columns is below.
HINT In some cases, the problem is not detected by the diagnostic system even though a problem
symptom is present. It is possible that the problem is occurring outside the detection range of the
diagnostic system, or that the problem is occurring in a completely different system.
7. CIRCUIT INSPECTION
A description of the main areas of each circuit inspection is below.
Page 5619
Page 5874
Parking Brake Warning Switch: Service and Repair Reassembly
PARKING BRAKE: PARKING BRAKE PEDAL: REASSEMBLY
1. INSTALL PARKING BRAKE SWITCH ASSEMBLY
(a) Install the switch with the screw.
Torque : 0.9 Nm (9 kgf-cm, 8 in-lbf)
Page 4634
(4) Connect the engine wire harness clamp.
3. INSTALL AIR CLEANER ASSEMBLY
(a) Install the air cleaner with the 2 bolts.
Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)
(b) Tighten the hose clamp.
Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf)
(c) Connect the ventilation hose and vacuum hose.
(d) Connect the MAF meter connector and clamp.
4. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Installation
Page 5371
Four Wheel Drive Selector Switch: Service and Repair Removal
JF1A TRANSFER: 4WD CONTROL SWITCH: REMOVAL
1. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Panel,
Gauges and Warning Indicators/Instrument Cluster
/ Carrier/Service and Repair/Combination Meter/Removal
2. REMOVE 4WD CONTROL SWITCH
(a) Detach the 3 claws to remove the switch.
Page 6932
(2) CONNECTORS
Slightly shake the connector vertically and horizontally.
(3) WIRE HARNESS
Slightly shake the wire harness vertically and horizontally.
HINT The connector joint and fulcrum of the vibration are the major areas that should be checked
thoroughly.
(b) HEAT METHOD:
When a malfunction seems to occur when the area in question is heated.
(1) Heat the component that is the possible cause of the malfunction with a hair dryer or similar
device. Check if the malfunction occurs.
NOTICE: *
Do not heat to more than 60°C (140°F). Exceeding this temperature may damage components.
* Do not apply heat directly to the parts in the ECU.
(c) WATER SPRINKLING METHOD:
When a malfunction seems to occur on a rainy day or in high-humidity.
(1) Sprinkle water onto the vehicle and check if the malfunction occurs.
NOTICE: *
Never sprinkle water directly into the engine compartment. Indirectly change the temperature and
humidity by spraying water onto the front of the radiator.
* Never apply water directly onto the electronic components.
HINT If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU
or connections. Look for evidence of corrosion or short circuits. Proceed with caution during water
tests.
(d) HIGH ELECTRICAL LOAD METHOD:
When a malfunction seems to occur when the electrical load is excessive.
(1) Turn on the heater blower, headlights, rear window defogger and all other electrical loads.
Check if the malfunction reoccurs.
5. DIAGNOSTIC TROUBLE CODE CHART
Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate
section's Diagnostic Trouble Code Chart. Use the chart to determine the trouble area and the
proper inspection procedure. A description of each of the chart's columns is below.
Page 6180
3. REMOVE FRONT SEAT ASSEMBLY LH (for Power Seat)
(a) Remove the front seat LH See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Power
Seat)/Removal.
4. REMOVE FRONT SEAT ASSEMBLY RH (for Power Seat)
HINT Use the same procedures described for the LH side.
5. REMOVE CENTER FRONT SEAT ASSEMBLY
(a) Remove the center front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Center
Seat)/Removal.
6. REMOVE POWER OUTLET SOCKET ASSEMBLY
(a) Disconnect the power outlet socket connector.
(b) Using a screwdriver, detach the claw and remove the power outlet socket.
HINT Tape the screwdriver tip before use.
7. REMOVE POWER OUTLET SOCKET COVER
(a) Detach the 2 claws and remove the power outlet socket cover.
8. REMOVE CENTER SEATBACK PANEL (for Double Cab) See: Body and Frame/Seats/Service
and Repair/Overhaul/Front Seat Assembly (for
Center Seat)/Disassembly
9. REMOVE REAR POWER OUTLET SOCKET ASSEMBLY (for Double Cab)
(a) Using a screwdriver, detach the claw and remove the power outlet socket.
Page 4666
Shift Interlock Control Module: Diagrams
Page 8572
Page 5589
Braking Sensor/Switch: Diagrams
Page 3906
Refer to the Technical Information System (TIS) applicable model and model year Repair Manual:
2. Verify the vehicle has the proper coolant and oil levels.
3. Clear all DTCs and confirm the condition has been corrected.
Page 526
Tire Pressure Module: Service and Repair Removal
TIRE AND WHEEL: TIRE PRESSURE WARNING ECU: REMOVAL
NOTICE: *
It is necessary to perform initialization See: Instrument Panel, Gauges and Warning Indicators/Tire
Monitoring System/Testing and Inspection/Programming and Relearning/Initialization after
registration See: Instrument Panel, Gauges and Warning Indicators/Tire Monitoring System/Testing
and Inspection/Programming and Relearning/Registration of the transmitter IDs into the tire
pressure warning ECU after the ECU has been replaced.
* When replacing the tire pressure warning ECU, read the transmitter IDs stored in the old ECU
using the intelligent tester or Techstream and write them down before removal.
1. REMOVE FRONT DOOR SCUFF PLATE RH (for Regular Cab)
(a) Remove the front door scuff plate RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Removal.
HINT Use the same procedures described for the LH side.
2. REMOVE FRONT DOOR SCUFF PLATE RH (for Double Cab, for CrewMax)
(a) Remove the front door scuff plate RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Removal.
HINT Use the same procedures described for the LH side.
3. REMOVE COWL SIDE TRIM BOARD RH
(a) Remove the cowl side trim board RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Removal.
HINT Use the same procedures described for the LH side.
4. REMOVE INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal
5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and
Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument
Panel Safety Pad (for Column Shift Type)/Removal
6. REMOVE TIRE PRESSURE WARNING ECU
(a) Disconnect the ECU connector.
(b) Remove the 2 nuts and ECU.
Page 3733
HINT The wavelength becomes shorter as the engine rpm increases.
(f) WAVEFORM 5:
HINT *
The wavelength becomes shorter as the engine rpm increases.
* The waveforms and amplitudes displayed differ slightly depending on the vehicle.
(g) WAVEFORM 6:
HINT The wavelength becomes shorter as engine rpm increases.
(h) WAVEFORM 7:
Components
Engine Control Module: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: ECM: COMPONENTS
Page 2828
HINT The wavelength becomes shorter as the engine rpm increases.
(n) WAVEFORM 13:
HINT The waveform varies depending on the CAN communication signal.
(o) WAVEFORM 14:
HINT The waveform varies depending on the CAN communication signal.
(p) WAVEFORM 15:
HINT The wavelength becomes shorter as the engine rpm increases.
Page 4274
C. Choose desired ECU group(s) in the Health Check dialog box.
D. Click Next.
E. Click Continue to view Health Check results.
F. Available calibration updates are indicated by a link in the Cal. Update? column. Click the link to
access the appropriate service bulletin on TIS.
NOTE
^ Note any DTCs stored in Systems that will be flash reprogrammed.
^ Clicking the link will automatically launch TIS and perform a calibration search.
G. Log in to TIS. (If already logged in skip this step.)
H. To review the TSB and access the calibration file click the service bulletin link in the Document
Title column of the Calibration Search Result
portlet.
Page 180
Remove the blown fuse and disconnect all loads of the fuse.
Connect a test light in place of the fuse.
Establish conditions in which the test light comes on.
Example:
- [A] - Ignition SW on
- [B] - Ignition SW and SW1 on
- [C] - Ignition SW, SW1 and Relay on (Connect the Relay) and SW2 off (or Disconnect SW2)
Disconnect and reconnect the connectors while watching the test light.
Components
Integrated Accessory Switch Assembly: Service and Repair Components
METER: DRIVE MONITOR SWITCH: COMPONENTS
Page 4589
"Case1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (/\ Mark) and pull the terminal retainer
up to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Page 244
Power Distribution Module: Service and Repair Removal
OTHER SYSTEM: VOLTAGE INVERTER (for CrewMax): REMOVAL
1. REMOVE BACK PANEL TRIM LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for
CrewMax)/Removal
2. REMOVE BACK PANEL TRIM RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for
CrewMax)/Removal
3. REMOVE REAR DOOR SCUFF PLATE LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining
(for CrewMax)/Removal
4. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH
5. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY LH See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (for CrewMax)/Removal
6. REMOVE VOLTAGE INVERTER ASSEMBLY
(a) Remove the 2 bolts.
(b) Disconnect the voltage inverter connector and removal the voltage inverter.
Page 8675
when inserting and after full engagement.
NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal.
(d) REPAIR METHOD OF CONNECTOR TERMINAL
(1) If there is any foreign matter on the terminal, clean the contact point using an air gun or cloth.
Never rub the contact point using sandpaper
as the plating may come off.
(2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is
gold-plated (gold color), use a gold-plated female
terminal; if it is silver-plated (silver color), use a silver-plated female terminal.
(3) Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock
into the housing, the housing may have to be
replaced.
(e) HANDLING OF WIRE HARNESS
(1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be
restored in the same way.
(2) Never twist, pull or slacken the wire harness more than necessary.
(3) The wire harness should never come into contact with a high temperature part, or rotating,
moving, vibrating or sharp-edged parts. Avoid
contact with panel edges, screw tips and other sharp items.
(4) When installing parts, never pinch the wire harness.
(5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with
vinyl tape.
2. CHECK FOR OPEN CIRCUIT
Page 7316
NOTICE: If the holes for the cotter pin are not aligned, tighten the nut further up to 60°.
5. CONNECT SKID CONTROL SENSOR WIRE
(a) Connect the sensor wire to the steering knuckle and upper arm with the 2 bolts.
for Bolt A - Torque : 13 Nm (133 kgf-cm, 10 ft-lbf)
for Bolt B - Torque : 29 Nm (296 kgf-cm, 21 ft-lbf)
6. TEMPORARILY INSTALL FRONT SHOCK ABSORBER WITH COIL SPRING LH See:
Suspension Strut / Shock Absorber/Service and
Repair/Removal and Replacement/Front Shock Absorber/Installation
7. STABILIZE SUSPENSION See: Suspension Strut / Shock Absorber/Service and
Repair/Removal and Replacement/Front Shock
Absorber/Installation
8. TIGHTEN FRONT SUSPENSION UPPER ARM ASSEMBLY LH
(a) Tighten the nut.
Torque : 235 Nm (2396 kgf-cm, 173 ft-lbf)
9. TIGHTEN FRONT SHOCK ABSORBER WITH COIL SPRING See: Suspension Strut / Shock
Absorber/Service and Repair/Removal and
Replacement/Front Shock Absorber/Installation
10. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
(a) Inspect and adjust the front wheel alignment See: Alignment/Service and Repair.
11. INSTALL FRONT WHEEL
for Aluminum Wheel - Torque : 131 Nm (1336 kgf-cm, 97 ft-lbf)
for Steel Wheel - Torque : 209 Nm (2131 kgf-cm, 154 ft-lbf)
Components
SUSPENSION: FRONT LOWER SUSPENSION ARM: COMPONENTS
Page 821
Traction Control Switch: Service and Repair Removal
BRAKE CONTROL: VSC OFF SWITCH: REMOVAL
1. REMOVE FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Removal
2. REMOVE FRONT DOOR SCUFF PLATE LH (for Double Cab, CrewMax) See: Body and
Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Removal
3. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Removal
4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Removal
5. REMOVE VSC OFF SWITCH
(a) Disconnect the VSC OFF switch connector.
(b) Using a screwdriver, detach the 2 claws and remove the VSC OFF switch from the lower
instrument panel finish panel LH.
Page 7460
Tire Pressure Warning Reset Switch: Service and Repair Installation
TIRE AND WHEEL: TIRE PRESSURE WARNING RESET SWITCH: INSTALLATION
1. INSTALL TIRE PRESSURE WARNING RESET SWITCH
(a) Attach the 2 claws to install the reset switch.
(b) Connect the switch connector.
2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Installation
3. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
4. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Installation
5. INSTALL FRONT DOOR SCUFF PLATE LH (for Double Cab, for CrewMax) See: Body and
Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation
6. INSTALL FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Installation
Components
Seat Position Sensor: Service and Repair Components
SUPPLEMENTAL RESTRAINT SYSTEM: SEAT POSITION SENSOR: COMPONENTS
Components
Air Flow Meter/Sensor: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: COMPONENTS
Page 6351
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: ELECTRONIC
CIRCUIT INSPECTION PROCEDURE
1. BASIC INSPECTION
(a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS
(1) Unless otherwise stated, all resistance measurements should be made at an ambient
temperature of 20°C (68°F). Resistance measurements
may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been
running. Measurements should be made after the engine has cooled down.
(b) HANDLING CONNECTORS
(1) When disconnecting a connector, first squeeze the mating halves tightly together to release the
lock, and then press the lock claw and
separate the connector.
(2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly
and separate it.
(3) Before connecting a connector, check that there are no deformed, damaged, loose or missing
terminals.
(4) When connecting a connector, press firmly until it locks with a "click" sound.
(5) If checking a connector with a TOYOTA electrical tester, check the connector from the backside
(harness side) using a mini test lead.
NOTICE: *
As a waterproof connector cannot be checked from the backside, check it by connecting a
sub-harness.
* Do not damage the terminals by moving the inserted tester needle.
(c) CHECKING CONNECTORS
(1) Checking when a connector is connected: Squeeze the connectors together to confirm that they
are fully connected and locked.
(2) Checking when a connector is disconnected: Check by pulling the wire harness lightly from the
backside of the connector. Look for
unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for
corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or
deformed terminals.
(3) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a
female terminal, and check for ample tension
Page 1816
^ Power Supply Mode is used to maintain battery voltage at 13.5 volts while flash reprogramming
the vehicle.
^ For details on how to use the GR8 Battery Diagnostic Station, refer to the located on TIS,
Diagnostics - Tools & Equipment - Battery Diagnostics.
3. Click the appropriate calibration ID and reprogram the vehicle's ECU with Techstream.
A. After reviewing the procedures outlined in the selected TSB, click the appropriate calibration ID
link by matching the vehicle's current
calibration ID to the Previous Calibration ID in the Calibration Identification Chart.
NOTE
^ Calibration files are embedded as live links in the service bulletin.
^ Some vehicles require special preparation - please review the selected TSB carefully.
B. Click Open to load calibration file information.
Techstream pulls calibration files as needed to ensure the latest calibration file is used. Do NOT
save calibrations locally on the hard drive or other media.
NOTICE
Errors during the flash reprogramming process can permanently damage the vehicle ECU.
Minimize the risk by following the steps below.
^ Battery voltage MUST NOT FALL BELOW 11.4 volts during reprogramming. Confirm battery
voltage is higher than 11.4 volts, but be sure voltage DOES NOT RISE ABOVE 16.0 volts during
reprogramming.
^ Turn OFF all vehicle accessories (e.g. audio system, A/C, interior lights, DRL, etc.). Do NOT add
to or significantly change the vehicle's electrical
Capacity Specifications
Refrigerant: Capacity Specifications
REFRIGERANT
Standard...............................................................................................................................................
........................................600 +/-30 g (21.2 +/-1.1 oz.)
Page 8790
Standard resistance:
(b) If the result is not as specified, replace the speaker assembly.
3. INSPECT FRONT NO. 4 SPEAKER ASSEMBLY (for 12 Speakers)
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the speaker assembly.
Instrument Panel Speaker (for Double Cab)
AUDIO / VISUAL: INSTRUMENT PANEL SPEAKER (for Double Cab): INSPECTION
1. INSPECT FRONT NO. 2 SPEAKER ASSEMBLY (for Standard)
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the speaker assembly.
2. INSPECT FRONT NO. 2 SPEAKER ASSEMBLY (for 10 Speakers)
Page 8086
Door/Service and Repair/Front Door (for Double Cab)/Disassembly
4. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH (for Front Side) See: Body
and Frame/Doors, Hood and
Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly
5. REMOVE COURTESY LIGHT ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood
and Trunk/Doors/Front Door/Service and
Repair/Front Door (for Double Cab)/Disassembly
6. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Disassembly
7. REMOVE FRONT SIDE AIRBAG SENSOR
(a) Disconnect the connector.
(b) Remove the screw and side airbag sensor.
8. REMOVE REAR SEAT ASSEMBLY (for Rear Side)
(a) Remove the rear seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Rear Seat Assembly (for Double
Cab)/Removal.
9. REMOVE REAR DOOR SCUFF PLATE LH (for Rear Side) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and Repair/Roof
Headlining (For Double Cab)/Removal
10. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH (for Rear Side)
11. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY LH (for Rear Side) See: Body and
Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal
12. REMOVE REAR SIDE AIRBAG SENSOR
(a) Remove the bolt and side airbag sensor.
(b) Disconnect the connector.
Installation
SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Double Cab):
INSTALLATION
1. INSTALL FRONT SIDE AIRBAG SENSOR
(a) Check that the ignition switch is OFF.
(b) Check that the cable is disconnected from the battery negative (-) terminal.
CAUTION:
Page 6698
Instrument Panel (Floor Shift)
Instrument Panel (Column Shift)
Page 9297
Component Tests and General Diagnostics
Engine Control Module: Component Tests and General Diagnostics
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: ECM Power Source Circuit - ECM Power
Source Circuit
DESCRIPTION
When the ignition switch is turned to ON, the battery voltage is applied to the IGSW terminal of the
ECM. The output signal from the MREL terminal of the ECM causes a current to flow to the coil,
closing the contacts of the integration relay (EFI relay) and supplying power to terminals +B and
+B2 of the ECM.
WIRING DIAGRAM
INSPECTION PROCEDURE
PROCEDURE
1. INSPECT FUSES (AM2, IG2 MAIN, EFI NO. 1, IGN)
Page 3082
when inserting and after full engagement.
NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal.
(d) REPAIR METHOD OF CONNECTOR TERMINAL
(1) If there is any foreign matter on the terminal, clean the contact point using an air gun or cloth.
Never rub the contact point using sandpaper
as the plating may come off.
(2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is
gold-plated (gold color), use a gold-plated female
terminal; if it is silver-plated (silver color), use a silver-plated female terminal.
(3) Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock
into the housing, the housing may have to be
replaced.
(e) HANDLING OF WIRE HARNESS
(1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be
restored in the same way.
(2) Never twist, pull or slacken the wire harness more than necessary.
(3) The wire harness should never come into contact with a high temperature part, or rotating,
moving, vibrating or sharp-edged parts. Avoid
contact with panel edges, screw tips and other sharp items.
(4) When installing parts, never pinch the wire harness.
(5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with
vinyl tape.
2. CHECK FOR OPEN CIRCUIT
Page 7766
8. INSTALL NO. 2 COOLER COVER
(a) Attach the 2 claws to install the cover.
(b) Install the 2 nuts.
Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)
9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
10. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Reading and Clearing Diagnostic Trouble
Codes/Check Mode Procedure.
11. ADD ENGINE COOLANT
(a) for 1GR-FE:
Add engine coolant See: Engine, Cooling and Exhaust/Cooling System/Coolant/Service and
Repair.
(b) for 1UR-FE:
Add engine coolant See: Engine, Cooling and Exhaust/Cooling System/Coolant/Service and
Repair.
(c) for 3UR-FE:
Add engine coolant See: Engine, Cooling and Exhaust/Cooling System/Coolant/Service and
Repair.
(d) for 3UR-FBE:
Add engine coolant See: Engine, Cooling and Exhaust/Cooling System/Coolant/Service and
Repair.
12. CHARGE REFRIGERANT See: Service and Repair
13. WARM UP ENGINE See: Service and Repair
14. CHECK FOR ENGINE COOLANT LEAK See: Service and Repair
15. CHECK FOR REFRIGERANT GAS LEAK
(a) Check for refrigerant gas leak See: Service and Repair.
Specifications
Brake Rotor/Disc: Specifications
FRONT BRAKE
DISC THICKNESS
Standard thickness...............................................................................................................................
........................................................32.0 mm (1.26 in.)
Minimum thickness...............................................................................................................................
......................................................29.0 mm (1.14 in.)
DISC RUNOUT
Maximum disc runout...........................................................................................................................
.................................................0.05 mm (0.00197 in.)
REAR BRAKE
DISC THICKNESS
Standard thickness...............................................................................................................................
......................................................18.0 mm (0.709 in.)
Minimum thickness...............................................................................................................................
....................................................16.0 mm (0.630 in.)
DISC RUNOUT
Maximum disc runout...........................................................................................................................
...................................................0.2 mm (0.00787 in.)
Page 8850
Up to 11/2009
AUDIO / VISUAL: REAR DOOR SPEAKER (for Double Cab): REMOVAL
HINT *
Use the same procedures for the LH side and RH side.
* The procedures listed below are for the LH side.
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE REAR DOOR FRAME GARNISH LH See: Body and Frame/Doors, Hood and
Trunk/Doors/Rear Door/Service and Repair/Rear
Door (for Double Cab)/Disassembly
3. REMOVE REAR DOOR INSIDE HANDLE BEZEL PLUG LH See: Body and Frame/Doors, Hood
and Trunk/Doors/Rear Door/Service and
Repair/Rear Door (for Double Cab)/Disassembly
4. REMOVE REAR UPPER DOOR ARMREST BASE PANEL LH See: Body and Frame/Doors,
Hood and Trunk/Doors/Rear Door/Service and
Repair/Rear Door (for Double Cab)/Disassembly
5. REMOVE COURTESY LIGHT ASSEMBLY See: Body and Frame/Doors, Hood and
Trunk/Doors/Rear Door/Service and Repair/Rear Door
(for Double Cab)/Disassembly
6. REMOVE REAR DOOR ARMREST COVER LH
7. REMOVE REAR DOOR TRIM BOARD SUB-ASSEMBLY LH See: Body and Frame/Doors, Hood
and Trunk/Doors/Rear Door/Service and
Repair/Rear Door (for Double Cab)/Disassembly
8. REMOVE REAR NO. 1 SPEAKER ASSEMBLY
(a) Disconnect the speaker connector.
Page 6607
4. SYMPTOM CONFIRMATION AND DTC (INCLUDING FREEZE FRAME DATA) CHECK
(a) Visually check the wire harnesses, connectors and fuses for open and short circuits.
(b) Warm up the engine to the normal operating temperature.
(c) Confirm the problem symptoms and conditions, and check for DTCs.
B -- Go to step 6 A -- Continue to next step.
5. DTC CHART
(a) Check the results obtained in the DTC check. Then find the output DTC in the DTC chart. Look
at the "Trouble Area" column for a list of
potentially malfunctioning circuits and / or parts.
NEXT -- Go to step 7
6. PROBLEM SYMPTOMS TABLE
(a) Check the results obtained in the symptom confirmation. Then find the problem symptoms in
the problem symptoms table. Look at the
"Suspected Area" column for a list of potentially malfunctioning circuits and / or parts.
NEXT -- Continue to next step.
7. CIRCUIT INSPECTION OR PARTS INSPECTION
(a) Confirm the malfunctioning circuit or part.
NEXT -- Continue to next step.
8. ADJUST, REPAIR OR REPLACE
(a) Adjust, repair or replace the malfunctioning circuit or parts.
NEXT -- Continue to next step.
9. CONFIRMATION TEST
(a) After the adjustment, repairs or replacement, confirm that the malfunction no longer exists. If the
malfunction does not reoccur, perform a
confirmation test under the same conditions and in the same environment as when the malfunction
occurred the first time.
NEXT -- END
2. CUSTOMER PROBLEM ANALYSIS
HINT *
In troubleshooting, confirm that the problem symptoms have been accurately identified.
Preconceptions should be discarded in order to make an accurate judgment. To clearly understand
what the problem symptoms are, it is extremely important to ask the customer about the problem
and the conditions at the time the malfunction occurred.
* Gather as much information as possible for reference. Past problems that seem unrelated may
also help in some cases.
* The following 5 questions are important points in the problem analysis:
Components
Tire Pressure Monitor Receiver / Transponder: Service and Repair Components
TIRE AND WHEEL: TIRE PRESSURE WARNING RECEIVER: COMPONENTS
Page 588
Integrated Accessory Switch Assembly: Service and Repair Installation
METER: DRIVE MONITOR SWITCH: INSTALLATION
1. INSTALL DRIVE MONITOR SWITCH
(a) Attach the 2 claws to install the monitor switch.
2. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Panel,
Gauges and Warning Indicators/Instrument Cluster
/ Carrier/Service and Repair/Combination Meter/Installation
Page 7882
Refrigerant Pressure Sensor / Switch: Service and Repair Removal
AIR CONDITIONING: PRESSURE SWITCH: REMOVAL
1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM See: Service and Repair
2. REMOVE PRESSURE SWITCH
(a) Disconnect the connector.
(b) Remove the switch.
(c) Remove the O-ring from the pressure switch.
NOTICE: Seal the openings of the disconnected parts using vinyl tape to prevent moisture and
foreign matter from entering them.
Page 8277
Engine Controls - ECM Update For Shift Performance
Engine Control Module: Customer Interest Engine Controls - ECM Update For Shift Performance
T-SB-0285-10
October 12, 2010
ECM Calibration: Enhancement to Shifting Performance
Service Category Drivetrain
Section Automatic Transmission/Transaxle
Market USA
Applicability
Introduction
Some vehicles may exhibit the following shifting conditions:
^ Harsh shift on acceleration below 20 mph during the 2-1 downshift.
^ Excessive lock-up operation at freeway speeds about 50 - 60 mph, sometimes referred to as
"busy shifting".
The Engine Control Module/ECM (SAE term: Powertrain Control Module/PCM) calibration has
been revised. Use the following repair procedure to address these conditions.
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Federal Emission Warranty. This warranty is in effect for
96 months or 80,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
A/C Amplifier, A/C Blower Assembly
Control Module HVAC: Diagrams A/C Amplifier, A/C Blower Assembly
Page 7883
Refrigerant Pressure Sensor / Switch: Service and Repair Installation
AIR CONDITIONING: PRESSURE SWITCH: INSTALLATION
1. INSTALL PRESSURE SWITCH
(a) Sufficiently apply compressor oil to a new O-ring and the fitting surface of the pressure switch.
Compressor oil:
ND-OIL 8 or equivalent
(b) Install the O-ring on the pressure switch.
(c) Install the switch.
Torque : 10.8 Nm (110 kgf-cm, 8 ft-lbf)
(d) Connect the connector.
2. CHARGE REFRIGERANT See: Service and Repair
3. WARM UP ENGINE See: Service and Repair
4. CHECK FOR LEAKAGE OF REFRIGERANT See: Service and Repair
Page 4632
(4) Remove the 2 bolts and disconnect the water by-pass pipe.
(5) Remove the 4 bolts and 4 ignition coils.
4. REMOVE SPARK PLUG
(a) Using a 16 mm plug wrench, remove the 8 spark plugs.
Page 5886
Page 1430
Removal
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Column
Shift Type): REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service
and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Removal
3. REMOVE CENTER AIRBAG SENSOR ASSEMBLY
Page 8373
Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)
NOTICE: *
If the side airbag sensor has been dropped, or there are any cracks, dents or other defects in the
case, bracket or connector, replace it with a new one.
* When installing the side airbag sensor, be careful that the SRS wiring does not interfere with
other parts and that it is not pinched between other parts.
(d) Check that there is no looseness in the installation parts of the side airbag sensor.
(e) Connect the connector.
8. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY LH (for Rear Side) See: Body and
Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation
9. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH (for Rear Side)
10. INSTALL REAR DOOR SCUFF PLATE LH (for Rear Side) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and Repair/Roof
Headlining (For Double Cab)/Installation
11. INSTALL REAR SEAT ASSEMBLY (for Rear Side)
(a) Install the rear seat assembly See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Rear Seat Assembly (for Double
Cab)/Installation.
12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
13. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Air Bag Systems/Testing and Inspection/Initial Inspection
and Diagnostic Overview/Diagnosis System.
Components
SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Double Cab):
COMPONENTS
Page 6392
Junction Connector
Page 5059
SST : 09950-60010
09951-00550
SST : 09950-40011
09951-04020
09952-04010
09953-04030
09954-04010
09955-04061
09957-04010
09958-04011
HINT Fix the claws of SST into the notch in the differential case assembly.
21. DISASSEMBLE DIFFERENTIAL CASE
(a) Using a pin punch and hammer, tap out the straight pin.
(b) Remove these parts from the differential case assembly.
(1) 2 differential side gears
(2) 2 differential side gear thrust washers
(3) Differential pinion shaft
(4) 2 differential pinion gears
(5) 2 differential pinion gear thrust washers
22. INSPECT DIFFERENTIAL GEAR KIT
(a) Check that there is no damage to the pinion gear and side gear.
If the pinion gear and/or side gear is damaged, replace the differential gear kit.
23. INSPECT FRONT DIFFERENTIAL CASE
Page 4931
(a) Move the shift lever to N.
(b) Fold back the floor carpet.
(c) Disconnect the column shift transmission control cable end from the column shift.
(d) Press the sides of the outer cable socket to detach the claws and disconnect the cable from the
steering column shaft bracket.
(e) Remove the 2 bolts and disconnect the 2 cable clamps.
(f) Remove the nut and clip, and disconnect the transmission control cable from the automatic
transmission.
(g) Remove the nut and disconnect the transmission control cable support.
Page 2823
HINT *: The ECM terminal voltage is constant regardless of the output voltage from the sensor.
(b) WAVEFORM 1:
Page 2082
(2) CONNECTORS
Slightly shake the connector vertically and horizontally.
(3) WIRE HARNESS
Slightly shake the wire harness vertically and horizontally.
HINT The connector joint and fulcrum of the vibration are the major areas that should be checked
thoroughly.
(b) HEAT METHOD:
When a malfunction seems to occur when the area in question is heated.
(1) Heat the component that is the possible cause of the malfunction with a hair dryer or similar
device. Check if the malfunction occurs.
NOTICE: *
Do not heat to more than 60°C (140°F). Exceeding this temperature may damage components.
* Do not apply heat directly to the parts in the ECU.
(c) WATER SPRINKLING METHOD:
When a malfunction seems to occur on a rainy day or in high-humidity.
(1) Sprinkle water onto the vehicle and check if the malfunction occurs.
NOTICE: *
Never sprinkle water directly into the engine compartment. Indirectly change the temperature and
humidity by spraying water onto the front of the radiator.
* Never apply water directly onto the electronic components.
HINT If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU
or connections. Look for evidence of corrosion or short circuits. Proceed with caution during water
tests.
(d) HIGH ELECTRICAL LOAD METHOD:
When a malfunction seems to occur when the electrical load is excessive.
(1) Turn on the heater blower, headlights, rear window defogger and all other electrical loads.
Check if the malfunction reoccurs.
5. DIAGNOSTIC TROUBLE CODE CHART
Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate
section's Diagnostic Trouble Code Chart. Use the chart to determine the trouble area and the
proper inspection procedure. A description of each of the chart's columns is below.
Locations
Switch: Locations
JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION
Page 6340
Remove the blown fuse and disconnect all loads of the fuse.
Connect a test light in place of the fuse.
Establish conditions in which the test light comes on.
Example:
- [A] - Ignition SW on
- [B] - Ignition SW and SW1 on
- [C] - Ignition SW, SW1 and Relay on (Connect the Relay) and SW2 off (or Disconnect SW2)
Disconnect and reconnect the connectors while watching the test light.
Page 6385
Locations
Seat Belt Buckle Switch: Locations
SUPPLEMENTAL RESTRAINT SYSTEM: OCCUPANT CLASSIFICATION SYSTEM: PARTS
LOCATION
Specifications
Firing Order: Specifications
Firing Order
1-8-4-3-6-5-7-2
Page 4190
IV. Background
There is a possibility that certain accelerator pedal mechanisms may in rare instances
mechanically stick in a partially depressed position or return slowly to the idle position.
Over time some accelerator pedal mechanisms may become worn. As a result of this wear
combined with certain operating and environmental conditions friction in the mechanism may
increase and intermittently result in the accelerator pedal being hard to depress slow to return or in
the worst case stick in a partially open position.
Page 6325
JQ1-LJ1
Locations
Overdrive Switch: Locations
A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS
LOCATION
Page 4593
Push the secondary locking device or terminal retainer in to the full lock position.
CONNECT CONNECTOR
Voltage Check
VOLTAGE CHECK
Page 850
Yaw Rate Sensor: Diagrams
Page 3316
(a) Remove the AM2 fuse, IG2 MAIN fuse, EFI NO. 1 fuse and IGN fuse from the engine room
relay block.
(b) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
NG -- CHECK FOR SHORT IN ALL HARNESSES AND CONNECTORS CONNECTED TO FUSE
AND REPLACE FUSE OK -- Continue to next step.
2. INSPECT RELAY (IG2, EFI)
(a) Remove the integration relay from the engine room relay block.
(b) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
Page 7163
Tire Pressure Warning Reset Switch: Service and Repair Installation
TIRE AND WHEEL: TIRE PRESSURE WARNING RESET SWITCH: INSTALLATION
1. INSTALL TIRE PRESSURE WARNING RESET SWITCH
(a) Attach the 2 claws to install the reset switch.
(b) Connect the switch connector.
2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Installation
3. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
4. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Installation
5. INSTALL FRONT DOOR SCUFF PLATE LH (for Double Cab, for CrewMax) See: Body and
Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation
6. INSTALL FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Installation
Page 1389
(e) Connect the holder (with connectors).
(f) Check that the waterproof sheet is properly set.
2. INSTALL FRONT CONSOLE BOX See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal
and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation
3. INSTALL REAR CONSOLE BOX ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation
4. INSTALL CONSOLE BOX CARPET
5. INSTALL REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
6. INSTALL UPPER CONSOLE REAR PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
7. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding
/ Trim/Dashboard / Instrument Panel/Service
and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
8. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation
9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
10. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
Front Power Window Switch
Power Window Switch: Diagrams Front Power Window Switch
Page 6610
* In the DTC check, it is very important to determine whether the problem indicated by the DTC is
either: 1) still occurring; or 2) occurred in the past but has since returned to normal. In addition, the
DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs
should be checked before and after confirmation of symptoms (i.e., whether or not problem
symptoms exist) to determine current system conditions, as shown in the flowchart below.
* Never skip the DTC check. Failing to check DTCs may, depending on the case, result in
unnecessary troubleshooting for systems operating normally or lead to repairs not related to the
problem. Follow the procedures listed in the flowchart in the correct order.
* The following flowchart shows how to proceed with troubleshooting using the DTC check.
Directions from the flowchart will indicate how to proceed either to DTC troubleshooting or to the
troubleshooting of each problem symptom.
1. DTC CHECK
NEXT -- Continue to next step.
2. MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR MEMORY
NEXT -- Continue to next step.
3. SYMPTOM CONFIRMATION
B -- Go to step 5 A -- Continue to next step.
4. SIMULATION TEST USING SYMPTOM SIMULATION METHODS
NEXT -- Continue to next step.
5. DTC CHECK
B -- TROUBLESHOOTING OF PROBLEM INDICATED BY DTC A -- Continue to next step.
6. SYMPTOM CONFIRMATION
Page 1320
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: ELECTRONIC
CIRCUIT INSPECTION PROCEDURE
1. BASIC INSPECTION
(a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS
(1) Unless otherwise stated, all resistance measurements should be made at an ambient
temperature of 20°C (68°F). Resistance measurements
may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been
running. Measurements should be made after the engine has cooled down.
(b) HANDLING CONNECTORS
(1) When disconnecting a connector, first squeeze the mating halves tightly together to release the
lock, and then press the lock claw and
separate the connector.
(2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly
and separate it.
(3) Before connecting a connector, check that there are no deformed, damaged, loose or missing
terminals.
(4) When connecting a connector, press firmly until it locks with a "click" sound.
(5) If checking a connector with a TOYOTA electrical tester, check the connector from the backside
(harness side) using a mini test lead.
NOTICE: *
As a waterproof connector cannot be checked from the backside, check it by connecting a
sub-harness.
* Do not damage the terminals by moving the inserted tester needle.
(c) CHECKING CONNECTORS
(1) Checking when a connector is connected: Squeeze the connectors together to confirm that they
are fully connected and locked.
(2) Checking when a connector is disconnected: Check by pulling the wire harness lightly from the
backside of the connector. Look for
unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for
corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or
deformed terminals.
(3) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a
female terminal, and check for ample tension
Page 2291
Variable Valve Timing Actuator: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT OIL CONTROL VALVE: INSTALLATION
1. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side of Bank 1)
(a) Apply a light coat of engine oil to the O-ring.
(b) Install a new O-ring to the oil control valve.
(c) Install the oil control valve with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(d) Connect the oil control valve connector.
2. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side of Bank 1)
(a) Apply a light coat of engine oil to the O-ring.
(b) Install a new O-ring to the oil control valve.
(c) Install the oil control valve with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(d) Connect the oil control valve connector.
3. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side of Bank 2)
(a) Apply a light coat of engine oil to the O-ring.
(b) Install a new O-ring to the oil control valve.
(c) Install the oil control valve with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(d) Connect the oil control valve connector.
4. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side of Bank 2)
Front Axle Hub Bolt
Wheel Fastener: Service and Repair Front Axle Hub Bolt
Components
AXLE: FRONT AXLE HUB BOLT: COMPONENTS
Replacement
AXLE: FRONT AXLE HUB BOLT: REPLACEMENT
HINT *
Use the same procedures for the LH side and RH side.
Page 6903
Page 4513
Crankshaft Position Sensor: Diagrams
Page 6582
Page 6360
Page 4578
Page 3295
When using Techstream Lite, select Generic J2534 Interface. Then click Next.
E. Confirm the following:
^ PC is connected to VIM.
^ VIM is connected to DLC3 connector.
^ Ignition is ON and engine is OFF or "READY" OFF (hybrid vehicles).
Page 3620
without SST - Torque : 44 Nm (449 kgf-cm, 32 ft-lbf)
with SST - Torque : 40 Nm (408 kgf-cm, 30 ft-lbf)
HINT *
Use a torque wrench with a fulcrum length of 30 cm (11.8 in.). When using a torque wrench with a
fulcrum length that is not 30 cm (11.8 in.), calculate the torque specification for the torque wrench
and SST based on the "without SST" torque specification See: Service Precautions
* Make sure SST and the wrench are connected in a straight line.
(c) for 2WD:
Connect the air fuel ratio sensor connector.
2. INSTALL FRONT NO. 2 EXHAUST PIPE ASSEMBLY (for 4WD)
(a) Connect the front No. 2 exhaust pipe to the exhaust pipe support.
(b) Install a new gasket and the front No. 2 exhaust pipe to the exhaust manifold LH with 3 new
nuts.
Torque : 54 Nm (554 kgf-cm, 40 ft-lbf)
(c) Connect the air fuel ratio sensor connector.
(d) Connect the heated oxygen sensor connector.
3. INSTALL AIR FUEL RATIO SENSOR (for Bank 2 Sensor 1)
(a) Install the sensor to the exhaust pipe by hand.
(b) Using SST, tighten the sensor.
SST : 09224-00010
without SST - Torque : 44 Nm (449 kgf-cm, 32 ft-lbf)
Locations
Dimmer Switch: Locations
LIGHTING: LIGHTING SYSTEM: PARTS LOCATION
Components
Power Distribution Module: Service and Repair Components
OTHER SYSTEM: VOLTAGE INVERTER (for CrewMax): COMPONENTS
Diagram Information and Instructions
Relay Box: Diagram Information and Instructions
Wiring Color Codes
Abbreviations Used Within Diagrams
Abbreviations Used Within Diagrams
Page 1553
Tire Pressure Sensor: Service and Repair Installation
TIRE AND WHEEL: TIRE PRESSURE WARNING VALVE AND TRANSMITTER: INSTALLATION
1. INSTALL TIRE PRESSURE WARNING VALVE AND TRANSMITTER
(a) Insert the tire pressure warning valve into the valve installation hole from the inside of the rim so
that the print surface can be seen.
NOTICE: *
Check that there is no visible deformation, damage or other abnormalities on the tire pressure
warning valve and transmitter.
* Check that there is no foreign matter on the inner grommet and around the rim hole.
* If the tire pressure warning valve and transmitter is installed in the reverse direction, it may be
damaged or fail to transmit signals when running at a high speed.
* If installing a new tire pressure warning valve and transmitter, write down the transmitter ID before
installation.
* The transmitter ID registration must be performed for all tire pressure warning valve and
transmitters, regardless of the number of tire pressure warning valve and transmitters replaced. If
all of the tire pressure warning valve and transmitters do not need to be replaced, check the DATA
LIST and write down the transmitter IDs of the tire pressure warning valve and transmitters that do
not need to be replaced before performing the transmitter ID registration See: Instrument Panel,
Gauges and Warning Indicators/Tire Monitoring System/Testing and Inspection/Programming and
Relearning/Registration
* It is necessary to perform initialization See: Instrument Panel, Gauges and Warning
Indicators/Tire Monitoring System/Testing and Inspection/Programming and
Relearning/Initialization after registration See: Instrument Panel, Gauges and Warning
Indicators/Tire Monitoring System/Testing and Inspection/Programming and
Relearning/Registration of the transmitter IDs into the tire pressure warning ECU after the tire
pressure warning valve and transmitter has been replaced.
(b) If reusing the tire pressure warning valve and transmitter:
Install a new grommet.
HINT A new tire pressure warning valve and transmitter is supplied with a grommet.
(c) Install the washer on the tire pressure warning valve from the rim side and tighten the nut.
Page 7320
(a) Install the lower suspension arm with the camber adjusting cam, No. 2 camber adjusting cam,
No. 2 toe adjusting plate, toe adjusting cam, bolt,
nut and washer.
(b) Align the matchmarks on the No. 2 camber adjusting cam and No. 2 toe adjusting plate.
Temporarily install the bolt and nut.
2. CONNECT FRONT LOWER BALL JOINT ATTACHMENT LH
(a) Connect the attachment to the steering knuckle with the 2 bolts.
Torque : 300 Nm (3059 kgf-cm, 221 ft-lbf)
3. CONNECT FRONT SHOCK ABSORBER WITH COIL SPRING LH
(a) Connect the shock absorber with the bolt and nut.
4. INSTALL FRONT STABILIZER LINK ASSEMBLY LH See: Stabilizer Bar/Service and
Repair/Installation
5. STABILIZE SUSPENSION See: Suspension Strut / Shock Absorber/Service and
Repair/Removal and Replacement/Front Shock
Absorber/Installation
6. TIGHTEN FRONT NO. 1 SUSPENSION ARM LOWER SUB-ASSEMBLY LH
(a) Tighten the bolt and nut.
Torque : 280 Nm (2855 kgf-cm, 207 ft-lbf)
7. TIGHTEN FRONT SHOCK ABSORBER WITH COIL SPRING
Page 8874
(a) Disconnect the connectors.
(b) Remove the 2 nuts and junction block.
(c) Remove the nut and ECU.
Page 6344
"Case2" Open the secondary locking device.
[B] For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray
Gray or White : Black
Page 872
Cruise Control Switch: Testing and Inspection
CRUISE CONTROL: CRUISE CONTROL MAIN SWITCH: INSPECTION
1. INSPECT CRUISE CONTROL MAIN SWITCH
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the cruise control main switch.
Page 6782
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Component Tests and General Diagnostics
Acceleration/Deceleration Sensor: Component Tests and General Diagnostics
BRAKE CONTROL: YAW RATE AND DECELERATION SENSOR: INSPECTION
1. CHECK YAW RATE SENSOR
(a) Check the yaw rate sensor.
Under any of the following conditions, replace the sensor with a new one:
* The surface of the sensor is cracked, dented, or chipped.
* The connector is scratched, cracked, or damaged.
* The sensor has been dropped.
Page 548
Control Module: Locations JF1A Transfer Case
JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION
Page 1414
Removal
SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for CrewMax): REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Disassembly
3. REMOVE FRONT UPPER ARMREST BASE PANEL LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Page 8660
Garage Door Opener Transmitter: Diagnostic Aids
Continuity and Resistance Check
CONTINUITY AND RESISTANCE CHECK
Disconnect the battery terminal or wire so there is no voltage between the check points.
Contact the two leads of an ohmmeter to each of the check points.
Page 6548
Engine Room R/B, J/B - Engine Compartment Left
Page 6533
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: ELECTRONIC
CIRCUIT INSPECTION PROCEDURE
1. BASIC INSPECTION
(a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS
(1) Unless otherwise stated, all resistance measurements should be made at an ambient
temperature of 20°C (68°F). Resistance measurements
may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been
running. Measurements should be made after the engine has cooled down.
(b) HANDLING CONNECTORS
(1) When disconnecting a connector, first squeeze the mating halves tightly together to release the
lock, and then press the lock claw and
separate the connector.
(2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly
and separate it.
(3) Before connecting a connector, check that there are no deformed, damaged, loose or missing
terminals.
(4) When connecting a connector, press firmly until it locks with a "click" sound.
(5) If checking a connector with a TOYOTA electrical tester, check the connector from the backside
(harness side) using a mini test lead.
NOTICE: *
As a waterproof connector cannot be checked from the backside, check it by connecting a
sub-harness.
* Do not damage the terminals by moving the inserted tester needle.
(c) CHECKING CONNECTORS
(1) Checking when a connector is connected: Squeeze the connectors together to confirm that they
are fully connected and locked.
(2) Checking when a connector is disconnected: Check by pulling the wire harness lightly from the
backside of the connector. Look for
unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for
corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or
deformed terminals.
(3) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a
female terminal, and check for ample tension
Page 5397
Control Module: Service and Repair Installation
JF1A TRANSFER: 4WD CONTROL ECU: INSTALLATION
1. INSTALL 4WD CONTROL ECU
(a) Install the ECU with the bolt.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
(b) Connect the 2 ECU connectors.
2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Installation
3. INSTALL INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
4. INSTALL COWL SIDE TRIM BOARD RH
(a) Install the cowl side trim board RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Installation.
HINT Use the same procedures described for the LH side.
5. INSTALL FRONT DOOR SCUFF PLATE RH (for Regular Cab)
(a) Install the front door scuff plate RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Installation.
HINT Use the same procedures described for the LH side.
6. INSTALL FRONT DOOR SCUFF PLATE RH (for Double Cab, for CrewMax)
(a) Install the front door scuff plate RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Installation.
HINT Use the same procedures described for the LH side.
Page 6585
Page 1002
(a) Remove the fuel suction with pump and gauge tube See: Powertrain Management/Fuel Delivery
and Air Induction/Fuel Pump/Service and
Repair/Removal and Replacement/Removal.
2. REMOVE FUEL SENDER GAUGE ASSEMBLY
(a) Disconnect the fuel sender gauge connector.
(b) Press down on the sender gauge claw labeled A. Then slide the sender gauge upward to
remove it.
Installation
1UR-FE FUEL: FUEL SENDER GAUGE ASSEMBLY: INSTALLATION
1. INSTALL FUEL SENDER GAUGE ASSEMBLY
(a) Set the sender gauge to the fuel sub tank. Then slide the sender gauge downward to install it.
(b) Connect the fuel sender gauge connector.
2. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY
(a) Install the fuel suction with pump and gauge tube See: Powertrain Management/Fuel Delivery
and Air Induction/Fuel Pump/Service and
Repair/Removal and Replacement/Installation.
Page 8383
(b) Check that the cable is disconnected from the battery negative (-) terminal.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation
(c) Install the door airbag sensor with the screw.
Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)
NOTICE: *
If the door airbag sensor has been dropped, or there are any cracks, dents or other defects in the
case, bracket or connector, replace it with a new one.
* When installing the door airbag sensor, be careful that the SRS wiring does not interfere with
other parts and that it is not pinched between other parts.
(d) Check that there is no looseness in the installation parts of the side airbag sensor.
(e) Connect the connector.
2. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Regular Cab)/Reassembly
3. INSTALL COURTESY LIGHT ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood
and Trunk/Doors/Front Door/Service and
Repair/Front Door (for Regular Cab)/Reassembly
4. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH LH (for Front Side) See: Body
and Frame/Doors, Hood and
Trunk/Doors/Front Door/Service and Repair/Front Door (for Regular Cab)/Reassembly
5. INSTALL FRONT DOOR WINDOW REGULATOR HANDLE ASSEMBLY (for Front Side) See:
Body and Frame/Doors, Hood and
Trunk/Doors/Front Door/Service and Repair/Front Door (for Regular Cab)/Reassembly
6. INSTALL FRONT ARMREST BASE PANEL UPPER LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Regular Cab)/Reassembly
7. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Regular Cab)/Reassembly
8. INSTALL REAR SIDE AIRBAG SENSOR
(a) Check that the ignition switch is OFF.
(b) Check that the cable is disconnected from the battery negative (-) terminal.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
(c) Install the side airbag sensor with the bolt.
Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)
NOTICE: *
If the side airbag sensor has been dropped, or there are any cracks, dents or other defects in the
case, bracket or connector, replace it with a new one.
* When installing the side airbag sensor, be careful that the SRS wiring does not interfere with
other parts and that it is not pinched
Page 405
Engine Control Module: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: ECM: INSTALLATION
1. INSTALL GASKET
(a) Clean the ECM seal's surface with non-residue solvent.
(b) Attach a new gasket to the ECM.
2. INSTALL ECM
(a) Install the ECM with the 4 bolts.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
NOTICE: *
Make sure the gasket is not folded or caught on any area on the surrounding part.
* Make sure there is no foreign matter caught between the gasket and surrounding part.
* Do not damage the gasket.
(b) Connect the 2 ECM connectors and push each lock lever down to lock the ECM connectors.
NOTICE: *
Make sure that the lock lever is raised 90° before connecting the ECM connectors. Failure to do
this may cause the lock lever and terminals to break.
* Do not twist the wire harness when connecting the ECM connectors.
(c) Connect the wire harness clamp.
3. CONNECT CONNECTOR HOLDER BLOCK
(a) Connect the connector holder block with the 3 bolts.
Torque : 7.3 Nm (74 kgf-cm, 65 in-lbf)
Page 3523
NG -- CHECK FOR SHORT TO GND IN CAN BUS WIRE (CENTER AIRBAG SENSOR)
OK -- REPAIR OR REPLACE NO. 1 JUNCTION CONNECTOR
13. CHECK FOR SHORT TO GND IN CAN BUS WIRE (COMBINATION METER ECU)
(a) Disconnect the J28 combination meter ECU connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE CAN MAIN WIRE CONNECTED TO COMBINATION METER ECU
(CANH, CANL)
OK -- REPLACE COMBINATION METER ASSEMBLY
14. CHECK FOR SHORT TO GND IN CAN BUS WIRE (MAIN BODY ECU)
(a) Disconnect the J2 main body ECU connector.
Page 2383
Drive Belt: Tools and Equipment
Toyota Serpentine Belt Wrench
AST tool# TOY 1914
The TOY 1914 is a Toyota serpentine belt wrench that is equipped with 14mm and 19mm, 12 point
secured attachments. Applications: 1998-2005 Corolla, 2004 Matrix, 2008 Highlander V6 (Non
Hybrid), 2002 RAV4 and 4.7L/5.7L V8 used in Tundra and Sequoia through 2008.
- Lightweight and Slim design
- Equipped with 14mm and 19mm, 12 point securing attachments
- Works on most Toyota applications (except Hybrids)
Contact AST for pricing.
Page 2603
* Never reuse the O-ring.
* When placing a new O-ring on the injector, do not damage it.
* Coat a new O-ring with spindle oil or gasoline before installing it. Do not use engine oil, gear oil or
brake oil.
(c) Install the injector to the delivery pipe and intake manifold as shown in the illustration.
NOTICE: Before installing the injector, apply spindle oil or gasoline on the place where the delivery
pipe contacts the O-ring of the injector.
(d) Observe these precautions when disconnecting the fuel tube connector (for Quick Type).
(1) for Fuel Hose Connector Cover Type:
Detach the lock claw by lifting up the cover, as shown in the illustration.
(2) for Fuel Pipe Clamp Type:
Remove the fuel pipe clamp from the fuel tube connector.
Locations
Tail Lamp Relay: Locations
LIGHTING: LIGHTING SYSTEM: PARTS LOCATION
Page 724
SEAT: FRONT POWER SEAT LUMBAR SWITCH (for Manual Seat): INSTALLATION
1. INSTALL FRONT POWER SEAT LUMBAR SWITCH LH
(a) Install the switch with the 2 screws.
2. INSTALL FRONT SEAT CUSHION SHIELD LH See: Body and Frame/Seats/Service and
Repair/Overhaul/Front Seat Assembly (for Manual
Seat)/Reassembly
3. INSTALL RECLINING ADJUSTER RELEASE HANDLE LH See: Body and Frame/Seats/Service
and Repair/Overhaul/Front Seat Assembly
(for Manual Seat)/Reassembly
4. INSTALL VERTICAL SEAT ADJUSTER KNOB LH See: Body and Frame/Seats/Service and
Repair/Overhaul/Front Seat Assembly (for
Manual Seat)/Reassembly
5. INSTALL VERTICAL ADJUSTING HANDLE LH (for 8 Way Seat) See: Body and
Frame/Seats/Service and Repair/Overhaul/Front Seat
Assembly (for Manual Seat)/Reassembly
6. INSTALL FRONT SEAT ASSEMBLY LH
(a) Install the front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Manual
Seat)/Installation.
Page 6024
Torque : 5.8 Nm (59 kgf-cm, 51 in-lbf)
4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY
(a) While pushing the 2 brushes toward the inside of the brush holder, insert a pin (diameter: 1.0
mm (0.0394 in.)) into the brush holder hole.
(b) Install the generator brush holder with the 2 screws.
Torque : 1.8 Nm (18 kgf-cm, 16 in-lbf)
(c) Pull out the pin from the generator brush holder.
5. INSTALL GENERATOR REAR END COVER
(a) Install the terminal insulator to the generator rectifier end frame.
NOTICE: Pay attention to the mounting orientation of the terminal insulator.
(b) Install the end cover with the 3 nuts.
Transponder Key ECU
Alarm Module: Diagrams Transponder Key ECU
Page 5768
Torque : 13 Nm (127 kgf-cm, 9 ft-lbf)
15. INSTALL INTERMEDIATE LEVER TENSION SPRING
(a) Install the tension spring.
16. INSTALL PARKING BRAKE SHOE LEVER RH
HINT Use the same procedures described for the LH side.
17. INSTALL NO. 2 PARKING BRAKE SHOE ASSEMBLY RH
HINT Use the same procedures described for the LH side.
18. INSTALL NO. 1 PARKING BRAKE SHOE ASSEMBLY RH
HINT Use the same procedures described for the LH side.
19. INSTALL PARKING BRAKE SHOE RETURN SPRING RH
HINT Use the same procedures described for the LH side.
20. CHECK PARKING BRAKE INSTALLATION See: Service and Repair/Reassembly
21. INSTALL REAR DISC RH
HINT Use the same procedures described for the LH side.
22. ADJUST PARKING BRAKE SHOE CLEARANCE See: Adjustments
23. CONNECT REAR DISC BRAKE CYLINDER ASSEMBLY RH
HINT Use the same procedures described for the LH side.
24. INSTALL REAR WHEEL RH See: Steering and Suspension/Suspension/Suspension Strut /
Shock Absorber/Service and Repair/Removal and
Replacement/Rear Shock Absorber/Installation
25. INSTALL NO. 1 PARKING BRAKE CABLE ASSEMBLY (for 3220 mm [10 ft. 6.8 in.] Wheelbase
Type)
(a) Install the No. 1 cable support bracket with the 3 bolts (labeled A).
Specifications
Axle Nut: Specifications
FRONT AXLE HUB NUT LH (for 4WD)
Using a 39 mm socket wrench, install the hub nut.
Torque..................................................................................................................................................
...............................338 Nm (3446 kgf-cm, 249 ft-lbf)
Page 7516
^ Subtract the expected lowest temperature (14°F) from the workshop temperature (68°F) = 54°F.
^ Using the Tire Pressure Chart (Figure 1), find the intersection of the warm tire line at the point
corresponding to 54°F and read off the value on the tire pressure change axis. In this case it would
be about 6.7 psi.
^ The tires should be filled to:
31.9 + 6.7 psi = 38.6 psi
Example 3: Temperature Compensation - "Hot" Tires
^ The vehicle has been driven to the shop on the highway for at least 60 minutes (vehicle has "hot"
tires) and tire pressures are set to 31.9 psi.
^ Workshop temperature is 68°F, and the expected lowest ambient temperature in the area is
expected to be 14°F.
^ Subtract the expected lowest temperature (14°F) from the workshop temperature (68°F) = 54°F.
^ Using the tire pressure chart (Figure 1), find the intersection of the hot tire line at the point
corresponding to 54°F, and read off the value on the tire pressure change axis. In this case it would
be about 9.0 psi.
^ The tires should be filled to:
31.9 + 9.0 psi = 40.9 psi
Page 6681
Engine Room R/B, J/B - Engine Compartment Left
Locations
Backup Lamp Relay: Locations
Instrument Panel (Floor Shift)
Instrument Panel (Column Shift)
Page 4750
Mongoose MFC Software and Driver MUST be installed before Mongoose MFC selection will be
available.
See TIS - Diagnostics - Scantool page for additional information.
^ If using TIS Techstream select TIS Techstream VIM (this is the default).
4. Click OK.
Operation Procedure
1. Verify the vehicle's applicability for recalibration and locate desired calibration file.
A. Connect Techstream and establish a vehicle connection.
B. Click the Health Check button on the System Select tab.
Recall 10V017000: Accelerator Pedal Sticking
Accelerator Pedal: All Technical Service Bulletins Recall 10V017000: Accelerator Pedal Sticking
VEHICLE MAKE/MODEL: MODEL YEAR(S): Toyota/Avalon 2005-2010 Toyota/Camry 2007-2010
Toyota/Corolla 2009-2010 Toyota/Corolla Matrix 2009-2010 Toyota/Highlander 2010 Toyota/ RAV4
2009-2010 Toyota/Sequoia 2008-2010 Toyota/Tundra 2007-2010 MANUFACTURER: Toyota
Motor North America, Inc.
MFR'S REPORT DATE: January 21, 2010
NHTSA CAMPAIGN ID NUMBER: 10V017000
NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Accelerator Assembly:
Pedal/Linkage
POTENTIAL NUMBER OF UNITS AFFECTED: ?
SUMMARY: Toyota is recalling certain model year 2005-2010 Avalon, model year 2007-2010
Camry, model year 2009-2010 Corolla, Corolla Matrix, RAV4, model year 2010 Highlander, model
year 2008-2010 Sequoia, and model year 2007-2010 Tundra. due to the manner in which the
friction lever interacts with the sliding surface of the accelerator pedal inside the pedal sensor
assembly, the sliding surface of the lever may become smooth during vehicle operation. In this
condition, if condensation occurs on the surface, as may occur from heater operation (without A/C)
when the pedal assembly is cold, the friction when the accelerator pedal is operated may increase,
which may result in the accelerator pedal becoming harder to depress, slower to return, or, in the
worst case, mechanically stuck in a partially depressed position.
CONSEQUENCE: The accelerator pedal may become hard to depress, slow to return to idle, or, in
the worst case, mechanically stuck in a partially depressed position, increasing the risk of a crash.
REMEDY: Toyota has not yet provided a remedy plan or an owner notification schedule. Owners
may contact Toyota at 1-800-331-4331.
NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle
Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov.
Page 6369
Page 2738
Body Control Module: Diagrams
Drivetrian - Rear End Howling/Growling Noises
Wheel Bearing: All Technical Service Bulletins Drivetrian - Rear End Howling/Growling Noises
T-SB-0151-10
June11, 2010
Rear Axle Bearing Abnormal Noise
Service Category Drivetrain
Section Axle/Differential
Market USA
Applicability
Introduction
Some 2007 - 2010 model year Tundra vehicles may exhibit a howling or growling noise from the
rear of the vehicle that increases with vehicle speed. Changes have been made to the rear axle
bearing to correct this condition. Follow the procedure in the bulletin to address customer concerns.
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60
months or 60,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Parts Information
Page 3525
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO SKID CONTROL ECU
WITH ACTUATOR (CANH, CANL)
OK -- REPLACE SKID CONTROL ECU WITH ACTUATOR See: Brakes and Traction
Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock
Brakes/Service and Repair/Removal and Replacement/Removal
16. CHECK FOR SHORT TO GND IN CAN BUS WIRE (STEERING ANGLE SENSOR)
(a) Disconnect the J6 steering angle sensor connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO STEERING ANGLE
SENSOR (CANH, CANL)
OK -- REPLACE STEERING ANGLE SENSOR
17. CHECK FOR SHORT TO GND IN CAN BUS WIRE (POWER STEERING ECU)
(a) Disconnect the J101 power steering ECU connector.
Page 8771
Speaker: Diagrams Front Door Tweeter
Page 5850
Acceleration/Deceleration Sensor: Service and Repair Installation
BRAKE CONTROL: YAW RATE AND DECELERATION SENSOR: INSTALLATION
1. INSTALL YAW RATE SENSOR
(a) Connect the sensor connector (labeled A), and then attach the clamp (labeled B) to the hole of
the sensor bracket.
(b) Install the yaw rate sensor with the 2 nuts (labeled C).
Torque : 13 Nm (127 kgf-cm, 9 ft-lbf)
NOTICE: *
Make sure that the sensor is oriented correctly.
* If the sensor is dropped, replace it.
* Securely connect the connector.
* When installing the sensor, make sure to avoid impacts to the sensor.
2. INSTALL CENTER FRONT SEAT (for Center Seat) See: Body and Frame/Seats/Service and
Repair/Removal and Replacement/Front Seat
Assembly (for Center Seat)/Installation
3. INSTALL CONSOLE BOX ASSEMBLY (for Separate Seat Type)
(a) Install the console box See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and
Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation.
4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
5. PERFORM YAW RATE SENSOR ZERO POINT CALIBRATION
(a) Perform the yaw rate sensor zero point calibration See: Antilock Brakes / Traction Control
Systems/Testing and Inspection/Programming
and Relearning.
6. CHECK YAW RATE SENSOR SIGNAL
(a) Check the yaw rate sensor signal See: Antilock Brakes / Traction Control Systems/Testing and
Inspection/Scan Tool Testing and
Procedures/Test Mode Procedure.
Locations
Central Control Module: Locations
NAVIGATION: NAVIGATION SYSTEM (w/ USB Audio System): PARTS LOCATION
m
Side Airbag Sensor
Impact Sensor: Diagrams Side Airbag Sensor
Components
Actuator: Service and Repair Components
DIFFERENTIAL: AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR (for 4WD):
COMPONENTS
Page 6319
MJ1-NP1
Page 5213
2. Install ChaSSiSEAR(TM) on the vehicle and attempt to isolate the source of the noise. Is the
noise loudest near the rear wheel bearing assembly?
^ YES - Go to step 3.
^ NO - This TSB does NOT apply. Continue diagnosis to isolate the source of the noise.
3. Replace the rear wheel bearing caliper bracket and related parts.
Refer to the Technical Information System (TIS) applicable model year Repair Manual:
4. Test drive the vehicle and confirm the noise is eliminated.
5. Re-check rear differential oil level and confirm NO leaks are present.
Page 8530
Ultrasonic Sensor: Service and Repair Glass Breakage Sensor (for Column Shift Type)
Components
THEFT DETERRENT: GLASS BREAKAGE SENSOR (for Column Shift Type): COMPONENTS
Removal
THEFT DETERRENT: GLASS BREAKAGE SENSOR (for Column Shift Type): REMOVAL
1. REMOVE FRONT DOOR SCUFF PLATE LH
Page 5654
Torque : 13 Nm (127 kgf-cm, 9 ft-lbf)
NOTICE: *
When installing the clamp, do not twist the wire harness.
* Make sure the clamp's rotation stopper touches the installation position.
(d) Attach the 3 clips (labeled E).
NOTICE: *
When installing the clips, do not twist the wire harness.
* When installing the clips, securely insert them as shown in the illustration.
(e) Connect the speed sensor connector (labeled F).
NOTICE: Securely connect the connector.
4. INSTALL FRONT SKID CONTROL SENSOR CLAMP RH
(a) Install the skid control sensor clamp (labeled A) with the bolt (labeled B).
Torque : 13 Nm (127 kgf-cm, 9 ft-lbf)
NOTICE: Install the bracket so that the rotation stopper (labeled C) touches the knuckle.
5. INSTALL FRONT SPEED SENSOR RH
(a) Install the speed sensor (labeled D) with the hexagon socket head cap bolt (labeled E).
Page 9135
Trailer Towing Part 3
Page 2072
(a) For an open circuit in the wire harness in Fig. 1, check the resistance or voltage, as described
below.
(b) Check the resistance.
(1) Disconnect connectors A and C and measure the resistance between them.
Standard resistance (Fig. 2):
HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally.
If the results match the examples above, an open circuit exists between terminal 1 of connector A
and terminal 1 of connector C.
(2) Disconnect connector B and measure the resistance between the connectors.
Standard resistance (Fig. 3):
* If the results match the examples above, an open circuit exists between terminal 1 of connector
B2 and terminal 1 of connector C.
(c) Check the voltage.
Page 1904
(b) Slowly pour coolant into the radiator reservoir until it reaches the FULL line.
(c) Install the reservoir cap.
(d) Press the inlet and outlet radiator hoses several times by hand, and then check the coolant
level. If the coolant level is low, add coolant.
(e) Install the radiator cap.
(f) Start the engine and warm it up until the thermostat opens.
HINT The thermostat opening timing can be confirmed by pressing the radiator inlet hose by hand,
and checking when the engine coolant starts to flow inside the hose.
(g) Maintain the engine speed at 2000 to 2500 rpm.
NOTICE: *
Make sure that the radiator reservoir still has some coolant in it.
* Pay attention to the needle of the water temperature meter. Make sure that the needle does not
show an abnormally high temperature.
* If there is not enough coolant, the engine may burn out or overheat.
* Immediately after starting the engine, if the radiator reservoir does not have any coolant, perform
the following: 1) stop the engine, 2) wait until the coolant has cooled down, and 3) add coolant until
the coolant is filled to the FULL line.
* Run the engine at 2000 rpm until the coolant level has stabilized.
(h) Press the inlet and outlet radiator hoses several times by hand to bleed air.
CAUTION: *
Wear protective gloves.
* Be careful as the radiator hoses are hot.
* Keep your hands away from the fan.
(i) Stop the engine, and wait until the engine coolant cools down to ambient temperature.
CAUTION: Do not remove the radiator cap while the engine and radiator are still hot. Pressurized,
hot engine coolant and steam may be released and cause serious burns.
(j) Check that the coolant level is between the FULL and LOW lines.
If the coolant level is below the LOW line, repeat all of the procedures above.
If the coolant level is above the FULL line, drain coolant so that the coolant level is between the
FULL and LOW lines.
4. INSPECT FOR COOLANT LEAK See: Engine, Cooling and Exhaust/Cooling System/Testing
and Inspection
5. INSTALL NO. 1 ENGINE UNDER COVER See: Engine Oil/Service and Repair/Replacement
Page 2018
General Information
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: GENERAL
INFORMATION
* A large number of ECU controlled systems are used in the TOYOTA TUNDRA. In general, ECU
controlled systems are considered to be very intricate, requiring a high level of technical knowledge
to troubleshoot. However, most problem checking procedures only involve inspecting the ECU
controlled system's circuits one by one. An adequate understanding of the system and a basic
knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and
necessary repairs.
1. TROUBLESHOOTING PROCEDURES
* The troubleshooting procedures consist of diagnosis procedures for when a DTC is stored and
diagnosis procedures for when no DTC is stored. The basic idea is explained in the following table.
* Vehicle systems are complex and use many ECUs that are difficult to inspect independently.
Therefore, a process of elimination is used, where components that can be inspected individually
are inspected, and if no problems are found in these components, the related ECU is identified as
the problem and replaced.
* It is extremely important to ask the customer about the environment and the conditions present
when the problem occurred (Customer Problem Analysis). This makes it possible to simulate the
conditions and confirm the symptom. If the symptom cannot be confirmed or the DTC does not
recur, the malfunctioning part may not be identified using the troubleshooting procedure, and the
ECU for the related system may be replaced even though it is not defective. If this happens, the
original problem will not be solved.
* In order to prevent endless expansion of troubleshooting procedures, the troubleshooting
procedures are written with the assumption that multiple malfunctions do not occur simultaneously
for a single problem symptom.
* To identify the malfunctioning part, troubleshooting procedures narrow down the target by
separating components, ECUs and wire harnesses during the inspection. If the wire harness is
identified as the cause of the problem, it is necessary to inspect not only the connections to
components and ECUs but also all of the wire harness connectors between the component and the
ECU.
DIAGNOSTIC TESTER
2. DESCRIPTION
System data and the Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector
3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the Techstream* to
check for a malfunction and perform repairs.
HINT *: Techstream is the name for the diagnostic tester in North America.
3. DATA LINK CONNECTOR 3 (DLC3)
(a) The vehicle's ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of
the DLC3 complies with SAE J1962 and
matches the ISO 15765-4 format.
Page 6560
Driver Side J/B Inner Circuit
Page 1951
Refrigerant: Fluid Type Specifications
REFRIGERANT TYPE
Refrigerant............................................................................................................................................
......................................................HFC-134a (R134a)
Page 1868
(4) for Fuel Pipe Clamp Type:
Install the fuel pipe clamp to the connector.
(5) for Fuel Hose Connector Cover Type:
Attach the lock claw to the connector by pushing down on the cover, as shown in the illustration.
(6) Check that there is no fuel leakage.
3. CHECK FOR FUEL LEAK
(a) Check that there are no fuel leaks after performing maintenance anywhere on the fuel system
See: Powertrain Management/Fuel Delivery and
Air Induction/Testing and Inspection.
Page 5312
(c) Replace the ATF in the torque converter clutch.
(1) If the ATF is discolored and/or has a foul odor, stir the ATF in the torque converter clutch
thoroughly and drain the ATF with the torque
converter facing upward.
(d) Prevent deformation of the torque converter clutch and damage to the oil pump gear.
(1) When any marks due to interference are found on the end of a bolt for the torque converter
clutch and on the bottom of the bolt hole,
replace the bolt and torque converter clutch.
(2) Make sure all of the bolts are the same length.
(3) Make sure no spring washers are missing.
2. INSPECT DRIVE PLATE
(a) Check the drive plate for damage.
(b) Set up a dial indicator and measure the runout of the 6 portions around the torque converter
clutch contact surfaces.
Maximum runout:
0.30 mm (0.0118 in.)
(c) If the runout is more than the maximum, or the drive plate is damaged, replace the drive plate
See: Engine, Cooling and
Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Assembly/Installation.
Page 9211
Front Door Panel: Service and Repair Front Door (for Double Cab)
Components
ENGINE HOOD / DOOR: FRONT DOOR (for Double Cab): COMPONENTS
Page 865
Engine Temperature Sensor: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: ENGINE COOLANT TEMPERATURE SENSOR:
REMOVAL
1. REMOVE NO. 1 ENGINE UNDER COVER See: Engine, Cooling and Exhaust/Engine/Engine
Lubrication/Engine Oil/Service and
Repair/Replacement
2. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Removal
3. DRAIN ENGINE COOLANT See: Engine, Cooling and Exhaust/Cooling System/Coolant/Service
and Repair
4. REMOVE ENGINE COOLANT TEMPERATURE SENSOR
(a) Disconnect the sensor connector.
(b) Using a 19 mm ball joint lock nut wrench, remove the sensor.
(c) Remove the gasket from the sensor.
Page 2463
Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)
(b) Connect the 2 vacuum hoses to the vacuum switching valve.
6. INSTALL STUD BOLT
(a) Using an E5 "TORX" socket wrench, install the 2 stud bolts.
Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)
7. INSTALL V-BANK COVER PIN
(a) Install the pin to the intake manifold.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
8. INSTALL V-BANK COVER BRACKET
(a) Install the bracket with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
9. INSTALL FUEL TUBE SUB-ASSEMBLY
(a) Install the fuel tube to the intake manifold with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
10. INSTALL INTAKE MANIFOLD
Page 849
Yaw Rate Sensor: Locations From 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 8912
Parking Assist Control Module: Service and Repair Installation
PARK ASSIST / MONITORING: CLEARANCE WARNING ECU: INSTALLATION
HINT A bolt without a torque specification is shown in the standard bolt chart See:
Specifications/Mechanical Specifications/Standard Bolt - Specified Torque For Standard Bolts
1. INSTALL CLEARANCE WARNING ECU ASSEMBLY
(a) Install the clearance warning ECU to the bracket with the 2 nuts.
NOTICE: *
Avoid any impact to the clearance warning ECU.
* Do not drop the ECU. If it is dropped, replace it with a new one.
2. INSTALL CLEARANCE WARNING ECU WITH BRACKET
(a) Install the ECU with bracket with the nut and bolt.
(b) Connect the ECU connectors and attach the harness clamp.
NOTICE: Do not apply excessive force to the wire harnesses.
3. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Installation
4. INSTALL LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY See: Restraint
Systems/Air Bag Systems/Air Bag/Service and
Repair/Removal and Replacement/Front Passenger Side Knee Airbag Assembly/Installation
5. INSTALL LOWER INSTRUMENT PANEL See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
6. INSTALL NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY See: Body and
Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Column Shift Type)/Installation
7. INSTALL INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
8. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
9. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Air Bag/Service and
Repair/Removal and Replacement/Driver Side
Knee Airbag Assembly/Installation.
Air Switching Valve (for Bank 1)
Air Injection Control Valve: Testing and Inspection Air Switching Valve (for Bank 1)
1UR-FE EMISSION CONTROL: AIR SWITCHING VALVE (for Bank 1): INSPECTION
1. INSPECT AIR SWITCHING VALVE ASSEMBLY
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) If the result is not as specified, replace the air switching valve.
(c) Check the operation of the air switching valve.
(1) Check that air does not flow from port A to port B.
NOTICE: Make sure the applied pressure is 30 kPa (0.3 kgf/cm2, 4.4 psi) or less.
(2) If the result is not as specified, replace the air switching valve.
(3) Apply battery voltage across terminals 1 and 2.
NOTICE: When applying voltage, do not touch terminals 3, 4 and 5.
Page 2093
J/B No.6 Assembly - Instrument Panel Center
Page 6756
AB1-DF1
Page 6317
JJ1-JL1
Page 8220
(3) Move SST at least 10 m (32.8 ft.) away from the wheel.
NOTICE: Take care not to damage SST wire harness.
(d) Activate the seat belt pretensioner.
(1) Connect SST's red clip to the battery's positive (+) terminal and the black clip to the battery's
negative (-) terminal.
(2) Check that no one is within 10 m (32.8 ft.) of the wheel.
(3) Press SST activation switch to activate the seat belt pretensioner.
HINT The seat belt pretensioner operates at the same time SST activation switch's LED
illuminates.
(e) Dispose of the front seat outer belt (with the seat belt pretensioner).
CAUTION: *
Do not touch the front seat outer belt for at least 30 minutes after the seat belt pretensioner has
been activated. It is very hot.
* Use gloves and safety glasses when handling a front seat outer belt whose pretensioner has
been activated.
* Always wash your hands with water after completing the disposal.
* Do not apply water to a front seat outer belt that has an activated pretensioner.
(1) Remove the tire (with wheel) and SST.
(2) Place the front seat outer belt in a plastic bag, tie the end tightly and dispose of it in the same
way as other general parts.
Front Seat Outer Belt Assembly (for Double Cab)
SEAT BELT: FRONT SEAT OUTER BELT ASSEMBLY (for Double Cab): DISPOSAL
HINT When scrapping vehicles equipped with a seat belt pretensioner or disposing of a front seat
outer belt (with seat belt pretensioner), always first activate the seat belt pretensioner in
accordance with the procedures described below. If any abnormality occurs during activation of the
seat belt pretensioner, contact the SERVICE DEPARTMENT of TOYOTA MOTOR SALES, U.S.A.,
INC.
CAUTION:
Page 8637
2. REMOVE ROOM NO. 1 LIGHT ASSEMBLY
(a) Detach the 4 clips and remove the light.
3. REMOVE TELEVISION DISPLAY ASSEMBLY
(a) Disconnect the connector.
(b) Remove the 4 bolts.
(c) Detach the 2 clips and 2 claws, and remove the television display.
4. REMOVE ROOF HEADLINING ASSEMBLY (for CrewMax)
(a) Remove the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for
CrewMax)/Removal.
5. REMOVE TELEVISION DISPLAY BRACKET
Page 4305
Mongoose MFC Software and Driver MUST be installed before Mongoose MFC selection will be
available.
See TIS - Diagnostics - Scantool page for additional information.
^ If using TIS Techstream select TIS Techstream VIM (this is the default).
4. Click OK.
Operation Procedure
1. Verify the vehicle's applicability for recalibration and locate desired calibration file.
A. Connect Techstream and establish a vehicle connection.
B. Click the Health Check button on the System Select tab.
Page 7053
(b) Inspect the camber, caster and steering axis inclination.
Standard camber inclination (unloaded vehicle):
for Regular Cab of Standard Deck
Standard camber inclination (unloaded vehicle):
for Regular Cab of Long Deck
Standard camber inclination (unloaded vehicle):
for Double Cab of Standard Deck
Page 4940
1. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY
(a) Insert the transmission control cable from the vehicle interior, and install the cable retainer with
the 2 bolts.
Torque : 5.5 Nm (56 kgf-cm, 49 in-lbf)
(b) Connect the transmission control cable to the shift lever retainer, and install a new clip.
(c) Connect the control cable end to the shift lever.
NOTICE: Make sure to connect the cable end so that the inner cable is not twisted. Confirm that
the ridged side of the cable end is facing upward.
(d) Move the shift lever to N.
(e) Turn the control shaft lever counterclockwise until it stops, and then turn it clockwise 2 notches
to set it to the N position.
(f) Connect the control cable with a new clip and the nut.
Page 7958
(2) Move SST at least 10 m (32.8 ft.) away from the steering pad tied down to the disc wheel.
(e) Cover the steering pad with a cardboard box or tires.
(1) Covering method using a cardboard box:
Cover the steering pad with the cardboard box and place the weights on the cardboard box in 4
places with at least 190 N (19 kgf, 41.9 lbf).
Cardboard box size:
Must exceed the following dimensions
X 460 mm (1.51 ft.)
Y 650 mm (2.13 ft.)
NOTICE: *
When the dimension Y of the cardboard box exceeds the diameter of the disc wheel with tire which
the steering pad is tied to, X should be the following size. X = 460 mm (18.1 in.) + width of tire.
* If a cardboard box which is smaller than the specified size is used, the cardboard box will be
broken by the shock from the airbag deployment.
(2) Covering method using tires:
Place at least 3 tires without disc wheels on the tire with disc wheel which the steering pad is tied
to. Place the tire with disc wheel on them.
Page 6425
Power Distribution Relay: Diagrams
Specifications
Firing Order: Specifications
Firing Order
1-8-4-3-6-5-7-2
Page 1422
Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to
prevent airbag and seat belt pretensioner activation.
(c) Install the door airbag sensor with the screw.
Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)
NOTICE: *
If the door airbag sensor has been dropped, or there are any cracks, dents or other defects in the
case, bracket or connector, replace it with a new one.
* When installing the door airbag sensor, be careful that the SRS wiring does not interfere with
other parts and that it is not pinched between other parts.
(d) Check that there is no looseness in the installation parts of the door airbag sensor.
(e) Connect the connector.
2. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Reassembly
3. INSTALL COURTESY LIGHT ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood
and Trunk/Doors/Front Door/Service and
Repair/Front Door (for Double Cab)/Reassembly
4. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH LH (for Front Side) See: Body
and Frame/Doors, Hood and
Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly
5. INSTALL FRONT ARMREST BASE PANEL UPPER LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Reassembly
6. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Reassembly
7. INSTALL REAR SIDE AIRBAG SENSOR
(a) Check that the ignition switch is OFF.
(b) Check that the cable is disconnected from the battery negative (-) terminal.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
(c) Install the side airbag sensor with the bolt.
Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)
NOTICE: *
If the side airbag sensor has been dropped, or there are any cracks, dents or other defects in the
case, bracket or connector, replace it with a new one.
* When installing the side airbag sensor, be careful that the SRS wiring does not interfere with
other parts and that it is not pinched between other parts.
(d) Check that there is no looseness in the installation parts of the side airbag sensor.
(e) Connect the connector.
8. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY LH (for Rear Side) See: Body and
Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation
Page 3800
Crankshaft Position Sensor: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: CRANKSHAFT POSITION SENSOR: REMOVAL
1. REMOVE CRANKSHAFT POSITION SENSOR PROTECTOR
(a) Remove the 2 bolts and sensor protector.
2. REMOVE CRANKSHAFT POSITION SENSOR
(a) Disconnect the sensor connector.
(b) Remove the bolt and sensor.
Page 6349
Push the secondary locking device or terminal retainer in to the full lock position.
CONNECT CONNECTOR
Voltage Check
VOLTAGE CHECK
Page 4002
This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown.
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60
months or 60,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Op Code EG9029 or EG9024: For California specification vehicles sold, registered, and operated
in California, Connecticut, Maine, Massachusetts, New Jersey, Oregon, Pennsylvania, Rhode
Island, Vermont, and Washington, this repair is covered under the California Emission Warranty.
This warranty is in effect for 84 months or 70,000 miles, whichever occurs first, from the vehicle's
in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Page 5803
Vacuum Brake Booster: Service and Repair Removal
BRAKE: BRAKE BOOSTER: REMOVAL
NOTICE: Release the vacuum from the booster by depressing the brake pedal several times. then
remove the brake master cylinder sub-assembly from the brake booster assembly.
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to disable the SRS system.
2. DRAIN BRAKE FLUID
NOTICE: Immediately wash off any brake fluid that comes into contact with any painted surfaces.
3. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY
(a) Remove the brake master cylinder See: Hydraulic System/Brake Master Cylinder/Service and
Repair/Removal and Replacement/Removal.
4. DISCONNECT VACUUM HOSE ASSEMBLY
(a) Slide the clip and disconnect the vacuum hose from the check valve.
5. DISCONNECT BRAKE BOOSTER CONNECTOR
(a) Disconnect the 2 brake booster connectors from the brake booster.
6. REMOVE FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Removal
7. REMOVE FRONT DOOR SCUFF PLATE LH (for Double Cab, CrewMax) See: Body and
Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Removal
8. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Removal
9. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Removal
10. REMOVE LOWER NO. 1 INSTRUMENT PANEL AIR BAG ASSEMBLY See: Restraint
Systems/Air Bag Systems/Air Bag/Service and
Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Removal
11. REMOVE PUSH ROD PIN
(a) Remove the clip and push rod pin.
12. REMOVE BRAKE BOOSTER ASSEMBLY
(a) Remove the 4 nuts, and then pull out the brake booster.
(b) Remove the brake booster gasket from the brake booster.
(c) Loosen the lock nut and then remove the clevis.
13. REMOVE BRAKE VACUUM CHECK VALVE ASSEMBLY
Diagram Information and Instructions
Relay Box: Diagram Information and Instructions
Wiring Color Codes
Abbreviations Used Within Diagrams
Abbreviations Used Within Diagrams
Page 74
Removal
DOOR LOCK: DOOR CONTROL RECEIVER (for Regular Cab): REMOVAL
1. REMOVE UPPER BACK PANEL GARNISH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining
(For Regular Cab)/Removal
2. REMOVE LUGGAGE COMPARTMENT BOX LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof
Headlining (For Regular Cab)/Removal
3. REMOVE LUGGAGE COMPARTMENT BOX RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof
Headlining (For Regular Cab)/Removal
4. REMOVE FRONT DOOR SCUFF PLATE RH
Page 7287
(b) Using a 32 mm hexagon wrench, remove the rack guide spring cap.
(c) Remove the spring and rack guide.
10. REMOVE POWER STEERING CONTROL VALVE
(a) Wind vinyl tape around the serrated portion of the control valve.
(b) Remove the dust cover from the control valve housing.
(c) Remove the 2 bolts.
(d) Pull out the control valve from the rack housing.
(e) Remove the control valve oil seal.
(f) To prevent the oil seal lip from getting damaged, wind vinyl tape around the serrated portion of
the control valve.
(g) Using a plastic hammer, remove the control valve from the control valve housing.
Locations
Fuel Pump Relay: Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 8102
Page 8911
Parking Assist Control Module: Service and Repair Removal
PARK ASSIST / MONITORING: CLEARANCE WARNING ECU: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to disable the SRS system.
2. REMOVE INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal
3. REMOVE NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY See: Body and
Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Column Shift Type)/Removal
4. REMOVE LOWER INSTRUMENT PANEL See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal
5. REMOVE LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY See: Restraint
Systems/Air Bag Systems/Air Bag/Service and
Repair/Removal and Replacement/Front Passenger Side Knee Airbag Assembly/Removal
6. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and
Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument
Panel Safety Pad (for Column Shift Type)/Removal
7. REMOVE CLEARANCE WARNING ECU WITH BRACKET
(a) Disconnect the ECU connectors and detach the harness clamp.
NOTICE: Do not apply excessive force to the wire harnesses.
(b) Remove the bolt, nut and ECU with bracket.
8. REMOVE CLEARANCE WARNING ECU ASSEMBLY
(a) Remove the 2 nuts and clearance warning ECU from the bracket.
NOTICE: *
Avoid any impact to the clearance warning ECU.
* Do not drop the ECU. If it is dropped, replace it with a new one.
Page 1196
Applicable Vehicles
Components
Headlamp Alignment Switch: Service and Repair Components
LIGHTING: HEADLIGHT LEVELING SWITCH: COMPONENTS
Page 532
Tire Pressure Monitor Receiver / Transponder: Diagrams
Page 8240
3. REMOVE CENTER FRONT SEAT ASSEMBLY
(a) Remove the front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Center
Seat)/Removal.
4. REMOVE CENTER SEAT CUSHION SHIELD LH See: Body and Frame/Seats/Service and
Repair/Overhaul/Front Seat Assembly (for Center
Seat)/Disassembly
5. REMOVE CENTER SEAT CUSHION SHIELD RH See: Body and Frame/Seats/Service and
Repair/Overhaul/Front Seat Assembly (for Center
Seat)/Disassembly
6. DISCONNECT CENTER FRONT SEAT BELT ASSEMBLY RH
(a) Remove the bolt and seat belt anchor.
7. REMOVE CENTER SEATBACK ASSEMBLY See: Body and Frame/Seats/Service and
Repair/Overhaul/Front Seat Assembly (for Center
Seat)/Disassembly
8. REMOVE FRONT SEAT HEADREST ASSEMBLY
9. REMOVE FRONT SEAT SHOULDER BELT COVER See: Body and Frame/Seats/Service and
Repair/Overhaul/Front Seat Assembly (for
Center Seat)/Disassembly
10. REMOVE UPPER REAR SEATBACK LOCK BEZEL See: Body and Frame/Seats/Service and
Repair/Overhaul/Front Seat Assembly (for
Center Seat)/Disassembly
11. REMOVE LOWER FRONT SEAT SHOULDER BELT COVER See: Body and
Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly
(for Center Seat)/Disassembly
12. REMOVE RECLINING REMOTE CONTROL BEZEL See: Body and Frame/Seats/Service and
Repair/Overhaul/Front Seat Assembly (for
Center Seat)/Disassembly
13. REMOVE FRONT SEAT TRAY See: Body and Frame/Seats/Service and
Repair/Overhaul/Front Seat Assembly (for Center Seat)/Disassembly
14. REMOVE CENTER FRONT SEAT ARMREST COVER See: Body and Frame/Seats/Service
and Repair/Overhaul/Front Seat Assembly (for
Center Seat)/Disassembly
15. REMOVE SEAT FASTENER COVER See: Body and Frame/Seats/Service and
Repair/Overhaul/Front Seat Assembly (for Center
Seat)/Disassembly
16. REMOVE FRONT SEATBACK BOARD SUB-ASSEMBLY See: Body and Frame/Seats/Service
and Repair/Overhaul/Front Seat Assembly
(for Center Seat)/Disassembly
17. REMOVE FRONT SEAT HEADREST SUPPORT See: Body and Frame/Seats/Service and
Repair/Overhaul/Front Seat Assembly (for Center
Seat)/Disassembly
18. REMOVE CENTER FRONT SEAT BELT ASSEMBLY RH
Page 6267
DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector.
Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
Diagram Information and Instructions
Data Link Connector: Diagram Information and Instructions
Wiring Color Codes
Abbreviations Used Within Diagrams
Abbreviations Used Within Diagrams
Restraints - OCS System Initialization
Seat Occupant Classification Module - Air Bag: Technical Service Bulletins Restraints - OCS
System Initialization
COLLISION REPAIR INFORMATION FOR THE COLLISION REPAIR PROFESSIONAL
TITLE: SRS OCCUPANT CLASSIFICATION SYSTEM INITIALIZATION
SECTION: ELECTRICAL BULLETIN # 177
MODELS: ALL EQUIPPED TOYOTA LEXUS and SCION MODELS
DATE: MARCH 2010
Models equipped with a Supplemental Restraint System (SRS) Occupant Classification System
(OCS) will enable or disable the passenger front and side airbags based on seat occupancy
passenger weight and seat belt latch engagement.
If an equipped vehicle sustains collision damage or if the front passenger seat or any of the OCS
components are serviced the SRS Malfunction Indicator Light (MIL) may illuminate setting a
Diagnostic Trouble Code (DTC).
NOTE:
It is necessary to diagnose and repair the root cause of a SRS or OCS DTC before initializing the
OCS system. If SRS and OCS DTC's are not cleared the system may not operate properly.
Be sure to check and clear DTC's and perform OCS initialization per repair manual instructions
with a Techstream Special Service Tool (SST) or capable diagnostic tester.
Any of the following conditions could set a DTC illuminate the SRS MIL or cause the PASSENGER
AIRBAG light to indicate incorrectly regardless of occupancy:
^ The OCS Electronic Control Unit (ECU) is replaced
^ Accessories such as a seatback tray are installed on the passenger seat
^ The passenger seat is removed and replaced or reinstalled
^ The vehicle is involved in an accident or collision
Model-specific repair manuals can be accessed through the Technical Information System (TIS)
www.techinfo.toyota.com
Page 9175
Page 7864
(1) Detach the claw and remove the main plate.
(2) Remove the 2 screws and damper servo.
11. REMOVE DAMPER SERVO SUB-ASSEMBLY
(a) Disconnect the connector.
(b) Remove the 3 screws and damper servo.
12. REMOVE BLOWER CASE SUB-ASSEMBLY
(a) Remove the 3 screws.
(b) Detach the 2 claws and remove the case.
13. REMOVE BLOWER DAMPER SERVO SUB-ASSEMBLY
Page 1476
DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector.
Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
Page 6179
Removal
OTHER SYSTEM: CENTER POWER OUTLET SOCKET (for Column Shift Type): REMOVAL
1. REMOVE FRONT SEAT ASSEMBLY LH (for Manual Seat)
(a) Remove the front seat LH See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Manual
Seat)/Removal.
2. REMOVE FRONT SEAT ASSEMBLY RH (for Manual Seat)
HINT Use the same procedures described for the LH side.
Page 3556
(a) Disconnect the DA and DD main body ECU (driver side junction block) connectors.
(b) Measure the voltage and resistance according to the value(s) in the table below.
* If the result is not as specified, there may be a malfunction on the wire harness side.
2. CHECK POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY (for Power Window
Control System [w/ Jam Protection
Function])
(a) Disconnect the N2 power window regulator master switch assembly connector.
(b) Measure the voltage and resistance according to the value(s) in the table below.
* If the result is not as specified, there may be a malfunction on the wire harness side.
3. CHECK FRONT POWER WINDOW REGULATOR MOTOR ASSEMBLY LH (for Power Window
Control System [w/ Jam Protection
Function])
Page 2631
8. CONNECT COOLER COMPRESSOR ASSEMBLY (w/ Oil Cooler) See: Heating and Air
Conditioning/Compressor HVAC/Service and
Repair/Removal and Replacement/Installation
9. INSTALL FRONT FENDER APRON SEAL LH See: Exhaust System/Exhaust Manifold/Service
and Repair/Installation
10. INSTALL WATER INLET SUB-ASSEMBLY WITH THERMOSTAT
(a) Install the water inlet with thermostat See: Cooling System/Thermostat/Service and
Repair/Installation.
11. INSTALL FAN SHROUD
(a) Install the fan shroud See: Cooling System/Radiator Cooling Fan/Service and
Repair/Installation.
Page 4767
Parts Information
Calibration Information
Required Tools & Equipment
Repair Procedure
Page 4786
^ Power Supply Mode is used to maintain battery voltage at 13.5 volts while flash reprogramming
the vehicle.
^ For details on how to use the GR8 Battery Diagnostic Station, refer to the located on TIS,
Diagnostics - Tools & Equipment - Battery Diagnostics.
3. Click the appropriate calibration ID and reprogram the vehicle's ECU with Techstream.
A. After reviewing the procedures outlined in the selected TSB, click the appropriate calibration ID
link by matching the vehicle's current
calibration ID to the Previous Calibration ID in the Calibration Identification Chart.
NOTE
^ Calibration files are embedded as live links in the service bulletin.
^ Some vehicles require special preparation - please review the selected TSB carefully.
B. Click Open to load calibration file information.
Techstream pulls calibration files as needed to ensure the latest calibration file is used. Do NOT
save calibrations locally on the hard drive or other media.
NOTICE
Errors during the flash reprogramming process can permanently damage the vehicle ECU.
Minimize the risk by following the steps below.
^ Battery voltage MUST NOT FALL BELOW 11.4 volts during reprogramming. Confirm battery
voltage is higher than 11.4 volts, but be sure voltage DOES NOT RISE ABOVE 16.0 volts during
reprogramming.
^ Turn OFF all vehicle accessories (e.g. audio system, A/C, interior lights, DRL, etc.). Do NOT add
to or significantly change the vehicle's electrical
Page 3218
Page 8897
(a) Attach the 8 claws and 2 clips to install the scuff plate.
5. INSTALL BACK PANEL TRIM RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for
CrewMax)/Installation
Components
Knock Sensor: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: COMPONENTS
Page 4197
Page 2769
Then click Next.
F. Verify correct current calibration and new calibration information. Then click Next.
NOTE
^ The total number of calibration IDs in the calibration file corresponds to the number of
reprogrammable processors in the ECU.
^ Each calibration file may contain up to three separate calibrations.
Engine Controls - A/F And O2 Sensor Identification
Oxygen Sensor: Technical Service Bulletins Engine Controls - A/F And O2 Sensor Identification
T-SB-0398-09
December 23, 2009
Engine Bank 1 and Bank 2 A/F and 02 Identification
Service Category Engine/Hybrid System
Section Engine Control
Market USA
Applicability
TSB SUPERSESSION NOTICE
The information contained in this TSB supersedes TSB No. EG034-07.
^ Applicability has been updated to include 2009 - 2010 model year vehicles and 2006 - 2010
model year Highlander HV.
TSB No. EG034-07 is Obsolete and any printed versions should be discarded. Be sure to review
the entire content of this service bulletin before proceeding.
Introduction
This service bulletin provides information on the proper identification of engine bank 1 and engine
bank 2 for correct A/F sensor and oxygen sensor replacement.
This bulletin contains information that identifies engine bank 1 and engine bank 2 on the following
engines: 1AZ-FE, 2AZ-FE, 2AZ-FE (PZEV), 1GR-FE, 2GR-FE, 2JZ-GE, 1MZ-FE, 3MZ-FE,
1UR-FE, 3UR-FE, 2UZ-FE 5VZ-FE and 1ZZ-FE.
^ Bank 1 (B1) refers to the bank that includes cylinder No. 1.
^ Bank 2 (B2) refers to the bank opposite bank 1.
^ Sensor 1 (S1) refers to the sensor that is located before the catalytic converters.
^ Sensor 2 (S2) refers to the sensor that is located after the catalytic converters.
Warranty Information
Page 8173
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
4. REMOVE UPPER CONSOLE REAR PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
5. REMOVE REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
6. REMOVE CONSOLE BOX CARPET
7. REMOVE REAR CONSOLE BOX ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal
8. REMOVE FRONT CONSOLE BOX See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal
and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal
9. REMOVE CENTER AIRBAG SENSOR ASSEMBLY
(a) Disconnect the holder (with connectors).
(b) Remove the 3 bolts and airbag sensor.
Installation
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift
Type): INSTALLATION
1. INSTALL CENTER AIRBAG SENSOR ASSEMBLY
(a) Check that the ignition switch is OFF.
(b) Check that the cable is disconnected from the battery negative (-) terminal.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
(c) Install the airbag sensor with the 3 bolts.
Torque : 18 Nm (184 kgf-cm, 13 ft-lbf)
NOTICE: *
If the center airbag sensor has been dropped, or there are any cracks, dents or other defects in the
case, bracket or connector, replace it with a new one.
* When installing the center airbag sensor, be careful that the SRS wiring does not interfere with
other parts and that it is not pinched between other parts.
(d) Check that there is no looseness in the installation parts of the center airbag sensor.
Page 1415
Door/Service and Repair/Front Door (for Double Cab)/Disassembly
4. REMOVE FRONT LOWER DOOR FRAME BRACKET GARNISH LH (for Front Side) See: Body
and Frame/Doors, Hood and
Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly
5. REMOVE COURTESY LIGHT ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood
and Trunk/Doors/Front Door/Service and
Repair/Front Door (for Double Cab)/Disassembly
6. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Disassembly
7. REMOVE FRONT SIDE AIRBAG SENSOR
(a) Disconnect the connector.
(b) Remove the screw and side airbag sensor.
8. REMOVE REAR SEAT ASSEMBLY (for Rear Side)
(a) Remove the rear seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Rear Seat Assembly (for Double
Cab)/Removal.
9. REMOVE REAR DOOR SCUFF PLATE LH (for Rear Side) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and Repair/Roof
Headlining (For Double Cab)/Removal
10. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH (for Rear Side)
11. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY LH (for Rear Side) See: Body and
Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal
12. REMOVE REAR SIDE AIRBAG SENSOR
(a) Remove the bolt and side airbag sensor.
(b) Disconnect the connector.
Installation
SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for CrewMax):
INSTALLATION
1. INSTALL FRONT SIDE AIRBAG SENSOR
(a) Check that the ignition switch is OFF.
Capacity Specifications
Fluid - Transfer Case: Capacity Specifications
Transfer Oil
Capacity ...............................................................................................................................................
............................................................ 1.2 qt (1.12L)
Page 8817
Repair/Front Door (for CrewMax)/Reassembly
8. INSTALL FRONT LOWER DOOR FRAME BRACKET GARNISH LH See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for CrewMax)/Reassembly
9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Components
AUDIO / VISUAL: FRONT DOOR SPEAKER (for Double Cab): COMPONENTS
Page 3728
Page 4581
Ignition Switch: Diagnostic Aids
Continuity and Resistance Check
CONTINUITY AND RESISTANCE CHECK
Disconnect the battery terminal or wire so there is no voltage between the check points.
Contact the two leads of an ohmmeter to each of the check points.
Page 7704
Wait at least 90 seconds after disconnecting the cable from the negative(-) battery terminal to
prevent airbag and seat belt pretensioner activation.
2. REMOVE FRONT DOOR SCUFF PLATE LH
(a) for Regular Cab:
Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Floor Shift Type)/Removal.
(b) for Double Cab:
Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Floor Shift Type)/Removal.
(c) for CrewMax:
Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Floor Shift Type)/Removal.
3. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Removal
4. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal
5. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP LH (for Regular Cab)
6. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP LH (for Double Cab, CrewMax)
7. REMOVE FRONT PILLAR GARNISH LH
8. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Floor Shift Type)/Removal
9. REMOVE LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY See: Restraint
Systems/Air Bag Systems/Air Bag/Service and
Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Removal
10. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and
Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
11. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal
12. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
13. REMOVE UPPER REAR CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
14. REMOVE REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
15. REMOVE CONSOLE BOX CARPET
16. REMOVE REAR CONSOLE BOX ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal
17. REMOVE FRONT CONSOLE BOX See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal
and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal
18. REMOVE CENTER LOWER INSTRUMENT PANEL FINISH PANEL See: Body and
Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
19. REMOVE INTEGRATION CONTROL AND PANEL ASSEMBLY
Page 9006
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Page 8040
Clockspring Assembly / Spiral Cable: Diagrams Spiral Cable, Driver Side Squib Circuit
Page 954
Refrigerant Pressure Sensor / Switch: Service and Repair Removal
AIR CONDITIONING: PRESSURE SWITCH: REMOVAL
1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM See: Heating and Air
Conditioning/Service and Repair
2. REMOVE PRESSURE SWITCH
(a) Disconnect the connector.
(b) Remove the switch.
(c) Remove the O-ring from the pressure switch.
NOTICE: Seal the openings of the disconnected parts using vinyl tape to prevent moisture and
foreign matter from entering them.
Page 3708
load while reprogramming.
^ Confirm the hood is open and ensure under hood temperature does NOT exceed 158°F (70°C).
^ Confirm cable connections between the vehicle and Techstream are secure.
^ Do NOT disconnect or turn off Techstream or vehicle ignition during reprogramming.
^ Set parking brake.
^ Complete ALL flash calibration updates provided for each ECU.
^ If the battery's state of charge or capacity are in question, test with SST. No. 00002-8150-KIT
"Digital Battery Analyze," and follow TSB No. PG001-06, "Battery Maintenance for In-Stock
Vehicles & Pre-Delivery" or the appropriate "Maintenance for HV & Auxiliary Batteries" service
bulletin.
^ The GR8 Battery Diagnostic Station MUST be used in Power Supply Mode to maintain battery
voltage at 13.5 volts while flash reprogramming the vehicle. For details on how to use the GR8
Battery Diagnostic Station, refer to the GR8 Instruction Manual located on TIS, Diagnostics - Tools
& Equipment - Battery Diagnostics.
3C. Click Next to start the calibration update process.
D. When using TIS Techstream select Techstream VIM as the desired programming device. Then
click Next.
Page 1072
Hazard Warning Switch: Diagrams
Page 8738
4. Refer to the applicable model and model year in the table for part replacement.
5. Register the new XM Receiver Radio Identification Number (RID).
A. Be prepared with the VIN OLD Radio Identification Number (RID) and NEW Radio Identification
Number (RID).
B. Call the XM Radio Listener line at 1-800-967-2346.
C. Provide the necessary information and the representative will complete the request.
D. If the customer has an active account confirm XM Satellite Radio service has been refreshed
and the radio is active. Once you can listen to
channels 4, 11, and 41 you know the activation was successful.
Page 5071
Standard backlash:
0.17 to 0.27 mm (0.00670 to 0.01064 in.)
(b) If the backlash is not within the specification, adjust it by either increasing or decreasing the
thickness of the washers on both sides by an equal
amount.
HINT *
There should be no clearance between the plate washer and differential case.
* Make sure that there is ring gear backlash.
Washer thickness:
21. INSPECT TOTAL PRELOAD
(a) Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in
contact.
Diagrams
Variable Valve Timing Actuator Position Sensor: Diagrams
Page 6390
Page 4569
Crankshaft Position Sensor: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: CRANKSHAFT POSITION SENSOR: REMOVAL
1. REMOVE CRANKSHAFT POSITION SENSOR PROTECTOR
(a) Remove the 2 bolts and sensor protector.
2. REMOVE CRANKSHAFT POSITION SENSOR
(a) Disconnect the sensor connector.
(b) Remove the bolt and sensor.
Page 7611
Step 6. Pull the filter out of the filter outlet.
Cleaning method.
Page 1309
Remove the blown fuse and disconnect all loads of the fuse.
Connect a test light in place of the fuse.
Establish conditions in which the test light comes on.
Example:
- [A] - Ignition SW on
- [B] - Ignition SW and SW1 on
- [C] - Ignition SW, SW1 and Relay on (Connect the Relay) and SW2 off (or Disconnect SW2)
Disconnect and reconnect the connectors while watching the test light.
Page 7587
"Case2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Diagram Information and Instructions
Headlamp Alignment Control Module: Diagram Information and Instructions
Wiring Color Codes
Abbreviations Used Within Diagrams
Abbreviations Used Within Diagrams
Page 1880
(f) Remove the oil filter element and O-ring from the oil filter cap.
NOTICE: Be sure to remove the O-ring for the cap by hand, without using any tools, to prevent
damage to the cap's O-ring groove.
4. INSTALL OIL FILTER ELEMENT
(a) Clean the inside of the oil filter cap, its threads and its O-ring groove.
(b) Apply a small amount of engine oil to a new O-ring and install it to the oil filter cap.
(c) Set a new oil filter element to the oil filter cap.
(d) Remove any dirt or foreign matter from the installation surface of the engine.
(e) Apply a small amount of engine oil to the O-ring again and temporarily install the oil filter cap.
(f) Using SST, tighten the oil filter cap.
SST : 09228-06501
Torque : 25 Nm (255 kgf-cm, 18 ft-lbf)
NOTICE: *
When tightening the oil filter cap, do not remove the oil filter bracket clip.
* Make sure that the oil filter is installed securely as shown in the illustration.
* Be careful that the O-ring does not get caught between any surrounding parts.
Locations
Seat Belt Buckle Switch: Locations
SUPPLEMENTAL RESTRAINT SYSTEM: OCCUPANT CLASSIFICATION SYSTEM: PARTS
LOCATION
Page 8285
3. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP
4. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY
(a) Detach the 2 claws and remove the cover.
(b) Remove the bolt and seat belt anchor.
(c) Detach the 6 clips and remove the quarter trim panel.
5. REMOVE FRONT QUARTER TRIM PANEL ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and Repair/Roof
Headlining (For Double Cab)/Removal
6. REMOVE REAR SEAT OUTER BELT ASSEMBLY
(a) Remove the bolt and shoulder anchor.
(b) Remove the bolt and disconnect the seat belt's shoulder anchor.
Page 7778
(a) Install the duct with the 2 screws.
11. INSTALL BLOWER WITH FAN MOTOR SUB-ASSEMBLY
(a) Install the motor with the 3 screws.
12. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY
(a) Install the amplifier with the 2 screws.
13. INSTALL NO. 2 AIR DUCT SUB-ASSEMBLY
(a) Install the duct with the screw.
14. INSTALL CLEAN AIR FILTER
Page 9352
(c) w/ Rear Fender Mudguard:
Install the rear wheel house liner (rear).
(1) Install the wheel house liner with 7 new clips.
(2) Install the screw.
(3) Install the mudguard See: Spoilers, Flaps, and Air Dams/Mud Flap/Service and
Repair/Installation.
(d) Install the rear wheel house liner (center).
(1) Install the wheel house liner with 9 new clips.
(2) Install the 6 screws.
Page 2708
Exhaust Manifold: Service and Repair Installation
1UR-FE EXHAUST: EXHAUST MANIFOLD: INSTALLATION
1. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH
(a) Install a new gasket to the cylinder head and a new gasket to the No. 3 air tube.
HINT *
Install the exhaust manifold gasket with the gasket tab facing toward the front of the engine.
* Install the air tube gasket with the gasket's claws facing the tube.
(b) Temporarily install the exhaust manifold with 9 new nuts, and then uniformly tighten the 7 nuts
that are not labeled A. Then tighten the 2 nuts
labeled A in the illustration.
for nut A - Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
except nut A - Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
2. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
(a) Install the heat insulator with the 3 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
3. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH
(a) Install a new gasket to the cylinder head and a new gasket to the No. 4 air tube.
HINT *
Install the exhaust manifold gasket with the gasket tab facing toward the rear of the engine.
* Install the air tube gasket with the gasket's claws facing the tube.
(b) Temporarily install the exhaust manifold with 9 new nuts, and then uniformly tighten the 7 nuts
that are not labeled A. Then tighten the 2 nuts
labeled A in the illustration.
Page 5909
Wheel Speed Sensor: Diagrams Front Speed Sensor
Page 603
3. INSTALL FRONT BUMPER COVER (for Resin Type Bumper) See: Body and
Frame/Bumper/Front Bumper/Service and Repair/Removal and
Replacement/Front Bumper (for Resin Type Bumper)/Installation
4. INSTALL FRONT END PANEL LH (for Resin Type Bumper) See: Body and
Frame/Bumper/Front Bumper/Service and Repair/Removal and
Replacement/Front Bumper (for Resin Type Bumper)/Installation
5. INSTALL FRONT END PANEL RH (for Resin Type Bumper) See: Body and
Frame/Bumper/Front Bumper/Service and Repair/Removal and
Replacement/Front Bumper (for Resin Type Bumper)/Installation
6. INSTALL FRONT BUMPER BAR (for Steel Type Bumper) See: Body and Frame/Bumper/Front
Bumper/Service and Repair/Removal and
Replacement/Front Bumper (for Steel Type Bumper)/Installation
7. INSTALL FRONT LOWER BUMPER COVER (for Steel Type Bumper) See: Body and
Frame/Bumper/Front Bumper/Service and
Repair/Removal and Replacement/Front Bumper (for Steel Type Bumper)/Installation
8. INSTALL FRONT END PANEL LH (for Steel Type Bumper) See: Body and Frame/Bumper/Front
Bumper/Service and Repair/Removal and
Replacement/Front Bumper (for Resin Type Bumper)/Installation
9. INSTALL FRONT END PANEL RH (for Steel Type Bumper) See: Body and Frame/Bumper/Front
Bumper/Service and Repair/Removal and
Replacement/Front Bumper (for Resin Type Bumper)/Installation
10. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH (for Steel Type Bumper)
See: Body and Frame/Bumper/Front
Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Steel Type
Bumper)/Installation
11. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH (for Steel Type Bumper)
See: Body and Frame/Bumper/Front
Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Steel Type
Bumper)/Installation
12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
13. ADJUST FOG LIGHT
(a) Adjust the fog light See: Lighting and Horns/Fog/Driving Lamp/Adjustments.
Page 9139
Connectors Part 3
Locations
Air Flow Meter/Sensor: Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 8782
Speaker: Testing and Inspection Front Door Speaker (for CrewMax)
AUDIO / VISUAL: FRONT DOOR SPEAKER (for CrewMax): INSPECTION
1. INSPECT FRONT NO. 1 SPEAKER ASSEMBLY (for Standard)
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the speaker assembly.
2. INSPECT FRONT NO. 1 SPEAKER ASSEMBLY (for 12 Speakers)
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the speaker assembly.
3. INSPECT FRONT NO. 3 SPEAKER ASSEMBLY (for 12 Speakers)
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
Locations
Hood Sensor/Switch (For Alarm): Locations
THEFT DETERRENT: THEFT DETERRENT SYSTEM: PARTS LOCATION
Page 453
Air Bag Control Module: Locations Seat Belt Warning System
SEAT BELT: SEAT BELT WARNING SYSTEM: PARTS LOCATION
Page 3110
Knock Sensor: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: REMOVAL
1. REMOVE INTAKE MANIFOLD
(a) Remove the intake manifold See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service
and Repair/Removal.
2. REMOVE SEPARATOR CASE
(a) Remove the 4 bolts and separator case.
3. REMOVE KNOCK SENSOR
(a) Disconnect the 4 knock sensor connectors.
(b) Remove the 4 bolts and 4 knock sensors.
Page 7600
3. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE
HINT The diagnostic system in the TOYOTA TUNDRA has various functions.
* The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU
memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a
previous malfunction's DTC can be checked by a technician during troubleshooting.
* Another function is the Input Signal Check, which checks if the signals from various switches are
sent to the ECU correctly.
* By using these functions, the problem areas can be narrowed down and troubleshooting is more
effective. Diagnostic functions are incorporated in the following systems in the TOYOTA TUNDRA.
Page 2078
3. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE
HINT The diagnostic system in the TOYOTA TUNDRA has various functions.
* The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU
memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a
previous malfunction's DTC can be checked by a technician during troubleshooting.
* Another function is the Input Signal Check, which checks if the signals from various switches are
sent to the ECU correctly.
* By using these functions, the problem areas can be narrowed down and troubleshooting is more
effective. Diagnostic functions are incorporated in the following systems in the TOYOTA TUNDRA.
Page 1213
Oxygen Sensor: Service and Repair Heated Oxygen Sensor
Components
1UR-FE ENGINE CONTROL SYSTEM: HEATED OXYGEN SENSOR: COMPONENTS
Removal
1UR-FE ENGINE CONTROL SYSTEM: HEATED OXYGEN SENSOR: REMOVAL
CAUTION: *
The procedures should be performed by at least 2 people.
* Wear protective gloves when removing the exhaust pipe.
* The exhaust pipe is extremely hot immediately after the engine has stopped.
* Confirm that the exhaust pipe has cooled down before removing it.
1. REMOVE PROPELLER SHAFT HEAT INSULATOR (for 4WD) See: Transmission and
Drivetrain/Drive/Propeller Shafts, Bearings and
Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Front Propeller Shaft
Assembly/Removal
2. REMOVE HEATED OXYGEN SENSOR (for Bank 1 Sensor 2)
(a) Disconnect the sensor connector.
(b) Using SST, remove the sensor.
SST : 09224-00010
3. REMOVE HEATED OXYGEN SENSOR (for Bank 2 Sensor 2)
(a) Disconnect the heated oxygen sensor connector and 2 clamps.
Page 6635
2. REMOVE NO. 2 CONSOLE BOX REGISTER ASSEMBLY See: Body and Frame/Seats/Service
and Repair/Overhaul/Front Seat Assembly (for
Center Seat)/Disassembly
3. REMOVE NO. 1 CONSOLE BOX REGISTER ASSEMBLY See: Body and Frame/Seats/Service
and Repair/Overhaul/Front Seat Assembly (for
Center Seat)/Disassembly
4. REMOVE NO. 2 SEATBACK LOCK CONTROL BEZEL
(a) for AC Power Supply:
Disconnect the clamp.
(b) Remove the 4 screws and bezel.
5. REMOVE REAR POWER OUTLET SOCKET (for Standard)
(a) Detach the claw and remove the power outlet socket.
6. REMOVE REAR POWER OUTLET SOCKET COVER (for Standard)
(a) Detach the 2 claws and remove the power outlet socket cover.
7. REMOVE REAR POWER POINT SOCKET (for AC Power Supply)
(a) Detach the 2 claws and remove the power outlet socket.
Page 1607
Four Wheel Drive Selector Switch: Service and Repair Removal
JF1A TRANSFER: 4WD CONTROL SWITCH: REMOVAL
1. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Panel,
Gauges and Warning Indicators/Instrument Cluster
/ Carrier/Service and Repair/Combination Meter/Removal
2. REMOVE 4WD CONTROL SWITCH
(a) Detach the 3 claws to remove the switch.
Page 5053
(b) Using a hammer handle, remove the actuator.
2. REMOVE FRONT DIFFERENTIAL TUBE ASSEMBLY
(a) Remove the 4 bolts.
(b) Using a plastic-faced hammer, remove the differential tube.
3. REMOVE DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL
(a) Using SST, tap out the oil seal.
SST : 09308-00010
4. REMOVE DIFFERENTIAL SIDE GEAR INTER SHAFT SUB-ASSEMBLY
(a) Using SST, remove the side gear inter shaft.
SST : 09350-20015
09369-20040
SST : 09950-40011
09951-04010
Page 4222
Accelerator Pedal: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: ACCELERATOR PEDAL: INSTALLATION
1. INSTALL ACCELERATOR PEDAL ROD ASSEMBLY
NOTICE: *
Avoid physical shocks to the accelerator pedal rod assembly.
* Do not disassemble the accelerator pedal rod assembly.
(a) Install the accelerator pedal rod with the 2 nuts.
Torque : 5.5 Nm (56 kgf-cm, 49 in-lbf)
(b) Connect the accelerator pedal position sensor connector.
Page 4781
^ Engine Control Module (ECM)
^ Transmission Control Module (TCM)
^ Or any other Toyota specific control unit
Warranty Information
Parts Information
Required Tools & Equipment
NOTE
Additional SSTs may be ordered by calling 1-800-933-8335.
Process Overview
Techstream ECU flash reprogramming is a 4-step process:
1. Verify the vehicle's applicability for recalibration and locate desired calibration file by performing
the Techstream Health Check function.
NOTE
Techstream will automatically search TIS for the appropriate service bulletin using the current
Calibration ID from the vehicle. Calibration file links can be found embedded in the corresponding
service bulletin.
2. Connect the GR8 Battery Diagnostic Station using "Power Supply Mode" only.
The GR8 Battery Diagnostic Station includes a Power Supply Mode to help maintain battery
voltage at 13.5 volts during ECU reprogramming.
ECU damage may occur if the correct battery charger mode setting is NOT used.
3. Locate appropriate calibration ID and reprogram the vehicle ECU with Techstream.
Techstream uses the Calibration Update Wizard (CUW) application to open calibration files and
facilitate the ECU flash reprogramming process.
Page 115
Electronic Brake Control Module: Diagrams
Page 3818
Knock Sensor: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: REMOVAL
1. REMOVE INTAKE MANIFOLD
(a) Remove the intake manifold See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service
and Repair/Removal.
2. REMOVE SEPARATOR CASE
(a) Remove the 4 bolts and separator case.
3. REMOVE KNOCK SENSOR
(a) Disconnect the 4 knock sensor connectors.
(b) Remove the 4 bolts and 4 knock sensors.
Page 6058
NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do
not operate the ignition switch, any other switches, or the doors.
(a) If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the
harness and connector.
(b) Connect the cable of the Techstream to the DLC3, turn the ignition switch ON and attempt to
use the tester. If the display indicates that a
communication error has occurred, there is a problem either with the vehicle or with the tester.
HINT *
If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of
the original vehicle.
* If communication is still not possible when the tester is connected to another vehicle, the problem
may be in the tester itself. Consult the Service Department listed in the tester's instruction manual.
How To Proceed With Troubleshooting
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: HOW TO
PROCEED WITH TROUBLESHOOTING
1. OPERATION FLOW
HINT Perform troubleshooting in accordance with the procedures below. The following is an outline
of basic troubleshooting procedures. Confirm the troubleshooting procedures for the circuit you are
working on before beginning troubleshooting.
1. VEHICLE BROUGHT TO WORKSHOP
NEXT -- Continue to next step.
2. CUSTOMER PROBLEM ANALYSIS
(a) Ask the customer about the conditions and environment when the problem occurred.
NEXT -- Continue to next step.
3. INSPECT BATTERY VOLTAGE
Standard voltage:
11 to 14 V
If the voltage is below 11 V, recharge or replace the battery before proceeding.
NEXT -- Continue to next step.
Inspection
Air Flow Meter/Sensor: Testing and Inspection Inspection
1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: INSPECTION
1. INSPECT MASS AIR FLOW METER
(a) Check the output voltage.
(1) Apply battery voltage across terminals 1 (+B) and 2 (E2G).
NOTICE: While using the battery during inspection, do not bring the positive and negative tester
probes too close to each other as a short circuit may occur.
(2) Using a voltmeter, connect the positive (+) tester probe to terminal 3 (VG), and negative (-)
tester probe to terminal 2 (E2G).
(3) Blow air into the MAF meter, and check that the voltage fluctuates.
If the result is not as specified, replace the MAF meter.
(b) Perform a visual check for any foreign matter on the platinum hot wire (heater) of the mass air
flow meter shown in the illustration.
OK:
There is no foreign material.
(c) If the result is not as specified, replace the mass air flow meter.
(d) Check the IAT sensor.
Page 5046
SST : 09504-00011
(f) Using SST, tighten the adjusting nut 1 to 1.5 notches from the 0 preload position.
(g) Using a dial indicator, adjust the ring gear backlash until it is within the specification.
SST : 09504-00011
Standard backlash:
0.10 to 0.20 mm (0.00394 to 0.00788 in.)
HINT *
The backlash is adjusted by turning the left and right adjusting nuts an equal amount. For example,
loosen the nut on the right side one notch and loosen the nut on the left side one notch.
* Perform the measurement at 3 or more positions around the circumference of the ring gear.
(h) Tighten the bearing cap bolts.
Torque : 103 Nm (1050 kgf-cm, 76 ft-lbf)
14. INSPECT TOTAL PRELOAD
(a) Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in
contact.
Standard total preload (at starting):
Page 6487
If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness
or connector in that circuit in the past. Check the wire harness and connectors.
B -- SYSTEM NORMAL
A -- TROUBLESHOOTING OF EACH PROBLEM SYMPTOM
The problem is still occurring in a place other than the diagnostic circuit (the DTC displayed first is
either for a past problem or a secondary problem).
4. SYMPTOM SIMULATION
HINT The most difficult case in troubleshooting is when no problem symptoms occur. In such a
case, a thorough problem analysis must be carried out. A simulation of the same or similar
conditions and environment in which the problem occurred in the customer's vehicle should be
carried out. No matter how much skill or experience a technician has, troubleshooting without
confirming the problem symptoms will lead to important repairs being overlooked and mistakes or
delays.
For example:
With a problem that only occurs when the engine is cold or as a result of vibration caused by the
road during driving, the problem can never be determined if the symptoms are being checked on a
stationary vehicle or on a vehicle with a warmed-up engine. Vibration, heat or water penetration
(moisture) is difficult to reproduce. The symptom simulation tests below are effective substitutes for
the conditions and can be applied on a stationary vehicle.
Important points in the symptom simulation test:
In the symptom simulation test, the problem symptoms as well as the problem area or parts must
be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then,
connect the tester and carry out the symptom simulation test, judging whether the circuit being
tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the
problem symptoms table for each system to narrow down the possible causes.
To reproduce DTCs, it is necessary to satisfy the respective DTC detection conditions.
(a) VIBRATION METHOD:
When a malfunction seems to occur as a result of vibration.
(1) PART AND SENSOR
Apply slight vibration with a finger to the part of the sensor suspected to be the cause of the
problem, and check whether or not the malfunction occurs.
NOTICE: Applying strong vibration to relays may open them.
Page 7636
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION: Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC
terminals are touched, the IC may be destroyed by static electricity.)
When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact with the terminals of leads from the IC, etc. of the
replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown on the left.
DISCONNECT CONNECTOR
Page 6150
"Case1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (/\ Mark) and pull the terminal retainer
up to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Page 5772
Install the front No. 2 exhaust pipe See: Engine, Cooling and Exhaust/Exhaust System/Exhaust
Pipe/Service and Repair/Exhaust Pipe (Except Regular Cab Standard Deck)/Installation.
32. INSTALL FRONT NO. 2 EXHAUST PIPE ASSEMBLY (for 3UR-FBE)
(a) except Regular Cab Standard Deck:
Install the front No. 2 exhaust pipe See: Engine, Cooling and Exhaust/Exhaust System/Exhaust
Pipe/Service and Repair/Exhaust Pipe (Except Regular Cab Standard Deck)/Installation.
33. REMOVE FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY (for 1UR-FE)
(a) for Regular Cab Standard Deck:
Install the front No. 3 exhaust pipe See: Engine, Cooling and Exhaust/Exhaust System/Exhaust
Pipe/Service and Repair/Exhaust Pipe (for Regular Cab Standard Deck)/Installation.
34. INSTALL FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY (for 3UR-FE)
(a) for Regular Cab Standard Deck:
Install the front No. 3 exhaust pipe See: Engine, Cooling and Exhaust/Exhaust System/Exhaust
Pipe/Service and Repair/Exhaust Pipe (for Regular Cab Standard Deck)/Installation.
35. INSTALL NO. 3 EXHAUST PIPE SUB-ASSEMBLY (for 3UR-FBE)
(a) for Regular Cab Standard Deck:
Install the front No. 3 exhaust pipe See: Engine, Cooling and Exhaust/Exhaust System/Exhaust
Pipe/Service and Repair/Exhaust Pipe (for Regular Cab Standard Deck)/Installation.
36. CONNECT NO. 1 PARKING BRAKE CABLE ASSEMBLY See: Parking Brake Pedal/Service
and Repair/Removal and
Replacement/Installation
37. SETTLE PARKING BRAKE SHOE AND DISC See: Service and Repair/Reassembly
38. CHECK PARKING BRAKE PEDAL TRAVEL See: Adjustments
39. ADJUST PARKING BRAKE PEDAL TRAVEL See: Adjustments
40. INSTALL LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY See: Restraint
Systems/Air Bag Systems/Air Bag/Service and
Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Installation
41. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Installation
42. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
43. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
44. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
45. INSPECT FOR EXHAUST GAS LEAK
(a) If gas is leaking, tighten the areas necessary to stop the leak. Replace damaged parts as
necessary.
Specifications
Wheel Fastener: Specifications
FRONT WHEEL
For Aluminum Wheel
Torque..................................................................................................................................................
.................................131 Nm (1336 kgf-cm, 97 ft-lbf)
For Steel Wheel
Torque..................................................................................................................................................
...............................209 Nm (2131 kgf-cm, 154 ft-lbf)
REAR WHEEL
For Aluminum Wheel
Torque..................................................................................................................................................
.................................131 Nm (1336 kgf-cm, 97 ft-lbf)
For Steel Wheel
Torque..................................................................................................................................................
...............................209 Nm (2131 kgf-cm, 154 ft-lbf)
Page 5615
Steering Angle Sensor: Programming and Relearning
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: CALIBRATION
PERFORM INITIALIZATION OF STEERING ANGLE SENSOR
NOTICE: Complete the adjustment of the steering wheel and wheel alignment, and then initialize
the steering angle sensor. If the order is reversed, the steering wheel and wheel alignment will
become misaligned.
(a) Check that the steering wheel is in the centered position.
(b) Disconnect the negative battery terminal for more than 2 seconds.
NOTICE: After the ignition switch is turned OFF, the navigation system requires approximately 90
seconds to record various types of memory and settings. As a result, after turning the ignition
switch OFF, wait 90 seconds or more before disconnecting the cable from the negative (-) battery
terminal.
(c) Reconnect the negative battery terminal.
Page 1775
Drive Belt: Tools and Equipment
Toyota Serpentine Belt Wrench
AST tool# TOY 1914
The TOY 1914 is a Toyota serpentine belt wrench that is equipped with 14mm and 19mm, 12 point
secured attachments. Applications: 1998-2005 Corolla, 2004 Matrix, 2008 Highlander V6 (Non
Hybrid), 2002 RAV4 and 4.7L/5.7L V8 used in Tundra and Sequoia through 2008.
- Lightweight and Slim design
- Equipped with 14mm and 19mm, 12 point securing attachments
- Works on most Toyota applications (except Hybrids)
Contact AST for pricing.
Page 1023
Ambient Light Sensor: Service and Repair Removal
LIGHTING: AUTOMATIC LIGHT CONTROL SENSOR: REMOVAL
1. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY
(a) for Column Shift Type:
Remove the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Column Shift Type)/Removal.
(b) for Floor Shift Type:
Remove the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Floor Shift Type)/Removal.
2. REMOVE AUTOMATIC LIGHT CONTROL SENSOR
(a) Disconnect the connector.
(b) Remove the 2 claws and sensor.
Components
Crankshaft Position Sensor: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: CRANKSHAFT POSITION SENSOR: COMPONENTS
Page 2875
Ignition Relay: Testing and Inspection
1UR-FE ENGINE CONTROL SYSTEM: IGNITION RELAY NO. 2: ON-VEHICLE INSPECTION
1. REMOVE INTEGRATION RELAY
(a) Remove the engine room relay block cover.
(b) Using a screwdriver, detach the 2 claws and remove the integration relay from the engine room
relay block.
HINT Tape the screwdriver tip before use.
(c) Disconnect the 3 connectors.
2. INSPECT INTEGRATION RELAY (IG2)
NOTICE: *
Some relays are built into the integration relay. The integration relay cannot be disassembled. If
there is a malfunction in the circuit of the integration relay, replace the integration relay.
* The internal circuit of the integration relay is as shown in the illustration below. Inspect the
integration relay using the following procedures.
(a) Measure the resistance of the IG2 MAIN fuse.
(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(2) If the result is not as specified, replace the IG2 MAIN fuse.
(b) Measure the resistance of the ignition relay No. 2 (IG2).
Page 4082
EGR Cooler: Service and Repair Installation
1UR-FE EMISSION CONTROL: EGR COOLER: INSTALLATION
1. INSTALL NO. 2 EGR PIPE SUB-ASSEMBLY
(a) Install a new gasket and the No. 2 EGR pipe with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
NOTICE: Make sure the gasket's claws are not caught between the No. 2 EGR pipe and EGR
cooler.
2. INSTALL EGR COOLER ASSEMBLY
(a) Install the EGR cooler with the 2 bolts.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
3. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Exhaust
System/Exhaust Manifold/Service and
Repair/Installation
4. CONNECT NO. 11 WATER BY-PASS HOSE
(a) Connect the No. 11 water by-pass hose.
HINT The direction of the hose clamp is indicated in the illustration.
5. CONNECT NO. 8 WATER BY-PASS HOSE
Page 6140
Page 7952
CAUTION: Make sure that the wire harnesses are tight. Looseness in the wire harnesses results in
the tires coming free due to the shock when the airbag is deployed.
(f) Install SST.
(1) Connect SST connector.
SST : 09082-00700
NOTICE: To avoid damaging SST connector and wire harness, do not lock the secondary lock of
the twin lock. Also, secure some slack for SST wire harness inside the tire.
(g) Deploy the airbag.
(1) Connect the red clip of SST to the battery positive (+) terminal and the black clip of SST to the
battery negative (-) terminal.
(2) Check that no one is within a 10 m (32.8 ft.) radius of the tire which the front passenger airbag
is tied to.
(3) Press SST activation switch and deploy the airbag.
CAUTION: When deploying the airbag, make sure that no one is near the tire.
HINT The airbag is deployed as the LED of SST activation switch comes on.
(h) Dispose of the front passenger airbag.
CAUTION:
Page 6660
4. INSTALL REAR UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
5. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding
/ Trim/Dashboard / Instrument Panel/Service
and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
6. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation
Page 5324
Control Module: Locations JF1A Transfer Case
JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION
Page 8508
Page 6383
Page 4911
7. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding
/ Trim/Dashboard / Instrument Panel/Service
and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
8. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation
9. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Floor Shift Type)/Installation
10. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Installation
11. INSTALL FRONT DOOR SCUFF PLATE LH (for Double Cab, CrewMax) See: Body and
Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Installation
12. INSTALL FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Installation
13. ADJUST SHIFT LEVER POSITION See: Adjustments/SHIFT LEVER ASSEMBLY (for Floor
Shift Type)
14. INSPECT SHIFT LEVER POSITION See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/SHIFT LEVER ASSEMBLY (for
Floor Shift Type)
Page 5025
4. INSTALL PROPELLER SHAFT ASSEMBLY
(a) Install the propeller shaft for 2WD See: Drive/Propeller Shafts, Bearings and
Joints/Drive/Propeller Shaft/Service and Repair/Removal and
Replacement/Propeller Shaft Assembly/Installation.
(b) Install the propeller shaft for 4WD See: Drive/Propeller Shafts, Bearings and
Joints/Drive/Propeller Shaft/Service and Repair/Removal and
Replacement/Propeller Shaft Assembly/Installation.
5. ADD DIFFERENTIAL OIL See: Fluid - Differential/Service and Repair
6. INSTALL REAR WHEEL
(a) Install the rear wheels.
for aluminum wheel - Torque : 131 Nm (1336 kgf-cm, 97 ft-lbf)
for steel wheel - Torque : 209 Nm (2131 kgf-cm, 154 ft-lbf)
Components
DIFFERENTIAL: FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD): COMPONENTS
Diagrams
Seat Memory Switch: Diagrams
Page 1421
Door/Service and Repair/Front Door (for Double Cab)/Disassembly
4. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH (for Front Side) See: Body
and Frame/Doors, Hood and
Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly
5. REMOVE COURTESY LIGHT ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood
and Trunk/Doors/Front Door/Service and
Repair/Front Door (for Double Cab)/Disassembly
6. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Disassembly
7. REMOVE FRONT SIDE AIRBAG SENSOR
(a) Disconnect the connector.
(b) Remove the screw and side airbag sensor.
8. REMOVE REAR SEAT ASSEMBLY (for Rear Side)
(a) Remove the rear seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Rear Seat Assembly (for Double
Cab)/Removal.
9. REMOVE REAR DOOR SCUFF PLATE LH (for Rear Side) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and Repair/Roof
Headlining (For Double Cab)/Removal
10. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH (for Rear Side)
11. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY LH (for Rear Side) See: Body and
Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal
12. REMOVE REAR SIDE AIRBAG SENSOR
(a) Remove the bolt and side airbag sensor.
(b) Disconnect the connector.
Installation
SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Double Cab):
INSTALLATION
1. INSTALL FRONT SIDE AIRBAG SENSOR
(a) Check that the ignition switch is OFF.
(b) Check that the cable is disconnected from the battery negative (-) terminal.
CAUTION:
Page 875
Cruise Control Switch: Service and Repair Removal
CRUISE CONTROL: CRUISE CONTROL MAIN SWITCH: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE LOWER NO. 2 STEERING WHEEL COVER See: Restraint Systems/Air Bag
Systems/Air Bag/Service and Repair/Removal and
Replacement/Steering Pad/Removal
3. REMOVE LOWER NO. 3 STEERING WHEEL COVER See: Restraint Systems/Air Bag
Systems/Air Bag/Service and Repair/Removal and
Replacement/Steering Pad/Removal
4. REMOVE STEERING PAD (w/o Steering Pad Switch) See: Restraint Systems/Air Bag
Systems/Air Bag/Service and Repair/Removal and
Replacement/Steering Pad/Removal
5. REMOVE STEERING PAD (w/ Steering Pad Switch) See: Restraint Systems/Air Bag
Systems/Air Bag/Service and Repair/Removal and
Replacement/Steering Pad/Removal
6. REMOVE CRUISE CONTROL MAIN SWITCH
(a) Disconnect the connector.
(b) Remove the 2 screws.
(c) Remove the switch, as shown in the illustration.
Page 6779
Specifications
Fuel Pressure: Specifications
FUEL PRESSURE
Page 4126
Page 7800
Refrigerant Pressure Sensor / Switch: Service and Repair Removal
AIR CONDITIONING: PRESSURE SWITCH: REMOVAL
1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM See: Service and Repair
2. REMOVE PRESSURE SWITCH
(a) Disconnect the connector.
(b) Remove the switch.
(c) Remove the O-ring from the pressure switch.
NOTICE: Seal the openings of the disconnected parts using vinyl tape to prevent moisture and
foreign matter from entering them.
Page 4163
Page 2134
Tire Pressure Module: Locations
TIRE AND WHEEL: TIRE PRESSURE WARNING SYSTEM: PARTS LOCATION
Page 296
Driver Side J/B - Cowl Side Left
Page 8268
for bolt C - Torque : 42 Nm (428 kgf-cm, 31 ft-lbf)
3. INSTALL REAR SEAT BELT RETRACTOR COVER
(a) Attach the 2 claws and 2 clips to install the cover.
4. INSTALL REAR SEAT ASSEMBLY
(a) Install the rear seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Rear Seat Assembly (for Double
Cab)/Installation.
5. CONNECT CENTER REAR SEAT OUTER BELT ASSEMBLY
(a) Connect the rear seat center seat outer belt with the bolt.
Torque : 42 Nm (428 kgf-cm, 31 ft-lbf)
NOTICE: Do not overlap the anchor part of the seat belt and protruding parts of the vehicle body.
Components
SEAT BELT: REAR SEAT INNER BELT ASSEMBLY (for CrewMax): COMPONENTS
Page 6143
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Page 6926
NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do
not operate the ignition switch, any other switches, or the doors.
(a) If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the
harness and connector.
(b) Connect the cable of the Techstream to the DLC3, turn the ignition switch ON and attempt to
use the tester. If the display indicates that a
communication error has occurred, there is a problem either with the vehicle or with the tester.
HINT *
If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of
the original vehicle.
* If communication is still not possible when the tester is connected to another vehicle, the problem
may be in the tester itself. Consult the Service Department listed in the tester's instruction manual.
How To Proceed With Troubleshooting
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: HOW TO
PROCEED WITH TROUBLESHOOTING
1. OPERATION FLOW
HINT Perform troubleshooting in accordance with the procedures below. The following is an outline
of basic troubleshooting procedures. Confirm the troubleshooting procedures for the circuit you are
working on before beginning troubleshooting.
1. VEHICLE BROUGHT TO WORKSHOP
NEXT -- Continue to next step.
2. CUSTOMER PROBLEM ANALYSIS
(a) Ask the customer about the conditions and environment when the problem occurred.
NEXT -- Continue to next step.
3. INSPECT BATTERY VOLTAGE
Standard voltage:
11 to 14 V
If the voltage is below 11 V, recharge or replace the battery before proceeding.
NEXT -- Continue to next step.
Page 7658
(2) CONNECTORS
Slightly shake the connector vertically and horizontally.
(3) WIRE HARNESS
Slightly shake the wire harness vertically and horizontally.
HINT The connector joint and fulcrum of the vibration are the major areas that should be checked
thoroughly.
(b) HEAT METHOD:
When a malfunction seems to occur when the area in question is heated.
(1) Heat the component that is the possible cause of the malfunction with a hair dryer or similar
device. Check if the malfunction occurs.
NOTICE: *
Do not heat to more than 60°C (140°F). Exceeding this temperature may damage components.
* Do not apply heat directly to the parts in the ECU.
(c) WATER SPRINKLING METHOD:
When a malfunction seems to occur on a rainy day or in high-humidity.
(1) Sprinkle water onto the vehicle and check if the malfunction occurs.
NOTICE: *
Never sprinkle water directly into the engine compartment. Indirectly change the temperature and
humidity by spraying water onto the front of the radiator.
* Never apply water directly onto the electronic components.
HINT If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU
or connections. Look for evidence of corrosion or short circuits. Proceed with caution during water
tests.
(d) HIGH ELECTRICAL LOAD METHOD:
When a malfunction seems to occur when the electrical load is excessive.
(1) Turn on the heater blower, headlights, rear window defogger and all other electrical loads.
Check if the malfunction reoccurs.
5. DIAGNOSTIC TROUBLE CODE CHART
Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate
section's Diagnostic Trouble Code Chart. Use the chart to determine the trouble area and the
proper inspection procedure. A description of each of the chart's columns is below.
Page 7653
4. SYMPTOM CONFIRMATION AND DTC (INCLUDING FREEZE FRAME DATA) CHECK
(a) Visually check the wire harnesses, connectors and fuses for open and short circuits.
(b) Warm up the engine to the normal operating temperature.
(c) Confirm the problem symptoms and conditions, and check for DTCs.
B -- Go to step 6 A -- Continue to next step.
5. DTC CHART
(a) Check the results obtained in the DTC check. Then find the output DTC in the DTC chart. Look
at the "Trouble Area" column for a list of
potentially malfunctioning circuits and / or parts.
NEXT -- Go to step 7
6. PROBLEM SYMPTOMS TABLE
(a) Check the results obtained in the symptom confirmation. Then find the problem symptoms in
the problem symptoms table. Look at the
"Suspected Area" column for a list of potentially malfunctioning circuits and / or parts.
NEXT -- Continue to next step.
7. CIRCUIT INSPECTION OR PARTS INSPECTION
(a) Confirm the malfunctioning circuit or part.
NEXT -- Continue to next step.
8. ADJUST, REPAIR OR REPLACE
(a) Adjust, repair or replace the malfunctioning circuit or parts.
NEXT -- Continue to next step.
9. CONFIRMATION TEST
(a) After the adjustment, repairs or replacement, confirm that the malfunction no longer exists. If the
malfunction does not reoccur, perform a
confirmation test under the same conditions and in the same environment as when the malfunction
occurred the first time.
NEXT -- END
2. CUSTOMER PROBLEM ANALYSIS
HINT *
In troubleshooting, confirm that the problem symptoms have been accurately identified.
Preconceptions should be discarded in order to make an accurate judgment. To clearly understand
what the problem symptoms are, it is extremely important to ask the customer about the problem
and the conditions at the time the malfunction occurred.
* Gather as much information as possible for reference. Past problems that seem unrelated may
also help in some cases.
* The following 5 questions are important points in the problem analysis:
Page 6846
Page 2432
Refer to the Technical Information System (TIS) when replacing the oil filter applicable model and
model year Repair Manual:
Page 8332
Impact Sensor: Diagrams Front Airbag Sensor
Page 1028
Brake Light Switch: Diagrams
Page 8710
Page 4215
Page 1706
Standard wheel angle (unloaded vehicle):
for Double Cab of Long Deck
Page 7974
2. INSTALL ROOF HEADLINING ASSEMBLY
(a) Refer to the procedures from "INSTALL ROOF HEADLINING ASSEMBLY" (for CrewMax) See:
Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation
3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
4. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
Components
SUPPLEMENTAL RESTRAINT SYSTEM: CURTAIN SHIELD AIRBAG ASSEMBLY:
COMPONENTS
Page 8554
Collision Avoidance Module: Diagrams
Page 364
Then click Start.
I. Do NOT disturb the vehicle during flash reprogramming.
NOTE
^ ECU flash reprogramming may take anywhere from 3 - 30 minutes per calibration file.
^ Reprogramming time will vary depending on model and ECU communication protocol. Vehicles
using CAN communication protocol will reprogram much faster (2 - 7 minutes).
NOTE
^ If vehicle requires only ONE calibration update, then proceed to step N in this bulletin.
^ If vehicle requires a SECOND calibration update, then continue as follows:
^ For serial communication vehicles, go to step J.
^ For CAN communication vehicles, go to step L.
Page 3041
Camshaft Position Sensor: Locations Ignition System
1UR-FE IGNITION: IGNITION SYSTEM: PARTS LOCATION
Page 7954
CAUTION: *
Do not connect SST connector (yellow colored) to the airbag.
* If the LED comes on when the activation switch is not being pressed, SST malfunction is
possible, so replace SST with a new one.
(3) Disconnect SST from the battery.
(b) Read the precaution See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
(c) Disconnect the cable from the negative battery terminal.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
(d) Remove the lower steering column cover.
(1) While turning the steering wheel assembly to the right and left, remove the 2 screws and
steering column cover lower.
(e) Install SST.
CAUTION: Check that there is no looseness in the steering wheel assembly and steering pad.
(1) Disconnect the airbag connector (yellow colored) from the spiral cable with steering sensor.
NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness.
(2) Connect SST connector to the airbag connector of the spiral cable with steering sensor.
SST : 09082-00700
SST : 09082-00780
NOTICE: To avoid damaging SST connector and wire harness, do not lock the secondary lock of
the twin lock.
Page 3045
Camshaft Position Sensor: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT POSITION SENSOR: REMOVAL
1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Removal
2. REMOVE CAMSHAFT POSITION SENSOR
(a) Disconnect the sensor connector.
(b) Remove the bolt and sensor.
A760F Automatic Transmission System
Transfer Case Actuator: Locations A760F Automatic Transmission System
A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS
LOCATION
Page 8221
* Never dispose of a front seat outer belt that has a non-activated pretensioner.
* The seat belt pretensioner produces a loud, exploding sound when it activates. Perform the
operation where it will not be a nuisance to nearby people.
* When activating a front seat outer belt (with seat belt pretensioner), stand at least 10 m (32.8 ft.)
away from the front seat outer belt.
* Use gloves and safety glasses when handling a front seat outer belt with an activated
pretensioner.
* Always wash your hands with water after completing the disposal.
* Do not apply water to a front seat outer belt that has an activated pretensioner.
* Perform procedures in a place away from electrical interference.
* When activating the seat belt pretensioner, always use the specified SST (SRS airbag
deployment tool).
1. DISPOSE OF FRONT SEAT OUTER BELT ASSEMBLY (WHEN INSTALLED IN VEHICLE)
HINT Prepare a battery to activate the seat belt pretensioner.
(a) Check if SST is functioning properly.
SST : 09082-00700
CAUTION: When activating the seat belt pretensioner, always use the specified SST.
(1) Connect SST's red clip to the battery's positive (+) terminal and the black clip to the battery's
negative (-) terminal.
HINT Do not connect the yellow connector. The yellow connector is used to connect to the seat belt
pretensioner.
Engine Controls - ECM Update For Shift Performance
Engine Control Module: All Technical Service Bulletins Engine Controls - ECM Update For Shift
Performance
T-SB-0285-10
October 12, 2010
ECM Calibration: Enhancement to Shifting Performance
Service Category Drivetrain
Section Automatic Transmission/Transaxle
Market USA
Applicability
Introduction
Some vehicles may exhibit the following shifting conditions:
^ Harsh shift on acceleration below 20 mph during the 2-1 downshift.
^ Excessive lock-up operation at freeway speeds about 50 - 60 mph, sometimes referred to as
"busy shifting".
The Engine Control Module/ECM (SAE term: Powertrain Control Module/PCM) calibration has
been revised. Use the following repair procedure to address these conditions.
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Federal Emission Warranty. This warranty is in effect for
96 months or 80,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Page 9171
Refer to the service kit instruction sheet for further detail.
Page 9363
3. Loosen and remove the No.3 cab mount nut on the bottom of each cab mount. These will be
reused when installing the new No.3 cab mount bolts.
4. Loosen and remove the two bolts on top of each of the cab mounts and save them for reuse.
5. Pull the carpet back in the rear of the cab and remove the body plugs to expose the cab mount
bolts.
Page 4870
Transmission Speed Sensor: Diagrams
Page 6118
5. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY
(a) Fit the clamp of the brush holder into the starter commutator end frame.
(b) Install the commutator end frame with the 2 screws.
Torque : 1.5 Nm (15 kgf-cm, 13 in-lbf)
6. INSTALL STARTER ARMATURE PLATE
(a) Install the starter armature plate to the starter yoke.
NOTICE: Install the starter plate so that the keyway is positioned between key-A and key-B.
7. INSTALL STARTER YOKE ASSEMBLY
(a) Align the key of the starter yoke with the keyway located on the starter drive housing.
(b) Using a T25 "TORX" socket wrench, install the 2 bolts.
Torque : 5.5 Nm (56 kgf-cm, 49 in-lbf)
8. INSTALL MAGNET STARTER SWITCH ASSEMBLY
(a) Apply high temperature grease to the plunger hook.
Page 4576
Symbols Used Within Diagrams
Symbols Used Within Diagrams
Page 3797
Crankshaft Position Sensor: Diagrams
Page 1679
for Double Cab of Long Deck
for CrewMax of standard deck
Capacity Specifications
Fluid - Differential: Capacity Specifications
Differential Fluid Capacity
Front (4WD models) Capacity .............................................................................................................
.............................................................................................. 2.2 qt (2.05L)
Rear Regular Cab Models Standard Bed ............................................................................................
......................................................................................................... 4.3 qt (4.05L) Long Bed .............
..............................................................................................................................................................
................................ 4.9 qt (4.60L)
Double Cab and Crew Max Models Capacity ......................................................................................
.................................................................................................................... 4.9 qt (4.60L)
Page 114
Electronic Brake Control Module: Locations From 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 4917
(c) Securely connect the 2 wire terminals to terminal 6 and 13 of the transmission control switch
connector.
3. CONNECT NO. 1 SHIFT LOCK PLATE SUB-ASSEMBLY
(a) Using a hammer, tap in the spring pin to connect the shift lock plate and shift lock solenoid.
4. INSTALL SHIFT LOCK SOLENOID
(a) Install the shift lock solenoid with No. 1 shift lock plate sub-assembly, 2 bushes and collar to the
column shift control shift lever retainer with
the screw.
Torque : 1.2 Nm (12 kgf-cm, 11 in-lbf)
(b) Attach the 2 claws to install the shift lock solenoid bracket.
(c) Securely connect the 2 wire terminals to terminal 1 and 8 of the transmission control switch
connector.
Components
Front Fender Liner: Service and Repair Components
EXTERIOR: FENDER LINER (for Front Side): COMPONENTS
Page 1319
Establish conditions in which voltage is present at the check point.
Example:
- [A] - Ignition SW on
- [B] - Ignition SW and SW1 on
- [C] - Ignition SW, SW1 and Relay on (SW2 off)
Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or component terminal.
This check can be done with a test light instead of a voltmeter.
Electronic Circuit Inspection Procedure
Page 6065
6. PROBLEM SYMPTOMS TABLE
When a "Normal" code is output during a DTC check but the problem is still occurring, use the
Problem Symptoms Table. The suspected areas (circuits or parts) for each problem symptom are
in the table. The suspected areas are listed in order of probability. A description of each of the
chart's columns is below.
HINT In some cases, the problem is not detected by the diagnostic system even though a problem
symptom is present. It is possible that the problem is occurring outside the detection range of the
diagnostic system, or that the problem is occurring in a completely different system.
7. CIRCUIT INSPECTION
A description of the main areas of each circuit inspection is below.
Page 2274
Refer to the Technical Information System (TIS) applicable model and model year Repair Manual:
2. Verify the vehicle has the proper coolant and oil levels.
3. Clear all DTCs and confirm the condition has been corrected.
Page 3085
(2) Disconnect connector B and measure the resistance.
Standard resistance (Fig. 7):
* If the results match the examples above, a short circuit exists between terminal 1 of connector B2
and terminal 1 of connector C.
4. CHECK AND REPLACE ECU
NOTICE: *
The connector should not be disconnected from the ECU. Perform the inspection from the backside
of the connector on the wire harness side.
* When no measuring condition is specified, perform the inspection with the engine stopped and
the ignition switch ON.
* Check that the connectors are fully seated. Check for loose, corroded or broken wires.
(a) First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be
faulty. Temporarily replace the ECU with a
normally functioning one and check if the symptoms occur. If the trouble symptoms disappear,
replace the original ECU.
(1) Measure the resistance between the ECU ground terminal and body ground.
Standard resistance:
Below 1 Ohms
(2) Disconnect the ECU connector. Check the ground terminal on the ECU side and wire harness
side for bending, corrosion or foreign matter.
Lastly, check the contact pressure of the female terminals.
Power Window Control System (w/ Jam Protection
Function)
Power Window Relay: Locations Power Window Control System (w/ Jam Protection Function)
WINDSHIELD / WINDOWGLASS: POWER WINDOW CONTROL SYSTEM (w/ Jam Protection
Function): PARTS LOCATION
Page 4965
Transmission Mode Switch: Diagrams Tow/Haul Pattern Select Switch
Page 7705
(a) Detach the 4 clips.
(b) Disconnect the connector and remove the panel.
20. REMOVE RADIO RECEIVER ASSEMBLY WITH BRACKET (w/ USB Audio System) See:
Accessories and Optional Equipment/Radio,
Stereo, and Compact Disc/Radio/Stereo/Service and Repair/Radio Receiver (for Floor Shift
Type)/Removal
21. REMOVE RADIO RECEIVER ASSEMBLY WITH BRACKET (w/o USB Audio System) See:
Accessories and Optional Equipment/Radio,
Stereo, and Compact Disc/Radio/Stereo/Service and Repair/Radio Receiver (for Floor Shift
Type)/Removal
22. REMOVE NAVIGATION RECEIVER ASSEMBLY WITH BRACKET (w/ Navigation System
without USB Audio System) See: Accessories
and Optional Equipment/Navigation System/Service and Repair/Navigation Receiver (for Floor
Shift Type)/Removal
23. REMOVE NAVIGATION RECEIVER ASSEMBLY WITH BRACKET (w/ Navigation System with
USB Audio System) See: Accessories and
Optional Equipment/Navigation System/Service and Repair/Navigation Receiver (for Floor Shift
Type)/Removal
Installation
AIR CONDITIONING: AIR CONDITIONING PANEL (for Floor Shift Type): INSTALLATION
1. INSTALL NAVIGATION RECEIVER ASSEMBLY WITH BRACKET (w/ Navigation System
without USB Audio System) See: Accessories
and Optional Equipment/Navigation System/Service and Repair/Navigation Receiver (for Floor
Shift Type)/Installation
2. INSTALL NAVIGATION RECEIVER ASSEMBLY WITH BRACKET (w/ Navigation System with
USB Audio System) See: Accessories and
Optional Equipment/Navigation System/Service and Repair/Navigation Receiver (for Floor Shift
Type)/Installation
3. INSTALL RADIO RECEIVER ASSEMBLY WITH BRACKET (w/o USB Audio System) See:
Accessories and Optional Equipment/Radio,
Stereo, and Compact Disc/Radio/Stereo/Service and Repair/Radio Receiver (for Floor Shift
Type)/Installation
4. INSTALL RADIO RECEIVER ASSEMBLY WITH BRACKET (w/ USB Audio System) See:
Accessories and Optional Equipment/Radio,
Stereo, and Compact Disc/Radio/Stereo/Service and Repair/Radio Receiver (for Floor Shift
Type)/Installation
5. INSTALL INTEGRATION CONTROL AND PANEL ASSEMBLY
Diagrams
Shift Interlock Solenoid: Diagrams
Page 5256
2. Inspect the front driveshaft (propeller shaft assembly) for a loose parts label that may be
contacting other components (see Figure 1).
Is the label on the front driveshaft (propeller shaft assembly) loose and contacting other
components?
^ YES - Go to step 3.
^ NO - This TSB does NOT apply. Continue diagnosis to isolate the cause of this condition.
3. Completely remove the front driveshaft parts label.
4. Test drive and confirm there is no abnormal noise present when in 4WD.
Page 6050
Push the secondary locking device or terminal retainer in to the full lock position.
CONNECT CONNECTOR
Voltage Check
VOLTAGE CHECK
Page 8470
Alarm System Transmitter: Service and Repair Installation
ENGINE IMMOBILISER: TRANSPONDER KEY ECU: INSTALLATION
1. INSTALL TRANSPONDER KEY ECU
(a) Hook the upper part of the ECU and the lower part in that order to install the ECU.
2. INSTALL TRANSPONDER KEY BRACKET (w/ Bracket)
(a) Install the transponder key bracket with the 2 screws.
3. INSTALL AIR CONDITIONING UNIT
(a) Install the air conditioning unit See: Heating and Air Conditioning/Housing Assembly
HVAC/Service and Repair/Removal and
Replacement/Installation.
4. REGISTER ECU - ECM COMMUNICATION ID
(a) Register the ECU - ECM communication ID See: Testing and Inspection/Programming and
Relearning/Engine Immobiliser System.
Page 7020
for Double Cab of Long Deck
for CrewMax of standard deck
Emissions - MIL ON/Multiple Air Injection DTC's Set
Air Injection Bypass Valve: All Technical Service Bulletins Emissions - MIL ON/Multiple Air Injection
DTC's Set
T-SB-0350-09
Rev1
October 1, 2009
Air Injection Pump With Water Intrusion: MIL "ON" DTC P04181P0419 and/or P244 #
Service Category Engine/Hybrid System
Section Engine Control
Market USA
Applicability
TSB REVISION NOTICE
May 21, 2010 Rev1:
^ DTCs P0418 and P0419 have been added to the TSB.
^ The Applicable Warranty has been updated in the Warranty Information section. Any previous
printed versions of this service bulletin should be discarded.
Introduction
Some 2010 model year Tundra vehicles built in the Texas plant may exhibit a MIL "ON" condition
with Diagnostic Trouble Code (DTC) P0418, P0419, P2440, P2441, P2442, P2443, P2446, and/or
P2447. This concern may be caused by water intrusion into the air injection pump assembly. Use
the following procedure to address this condition.
Parts Information
Production Change Information
Page 3734
HINT The wavelength becomes shorter as engine rpm increases.
(i) WAVEFORM 8:
HINT If the waveform is not similar to the illustration, check the waveform again after idling for 10
minutes or more.
(j) WAVEFORM 9:
Page 3505
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- CHECK FOR SHORT TO B+ IN CAN BUS WIRE (MAIN BODY ECU) OK -- Continue to next
step.
9. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (NO. 1 JUNCTION CONNECTOR - SKID
CONTROL ECU WITH ACTUATOR)
(a) Disconnect the A46 No. 1 junction connector connector.
(b) Measure the resistance according to the value(s) in the table below.
Drivetrain - Rear Differential Growl/Whine While Driving
Differential Case: Customer Interest Drivetrain - Rear Differential Growl/Whine While Driving
T-SB-0297-10
November 2, 2010
Rear Differential Housing Oil Baffle Growl/Whine Noise
Service Category Drivetrain
Section Axle/Differential
Market USA
Applicability
Introduction
Some vehicles may exhibit a growl or whine noise from the rear when the vehicle is in motion.
Production changes have been made to prevent this noise. Follow the procedure in the bulletin to
address this noise condition.
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60
months or 60,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Production Change Information
Page 4364
4. INSTALL V-BANK COVER See: Engine, Cooling and Exhaust/Engine/Service and
Repair/Removal and Replacement/Engine
Assembly/Installation
5. CHECK FOR FUEL LEAK See: Fuel Injector/Service and Repair/Installation
Components
Steering Angle Sensor: Service and Repair Components
BRAKE CONTROL: STEERING ANGLE SENSOR: COMPONENTS
Page 5464
Transfer Case Actuator: Diagrams
Page 6113
(a) Remove the exhaust manifold RH See: Engine, Cooling and Exhaust/Exhaust System/Exhaust
Manifold/Service and Repair/Removal.
2. REMOVE STARTER COVER
(a) Remove the 3 bolts and starter cover.
3. REMOVE STARTER ASSEMBLY
(a) Disconnect the 2 wire harness clamps.
(b) Disconnect the starter connector.
(c) Remove the nut and disconnect the starter wire.
(d) Remove the 2 bolts and starter.
Page 8975
Shock Sensor: Diagrams
Page 6564
J/B No.6 Assembly Inner Circuit
Page 2313
(a) While raising up the No. 2 chain tensioner, insert a pin of dia1.0 mm (0.0394 in.) into the hole to
fix it in place.
(b) Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt.
NOTICE: *
Be careful not to damage the cylinder head with the wrench.
* Do not disassemble the camshaft timing gear.
(c) Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt.
NOTICE: Be careful not to damage the cylinder head with the wrench.
(d) Remove the 2 bolts. Then with the No. 1 and No. 2 chains still connected to the gears, remove
the camshaft timing gear, camshaft timing
exhaust gear and crankshaft timing sprocket RH.
(e) Remove the No. 1 and No. 2 chains from the gears.
11. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY
(a) Remove the 2 bolts and chain tensioner.
12. REMOVE CAMSHAFT BEARING CAP RH
(a) Make sure that the knock pin of the camshaft is positioned as shown in the illustration.
Page 827
Wheel Speed Sensor: Locations From 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 3429
(a) Reconnect the J86 No. 1 junction connector connector.
NEXT -- Continue to next step.
4. CHECK FOR SHORT IN CAN BUS WIRES (NO. 2 JUNCTION CONNECTOR)
(a) Disconnect the J113 No. 2 junction connector connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- CHECK FOR SHORT IN CAN BUS WIRES (NO. 2 JUNCTION CONNECTOR - AIR
CONDITIONING AMPLIFIER) OK -- Continue to next step.
5. CHECK FOR SHORT IN CAN BUS WIRES (NO. 1 JUNCTION CONNECTOR - NO. 2
JUNCTION CONNECTOR)
(a) Disconnect the J94 No. 1 junction connector connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE CAN MAIN WIRE OR CONNECTOR (NO. 1 JUNCTION
CONNECTOR - NO. 2 JUNCTION CONNECTOR) OK -- Continue to next step.
6. CONNECT CONNECTOR
(a) Reconnect the J94 No. 1 junction connector connector.
(b) Reconnect the J113 No. 2 junction connector connector.
Page 1515
Neutral Safety Switch: Service and Repair Removal
A760F AUTOMATIC TRANSMISSION: PARK / NEUTRAL POSITION SWITCH: REMOVAL
1. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY
(a) Remove the nut and disconnect the cable.
2. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY
(a) Disconnect the switch connector.
(b) Remove the nut, spring washer and transmission control shaft lever RH.
(c) Using a screwdriver, bend the tabs of the lock washer.
(d) Remove the lock nut and lock washer.
(e) Remove the bolt and switch.
Page 2973
with SST - Torque : 40 Nm (408 kgf-cm, 30 ft-lbf)
HINT *
Use a torque wrench with a fulcrum length of 30 cm (11.8 in.). When using a torque wrench with a
fulcrum length that is not 30 cm (11.8 in.), calculate the torque specification for the torque wrench
and SST based on the "without SST" torque specification See: Service Precautions
* Make sure SST and the wrench are connected in a straight line.
4. INSTALL PROPELLER SHAFT HEAT INSULATOR (for 4WD) See: Transmission and
Drivetrain/Drive/Propeller Shafts, Bearings and
Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Front Propeller Shaft
Assembly/Installation
5. INSTALL FRONT EXHAUST PIPE ASSEMBLY
(a) Install a new gasket and the front exhaust pipe to the exhaust manifold RH with 3 new nuts.
Torque : 54 Nm (554 kgf-cm, 40 ft-lbf)
(b) Connect the air fuel ratio sensor connector.
(c) Connect the heated oxygen sensor connector and 2 clamps.
6. INSTALL CENTER EXHAUST PIPE ASSEMBLY See: Engine, Cooling and Exhaust/Exhaust
System/Exhaust Pipe/Service and
Repair/Exhaust Pipe (for Regular Cab Standard Deck)/Installation
7. INSTALL TAILPIPE ASSEMBLY See: Engine, Cooling and Exhaust/Exhaust System/Exhaust
Pipe/Service and Repair/Exhaust Pipe (for
Regular Cab Standard Deck)/Installation
8. INSPECT FOR EXHAUST GAS LEAK See: Engine, Cooling and Exhaust/Exhaust
System/Exhaust Manifold/Service and Repair/Installation
Page 7322
Control Arm: Overhaul
Disassembly
SUSPENSION: FRONT LOWER SUSPENSION ARM: DISASSEMBLY
1. REMOVE FRONT NO. 1 LOWER ARM BUSH LH
(a) Using a chisel and hammer, pry the flange of the bush outward.
(b) Using SST, remove the bush.
SST : 09950-40011
09951-04010
09952-04010
09953-04020
09954-04010
09955-04011
09957-04010
09958-04011
SST : 09950-60010
09951-00540
2. REMOVE FRONT NO. 2 LOWER ARM BUSH LH
Page 1994
Symbols Used Within Diagrams
Symbols Used Within Diagrams
Page 7299
Torque : 18 Nm (184 kgf-cm, 13 ft-lbf)
NOTICE: Use the formula calculate special torque values for situations for situations where a union
nut wrench is combined with a torque wrench See: Service Precautions
Drivetrian - Rear End Howling/Growling Noises
Axle Bearing: All Technical Service Bulletins Drivetrian - Rear End Howling/Growling Noises
T-SB-0151-10
June11, 2010
Rear Axle Bearing Abnormal Noise
Service Category Drivetrain
Section Axle/Differential
Market USA
Applicability
Introduction
Some 2007 - 2010 model year Tundra vehicles may exhibit a howling or growling noise from the
rear of the vehicle that increases with vehicle speed. Changes have been made to the rear axle
bearing to correct this condition. Follow the procedure in the bulletin to address customer concerns.
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60
months or 60,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Parts Information
Front Power Seat Lumbar Switch (for Manual Seat)
Power Seat Switch: Testing and Inspection Front Power Seat Lumbar Switch (for Manual Seat)
SEAT: FRONT POWER SEAT LUMBAR SWITCH (for Manual Seat): INSPECTION
1. INSPECT FRONT POWER SEAT LUMBAR SWITCH LH
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the switch.
Locations
Impact Sensor: Locations
SUPPLEMENTAL RESTRAINT SYSTEM: AIRBAG SYSTEM: PARTS LOCATION
Page 8139
Seat Occupant Sensor: Locations Seat Belt Warning System
SEAT BELT: SEAT BELT WARNING SYSTEM: PARTS LOCATION
Page 4313
Then click Start.
I. Do NOT disturb the vehicle during flash reprogramming.
NOTE
^ ECU flash reprogramming may take anywhere from 3 - 30 minutes per calibration file.
^ Reprogramming time will vary depending on model and ECU communication protocol. Vehicles
using CAN communication protocol will reprogram much faster (2 - 7 minutes).
NOTE
^ If vehicle requires only ONE calibration update, then proceed to step N in this bulletin.
^ If vehicle requires a SECOND calibration update, then continue as follows:
^ For serial communication vehicles, go to step J.
^ For CAN communication vehicles, go to step L.
Components
Steering Angle Sensor: Service and Repair Components
BRAKE CONTROL: STEERING ANGLE SENSOR: COMPONENTS
Page 1705
Standard wheel angle (unloaded vehicle):
for Double Cab of Standard Deck
Page 2043
J/B No.3 Inner Circuit
J/B No.4 Inner Circuit
J/B No.5 Inner Circuit
Page 797
Parking Brake Warning Switch: Service and Repair Reassembly
PARKING BRAKE: PARKING BRAKE PEDAL: REASSEMBLY
1. INSTALL PARKING BRAKE SWITCH ASSEMBLY
(a) Install the switch with the screw.
Torque : 0.9 Nm (9 kgf-cm, 8 in-lbf)
Page 7515
Tire Pressure Adjustment
Recommended Tire Pressure Adjustment:
NOTE
Use a high quality accurate tire pressure gauge, and check its accuracy regularly.
^ Consider the difference of the air temperature in the workshop and the lowest ambient
temperature that may be expected in the next few weeks (especially in winter).
^ Use the chart (Figure 1) to compensate for temperature of the tires when adjusting tire pressure.
Use temperature compensation Example 1 for the spare tire.
Example 1: Temperature Compensation - "Cold" Tires
^ The vehicle has been parked overnight outside shop (vehicle has "cold" tires) and tire pressures
are set to 31.9 psi.
^ Workshop temperature is 68°F and expected lowest ambient temperature in the local area is to
be 14°F.
^ Subtract the expected lowest temperature (14 F) from the workshop temperature (68°F) = 54°F.
^ Using the tire pressure chart (Figure 1) find the intersection of the cold tire line at the point
corresponding to 54°F and read oft the value on the tire pressure change axis. In this case it would
be about 4.9 psi.
^ The tires should be filled to:
31.9 + 4.9 psi = 36.8 psi
Example 2: Temperature Compensation - "Warm" Tires
^ The vehicle has been driven to the shop on surface streets for about 30 minutes (vehicle has
"warm" tires) and tire pressures are set to 31.9 psi.
^ Workshop temperature is 68 F and expected lowest ambient temperature in your area is to be
14°F.
Air Fuel Ratio Sensor
Oxygen Sensor: Service and Repair Air Fuel Ratio Sensor
Components
1UR-FE ENGINE CONTROL SYSTEM: AIR FUEL RATIO SENSOR: COMPONENTS
Page 3848
without SST - Torque : 44 Nm (449 kgf-cm, 32 ft-lbf)
with SST - Torque : 40 Nm (408 kgf-cm, 30 ft-lbf)
HINT *
Use a torque wrench with a fulcrum length of 30 cm (11.8 in.). When using a torque wrench with a
fulcrum length that is not 30 cm (11.8 in.), calculate the torque specification for the torque wrench
and SST based on the "without SST" torque specification See: Service Precautions
* Make sure SST and the wrench are connected in a straight line.
(c) for 2WD:
Connect the air fuel ratio sensor connector.
2. INSTALL FRONT NO. 2 EXHAUST PIPE ASSEMBLY (for 4WD)
(a) Connect the front No. 2 exhaust pipe to the exhaust pipe support.
(b) Install a new gasket and the front No. 2 exhaust pipe to the exhaust manifold LH with 3 new
nuts.
Torque : 54 Nm (554 kgf-cm, 40 ft-lbf)
(c) Connect the air fuel ratio sensor connector.
(d) Connect the heated oxygen sensor connector.
3. INSTALL AIR FUEL RATIO SENSOR (for Bank 2 Sensor 1)
(a) Install the sensor to the exhaust pipe by hand.
(b) Using SST, tighten the sensor.
SST : 09224-00010
without SST - Torque : 44 Nm (449 kgf-cm, 32 ft-lbf)
Page 6689
Page 6887
Power Distribution Module: Service and Repair Installation
OTHER SYSTEM: VOLTAGE INVERTER (for CrewMax): INSTALLATION
1. INSTALL VOLTAGE INVERTER ASSEMBLY
(a) Connect the voltage inverter connector.
(b) Install the voltage inverter with the 2 bolts.
Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
2. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY LH See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (for CrewMax)/Installation
3. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH
4. INSTALL REAR DOOR SCUFF PLATE LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for
CrewMax)/Installation
5. INSTALL BACK PANEL TRIM LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for
CrewMax)/Installation
6. INSTALL BACK PANEL TRIM RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for
CrewMax)/Installation
Page 4793
M. Turn ignition OFF for a minimum of 10 seconds. Then click Next.
N. Turn ignition to the ON position. Then click Next.
0. Confirm all calibrations were updated as specified in the service bulletin. Then click Finish.
Page 8689
Integrated Accessory Switch Assembly: Diagrams
Page 181
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION: Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC
terminals are touched, the IC may be destroyed by static electricity.)
When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact with the terminals of leads from the IC, etc. of the
replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown on the left.
DISCONNECT CONNECTOR
Locations
Actuator: Locations
JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION
Page 4995
6. REMOVE SHIFT SOLENOID VALVE S1
(a) Remove the bolt, valve body wire harness clamp and shift solenoid valve.
7. REMOVE SHIFT SOLENOID VALVE S4
(a) Remove the bolt and shift solenoid valve.
8. REMOVE SHIFT SOLENOID VALVE S2
9. REMOVE SHIFT SOLENOID VALVE S3
(a) Remove the bolt and shift solenoid valve.
Reassembly
A760F AUTOMATIC TRANSMISSION: VALVE BODY ASSEMBLY: REASSEMBLY
Page 9079
Trailer Lamps: Electrical Diagrams
Trailer Towing Part 1
Page 3985
6. In some instances where water has entered the system DTCs P2440/P2441/P2442/P2443 may
set.
Refer to TIS 2010 model year Tundra Repair Manual to diagnose and inspect the emission control
valves if necessary:
7. If there is NO liquid found in the air pump assemblies or the DTC is still present after
replacement inspect the air injection system.
Refer to TIS 2010 model year Tundra Repair Manual:
8. Clear the DTC and road test the vehicle to confirm the condition has been corrected.
Page 969
Dimmer Switch: Testing and Inspection
METER: LIGHT CONTROL RHEOSTAT: INSPECTION
1. INSPECT LIGHT CONTROL RHEOSTAT (w/o TAIL Cancel Switch)
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the rheostat.
2. INSPECT LIGHT CONTROL RHEOSTAT (w/ TAIL Cancel Switch)
(a) Measure the resistance according to the value(s) in the table below.
Diagrams
Shift Interlock Solenoid: Diagrams
Page 7030
for Double Cab of Long Deck
Page 4939
(a) Move the shift lever to N.
(b) Disconnect the transmission control cable end from the shift lever.
(c) Remove the clip and disconnect the transmission control cable from the shift lever retainer.
(d) Remove the nut and clip, and disconnect the transmission control cable from the automatic
transmission.
(e) Remove the nut and disconnect the transmission control cable support.
(f) Remove the 2 bolts and then pull the transmission control cable into the vehicle to remove it.
Installation
A760F AUTOMATIC TRANSMISSION: TRANSMISSION CONTROL CABLE (for Floor Shift Type):
INSTALLATION
Page 3323
Page 5760
17. REMOVE NO. 1 PARKING BRAKE CABLE ASSEMBLY (for 4180 mm [13 ft. 8.6 in.]
Wheelbase Type)
(a) Remove the adjustment nut and lock nut (labeled A).
(b) Remove the bolt (labeled B) and cable retainer.
(c) Remove the 3 nuts (labeled C) and 3 clamps from the body.
(d) Disconnect the 3 clamps (labeled D) from the No. 1 parking brake cable.
(e) Remove the 2 bolts (labeled E) and No. 1 parking brake cable from the inside of the vehicle.
NOTICE: Do not bend and twist the parking brake cable.
(f) Remove the 3 bolts (labeled F) and No. 1 cable support bracket.
18. REMOVE REAR WHEEL LH
19. DISCONNECT REAR DISC BRAKE CYLINDER ASSEMBLY LH See: Service and
Repair/Disassembly
20. REMOVE REAR DISC LH See: Disc Brake System/Service and Repair/Removal and
Replacement/Rear Brake/Removal
21. REMOVE PARKING BRAKE SHOE RETURN SPRING LH See: Service and
Repair/Disassembly
22. REMOVE NO. 1 PARKING BRAKE SHOE ASSEMBLY LH See: Service and
Repair/Disassembly
23. REMOVE NO. 2 PARKING BRAKE SHOE ASSEMBLY LH See: Service and
Repair/Disassembly
24. REMOVE PARKING BRAKE SHOE LEVER LH See: Service and Repair/Disassembly
25. REMOVE INTERMEDIATE LEVER TENSION SPRING
(a) Remove the tension spring.
Page 1637
* If the result is not as specified, replace the power window regulator switch.
Page 6694
Page 7508
Tire Pressure Warning Reset Switch: Service and Repair Removal
TIRE AND WHEEL: TIRE PRESSURE WARNING RESET SWITCH: REMOVAL
1. REMOVE FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Removal
2. REMOVE FRONT DOOR SCUFF PLATE LH (for Double Cab, for CrewMax) See: Body and
Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal
3. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Removal
4. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal
5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Removal
6. REMOVE TIRE PRESSURE WARNING RESET SWITCH
(a) Disconnect the switch connector.
(b) Detach the 2 claws and remove the reset switch.
Locations
Fuse: Locations
Engine Room R/B, J/B - Engine Compartment Left
Page 6686
Fuse: Application and ID
Fuse Layout and Amperage Ratings
Fuse Block Location - Engine Compartment
Fuse Location - Engine Compartment
Locations
Steering Control Module: Locations
Instrument Panel (Floor Shift)
Instrument Panel (Column Shift)
Page 1350
Knock Sensor: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: INSTALLATION
1. INSTALL KNOCK SENSOR
(a) Install the 4 sensors with the 4 bolts so that the sensors are angled as shown in the illustration.
Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)
NOTICE: The acceptable installation angle of the sensor is between 10° upward and downward
from the horizontal position.
(b) Connect the 4 sensor connectors.
2. INSTALL SEPARATOR CASE
(a) Install the separator case with the 4 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
3. INSTALL INTAKE MANIFOLD
(a) Install the intake manifold See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service
and Repair/Installation.
Page 8905
6. INSTALL LUGGAGE COMPARTMENT BOX RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof
Headlining (For Regular Cab)/Installation
7. INSTALL LUGGAGE COMPARTMENT BOX LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof
Headlining (For Regular Cab)/Installation
8. INSTALL UPPER BACK PANEL GARNISH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining
(For Regular Cab)/Installation
Page 6853
Page 7698
Removal
AIR CONDITIONING: AIR CONDITIONING PANEL (for Column Shift Type): REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative(-) battery
terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE FRONT DOOR SCUFF PLATE LH
(a) for Regular Cab:
Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Column Shift Type)/Removal.
(b) for Double Cab:
Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Column Shift Type)/Removal.
(c) for CrewMax:
Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Column Shift Type)/Removal.
3. REMOVE COWL SIDE TRIM BOARD LH
(a) for Regular Cab:
Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Column Shift Type)/Removal.
(b) for Double Cab:
Page 6646
(a) Attach the claw to install the power outlet socket.
6. INSTALL CONSOLE BOX BEZEL
(a) Attach the 5 claws to install the console box bezel.
(b) Connect the connector.
7. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding
/ Trim/Dashboard / Instrument Panel/Service
and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
Components
OTHER SYSTEM: POWER OUTLET SOCKET (for Column Shift Type): COMPONENTS
Page 549
Control Module: Diagrams
Page 6839
Page 7003
Engine Room R/B And Engine Room J/B Inner Circuit
Page 3568
Page 1481
Push the terminal retainer down to the temporary lock position.
Page 8242
12. INSTALL CENTER SEATBACK ASSEMBLY See: Body and Frame/Seats/Service and
Repair/Overhaul/Front Seat Assembly (for Center
Seat)/Reassembly
13. CONNECT CENTER FRONT SEAT BELT ASSEMBLY RH
(a) Install the belt anchor with the bolt.
Torque : 42 Nm (428 kgf-cm, 31 ft-lbf)
14. INSTALL CENTER SEAT CUSHION SHIELD RH See: Body and Frame/Seats/Service and
Repair/Overhaul/Front Seat Assembly (for Center
Seat)/Reassembly
15. INSTALL CENTER SEAT CUSHION SHIELD LH See: Body and Frame/Seats/Service and
Repair/Overhaul/Front Seat Assembly (for Center
Seat)/Reassembly
16. INSTALL CENTER FRONT SEAT ASSEMBLY
(a) Install the front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Center
Seat)/Installation.
17. INSTALL FRONT SEAT ASSEMBLY (for Power Seat)
(a) Install the front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Power
Seat)/Installation.
18. INSTALL FRONT SEAT ASSEMBLY (for Manual Seat)
(a) Install the front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Manual
Seat)/Installation.
Components
SEAT BELT: FRONT SEAT OUTER BELT ASSEMBLY (for CrewMax): COMPONENTS
Page 3737
(q) WAVEFORM 16:
HINT The wavelength changes when the air injection control driver detects malfunctions in the air
injection system See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated
Procedures/P Code Charts/P0412
(r) WAVEFORM 17:
HINT The wavelength becomes shorter as engine rpm increases.
(s) WAVEFORM 18:
Page 9251
Locations
Collision Avoidance System Switch: Locations
PARK ASSIST / MONITORING: INTUITIVE PARKING ASSIST SYSTEM: PARTS LOCATION
Page 8966
Remote Switch: Locations Navigation System (w/ USB Audio System)
NAVIGATION: NAVIGATION SYSTEM (w/ USB Audio System): PARTS LOCATION
Page 6793
Push the secondary locking device or terminal retainer in to the full lock position.
CONNECT CONNECTOR
Voltage Check
VOLTAGE CHECK
Page 702
Power Seat Switch: Locations Power Mirror Control System (w/ Memory)
MIRROR: POWER MIRROR CONTROL SYSTEM (w/ Memory): PARTS LOCATION
Page 3742
(b) Spray gasket remover or equivalent on the remaining tape of the gasket.
NOTICE: When using gasket remover or equivalent, cover the ECM connector with a cloth.
(c) Remove the tape of the gasket without using bladed objects.
Page 7728
Evaporator Temperature Sensor / Switch: Locations Air Conditioning System (for Manual Air
Conditioning System)
AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Manual Air Conditioning System):
PARTS LOCATION
Page 1638
Power Window Switch: Testing and Inspection Power Window Master Switch
WINDSHIELD / WINDOWGLASS: POWER WINDOW MASTER SWITCH: ON-VEHICLE
INSPECTION
1. CHECK POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY (w/o Jam Protection
Function)
(a) for Regular Cab:
(1) Remove the master switch See: Service and Repair/Power Window Master Switch/Removal.
(2) Reconnect the switch connector.
(3) Measure the voltage according to the value(s) in the table below.
Standard voltage:
(b) for Double Cab:
(1) Remove the power window regulator master switch See: Service and Repair/Power Window
Master Switch/Removal.
(2) Reconnect the switch connector.
(3) Measure the voltage according to the value(s) in the table below.
Standard voltage:
Page 9083
Connectors Part 1
Page 3358
Symbols Used Within Diagrams
Symbols Used Within Diagrams
Locations
Transmission Position Switch/Sensor: Locations
A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS
LOCATION
Page 7362
Removal
SUSPENSION: FRONT SHOCK ABSORBER: REMOVAL
HINT *
Use the same procedures for the RH side and LH side.
* The procedures listed below are for the LH side.
1. REMOVE FRONT WHEEL
2. REMOVE FRONT SHOCK ABSORBER WITH COIL SPRING LH
Testing and Inspection
Steering Gear: Testing and Inspection
POWER STEERING: STEERING GEAR: INSPECTION
1. INSPECT TIE ROD END SUB-ASSEMBLY LH
(a) Secure the tie rod end LH in a vise.
(b) Install the nut to the stud bolt.
(c) Flip the ball joint back and forth 5 times or more.
(d) Using a torque wrench, turn the nut continuously at a rate of 3 to 5 seconds per turn and take
the torque reading on the fifth turn.
Standard turning torque:
1.0 to 3.9 N*m (10 to 40 kgf*cm, 9 to 34 in.*lbf)
(e) If turning torque is not within the specified range, replace the tie rod end LH.
2. INSPECT TIE ROD END SUB-ASSEMBLY RH
HINT Use the same procedures described for the LH side.
Power Steering Oil Pressure Sensor
Power Steering Pressure Switch: Diagrams Power Steering Oil Pressure Sensor
Page 3595
Manifold Pressure/Vacuum Sensor: Diagrams
Page 5975
Ignition Switch: Testing and Inspection
1UR-FE STARTING: IGNITION SWITCH: INSPECTION
1. INSPECT IGNITION SWITCH ASSEMBLY
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) If the result is not as specified, replace the ignition switch assembly.
Page 6807
(2) CONNECTORS
Slightly shake the connector vertically and horizontally.
(3) WIRE HARNESS
Slightly shake the wire harness vertically and horizontally.
HINT The connector joint and fulcrum of the vibration are the major areas that should be checked
thoroughly.
(b) HEAT METHOD:
When a malfunction seems to occur when the area in question is heated.
(1) Heat the component that is the possible cause of the malfunction with a hair dryer or similar
device. Check if the malfunction occurs.
NOTICE: *
Do not heat to more than 60°C (140°F). Exceeding this temperature may damage components.
* Do not apply heat directly to the parts in the ECU.
(c) WATER SPRINKLING METHOD:
When a malfunction seems to occur on a rainy day or in high-humidity.
(1) Sprinkle water onto the vehicle and check if the malfunction occurs.
NOTICE: *
Never sprinkle water directly into the engine compartment. Indirectly change the temperature and
humidity by spraying water onto the front of the radiator.
* Never apply water directly onto the electronic components.
HINT If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU
or connections. Look for evidence of corrosion or short circuits. Proceed with caution during water
tests.
(d) HIGH ELECTRICAL LOAD METHOD:
When a malfunction seems to occur when the electrical load is excessive.
(1) Turn on the heater blower, headlights, rear window defogger and all other electrical loads.
Check if the malfunction reoccurs.
5. DIAGNOSTIC TROUBLE CODE CHART
Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate
section's Diagnostic Trouble Code Chart. Use the chart to determine the trouble area and the
proper inspection procedure. A description of each of the chart's columns is below.
Page 6733
6. PROBLEM SYMPTOMS TABLE
When a "Normal" code is output during a DTC check but the problem is still occurring, use the
Problem Symptoms Table. The suspected areas (circuits or parts) for each problem symptom are
in the table. The suspected areas are listed in order of probability. A description of each of the
chart's columns is below.
HINT In some cases, the problem is not detected by the diagnostic system even though a problem
symptom is present. It is possible that the problem is occurring outside the detection range of the
diagnostic system, or that the problem is occurring in a completely different system.
7. CIRCUIT INSPECTION
A description of the main areas of each circuit inspection is below.
Page 4017
(a) Install a new gasket and the air switching valve with the 3 bolts.
Torque : 24 Nm (245 kgf-cm, 18 ft-lbf)
NOTICE: Make sure the gasket's claws are not caught between the air switching valve and No. 3
air tube.
(b) Install the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(c) Connect the wire harness clamp bracket with the bolt.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
(d) Connect the clamp and connector.
2. CONNECT NO. 1 AIR HOSE
(a) Align the paint mark with the projection and connect the No. 1 air hose.
HINT Make sure the direction of the hose clamp is as shown in the illustration.
3. CONNECT NO. 3 VENTILATION HOSE
(a) Connect the No. 3 ventilation hose.
HINT The direction of the hose clamp is indicated in the illustration.
Page 3388
If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness
or connector in that circuit in the past. Check the wire harness and connectors.
B -- SYSTEM NORMAL
A -- TROUBLESHOOTING OF EACH PROBLEM SYMPTOM
The problem is still occurring in a place other than the diagnostic circuit (the DTC displayed first is
either for a past problem or a secondary problem).
4. SYMPTOM SIMULATION
HINT The most difficult case in troubleshooting is when no problem symptoms occur. In such a
case, a thorough problem analysis must be carried out. A simulation of the same or similar
conditions and environment in which the problem occurred in the customer's vehicle should be
carried out. No matter how much skill or experience a technician has, troubleshooting without
confirming the problem symptoms will lead to important repairs being overlooked and mistakes or
delays.
For example:
With a problem that only occurs when the engine is cold or as a result of vibration caused by the
road during driving, the problem can never be determined if the symptoms are being checked on a
stationary vehicle or on a vehicle with a warmed-up engine. Vibration, heat or water penetration
(moisture) is difficult to reproduce. The symptom simulation tests below are effective substitutes for
the conditions and can be applied on a stationary vehicle.
Important points in the symptom simulation test:
In the symptom simulation test, the problem symptoms as well as the problem area or parts must
be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then,
connect the tester and carry out the symptom simulation test, judging whether the circuit being
tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the
problem symptoms table for each system to narrow down the possible causes.
To reproduce DTCs, it is necessary to satisfy the respective DTC detection conditions.
(a) VIBRATION METHOD:
When a malfunction seems to occur as a result of vibration.
(1) PART AND SENSOR
Apply slight vibration with a finger to the part of the sensor suspected to be the cause of the
problem, and check whether or not the malfunction occurs.
NOTICE: Applying strong vibration to relays may open them.
Engine Controls - ECM Update For Shift Performance
Engine Control Module: All Technical Service Bulletins Engine Controls - ECM Update For Shift
Performance
T-SB-0285-10
October 12, 2010
ECM Calibration: Enhancement to Shifting Performance
Service Category Drivetrain
Section Automatic Transmission/Transaxle
Market USA
Applicability
Introduction
Some vehicles may exhibit the following shifting conditions:
^ Harsh shift on acceleration below 20 mph during the 2-1 downshift.
^ Excessive lock-up operation at freeway speeds about 50 - 60 mph, sometimes referred to as
"busy shifting".
The Engine Control Module/ECM (SAE term: Powertrain Control Module/PCM) calibration has
been revised. Use the following repair procedure to address these conditions.
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Federal Emission Warranty. This warranty is in effect for
96 months or 80,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Page 3446
OK -- REPAIR OR REPLACE NO. 1 JUNCTION CONNECTOR
13. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (COMBINATION METER ECU)
(a) Disconnect the J28 combination meter ECU connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE CAN MAIN WIRE CONNECTED TO COMBINATION METER ECU
(CANH, CANL)
OK -- REPLACE COMBINATION METER ASSEMBLY
14. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (MAIN BODY ECU)
(a) Disconnect the J2 main body ECU connector.
Page 766
Acceleration/Deceleration Sensor: Programming and Relearning
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: CALIBRATION
1. DESCRIPTION
* After replacing components relating to the VSC or performing "Front wheel alignment
adjustment", clear and read the sensor calibration data.
* Follow the chart to perform calibration.
2. CLEAR ZERO POINT CALIBRATION DATA (WHEN USING TECHSTREAM)
(a) Connect the Techstream to the DLC3.
(b) Turn the ignition switch to ON.
(c) Operate the Techstream to erase the codes (select Reset Memory).
HINT Refer to the Techstream operator's manual for further details.
3. PERFORM ZERO POINT CALIBRATION OF MASTER CYLINDER PRESSURE SENSOR AND
DECELERATION SENSOR (WHEN
USING TECHSTREAM)
NOTICE: *
While obtaining the zero point, do not vibrate the vehicle by tilting, moving or shaking it and keep it
stationary. (Do not start the engine.)
* While obtaining the zero point, do not depress the brake and accelerator pedal.
* Obtain the zero point on a level surface (with an inclination of 1° or less).
(a) Enter Test Mode.
(1) Turn the ignition switch off.
(2) Check that the shift lever is in parking or neutral and apply the parking brake.
CAUTION: Application of the parking brake is not necessary for entering test mode. However,
apply the parking brake for safety.
(3) Connect the Techstream to the DLC3.
(4) Turn the ignition switch to ON.
NOTICE: Do not start the engine.
(5) Set the Techstream to test mode (select Test Mode).
HINT Refer to the Techstream operator's manual for further details.
(b) Obtain the zero points of the master cylinder pressure sensor and deceleration sensor.
(1) Keep the vehicle stationary on a level surface for 1 second or more.
HINT
Diagrams
EGR Valve: Diagrams
ACC Cut Relay
Power Distribution Relay: Testing and Inspection ACC Cut Relay
1UR-FE STARTING: ACC CUT RELAY: ON-VEHICLE INSPECTION
1. REMOVE ACC CUT RELAY
(a) Remove the clip.
(b) Detach the 2 clips and remove the cowl side trim board RH.
(c) Remove the relay.
2. INSPECT ACC CUT RELAY
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) If the result is not as specified, replace the relay.
3. INSTALL ACC CUT RELAY
(a) Install the relay.
(b) Attach the 2 clips to install the cowl side trim board RH.
(c) Install the clip.
Page 305
Driver Side J/B Inner Circuit
Page 309
J/B No.6 Assembly Inner Circuit
Page 497
6. REMOVE LOWER NO. 1 INSTRUMENT PANEL AIR BAG ASSEMBLY See: Restraint
Systems/Air Bag Systems/Air Bag/Service and
Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Removal
7. REMOVE NO. 1 AIR DUCT SUB-ASSEMBLY See: Steering and Suspension/Steering/Steering
Column/Service and Repair/Removal and
Replacement/Steering Column Assembly (for Manual Tilt)/Removal
8. REMOVE MULTIPLEX TILT AND TELESCOPIC ECU
(a) Disconnect the 2 ECU connectors.
(b) Remove the 2 screws and ECU.
Page 2438
Oil Pressure Sender: Testing and Inspection
1UR-FE LUBRICATION: OIL PRESSURE SWITCH: ON-VEHICLE INSPECTION
1. INSPECT OIL PRESSURE SENDER GAUGE ASSEMBLY
(a) Disconnect the sender gauge connector.
(b) Apply battery positive (+) voltage to the sender gauge terminal through a test LED.
(c) Check that the LED does not illuminate when the engine is stopped.
(d) Check that the LED flashes when the engine is running. The number of flashes varies with
engine speed.
If the operation is not as specified, replace the oil pressure sender gauge assembly.
Page 8950
Removal
PARK ASSIST / MONITORING: ULTRASONIC SENSOR (for Rear Side): REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE LICENSE PLATE LIGHT ASSEMBLY LH (for Resin Type Bumper) See: Body and
Frame/Bumper/Rear Bumper/Service and
Repair/Removal and Replacement/Rear Bumper (for Resin Type Bumper)/Removal
3. REMOVE LICENSE PLATE LIGHT ASSEMBLY LH (for Steel Type Bumper) See: Body and
Frame/Bumper/Rear Bumper/Service and
Repair/Removal and Replacement/Rear Bumper (for Steel Type Bumper)/Removal
Page 1399
Impact Sensor: Service and Repair Side Airbag Sensor (for Double Cab)
Components
SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Double Cab):
COMPONENTS
Engine Control System - SFI System
Camshaft Position Sensor: Locations Engine Control System - SFI System
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Components
Evaporator Temperature Sensor / Switch: Service and Repair Components
AIR CONDITIONING: FRONT EVAPORATOR TEMPERATURE SENSOR: COMPONENTS
Page 3416
Information Bus: Symptom Related Diagnostic Procedures
Problem Symptoms Table
MULTIPLEX COMMUNICATION: LIN COMMUNICATION SYSTEM: PROBLEM SYMPTOMS
TABLE
HINT *
Use the table below to help determine the cause of the problem symptom. The potential causes of
the symptoms are listed in order of probability in the "Suspected Area" column of the table. Check
each symptom by checking the suspected areas in the order they are listed. Replace parts as
necessary.
* Inspect the fuses and relays related to the system before inspecting the suspected areas below.
Integration Control and Panel Assembly Communication Error
MULTIPLEX COMMUNICATION: LIN COMMUNICATION SYSTEM: Integration Control and Panel
Assembly Communication Error - Integration Control and Panel Assembly Communication Error
DESCRIPTION
The LIN communication of the components related to the mirror heater occurs between the air
conditioning amplifier assembly (A/C ECU) and integration control and panel assembly.
WIRING DIAGRAM
INSPECTION PROCEDURE
NOTICE: When using the Techstream with the ignition switch OFF to troubleshoot:
Connect the Techstream to the vehicle, and turn a courtesy switch on and off at 1.5 second
intervals until communication between the tester and vehicle begins.
PROCEDURE
1. CHECK HARNESS AND CONNECTOR (AIR CONDITIONING AMPLIFIER - INTEGRATION
CONTROL AND PANEL)
Page 1683
for CrewMax of standard deck
Diagram Information and Instructions
Ignition Switch: Diagram Information and Instructions
Wiring Color Codes
Abbreviations Used Within Diagrams
Abbreviations Used Within Diagrams
Page 3065
Page 9016
Release the locking lug from terminal and pull the terminal out from rear.
INSTALL TERMINAL TO CONNECTOR
Insert the terminal.
HINT: Make sure the terminal is positioned correctly.
Insert the terminal until the locking lug locks firmly.
Insert the terminal with terminal retainer in the temporary lock position.
Components
Ignition Coil: Service and Repair Components
1UR-FE IGNITION: IGNITION COIL AND SPARK PLUG: COMPONENTS
Page 8186
Seat Occupant Classification Module - Air Bag: Testing and Inspection
SUPPLEMENTAL RESTRAINT SYSTEM: OCCUPANT CLASSIFICATION ECU: ON-VEHICLE
INSPECTION
1. CHECK OCCUPANT CLASSIFICATION ECU (VEHICLE NOT INVOLVED IN COLLISION)
(a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnosis System.
2. CHECK OCCUPANT CLASSIFICATION ECU (VEHICLE INVOLVED IN COLLISION AND
AIRBAG HAS NOT DEPLOYED)
(a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnosis System.
3. CHECK OCCUPANT CLASSIFICATION ECU (VEHICLE INVOLVED IN COLLISION AND
AIRBAG IS DEPLOYED)
(a) Replace the ECU.
CAUTION: *
For removal and installation procedures of the occupant classification ECU, be sure to follow the
correct procedure.
* If the airbags have deployed, replace the occupant classification ECU on the side in which the
collision occurred. Replace both if necessary.
Page 643
11. INSTALL FRONT DOOR SCUFF PLATE LH
(a) for Regular Cab:
Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular Cab)/Installation.
(b) for Double Cab:
Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Installation.
(c) for CrewMax:
Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for CrewMax)/Installation.
Page 4135
Page 7279
Removal
POWER STEERING: STEERING GEAR: REMOVAL
1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
2. REMOVE FRONT WHEELS
3. REMOVE ENGINE ASSEMBLY
(a) for 1GR-FE:
Page 9039
Connectors Part 2
Page 7919
Air Bag: Testing and Inspection Front Passenger Side Knee Airbag Assembly
SUPPLEMENTAL RESTRAINT SYSTEM: FRONT PASSENGER SIDE KNEE AIRBAG
ASSEMBLY: ON-VEHICLE INSPECTION
1. CHECK LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY (VEHICLE NOT
INVOLVED IN COLLISION)
(a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnosis System.
(b) With the lower No. 2 instrument panel airbag installed on the vehicle, perform a visual check. If
there are any defects as mentioned below,
replace the lower No. 2 instrument panel airbag with a new one:
Cuts, minute cracks or marked discoloration on the lower No. 2 instrument panel airbag.
2. CHECK LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY (VEHICLE INVOLVED IN
COLLISION AND AIRBAG HAS NOT
DEPLOYED)
(a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnosis System.
(b) With the lower No. 2 instrument panel airbag removed from the vehicle, perform a visual check.
If there are any defects as mentioned below,
replace the lower No. 2 instrument panel airbag with a new one:
* Cuts, minute cracks or marked discoloration on the lower No. 2 instrument panel airbag.
* Cracks or other damage to the connector.
* Deformation or cracks on the instrument panel reinforcement.
CAUTION: For removal and installation procedures of the lower No. 2 instrument panel airbag, be
sure to follow the correct procedure.
Page 1265
(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(2) If the result is not as specified, replace the MAF meter.
Page 1847
NOTE
Only Toyota Certified Technicians and above may access calibration files.
2. Connect the GR8 Battery Diagnostic Station.
A. Connect the GR8 Battery Diagnostic Station to the vehicle and turn it ON.
B. Select Power Supply Mode by following the screen flow below.
NOTICE
^ ECU damage may occur if the correct battery charger and mode setting are NOT used.
Page 3526
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO POWER STEERING ECU
(CANH, CANL)
OK -- REPLACE POWER STEERING ECU See: Relays and Modules/Relays and Modules Steering and Suspension/Relays and Modules - Steering/Steering Control Module/Service and
Repair/Removal
18. CHECK FOR SHORT TO GND IN CAN BUS WIRE (CENTER AIRBAG SENSOR)
(a) Disconnect the J46 center airbag sensor connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
Inspection
Air Flow Meter/Sensor: Testing and Inspection Inspection
1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: INSPECTION
1. INSPECT MASS AIR FLOW METER
(a) Check the output voltage.
(1) Apply battery voltage across terminals 1 (+B) and 2 (E2G).
NOTICE: While using the battery during inspection, do not bring the positive and negative tester
probes too close to each other as a short circuit may occur.
(2) Using a voltmeter, connect the positive (+) tester probe to terminal 3 (VG), and negative (-)
tester probe to terminal 2 (E2G).
(3) Blow air into the MAF meter, and check that the voltage fluctuates.
If the result is not as specified, replace the MAF meter.
(b) Perform a visual check for any foreign matter on the platinum hot wire (heater) of the mass air
flow meter shown in the illustration.
OK:
There is no foreign material.
(c) If the result is not as specified, replace the mass air flow meter.
(d) Check the IAT sensor.
Page 7390
2. Install ChaSSiSEAR(TM) on the vehicle and attempt to isolate the source of the noise. Is the
noise loudest near the rear wheel bearing assembly?
^ YES - Go to step 3.
^ NO - This TSB does NOT apply. Continue diagnosis to isolate the source of the noise.
3. Replace the rear wheel bearing caliper bracket and related parts.
Refer to the Technical Information System (TIS) applicable model year Repair Manual:
4. Test drive the vehicle and confirm the noise is eliminated.
5. Re-check rear differential oil level and confirm NO leaks are present.
Page 7057
Standard caster inclination (unloaded vehicle):
for Regular Cab of Long Deck
Standard caster inclination (unloaded vehicle):
for Double Cab of Standard Deck
Page 7051
Standard wheel angle (unloaded vehicle):
for CrewMax of standard deck
Engine - Snow Ingestion Into Air Cleaner Box
Air Cleaner Housing: Customer Interest Engine - Snow Ingestion Into Air Cleaner Box
T-SB-0396-09
December 8, 2009
Snow Entry Into Air Cleaner Box
Service Category Engine/Hybrid System
Section Intake/Exhaust
Market USA
Applicability
Introduction
Some Sequoia and Tundra vehicles operated in areas with significant snow volume may
experience snow accumulation in the air cleaner box which can cause the lid to fracture. The air
cleaner lid and fender liner have been revised to reduce accumulation.
Parts Information
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for
36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Production Change Information
Page 2329
Parts Information
Required Tools & Equipment
Additional TIS Techstream units may be ordered by calling Approved Dealer Equipment (ADE).
TSB Overview
1. Confirm that DTC P0012 and/or P0022 is stored in the ECM.
2. Diagnose the Oil Control Valves (OCVs) for proper operation.
3. If the OCVs operate correctly replace both intake VVTi gear assemblies following the Repair
Manual.
Diagnostic Procedure
1. Using TIS Techstream confirm that DTC P0012 and/or P0022 is stored in the ECM.
2. Remove the affected Oil Control Valve (OCV) and inspect for debris in the valve or evidence that
the valve is stuck.
3. Check valve operation by applying positive (+) battery voltage to terminal 1 and negative (-)
battery voltage to terminal 2. Valve should move
quickly when voltage is applied. If NOT valve should be replaced.
4. Reinstall the OCVs warm up the engine to over 167°F (75°C) and perform an Active Test using
Tech stream.
Powertrain / Engine and ECT / Active Test / Control the WT System (Bank 1) or (Bank 2)
5. If there is NO debris and the OCV moves with battery voltage and Active Test functions Replace both intake VVTi gears following the repair
procedure below.
Repair Procedure
1. Replace both intake VVTi gears.
Page 4183
Page 4812
Actuator: Service and Repair Installation
DIFFERENTIAL: AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR (for 4WD):
INSTALLATION
1. INSTALL AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR
(a) Remove any old FIPG material and be careful not to drop oil on the contact surfaces of the
differential tube and actuator.
(b) Clean the contact surfaces with any residual FIPG material using gasoline or alcohol.
(c) Apply seal packing to the differential tube as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
HINT Install the actuator within 10 minutes of applying seal packing.
(d) Clean the threads of the 4 bolts and retainer bolt holes with toluene or trichloroethylene.
(e) Install the actuator onto the differential tube.
(f) Apply adhesive to 2 to 3 threads of each bolt end.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
(g) Install the 4 bolts.
Torque : 21 Nm (210 kgf-cm, 15 ft-lbf)
(h) Connect the actuator hose.
(i) Connect the actuator connector.
2. INSTALL NO. 1 ENGINE UNDER COVER See: Engine, Cooling and Exhaust/Engine/Drive
Belts, Mounts, Brackets and Accessories/Drive
Belt/Service and Repair/Installation
3. INSPECT AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR
(a) Inspect the automatic disconnecting differential actuator See: Transfer Case/Testing and
Inspection/Component Tests and General
Diagnostics/Touch Select 2-4 and High-Low System.
Page 7500
Tire Pressure Sensor: Service and Repair Disposal
TIRE AND WHEEL: TIRE PRESSURE WARNING VALVE AND TRANSMITTER: DISPOSAL
HINT The tire pressure warning valve is powered by a lithium battery. When disposing of the tire
pressure warning valve and transmitter, remove the battery and dispose of it correctly.
1. DISPOSE OF TIRE PRESSURE WARNING VALVE AND TRANSMITTER
(a) Use the tip of a screwdriver to pry off the back cover.
(b) The battery and base board are exposed. While taking out the battery, cut the 2 terminals that
connect the battery to the base board.
Page 3196
Camshaft Position Sensor: Diagrams
Page 9282
Hood Sensor/Switch (For Alarm): Diagrams
Page 6745
Fuse Block: Electrical Diagrams
Engine Room R/B And Engine Room J/B Inner Circuit
Page 3080
Establish conditions in which voltage is present at the check point.
Example:
- [A] - Ignition SW on
- [B] - Ignition SW and SW1 on
- [C] - Ignition SW, SW1 and Relay on (SW2 off)
Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or component terminal.
This check can be done with a test light instead of a voltmeter.
Electronic Circuit Inspection Procedure
Engine - Controls - Non-Linear Acceleration From A Stop
Engine Control Module: Customer Interest Engine - Controls - Non-Linear Acceleration From A
Stop
T-SB-0273-10
September 28, 2010
Non-Linear Acceleration from a Stop
Service Category Engine/Hybrid System
Section Engine Control
Market USA
Applicability
Introduction
Some 2010 model year Tundra vehicles with the 1UR-FE (4.6 L) engine may exhibit non-linear
acceleration from a stop under certain conditions of low engine rpm with high engine load. The
Engine Control Module/ECM (SAE term: Powertrain Control Module/PCM) logic has been revised
to address this condition. Use the following repair procedure to recalibrate the ECM (PCM).
Calibration Information
Warranty Information
Applicable Warranty
^ This repair is covered under the Toyota Federal Emission Warranty. This warranty is in effect for
96 months or 80,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Page 421
Fuel Pump Control Unit: Locations Double Cab
Body
Page 4697
Transmission Speed Sensor: Testing and Inspection
A760F AUTOMATIC TRANSMISSION: SPEED SENSOR: INSPECTION
1. INSPECT SPEED SENSOR NT
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) If the result is not as specified, replace the sensor.
2. INSPECT SPEED SENSOR SP2
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) If the result is not as specified, replace the sensor.
Page 3542
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(c) Measure the voltage according to the value(s) in the table below.
Standard voltage:
NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- REPLACE COMBINATION METER ASSEMBLY
ECM Communication Stop Mode
CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: ECM Communication Stop Mode ECM Communication Stop Mode
DESCRIPTION
WIRING DIAGRAM
Page 4400
Parts Information
NOTE
The fuel sending unit lower cover is installed and supplied as part of the fuel tank assembly part
numbers listed in the part information table above.
Warranty Information
Installation Procedure
1. Insert the tip of the fuel sender unit upper cover into the hole on the fuel sender unit lower cover
(2 places).
2. Fasten the tab of the fuel sender unit upper cover to the lip on the fuel sender unit lower cover (1
place).
Locations
Electronic Throttle Actuator: Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 6175
Connectors Part 1
Connectors Part 2
Locations
Hazard Flasher Relay: Locations
Instrument Panel (Floor Shift)
Instrument Panel (Column Shift)
Page 7721
Control Module HVAC: Service and Repair Installation
AIR CONDITIONING: AIR CONDITIONING AMPLIFIER: INSTALLATION
1. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY
(a) Install the amplifier with the 2 screws.
(b) for Manual Air Conditioning System:
Connect the 2 connectors.
(c) for Automatic Air Conditioning System:
Connect the 3 connectors.
2. INSTALL NO. 2 AIR DUCT SUB-ASSEMBLY
(a) Install the duct with the screw.
3. INSTALL LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY
for Column Shift Type:
Install the lower No. 2 instrument panel airbag assembly See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument
Panel Safety Pad (for Column Shift Type)/Installation.
for Floor Shift Type:
Install the lower No. 2 instrument panel airbag assembly See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument
Panel Safety Pad (for Floor Shift Type)/Installation.
4. INSTALL LOWER INSTRUMENT PANEL
for Column Shift Type:
Page 7957
CAUTION: *
Tightly wind the wire harnesses around the bolts so that there is no slack.
* Make sure that the wire harnesses are tight. If there is slack in the wire harnesses, the steering
pad may become loose due to the shock when the airbag is deployed.
(4) Face the airbag deployment side of the steering pad upward. Separately tie the left and right
sides of the steering pad to the disc wheel
through the hub nut holes. Position SST connector so that it hangs downward through the hub hole
of the disc wheel.
CAUTION: *
Make sure that the wire harnesses are tight. If there is slack in the wire harnesses, the steering pad
may become loose due to the shock when the airbag is deployed.
* Always tie down the steering pad with the airbag deployment side facing upward.
NOTICE: As the disc wheel may be damaged by the airbag deployment, use a disc wheel that you
are planning to throw away.
(d) Install SST.
CAUTION: Place the disc wheel on level ground.
(1) Connect SST connector.
SST : 09082-00700
NOTICE: To avoid damaging SST connector and wire harness, do not lock the secondary lock of
the twin lock. Also, secure some slack for SST wire harness inside the disc wheel.
Page 8303
When the Seat Belt Extender is provided for rear seat positions (with automatic locking retractor)
make sure the retractor is locked when in use.
To connect the extender to the seat belt, insert the tab into the seat belt buckle so that the
buckle-release buttons of the extender and the seat belt are both facing outward as shown in
Figure 4.
You will hear a click when the tab locks into the buckle. When not in use, remove the extender and
store in the vehicle for future use.
On vehicles equipped with SRS - Occupant Classification System (OCS)*, the extender tab should
be buckled into the buckle AFTER the occupant sits down in the seat.
Leaving extender installed in the buckle before sitting down will cause the OCS to be in the "airbag
off" or disarmed state.
*OCS will enable or disable the passenger front and side airbags based on passenger weight and
seat belt latch position classifying the passenger as a child or adult.
When using the Seat Belt Extender, observe the following. Failure to follow these instructions could
result in reduced effectiveness of the seat belt restraint system in case of vehicle accident,
increasing the possibility of personal injury.
^ NEVER use the Seat Belt Extender if you can COMFORTABLY fasten the seat belt without it.
^ The Seat Belt Extender must never be used with any child safety seats.
^ Remember that the extender provided for you may not be safe when used on a different vehicle,
or for another person or at a different seating position than the one originally intended for.
Page 9111
"Case2" Open the secondary locking device.
[B] For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray
Gray or White : Black
Page 4252
This TSB applies to all Sequoia and Tundra vehicles equipped with lUR-FE (4.6L) 2UZ-FE (4.7L)
and 3UR-FE/FBE (5.7L) engines produced BEFORE the Production Change Effective VINs shown.
Repair Procedure
1. Remove and replace the air cleaner lid.
2. Remove and replace the front right hand (RH) fender liner.
Page 596
Parking Assist Distance Sensor: Diagrams
Page 2947
Manifold Pressure/Vacuum Sensor: Diagrams
Page 6727
4. SYMPTOM CONFIRMATION AND DTC (INCLUDING FREEZE FRAME DATA) CHECK
(a) Visually check the wire harnesses, connectors and fuses for open and short circuits.
(b) Warm up the engine to the normal operating temperature.
(c) Confirm the problem symptoms and conditions, and check for DTCs.
B -- Go to step 6 A -- Continue to next step.
5. DTC CHART
(a) Check the results obtained in the DTC check. Then find the output DTC in the DTC chart. Look
at the "Trouble Area" column for a list of
potentially malfunctioning circuits and / or parts.
NEXT -- Go to step 7
6. PROBLEM SYMPTOMS TABLE
(a) Check the results obtained in the symptom confirmation. Then find the problem symptoms in
the problem symptoms table. Look at the
"Suspected Area" column for a list of potentially malfunctioning circuits and / or parts.
NEXT -- Continue to next step.
7. CIRCUIT INSPECTION OR PARTS INSPECTION
(a) Confirm the malfunctioning circuit or part.
NEXT -- Continue to next step.
8. ADJUST, REPAIR OR REPLACE
(a) Adjust, repair or replace the malfunctioning circuit or parts.
NEXT -- Continue to next step.
9. CONFIRMATION TEST
(a) After the adjustment, repairs or replacement, confirm that the malfunction no longer exists. If the
malfunction does not reoccur, perform a
confirmation test under the same conditions and in the same environment as when the malfunction
occurred the first time.
NEXT -- END
2. CUSTOMER PROBLEM ANALYSIS
HINT *
In troubleshooting, confirm that the problem symptoms have been accurately identified.
Preconceptions should be discarded in order to make an accurate judgment. To clearly understand
what the problem symptoms are, it is extremely important to ask the customer about the problem
and the conditions at the time the malfunction occurred.
* Gather as much information as possible for reference. Past problems that seem unrelated may
also help in some cases.
* The following 5 questions are important points in the problem analysis:
Page 6184
2. REMOVE CONSOLE BOX BEZEL
(a) Disconnect the connector.
(b) Using a screwdriver, detach the 5 claws and remove the console box bezel.
HINT Tape the screwdriver tip before use.
3. REMOVE POWER OUTLET SOCKET ASSEMBLY
(a) Using a screwdriver, detach the claw and remove the power outlet socket.
HINT Tape the screwdriver tip before use.
4. REMOVE POWER OUTLET SOCKET COVER
(a) Detach the 2 claws and remove the power outlet socket cover.
5. REMOVE REAR CONSOLE END PANEL SUB-ASSEMBLY (for Double Cab) See: Body and
Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Floor Shift Type)/Removal
6. REMOVE REAR POWER OUTLET SOCKET ASSEMBLY (for Double Cab)
(a) Using a screwdriver, detach the claw and remove the power outlet socket.
Page 8902
Keyless Entry Module: Service and Repair Door Control Receiver (for Regular Cab)
Components
DOOR LOCK: DOOR CONTROL RECEIVER (for Regular Cab): COMPONENTS
Page 575
Page 1504
Ignition Switch: Service and Repair Removal
1UR-FE STARTING: IGNITION SWITCH: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE STEERING COLUMN ASSEMBLY
(a) for Manual Tilt:
Remove the steering column See: Steering and Suspension/Steering/Steering Column/Service and
Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Removal.
(b) for Manual Tilt and Manual Telescopic Steering Column:
Remove the steering column See: Steering and Suspension/Steering/Steering Column/Service and
Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt and Manual
Telescopic Steering Column)/Removal.
(c) for Power Tilt and Power Telescopic Steering Column:
Remove the steering column See: Steering and Suspension/Steering/Steering Column/Service and
Repair/Removal and Replacement/Steering Column Assembly (for Power Tilt and Power
Telescopic Steering Column)/Removal.
3. REMOVE UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Manual
Tilt) See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering Column Assembly
(for Manual Tilt)/Disassembly
4. REMOVE UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Manual Tilt
and Manual Telescopic Steering Column)
See: Steering and Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering
Column Assembly (for Manual Tilt and Manual Telescopic Steering Column)/Disassembly
5. REMOVE UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Power Tilt
and Power Telescopic Steering Column)
See: Steering and Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering
Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Disassembly
6. REMOVE IGNITION SWITCH ASSEMBLY
(a) Detach the 2 claws and remove the ignition switch from the steering lock.
Page 7665
(a) Remove the 6 clips and seal.
3. REMOVE FAN AND GENERATOR V BELT See: Engine, Cooling and Exhaust/Engine/Drive
Belts, Mounts, Brackets and Accessories/Drive
Belt/Service and Repair/Removal
4. DISCONNECT DISCHARGE HOSE
(a) Remove the bolt and disconnect the cooler refrigerant discharge hose from the cooler
compressor.
(b) Remove the O-ring from the cooler refrigerant discharge hose.
NOTICE: Seal the openings of the disconnected parts using vinyl tape to prevent moisture and
foreign matter from entering them.
5. DISCONNECT SUCTION HOSE
(a) Remove the bolt and disconnect the cooler refrigerant suction hose from the cooler compressor.
(b) Remove the O-ring from the cooler refrigerant suction hose.
NOTICE: Seal the openings of the disconnected parts using vinyl tape to prevent moisture and
foreign matter from entering them.
6. REMOVE COOLER COMPRESSOR ASSEMBLY
(a) Disconnect the connector.
Page 6054
(a) For an open circuit in the wire harness in Fig. 1, check the resistance or voltage, as described
below.
(b) Check the resistance.
(1) Disconnect connectors A and C and measure the resistance between them.
Standard resistance (Fig. 2):
HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally.
If the results match the examples above, an open circuit exists between terminal 1 of connector A
and terminal 1 of connector C.
(2) Disconnect connector B and measure the resistance between the connectors.
Standard resistance (Fig. 3):
* If the results match the examples above, an open circuit exists between terminal 1 of connector
B2 and terminal 1 of connector C.
(c) Check the voltage.
Page 2975
(b) Using SST, remove the sensor.
SST : 09224-00010
Installation
1UR-FE ENGINE CONTROL SYSTEM: HEATED OXYGEN SENSOR: INSTALLATION
1. INSTALL HEATED OXYGEN SENSOR (for Bank 2 Sensor 2)
(a) Install the sensor to the exhaust pipe by hand.
(b) Using SST, tighten the sensor.
SST : 09224-00010
without SST - Torque : 44 Nm (449 kgf-cm, 32 ft-lbf)
with SST - Torque : 40 Nm (408 kgf-cm, 30 ft-lbf)
HINT *
Use a torque wrench with a fulcrum length of 30 cm (11.8 in.). When using a torque wrench with a
fulcrum length that is not 30 cm (11.8 in.), calculate the torque specification for the torque wrench
and SST based on the "without SST" torque specification See: Service Precautions
* Make sure SST and the wrench are connected in a straight line.
2. INSTALL HEATED OXYGEN SENSOR (for Bank 1 Sensor 2)
(a) Install the sensor to the exhaust pipe by hand.
(b) Using SST, tighten the sensor.
Page 8245
(c) Detach the 7 clips and 2 claws, and remove the pillar garnish.
7. REMOVE CENTER PILLAR GARNISH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Removal
8. REMOVE FRONT SEAT OUTER BELT ASSEMBLY
(a) Remove the nut and shoulder anchor.
(b) Disconnect the pretensioner connector as shown in the illustration.
(c) Remove the 2 bolts and seat belt.
Installation
SEAT BELT: FRONT SEAT OUTER BELT ASSEMBLY (for CrewMax): INSTALLATION
HINT *
Use the same procedures for the LH side and RH side.
* The procedures listed below are for the LH side.
1. INSTALL FRONT SEAT OUTER BELT ASSEMBLY
Page 3552
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE STEERING ANGLE SENSOR BRANCH WIRE OR CONNECTOR
(CANH, CANL) OK -- Continue to next step.
3. CHECK HARNESS AND CONNECTOR (STEERING ANGLE SENSOR - BATTERY AND BODY
GROUND)
(a) Reconnect the cable to the negative (-) battery terminal before measuring the resistances of the
main wire and the branch wire.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(c) Measure the voltage according to the value(s) in the table below.
Standard voltage:
NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- REPLACE STEERING ANGLE SENSOR
4WD Control ECU Communication Stop Mode
Page 9048
Page 6546
6. PROBLEM SYMPTOMS TABLE
When a "Normal" code is output during a DTC check but the problem is still occurring, use the
Problem Symptoms Table. The suspected areas (circuits or parts) for each problem symptom are
in the table. The suspected areas are listed in order of probability. A description of each of the
chart's columns is below.
HINT In some cases, the problem is not detected by the diagnostic system even though a problem
symptom is present. It is possible that the problem is occurring outside the detection range of the
diagnostic system, or that the problem is occurring in a completely different system.
7. CIRCUIT INSPECTION
A description of the main areas of each circuit inspection is below.
Components
Variable Valve Timing Actuator: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT OIL CONTROL VALVE: COMPONENTS
Page 1063
Door Switch: Service and Repair Rear Door Courtesy Switch
Components
LIGHTING: REAR DOOR COURTESY SWITCH: COMPONENTS
Page 8717
Amplifier: Service and Repair Removal
AUDIO / VISUAL: STEREO COMPONENT AMPLIFIER: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE FRONT SEAT ASSEMBLY RH
(a) for Manual Seat:
Remove the front seat RH See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Manual Seat)/Removal.
(b) for Power Seat:
Remove the front seat RH See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Power Seat)/Removal.
3. REMOVE AUDIO AMPLIFIER COVER
(a) Detach the 3 clips and remove the cover.
4. REMOVE STEREO COMPONENT AMPLIFIER ASSEMBLY
(a) Disconnect the 3 connectors.
(b) Remove the 3 bolts and amplifier.
Page 188
Release the locking lug from terminal and pull the terminal out from rear.
INSTALL TERMINAL TO CONNECTOR
Insert the terminal.
HINT: Make sure the terminal is positioned correctly.
Insert the terminal until the locking lug locks firmly.
Insert the terminal with terminal retainer in the temporary lock position.
Page 8083
Impact Sensor: Service and Repair Side Airbag Sensor (for Double Cab)
Components
SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Double Cab):
COMPONENTS
Page 3605
Applicable Vehicles
Drivetrian - Rear End Howling/Growling Noises
Wheel Bearing: Customer Interest Drivetrian - Rear End Howling/Growling Noises
T-SB-0151-10
June11, 2010
Rear Axle Bearing Abnormal Noise
Service Category Drivetrain
Section Axle/Differential
Market USA
Applicability
Introduction
Some 2007 - 2010 model year Tundra vehicles may exhibit a howling or growling noise from the
rear of the vehicle that increases with vehicle speed. Changes have been made to the rear axle
bearing to correct this condition. Follow the procedure in the bulletin to address customer concerns.
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60
months or 60,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Parts Information
Page 2796
Mongoose MFC Software and Driver MUST be installed before Mongoose MFC selection will be
available.
See TIS - Diagnostics - Scantool page for additional information.
^ If using TIS Techstream select TIS Techstream VIM (this is the default).
4. Click OK.
Operation Procedure
1. Verify the vehicle's applicability for recalibration and locate desired calibration file.
A. Connect Techstream and establish a vehicle connection.
B. Click the Health Check button on the System Select tab.
Page 5147
(b) Coat the threads of a new nut with hypoid gear oil.
(c) Using SST to hold the companion flange, tighten the nut.
SST : 09330-00021
09330-00030
Torque : 441 Nm (4497 kgf-cm, 325 ft-lb for less)
14. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD
(a) Using a torque wrench, measure the preload.
Standard preload (at starting):
(b) If the result is not as specified, adjust the preload.
15. STAKE REAR DRIVE PINION NUT
(a) Using a chisel and hammer, stake the nut.
16. INSTALL PROPELLER SHAFT ASSEMBLY
(a) Install the propeller shaft for 2WD See: Drive/Propeller Shafts, Bearings and
Joints/Drive/Propeller Shaft/Service and Repair/Removal and
Replacement/Propeller Shaft Assembly/Installation.
(b) Install the propeller shaft for 4WD See: Drive/Propeller Shafts, Bearings and
Joints/Drive/Propeller Shaft/Service and Repair/Removal and
Replacement/Propeller Shaft Assembly/Installation.
17. ADD DIFFERENTIAL OIL See: Fluid - Differential/Service and Repair
Page 8793
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the speaker assembly.
Rear Door Speaker (for Double Cab)
AUDIO / VISUAL: REAR DOOR SPEAKER (for Double Cab): INSPECTION
1. INSPECT REAR NO. 1 SPEAKER ASSEMBLY (for Standard)
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the speaker assembly.
2. INSPECT REAR NO. 1 SPEAKER ASSEMBLY (for 10 Speakers)
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the speaker assembly.
Page 8244
After the ignition switch is turned LOCK, the navigation system requires approximately 90 seconds
to record various types of memory and settings. As a result, after turning the ignition switch LOCK,
wait 90 seconds or more before disconnecting the cable from the negative (-) battery terminal.
2. REMOVE FRONT SEAT ASSEMBLY
(a) for Manual Seat:
Remove the front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Manual Seat)/Removal.
(b) for Power Seat:
Remove the front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Power Seat)/Removal.
3. REMOVE FRONT DOOR SCUFF PLATE See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Removal
4. REMOVE REAR DOOR SCUFF PLATE See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Removal
5. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP
(a) Partially remove the front door opening trim weatherstrip so that the center lower pillar garnish
and center pillar garnish can be removed.
6. REMOVE LOWER CENTER PILLAR GARNISH
(a) Detach the 2 claws and remove the cover.
(b) Remove the bolt and seat belt anchor.
Page 8048
Page 2140
(a) After repairs, confirm that the actual tire pressures are displayed in the DATA LIST See: Tire
Monitoring System/Testing and
Inspection/Scan Tool Testing and Procedures/Data List / Active Test.
Page 6103
(2) Using a dial gauge, measure the circle runout.
Standard runout:
0.02 mm (0.000787 in.)
Maximum runout:
0.05 mm (0.00197 in.)
(3) If the circle runout is more than the maximum, replace the starter armature assembly.
(d) Using a vernier caliper, measure the commutator diameter.
Standard diameter:
29.0 mm (1.14 in.)
Minimum diameter:
28.0 mm (1.10 in.)
(e) If the diameter is less than the minimum, replace the starter armature assembly.
(f) Check that the undercut portion is clean and free of foreign matter. Smooth out the edge.
Standard undercut depth:
0.7 mm (0.0276 in.)
Minimum undercut depth:
0.2 mm (0.00787 in.)
(g) If the undercut depth is less than the minimum, increase the depth using a hacksaw blade.
4. INSPECT STARTER BRUSH HOLDER ASSEMBLY
(a) Using a vernier caliper, measure the brush length.
Standard length:
14.4 mm (0.567 in.)
Page 3531
C -- REPLACE ECM See: Engine Control Module/Service and Repair/Removal
B -- REPLACE ECM See: Engine Control Module/Service and Repair/Removal
A -- REPLACE ECM See: Engine Control Module/Service and Repair/Removal
Open In CAN Main Wire
CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: Open in CAN Main Wire - Open in
CAN Main Wire
DESCRIPTION
There may be an open circuit in the CAN main wire and/or the DLC3 branch wire when the
resistance between terminals 6 (CANH) and 14 (CANL) of the DLC3 is 69 Ohms or higher.
WIRING DIAGRAM
INSPECTION PROCEDURE
HINT Operating the ignition switch, any switches or any doors triggers related ECU and sensor
communication with the CAN, which causes resistance variation.
PROCEDURE
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
(a) Disconnect the cable from the negative (-) battery terminal before measuring the resistances of
the main wire and the branch wire.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
NEXT -- Continue to next step.
Page 9159
Refer to the service kit instruction sheet for further detail.
Page 6361
* In the DTC check, it is very important to determine whether the problem indicated by the DTC is
either: 1) still occurring; or 2) occurred in the past but has since returned to normal. In addition, the
DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs
should be checked before and after confirmation of symptoms (i.e., whether or not problem
symptoms exist) to determine current system conditions, as shown in the flowchart below.
* Never skip the DTC check. Failing to check DTCs may, depending on the case, result in
unnecessary troubleshooting for systems operating normally or lead to repairs not related to the
problem. Follow the procedures listed in the flowchart in the correct order.
* The following flowchart shows how to proceed with troubleshooting using the DTC check.
Directions from the flowchart will indicate how to proceed either to DTC troubleshooting or to the
troubleshooting of each problem symptom.
1. DTC CHECK
NEXT -- Continue to next step.
2. MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR MEMORY
NEXT -- Continue to next step.
3. SYMPTOM CONFIRMATION
B -- Go to step 5 A -- Continue to next step.
4. SIMULATION TEST USING SYMPTOM SIMULATION METHODS
NEXT -- Continue to next step.
5. DTC CHECK
B -- TROUBLESHOOTING OF PROBLEM INDICATED BY DTC A -- Continue to next step.
6. SYMPTOM CONFIRMATION
Page 6562
Driver Side J/B Inner Circuit
Page 6388
Page 8945
Page 8339
(b) When the front bumper of the vehicle or its area is damaged, check if there is any damage to
the front airbag sensor. If the front airbag sensor
has defects as mentioned below, replace it with a new one:
* Cracks, dents or chips on the sensor housing.
* Cracks or other damage to the connector.
* Peeling off of the label or damage to the serial number.
CAUTION: For removal and installation procedures of the front airbag sensor, be sure to follow the
correct procedure.
3. CHECK FRONT AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS
DEPLOYED)
(a) Replace the front airbag sensor.
CAUTION: *
For removal and installation procedures of the front airbag sensor, be sure to follow the correct
procedure.
* If the airbags have deployed, replace the front airbag sensor on the side in which the collision
occurred. Replace both if necessary.
Side Airbag Sensor (for CrewMax)
SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for CrewMax): ON-VEHICLE
INSPECTION
1. CHECK REAR AIRBAG SENSOR (VEHICLE NOT INVOLVED IN COLLISION)
(a) Perform a diagnostic system check See: Air Bag Systems/Testing and Inspection/Initial
Inspection and Diagnostic Overview/Diagnosis
System.
2. CHECK REAR AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS
NOT DEPLOYED)
(a) Perform a diagnostic system check See: Air Bag Systems/Testing and Inspection/Initial
Inspection and Diagnostic Overview/Diagnosis
System.
(b) When the quarter panel of the vehicle or its area is damaged, check if there is any damage to
the rear airbag sensor. If there are any defects as
mentioned below, replace the side airbag sensor with a new one:
* Cracks, dents or chips on the sensor housing.
* Cracks or other damage to the connector.
* Peeling off of the label or damage to the serial number.
CAUTION: For removal and installation procedures of the side airbag sensor, be sure to follow the
correct procedure.
3. CHECK REAR AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS
DEPLOYED)
(a) Replace the side airbag sensor.
CAUTION: *
For removal and installation procedures of the side airbag sensor, be sure to follow the correct
procedure.
* If the airbags have deployed, replace the rear airbag sensor on the side in which the collision
occurred. Replace both if necessary.
Side Airbag Sensor (for Double Cab)
SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Double Cab):
ON-VEHICLE INSPECTION
1. CHECK REAR AIRBAG SENSOR (VEHICLE NOT INVOLVED IN COLLISION)
(a) Perform a diagnostic system check See: Air Bag Systems/Testing and Inspection/Initial
Inspection and Diagnostic Overview/Diagnosis
System.
2. CHECK REAR AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS
NOT DEPLOYED)
(a) Perform a diagnostic system check See: Air Bag Systems/Testing and Inspection/Initial
Inspection and Diagnostic Overview/Diagnosis
Page 1491
NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do
not operate the ignition switch, any other switches, or the doors.
(a) If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the
harness and connector.
(b) Connect the cable of the Techstream to the DLC3, turn the ignition switch ON and attempt to
use the tester. If the display indicates that a
communication error has occurred, there is a problem either with the vehicle or with the tester.
HINT *
If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of
the original vehicle.
* If communication is still not possible when the tester is connected to another vehicle, the problem
may be in the tester itself. Consult the Service Department listed in the tester's instruction manual.
How To Proceed With Troubleshooting
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: HOW TO
PROCEED WITH TROUBLESHOOTING
1. OPERATION FLOW
HINT Perform troubleshooting in accordance with the procedures below. The following is an outline
of basic troubleshooting procedures. Confirm the troubleshooting procedures for the circuit you are
working on before beginning troubleshooting.
1. VEHICLE BROUGHT TO WORKSHOP
NEXT -- Continue to next step.
2. CUSTOMER PROBLEM ANALYSIS
(a) Ask the customer about the conditions and environment when the problem occurred.
NEXT -- Continue to next step.
3. INSPECT BATTERY VOLTAGE
Standard voltage:
11 to 14 V
If the voltage is below 11 V, recharge or replace the battery before proceeding.
NEXT -- Continue to next step.
Page 2637
Coolant: Fluid Type Specifications
Coolant Type
Use either of the following:
"Toyota Super Long Life Coolant"
Similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, and non-borate
coolant with long-life hybrid organic acid technology.
Do not use plain water alone.
Page 1274
Throttle Position Sensor: Diagrams
Page 9017
Push the secondary locking device or terminal retainer in to the full lock position.
CONNECT CONNECTOR
Voltage Check
VOLTAGE CHECK
Page 6712
[A] For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
"Case1" Raise the terminal retainer up to the temporary lock position.
Page 7744
15. INSTALL NO. 3 AIR DUCT SUB-ASSEMBLY
(a) Attach the 4 claws to install the duct.
16. INSTALL LOWER DEFROSTER NOZZLE ASSEMBLY
(a) Attach the 4 claws to install the nozzle.
17. INSTALL AIR CONDITIONING UNIT
(a) Install the air conditioning unit See: Housing Assembly HVAC/Service and Repair/Removal and
Replacement/Installation.
Page 6705
Page 1786
This TSB applies to all Sequoia and Tundra vehicles equipped with lUR-FE (4.6L) 2UZ-FE (4.7L)
and 3UR-FE/FBE (5.7L) engines produced BEFORE the Production Change Effective VINs shown.
Repair Procedure
1. Remove and replace the air cleaner lid.
2. Remove and replace the front right hand (RH) fender liner.
Page 5288
Drive/Propeller Shaft: Overhaul
Disassembly
PROPELLER SHAFT: FRONT PROPELLER SHAFT ASSEMBLY: DISASSEMBLY
1. REMOVE FRONT PROPELLER SHAFT JOINT SPIDER BEARING SNAP RING
(a) Place matchmarks on the flange yoke.
(b) Using a brass bar and hammer, slightly tap in the spider bearing outer races.
(c) Using needle-nose pliers, remove the 4 snap rings from the grooves.
2. REMOVE SPIDER BEARING
(a) Using SST, push out the bearing from the flange yoke.
SST : 09332-25010
HINT Before installing SST, sufficiently raise the part labeled A. If part A is too low, SST may be
difficult to install.
(b) Clamp the spider bearing outer race in a vise and tap off the propeller shaft with a hammer.
NOTICE:
EFI Relay
Fuel Pump Relay: Testing and Inspection EFI Relay
1UR-FE ENGINE CONTROL SYSTEM: EFI RELAY: ON-VEHICLE INSPECTION
1. REMOVE INTEGRATION RELAY See: Ignition System/Ignition Relay/Testing and Inspection
2. INSPECT INTEGRATION RELAY (EFI)
NOTICE: *
Some relays are built into the integration relay. The integration relay cannot be disassembled. If
there is a malfunction in the circuit of the integration relay, replace the integration relay.
* The internal circuit of the integration relay is as shown in the illustration below. Inspect the
integration relay using the following procedures.
(a) Measure the resistance of the EFI No. 1 fuse.
(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(2) If the result is not as specified, replace the EFI No. 1 fuse.
(b) Measure the resistance of the EFI relay.
(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
Regular Cab
Fuel Pump Control Unit: Locations Regular Cab
Body
Page 5973
6. PROBLEM SYMPTOMS TABLE
When a "Normal" code is output during a DTC check but the problem is still occurring, use the
Problem Symptoms Table. The suspected areas (circuits or parts) for each problem symptom are
in the table. The suspected areas are listed in order of probability. A description of each of the
chart's columns is below.
HINT In some cases, the problem is not detected by the diagnostic system even though a problem
symptom is present. It is possible that the problem is occurring outside the detection range of the
diagnostic system, or that the problem is occurring in a completely different system.
7. CIRCUIT INSPECTION
A description of the main areas of each circuit inspection is below.
Page 8718
Amplifier: Service and Repair Installation
AUDIO / VISUAL: STEREO COMPONENT AMPLIFIER: INSTALLATION
1. INSTALL STEREO COMPONENT AMPLIFIER ASSEMBLY
(a) Set the bracket's aligning protrusion labeled A into the floor's hole.
(b) Install the amplifier with the 3 bolts.
HINT Tighten the bolts in the order shown in the illustration.
(c) Connect the 3 connectors.
2. INSTALL AUDIO AMPLIFIER COVER
(a) Set the cover on the stereo amplifier assembly.
(b) Attach the 3 clips.
3. INSTALL FRONT SEAT ASSEMBLY RH
(a) for Manual Seat:
Install the front seat RH See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Manual Seat)/Installation.
(b) for Power Seat:
Install the front seat RH See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Power Seat)/Installation.
4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Page 1903
Coolant: Service and Repair
1UR-FE COOLING: COOLANT: REPLACEMENT
1. REMOVE NO. 1 ENGINE UNDER COVER See: Engine Oil/Service and Repair/Replacement
2. DRAIN ENGINE COOLANT
CAUTION: Do not remove the radiator cap while the engine and radiator are still hot. Pressurized,
hot engine coolant and steam may be released and cause serious burns.
HINT Collect the coolant in a container and dispose of it according to the regulations in your area.
(a) Loosen the radiator drain cock plug.
(b) Remove the radiator cap. Then drain the coolant from the radiator.
(c) Loosen the 2 cylinder block drain cock plugs. Then drain the coolant from the engine.
(d) Tighten the 2 cylinder block drain cock plugs.
Torque : 13 Nm (130 kgf-cm, 9 ft-lbf)
(e) Tighten the radiator drain cock plug by hand.
3. ADD ENGINE COOLANT
(a) Add engine coolant.
Standard Capacity:
NOTICE: Do not substitute plain water for engine coolant.
HINT TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to
the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high
quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life
hybrid organic acid technology (coolant with long-life hybrid organic acid technology is a
combination of low phosphates and organic acids).
Page 3231
Push the terminal retainer down to the temporary lock position.
Page 410
Main Relay (Computer/Fuel System): Testing and Inspection
1UR-FE ENGINE CONTROL SYSTEM: CIRCUIT OPENING RELAY: ON-VEHICLE INSPECTION
1. REMOVE CIRCUIT OPENING RELAY (C/OPN)
(a) Remove the circuit opening relay from the engine room relay block.
2. INSPECT CIRCUIT OPENING RELAY
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) If the result is not as specified, replace the circuit opening relay.
3. INSTALL CIRCUIT OPENING RELAY
(a) Install the circuit opening relay to the engine room relay block.
Page 167
Hazard Flasher Relay: Diagrams
Page 3538
INSPECTION PROCEDURE
HINT Operating the ignition switch, any switches or any doors triggers related ECU and sensor
communication with the CAN, which causes resistance variation.
PROCEDURE
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
(a) Disconnect the cable from the negative (-) battery terminal before measuring the resistances of
the main wire and the branch wire.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
NEXT -- Continue to next step.
2. CHECK FOR OPEN IN CAN BUS WIRE (BUS BUFFER ECU BRANCH WIRE)
(a) Disconnect the J59 bus buffer ECU connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE BUS BUFFER ECU BRANCH WIRE OR CONNECTOR (CAN+,
CAN-)
OK -- REPLACE BUS BUFFER ECU
Center Airbag Sensor Communication Stop Mode
CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: Center Airbag Sensor
Communication Stop Mode - Center Airbag Sensor Communication Stop Mode
Page 6824
Page 8441
(a) Remove the antenna pole by turning it counterclockwise.
Installation
AUDIO / VISUAL: RADIO ANTENNA POLE: INSTALLATION
1. INSTALL PULL TOP ANTENNA POLE SUB-ASSEMBLY
(a) Install the antenna pole by turning it clockwise.
Page 152
Backup Lamp Relay: Diagrams
Recall - Accelerator Pedal Modification
Technical Service Bulletin # SC-A0A Date: 110219
Page 7659
6. PROBLEM SYMPTOMS TABLE
When a "Normal" code is output during a DTC check but the problem is still occurring, use the
Problem Symptoms Table. The suspected areas (circuits or parts) for each problem symptom are
in the table. The suspected areas are listed in order of probability. A description of each of the
chart's columns is below.
HINT In some cases, the problem is not detected by the diagnostic system even though a problem
symptom is present. It is possible that the problem is occurring outside the detection range of the
diagnostic system, or that the problem is occurring in a completely different system.
7. CIRCUIT INSPECTION
A description of the main areas of each circuit inspection is below.
Engine - MIL ON/DTC's P0012/P0022 Set
Variable Valve Timing Actuator: All Technical Service Bulletins Engine - MIL ON/DTC's
P0012/P0022 Set
T-SB-0019-10
January 20, 2010
MIL "ON" DTC P0012 and/or P0022
Service Category Engine/Hybrid System
Section Engine Control
Market USA
Applicability
Introduction
Some 2010 model year Sequoia and Tundra vehicles may exhibit a MIL "ON" condition for
Diagnostic Trouble Code (DTC) P0012 and/or P0022 ( Camshaft Position "A" - Timing
Over-Retarded Bank 1/2).
Please refer to the following repair procedure to address this condition.
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60
months or 60,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Production Change Information
Locations
Knock Sensor: Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 271
"Case2" Open the secondary locking device.
[B] For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray
Gray or White : Black
Page 1305
Page 4100
Positive Crankcase Ventilation Valve: Service and Repair Removal
1UR-FE EMISSION CONTROL: PCV VALVE: REMOVAL
1. REMOVE INTAKE MANIFOLD
(a) Remove the intake manifold See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service
and Repair/Removal.
2. REMOVE NO. 4 ENGINE COVER
(a) Remove the No. 4 engine cover.
3. REMOVE NO. 3 ENGINE COVER
(a) Remove the No. 3 engine cover.
4. DISCONNECT PCV VALVE HOSE
5. REMOVE PCV VALVE SUB-ASSEMBLY
(a) Remove the PCV valve.
Page 3437
Standard resistance:
NG -- CHECK FOR SHORT IN CAN BUS WIRES (ECM)
OK -- REPAIR OR REPLACE NO. 2 JUNCTION CONNECTOR
23. CHECK FOR SHORT IN CAN BUS WIRES (AIR CONDITIONING AMPLIFIER)
(a) Disconnect the J19 air conditioning amplifier connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO AIR CONDITIONING
AMPLIFIER (CANH, CANL)
OK -- REPLACE AIR CONDITIONING AMPLIFIER ASSEMBLY
24. CHECK FOR SHORT IN CAN BUS WIRES (BUS BUFFER ECU)
(a) Disconnect the J59 bus buffer ECU connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO BUS BUFFER ECU (CAN+,
CAN-)
Page 304
Engine Room R/B And Engine Room J/B Inner Circuit
Page 6545
(2) CONNECTORS
Slightly shake the connector vertically and horizontally.
(3) WIRE HARNESS
Slightly shake the wire harness vertically and horizontally.
HINT The connector joint and fulcrum of the vibration are the major areas that should be checked
thoroughly.
(b) HEAT METHOD:
When a malfunction seems to occur when the area in question is heated.
(1) Heat the component that is the possible cause of the malfunction with a hair dryer or similar
device. Check if the malfunction occurs.
NOTICE: *
Do not heat to more than 60°C (140°F). Exceeding this temperature may damage components.
* Do not apply heat directly to the parts in the ECU.
(c) WATER SPRINKLING METHOD:
When a malfunction seems to occur on a rainy day or in high-humidity.
(1) Sprinkle water onto the vehicle and check if the malfunction occurs.
NOTICE: *
Never sprinkle water directly into the engine compartment. Indirectly change the temperature and
humidity by spraying water onto the front of the radiator.
* Never apply water directly onto the electronic components.
HINT If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU
or connections. Look for evidence of corrosion or short circuits. Proceed with caution during water
tests.
(d) HIGH ELECTRICAL LOAD METHOD:
When a malfunction seems to occur when the electrical load is excessive.
(1) Turn on the heater blower, headlights, rear window defogger and all other electrical loads.
Check if the malfunction reoccurs.
5. DIAGNOSTIC TROUBLE CODE CHART
Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate
section's Diagnostic Trouble Code Chart. Use the chart to determine the trouble area and the
proper inspection procedure. A description of each of the chart's columns is below.
Page 950
Refrigerant Pressure Sensor / Switch: Locations Air Conditioning System (for Manual Air
Conditioning System)
AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Manual Air Conditioning System):
PARTS LOCATION
Page 6937
Driver Side J/B - Cowl Side Left
Components
Steering Column Control Module: Service and Repair Components
STEERING COLUMN: MULTIPLEX TILT AND TELESCOPIC ECU (for Power Tilt and Power
Telescopic Steering Column): COMPONENTS
Page 4466
Air Flow Meter/Sensor: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: INSTALLATION
1. INSTALL MASS AIR FLOW METER
(a) Install the MAF meter with the 2 screws.
Torque : 1.7 Nm (17 kgf-cm, 15 in-lbf)
(b) Connect the MAF connector.
Engine - Controls - Non-Linear Acceleration From A Stop
Engine Control Module: Customer Interest Engine - Controls - Non-Linear Acceleration From A
Stop
T-SB-0273-10
September 28, 2010
Non-Linear Acceleration from a Stop
Service Category Engine/Hybrid System
Section Engine Control
Market USA
Applicability
Introduction
Some 2010 model year Tundra vehicles with the 1UR-FE (4.6 L) engine may exhibit non-linear
acceleration from a stop under certain conditions of low engine rpm with high engine load. The
Engine Control Module/ECM (SAE term: Powertrain Control Module/PCM) logic has been revised
to address this condition. Use the following repair procedure to recalibrate the ECM (PCM).
Calibration Information
Warranty Information
Applicable Warranty
^ This repair is covered under the Toyota Federal Emission Warranty. This warranty is in effect for
96 months or 80,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Page 1237
Page 6518
Page 3389
(2) CONNECTORS
Slightly shake the connector vertically and horizontally.
(3) WIRE HARNESS
Slightly shake the wire harness vertically and horizontally.
HINT The connector joint and fulcrum of the vibration are the major areas that should be checked
thoroughly.
(b) HEAT METHOD:
When a malfunction seems to occur when the area in question is heated.
(1) Heat the component that is the possible cause of the malfunction with a hair dryer or similar
device. Check if the malfunction occurs.
NOTICE: *
Do not heat to more than 60°C (140°F). Exceeding this temperature may damage components.
* Do not apply heat directly to the parts in the ECU.
(c) WATER SPRINKLING METHOD:
When a malfunction seems to occur on a rainy day or in high-humidity.
(1) Sprinkle water onto the vehicle and check if the malfunction occurs.
NOTICE: *
Never sprinkle water directly into the engine compartment. Indirectly change the temperature and
humidity by spraying water onto the front of the radiator.
* Never apply water directly onto the electronic components.
HINT If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU
or connections. Look for evidence of corrosion or short circuits. Proceed with caution during water
tests.
(d) HIGH ELECTRICAL LOAD METHOD:
When a malfunction seems to occur when the electrical load is excessive.
(1) Turn on the heater blower, headlights, rear window defogger and all other electrical loads.
Check if the malfunction reoccurs.
5. DIAGNOSTIC TROUBLE CODE CHART
Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate
section's Diagnostic Trouble Code Chart. Use the chart to determine the trouble area and the
proper inspection procedure. A description of each of the chart's columns is below.
Page 6814
Page 2575
Variable Valve Timing Actuator Position Sensor: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: VVT SENSOR: INSTALLATION
1. INSTALL VVT SENSOR
(a) Install the 4 sensors with the 4 bolts.
Components
Four Wheel Drive Selector Switch: Service and Repair Components
JF1A TRANSFER: 4WD CONTROL SWITCH: COMPONENTS
Page 473
Seat Occupant Classification Module - Air Bag: Locations Occupant Classification System
SUPPLEMENTAL RESTRAINT SYSTEM: OCCUPANT CLASSIFICATION SYSTEM: PARTS
LOCATION
Page 3921
Page 2441
Oil Pressure Sender: Service and Repair Removal
1UR-FE LUBRICATION: OIL PRESSURE SWITCH: REMOVAL
1. REMOVE NO. 1 ENGINE UNDER COVER See: Engine Oil/Service and Repair/Replacement
2. REMOVE OIL PRESSURE SENDER GAUGE ASSEMBLY
(a) Disconnect the sender gauge connector.
(b) Remove the oil pressure sender gauge.
Page 3062
Symbols Used Within Diagrams
Symbols Used Within Diagrams
Page 7994
Page 3476
Page 7934
Seat)/Removal for power seat).
HINT Keep the front seat in the cabin.
(e) Install SST.
(1) Disconnect the connector (yellow colored) from the front seat side airbag.
NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness.
(2) Connect SST connector to the front seat side airbag connector.
SST : 09082-00700
SST : 09082-00820
NOTICE: To avoid damaging SST connector and wire harness, do not lock the secondary lock of
the twin lock.
(3) Install the front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Manual
Seat)/Installation for manual seat, See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Power Seat)/Installation for power seat).
(4) Move SST at least 10 m (32.8 ft.) away from the vehicle front side window.
(5) Maintaining enough clearance for SST wire harness in the front side window, close all doors
and windows of the vehicle.
NOTICE: Take care not to damage SST wire harness.
(6) Connect the red clip of SST to the battery positive (+) terminal and the black clip of SST to the
battery negative (-) terminal.
(f) Deploy the airbag.
(1) Check that no one is inside the vehicle or within a 10 m (32.8 ft.) radius of the vehicle.
(2) Press SST activation switch and deploy the airbag.
CAUTION: *
When deploying the airbag, make sure that no one is near the vehicle.
* The front seat side airbag becomes extremely hot when the airbag is deployed, so do not touch it
for at least 30 minutes after deployment.
* Use gloves and safety glasses when handling a front seat side airbag with a deployed airbag.
* Do not apply water to a front seat side airbag with a deployed airbag.
Recall 10V017000: Accelerator Pedal Sticking
Accelerator Pedal Position Sensor: Recalls Recall 10V017000: Accelerator Pedal Sticking
VEHICLE MAKE/MODEL: MODEL YEAR(S): Toyota/Avalon 2005-2010 Toyota/Camry 2007-2010
Toyota/Corolla 2009-2010 Toyota/Corolla Matrix 2009-2010 Toyota/Highlander 2010 Toyota/ RAV4
2009-2010 Toyota/Sequoia 2008-2010 Toyota/Tundra 2007-2010 MANUFACTURER: Toyota
Motor North America, Inc.
MFR'S REPORT DATE: January 21, 2010
NHTSA CAMPAIGN ID NUMBER: 10V017000
NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Accelerator Assembly:
Pedal/Linkage
POTENTIAL NUMBER OF UNITS AFFECTED: ?
SUMMARY: Toyota is recalling certain model year 2005-2010 Avalon, model year 2007-2010
Camry, model year 2009-2010 Corolla, Corolla Matrix, RAV4, model year 2010 Highlander, model
year 2008-2010 Sequoia, and model year 2007-2010 Tundra. due to the manner in which the
friction lever interacts with the sliding surface of the accelerator pedal inside the pedal sensor
assembly, the sliding surface of the lever may become smooth during vehicle operation. In this
condition, if condensation occurs on the surface, as may occur from heater operation (without A/C)
when the pedal assembly is cold, the friction when the accelerator pedal is operated may increase,
which may result in the accelerator pedal becoming harder to depress, slower to return, or, in the
worst case, mechanically stuck in a partially depressed position.
CONSEQUENCE: The accelerator pedal may become hard to depress, slow to return to idle, or, in
the worst case, mechanically stuck in a partially depressed position, increasing the risk of a crash.
REMEDY: Toyota has not yet provided a remedy plan or an owner notification schedule. Owners
may contact Toyota at 1-800-331-4331.
NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle
Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov.
Transmission Control Switch
Transmission Mode Switch: Diagrams Transmission Control Switch
Restraints - OCS System Initialization
Seat Occupant Classification Module - Air Bag: Technical Service Bulletins Restraints - OCS
System Initialization
COLLISION REPAIR INFORMATION FOR THE COLLISION REPAIR PROFESSIONAL
TITLE: SRS OCCUPANT CLASSIFICATION SYSTEM INITIALIZATION
SECTION: ELECTRICAL BULLETIN # 177
MODELS: ALL EQUIPPED TOYOTA LEXUS and SCION MODELS
DATE: MARCH 2010
Models equipped with a Supplemental Restraint System (SRS) Occupant Classification System
(OCS) will enable or disable the passenger front and side airbags based on seat occupancy
passenger weight and seat belt latch engagement.
If an equipped vehicle sustains collision damage or if the front passenger seat or any of the OCS
components are serviced the SRS Malfunction Indicator Light (MIL) may illuminate setting a
Diagnostic Trouble Code (DTC).
NOTE:
It is necessary to diagnose and repair the root cause of a SRS or OCS DTC before initializing the
OCS system. If SRS and OCS DTC's are not cleared the system may not operate properly.
Be sure to check and clear DTC's and perform OCS initialization per repair manual instructions
with a Techstream Special Service Tool (SST) or capable diagnostic tester.
Any of the following conditions could set a DTC illuminate the SRS MIL or cause the PASSENGER
AIRBAG light to indicate incorrectly regardless of occupancy:
^ The OCS Electronic Control Unit (ECU) is replaced
^ Accessories such as a seatback tray are installed on the passenger seat
^ The passenger seat is removed and replaced or reinstalled
^ The vehicle is involved in an accident or collision
Model-specific repair manuals can be accessed through the Technical Information System (TIS)
www.techinfo.toyota.com
Page 7027
for CrewMax of standard deck
Page 973
Dimmer Switch: Service and Repair Removal
METER: LIGHT CONTROL RHEOSTAT: REMOVAL
1. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Panel,
Gauges and Warning Indicators/Instrument Cluster
/ Carrier/Service and Repair/Combination Meter/Removal
2. REMOVE LIGHT CONTROL RHEOSTAT
(a) Detach the 2 claws and remove the rheostat.
Locations
Tire Pressure Sensor: Locations
TIRE AND WHEEL: TIRE PRESSURE WARNING SYSTEM: PARTS LOCATION
Page 4751
C. Choose desired ECU group(s) in the Health Check dialog box.
D. Click Next.
E. Click Continue to view Health Check results.
F. Available calibration updates are indicated by a link in the Cal. Update? column. Click the link to
access the appropriate service bulletin on TIS.
NOTE
^ Note any DTCs stored in Systems that will be flash reprogrammed.
^ Clicking the link will automatically launch TIS and perform a calibration search.
G. Log in to TIS. (If already logged in skip this step.)
H. To review the TSB and access the calibration file click the service bulletin link in the Document
Title column of the Calibration Search Result
portlet.
Page 3096
Ignition Switch: Testing and Inspection
1UR-FE STARTING: IGNITION SWITCH: INSPECTION
1. INSPECT IGNITION SWITCH ASSEMBLY
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) If the result is not as specified, replace the ignition switch assembly.
Page 3712
Then click Start.
I. Do NOT disturb the vehicle during flash reprogramming.
NOTE
^ ECU flash reprogramming may take anywhere from 3 - 30 minutes per calibration file.
^ Reprogramming time will vary depending on model and ECU communication protocol. Vehicles
using CAN communication protocol will reprogram much faster (2 - 7 minutes).
NOTE
^ If vehicle requires only ONE calibration update, then proceed to step N in this bulletin.
^ If vehicle requires a SECOND calibration update, then continue as follows:
^ For serial communication vehicles, go to step J.
^ For CAN communication vehicles, go to step L.
EFI Relay
Fuel Pump Relay: Testing and Inspection EFI Relay
1UR-FE ENGINE CONTROL SYSTEM: EFI RELAY: ON-VEHICLE INSPECTION
1. REMOVE INTEGRATION RELAY See: Relays and Modules - Ignition System/Ignition
Relay/Testing and Inspection
2. INSPECT INTEGRATION RELAY (EFI)
NOTICE: *
Some relays are built into the integration relay. The integration relay cannot be disassembled. If
there is a malfunction in the circuit of the integration relay, replace the integration relay.
* The internal circuit of the integration relay is as shown in the illustration below. Inspect the
integration relay using the following procedures.
(a) Measure the resistance of the EFI No. 1 fuse.
(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(2) If the result is not as specified, replace the EFI No. 1 fuse.
(b) Measure the resistance of the EFI relay.
(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
Locations
Overdrive Switch: Locations
A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS
LOCATION
Page 7779
(a) Install the filter as shown in the illustration.
15. INSTALL AIR FILTER COVER PLATE
(a) Attach the 2 clips to install the plate.
16. INSTALL NO. 3 AIR DUCT SUB-ASSEMBLY
(a) Attach the 4 claws to install the duct.
17. INSTALL LOWER DEFROSTER NOZZLE ASSEMBLY
(a) Attach the 4 claws to install the nozzle.
Page 3382
General Information
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: GENERAL
INFORMATION
* A large number of ECU controlled systems are used in the TOYOTA TUNDRA. In general, ECU
controlled systems are considered to be very intricate, requiring a high level of technical knowledge
to troubleshoot. However, most problem checking procedures only involve inspecting the ECU
controlled system's circuits one by one. An adequate understanding of the system and a basic
knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and
necessary repairs.
1. TROUBLESHOOTING PROCEDURES
* The troubleshooting procedures consist of diagnosis procedures for when a DTC is stored and
diagnosis procedures for when no DTC is stored. The basic idea is explained in the following table.
* Vehicle systems are complex and use many ECUs that are difficult to inspect independently.
Therefore, a process of elimination is used, where components that can be inspected individually
are inspected, and if no problems are found in these components, the related ECU is identified as
the problem and replaced.
* It is extremely important to ask the customer about the environment and the conditions present
when the problem occurred (Customer Problem Analysis). This makes it possible to simulate the
conditions and confirm the symptom. If the symptom cannot be confirmed or the DTC does not
recur, the malfunctioning part may not be identified using the troubleshooting procedure, and the
ECU for the related system may be replaced even though it is not defective. If this happens, the
original problem will not be solved.
* In order to prevent endless expansion of troubleshooting procedures, the troubleshooting
procedures are written with the assumption that multiple malfunctions do not occur simultaneously
for a single problem symptom.
* To identify the malfunctioning part, troubleshooting procedures narrow down the target by
separating components, ECUs and wire harnesses during the inspection. If the wire harness is
identified as the cause of the problem, it is necessary to inspect not only the connections to
components and ECUs but also all of the wire harness connectors between the component and the
ECU.
DIAGNOSTIC TESTER
2. DESCRIPTION
System data and the Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector
3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the Techstream* to
check for a malfunction and perform repairs.
HINT *: Techstream is the name for the diagnostic tester in North America.
3. DATA LINK CONNECTOR 3 (DLC3)
(a) The vehicle's ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of
the DLC3 complies with SAE J1962 and
matches the ISO 15765-4 format.
Page 4760
M. Turn ignition OFF for a minimum of 10 seconds. Then click Next.
N. Turn ignition to the ON position. Then click Next.
0. Confirm all calibrations were updated as specified in the service bulletin. Then click Finish.
Page 6744
Junction Connector (CAN No.2) - Lower Finish Panel
Page 4423
Fuel Pump Control Unit: Diagrams
Up to 11/2009
Parking Brake Warning Switch: Locations Up to 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 1392
NOTICE: *
If the front airbag sensor has been dropped, or there are any cracks, dents or other defects in the
case, bracket or connector, replace it with a new one.
* When installing the front airbag sensor, be careful that the SRS wiring does not interfere with
other parts and that it is not pinched between other parts.
(e) Check that there is no looseness in the installation parts of the front airbag sensor.
2. INSTALL BATTERY
(a) Set the battery in the vehicle. Then move the stay onto the battery and tighten the nut to fix the
battery in place.
(b) Connect the cable to the positive (+) battery terminal.
3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
4. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
Page 6638
Auxiliary Power Outlet: Service and Repair
Components
OTHER SYSTEM: CENTER POWER OUTLET SOCKET (for Column Shift Type): COMPONENTS
Page 2039
Engine Room R/B And Engine Room J/B Inner Circuit
Page 4521
Page 9242
REAR DOOR TRIM BOARD SUB-ASSEMBLY LH
HINT *
Use the same procedures for the RH side and LH side.
* The procedures listed below are for the LH side.
* A bolt without a torque specification is shown in the standard bolt chart See:
Specifications/Mechanical Specifications/Standard Bolt - Specified Torque For Standard Bolts
1. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY LH
(a) Connect the 2 cables to the inside handle.
(b) Attach the inside handle's knob to the door trim board.
(c) for 12 Speakers:
(1) Connect the connector.
(d) Attach the 10 clips to install the door trim board.
(e) Install the inside handle and door trim board to the door trim panel with the screw.
(f) Install the door trim board to the door panel with the screw.
(g) Install the clip.
2. INSTALL REAR DOOR ARMREST COVER LH
3. INSTALL COURTESY LIGHT ASSEMBLY
(a) Connect the connector.
Page 6357
NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do
not operate the ignition switch, any other switches, or the doors.
(a) If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the
harness and connector.
(b) Connect the cable of the Techstream to the DLC3, turn the ignition switch ON and attempt to
use the tester. If the display indicates that a
communication error has occurred, there is a problem either with the vehicle or with the tester.
HINT *
If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of
the original vehicle.
* If communication is still not possible when the tester is connected to another vehicle, the problem
may be in the tester itself. Consult the Service Department listed in the tester's instruction manual.
How To Proceed With Troubleshooting
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: HOW TO
PROCEED WITH TROUBLESHOOTING
1. OPERATION FLOW
HINT Perform troubleshooting in accordance with the procedures below. The following is an outline
of basic troubleshooting procedures. Confirm the troubleshooting procedures for the circuit you are
working on before beginning troubleshooting.
1. VEHICLE BROUGHT TO WORKSHOP
NEXT -- Continue to next step.
2. CUSTOMER PROBLEM ANALYSIS
(a) Ask the customer about the conditions and environment when the problem occurred.
NEXT -- Continue to next step.
3. INSPECT BATTERY VOLTAGE
Standard voltage:
11 to 14 V
If the voltage is below 11 V, recharge or replace the battery before proceeding.
NEXT -- Continue to next step.
Page 2308
* Make sure that the knock pin of the camshaft is positioned as shown in the illustration before
installing the camshaft housing.
(d) Tighten the 10 bolts in the order shown in the illustration.
Torque : 16 Nm (163 kgf-cm, 12 ft-lbf)
NOTICE: Thoroughly wipe clean any seal packing.
3. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY
(a) Install the chain tensioner with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(b) While pushing down the No. 2 chain tensioner, insert a pin of dia1.0 mm (0.0394 in.) into the
hole to fix it in place.
4. INSTALL NO. 1 CHAIN SUB-ASSEMBLY LH
(a) Align the No. 1 chain's orange mark plates with the camshaft timing gear's timing mark, and
attach the chain to the gear as shown in the
illustration.
(b) Align the No. 1 chain's orange mark plate with the crankshaft timing gear's timing mark, and
attach the chain to the gear as shown in the
illustration.
(c) Align the No. 2 chain's yellow mark plates with the timing marks of the camshaft timing gear and
camshaft timing exhaust gear, and attach the
No. 2 chain to the gears as shown in the illustration.
Page 5041
5. INSTALL DIFFERENTIAL RING GEAR
(a) Clean the contact surfaces of the differential case and ring gear.
(b) Heat the ring gear to approximately 100°C (212°F) in boiling water.
(c) Carefully take the ring gear out of the boiling water.
(d) After the moisture on the ring gear has completely evaporated, quickly set the ring gear onto the
differential case.
HINT Align the matchmarks on the ring gear and differential case.
(e) After the ring gear cools down sufficiently, apply adhesive to the bolts and install them.
Adhesive:
Toyota Genuine Adhesive 1360K, Three Bond 1360K or equivalent
Torque : 137 Nm (1397 kgf-cm, 101 ft-lbf)
6. INSPECT DIFFERENTIAL RING GEAR RUNOUT
(a) Install the differential case onto the carrier, and install the 2 adjusting nuts so that there is no
play in the bearing.
(b) Install the 2 bearing caps with the 4 bolts.
Page 1792
This TSB applies to all Sequoia and Tundra vehicles equipped with lUR-FE (4.6L) 2UZ-FE (4.7L)
and 3UR-FE/FBE (5.7L) engines produced BEFORE the Production Change Effective VINs shown.
Repair Procedure
1. Remove and replace the air cleaner lid.
2. Remove and replace the front right hand (RH) fender liner.
Page 6796
when inserting and after full engagement.
NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal.
(d) REPAIR METHOD OF CONNECTOR TERMINAL
(1) If there is any foreign matter on the terminal, clean the contact point using an air gun or cloth.
Never rub the contact point using sandpaper
as the plating may come off.
(2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is
gold-plated (gold color), use a gold-plated female
terminal; if it is silver-plated (silver color), use a silver-plated female terminal.
(3) Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock
into the housing, the housing may have to be
replaced.
(e) HANDLING OF WIRE HARNESS
(1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be
restored in the same way.
(2) Never twist, pull or slacken the wire harness more than necessary.
(3) The wire harness should never come into contact with a high temperature part, or rotating,
moving, vibrating or sharp-edged parts. Avoid
contact with panel edges, screw tips and other sharp items.
(4) When installing parts, never pinch the wire harness.
(5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with
vinyl tape.
2. CHECK FOR OPEN CIRCUIT
Components
Tire Pressure Warning Reset Switch: Service and Repair Components
TIRE AND WHEEL: TIRE PRESSURE WARNING RESET SWITCH: COMPONENTS
Removal and Replacement
Alternator: Removal and Replacement
Components
1UR-FE CHARGING: GENERATOR: COMPONENTS
Removal
Locations
Transmission Speed Sensor: Locations
A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS
LOCATION
Page 1111
Interior Light Switch: Service and Repair Removal
LIGHTING: ROOM LIGHT SWITCH: REMOVAL
1. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Panel,
Gauges and Warning Indicators/Instrument Cluster
/ Carrier/Service and Repair/Combination Meter/Removal
2. REMOVE ROOM LIGHT SWITCH ASSEMBLY
(a) Detach the 2 claws and remove the light switch.
Up to 11/2009
Acceleration/Deceleration Sensor: Locations Up to 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
A760F Automatic Transmission System
Control Module: Locations A760F Automatic Transmission System
A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS
LOCATION
Page 6039
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Page 6116
NOTICE: While holding down the lead wire, remove the starter commutator end frame.
3. REMOVE STARTER BRUSH HOLDER ASSEMBLY
(a) Using a screwdriver, pry the end of the spring away from each brush and pull out the 4 brushes
from the brush holder so that they are held in
place by the springs.
(b) Remove the brush holder.
4. REMOVE STARTER ARMATURE ASSEMBLY
(a) Remove the starter armature from the starter yoke.
5. REMOVE STARTER ARMATURE PLATE
(a) Remove the starter armature plate from the starter drive housing or starter yoke.
6. REMOVE PLANETARY GEAR
(a) Remove the 3 planetary gears from the starter center bearing clutch.
7. REMOVE STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY
(a) Remove the starter center bearing clutch with the starter pinion drive lever and rubber seal from
the starter drive housing.
(b) Remove the starter pinion drive lever and rubber seal from the starter center bearing clutch.
Reassembly
Page 6715
"Case2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 8255
(a) for Manual Seat:
Remove the front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Manual Seat)/Removal.
(b) for Power Seat:
Remove the front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Power Seat)/Removal.
3. REMOVE FRONT DOOR SCUFF PLATE See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Removal
4. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP
(a) Partially remove the front door opening trim weatherstrip so that the lower quarter trim panel
assembly can be removed See: Body and
Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Regular
Cab)/Removal.
5. REMOVE UPPER BACK PANEL GARNISH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining
(For Regular Cab)/Removal
6. REMOVE LUGGAGE COMPARTMENT BOX LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof
Headlining (For Regular Cab)/Removal
7. REMOVE LUGGAGE COMPARTMENT BOX RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof
Headlining (For Regular Cab)/Removal
8. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY
(a) Detach the 2 claws and remove the cover.
(b) Remove the bolt and seat belt anchor.
(c) Detach the 7 clips and remove the quarter trim panel.
Page 7735
(1) Detach the claw and remove the main plate.
(2) Remove the 2 screws and damper servo.
11. REMOVE DAMPER SERVO SUB-ASSEMBLY
(a) Disconnect the connector.
(b) Remove the 3 screws and damper servo.
12. REMOVE BLOWER CASE SUB-ASSEMBLY
(a) Remove the 3 screws.
(b) Detach the 2 claws and remove the case.
13. REMOVE BLOWER DAMPER SERVO SUB-ASSEMBLY
Page 712
Reclining switch
(b) If the result is not as specified, replace the switch.
2. INSPECT FRONT POWER SEAT SWITCH RH
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
Slide switch
Page 4139
Page 7631
Page 4143
Page 5220
2. Install ChaSSiSEAR(TM) on the vehicle and attempt to isolate the source of the noise. Is the
noise loudest near the rear wheel bearing assembly?
^ YES - Go to step 3.
^ NO - This TSB does NOT apply. Continue diagnosis to isolate the source of the noise.
3. Replace the rear wheel bearing caliper bracket and related parts.
Refer to the Technical Information System (TIS) applicable model year Repair Manual:
4. Test drive the vehicle and confirm the noise is eliminated.
5. Re-check rear differential oil level and confirm NO leaks are present.
Page 1401
Removal
SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Double Cab): REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Disassembly
3. REMOVE FRONT ARMREST BASE PANEL UPPER LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Page 5573
Acceleration/Deceleration Sensor: Service and Repair Installation
BRAKE CONTROL: YAW RATE AND DECELERATION SENSOR: INSTALLATION
1. INSTALL YAW RATE SENSOR
(a) Connect the sensor connector (labeled A), and then attach the clamp (labeled B) to the hole of
the sensor bracket.
(b) Install the yaw rate sensor with the 2 nuts (labeled C).
Torque : 13 Nm (127 kgf-cm, 9 ft-lbf)
NOTICE: *
Make sure that the sensor is oriented correctly.
* If the sensor is dropped, replace it.
* Securely connect the connector.
* When installing the sensor, make sure to avoid impacts to the sensor.
2. INSTALL CENTER FRONT SEAT (for Center Seat) See: Body and Frame/Seats/Service and
Repair/Removal and Replacement/Front Seat
Assembly (for Center Seat)/Installation
3. INSTALL CONSOLE BOX ASSEMBLY (for Separate Seat Type)
(a) Install the console box See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and
Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation.
4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
5. PERFORM YAW RATE SENSOR ZERO POINT CALIBRATION
(a) Perform the yaw rate sensor zero point calibration See: Testing and Inspection/Programming
and Relearning.
6. CHECK YAW RATE SENSOR SIGNAL
(a) Check the yaw rate sensor signal See: Testing and Inspection/Scan Tool Testing and
Procedures/Test Mode Procedure.
Specifications
Brake Fluid: Specifications
Brake Fluid
Type .....................................................................................................................................................
.................... SAE J1703 or FMVSS No. 116 DOT 3
Locations
Transmission Speed Sensor: Locations
A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS
LOCATION
Diagram Information and Instructions
Garage Door Opener Transmitter: Diagram Information and Instructions
Wiring Color Codes
Abbreviations Used Within Diagrams
Abbreviations Used Within Diagrams
Page 7297
HINT Align the claws of the claw washers with the power steering rack grooves.
(b) Using 2 SST, install the 2 steering rack ends.
SST : 09922-10010
without SST - Torque : 195 Nm (1988 kgf-cm, 144 ft-lbf)
with SST - Torque : 142 Nm (1448 kgf-cm, 105 ft-lbf)
NOTICE: Turn SST 09922-10010 in the direction shown in the illustration.
HINT *
Using SST, hold the power steering rack and install the rack end sub-assembly.
* Use a torque wrench with a fulcrum length of 345 mm (13.6 in.).
(c) Using a brass bar and hammer, stake the 2 claw washers.
NOTICE: Avoid any impact to the power steering rack.
12. INSPECT STEERING RACK END SUB-ASSEMBLY
(a) Ensure that the steering rack end hole is not clogged with grease.
HINT If the hole is clogged, the pressure inside the boot will change after it has been assembled,
when the steering wheel is turned.
13. INSTALL STEERING RACK BOOT NO. 1
14. INSTALL STEERING RACK BOOT NO. 2
15. INSTALL STEERING RACK BOOT NO. 1 CLAMP
(a) Using SST, tighten the rack boot No. 1 clamp as shown in the illustration.
Specifications
Spark Plug: Specifications
SPARK PLUG
Using a 16 mm plug wrench, install the 8 spark plugs.
Torque..................................................................................................................................................
.....................................21 Nm (214 kgf-cm, 15 ft-lbf)
GAP
Restraints - OCS System Initialization
Seat Occupant Sensor: Technical Service Bulletins Restraints - OCS System Initialization
COLLISION REPAIR INFORMATION FOR THE COLLISION REPAIR PROFESSIONAL
TITLE: SRS OCCUPANT CLASSIFICATION SYSTEM INITIALIZATION
SECTION: ELECTRICAL BULLETIN # 177
MODELS: ALL EQUIPPED TOYOTA LEXUS and SCION MODELS
DATE: MARCH 2010
Models equipped with a Supplemental Restraint System (SRS) Occupant Classification System
(OCS) will enable or disable the passenger front and side airbags based on seat occupancy
passenger weight and seat belt latch engagement.
If an equipped vehicle sustains collision damage or if the front passenger seat or any of the OCS
components are serviced the SRS Malfunction Indicator Light (MIL) may illuminate setting a
Diagnostic Trouble Code (DTC).
NOTE:
It is necessary to diagnose and repair the root cause of a SRS or OCS DTC before initializing the
OCS system. If SRS and OCS DTC's are not cleared the system may not operate properly.
Be sure to check and clear DTC's and perform OCS initialization per repair manual instructions
with a Techstream Special Service Tool (SST) or capable diagnostic tester.
Any of the following conditions could set a DTC illuminate the SRS MIL or cause the PASSENGER
AIRBAG light to indicate incorrectly regardless of occupancy:
^ The OCS Electronic Control Unit (ECU) is replaced
^ Accessories such as a seatback tray are installed on the passenger seat
^ The passenger seat is removed and replaced or reinstalled
^ The vehicle is involved in an accident or collision
Model-specific repair manuals can be accessed through the Technical Information System (TIS)
www.techinfo.toyota.com
Page 7262
6. REMOVE LOWER NO. 1 INSTRUMENT PANEL AIR BAG ASSEMBLY See: Restraint
Systems/Air Bag Systems/Air Bag/Service and
Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Removal
7. REMOVE NO. 1 AIR DUCT SUB-ASSEMBLY See: Service and Repair/Removal and
Replacement/Steering Column Assembly (for Manual
Tilt)/Removal
8. REMOVE MULTIPLEX TILT AND TELESCOPIC ECU
(a) Disconnect the 2 ECU connectors.
(b) Remove the 2 screws and ECU.
Components
Antenna, Navigation: Service and Repair Components
NAVIGATION: NAVIGATION ANTENNA: COMPONENTS
Page 3768
Accelerator Pedal Position Sensor: Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 4402
Fuel Gauge Sender: Testing and Inspection
1UR-FE FUEL: FUEL SENDER GAUGE ASSEMBLY: INSPECTION
1. INSPECT FUEL SENDER GAUGE ASSEMBLY
(a) Check that the float moves smoothly between F and E.
(b) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(c) If the result is not as specified, replace the fuel sender gauge assembly.
Page 1855
M. Turn ignition OFF for a minimum of 10 seconds. Then click Next.
N. Turn ignition to the ON position. Then click Next.
0. Confirm all calibrations were updated as specified in the service bulletin. Then click Finish.
Page 1703
(b) * for 5 leaf spring
* If the toe-in is not as specified, adjust it at the rack ends.
4. ADJUST TOE-IN
(a) Release the rack boot set clips.
(b) Loosen the tie rod end lock nuts.
(c) Turn the right and left rack ends by an equal amount to adjust the toe-in to the center value.
(d) Check that the length of the right and left rack ends are approximately the same.
Page 5153
Seals and Gaskets: Service and Repair Front Differential Side Gear Shaft Oil Seal
Components
DIFFERENTIAL: FRONT DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL (for 4WD):
COMPONENTS
Replacement
DIFFERENTIAL: FRONT DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL (for 4WD):
REPLACEMENT
HINT The procedure described below is for the LH side. Use the same procedure for both the RH
and LH sides, unless otherwise specified.
Page 15
Alarm Module: Locations Theft Deterrent System
THEFT DETERRENT: THEFT DETERRENT SYSTEM: PARTS LOCATION
Page 4820
Transfer Case Actuator: Diagrams
Page 5303
* Use new snap rings.
* If possible, use snap rings of the same thickness for both sides.
(f) Temporarily install the universal joint spider and 2 universal joint spider bearings into the
propeller shaft yoke.
(g) Using SST, press the universal joint spider bearing into the propeller shaft yoke until the groove
can be seen.
SST : 09950-40011
09951-04020
09952-04010
09953-04020
09954-04020
09955-04051
09957-04010
SST : 09950-60010
09951-00290
SST : 09336-16010
NOTICE: Confirm that the universal joint spider moves smoothly while pressing in the bearing.
(h) Using needle-nose pliers, install the previously selected snap ring into the groove of the yoke.
HINT Use the same installation procedure for the universal joint spider bearing on the opposite
side.
(i) Align the matchmarks on the propeller shaft yoke and universal joint yoke, and temporarily install
the spider and 2 universal joint spider
bearings into the universal joint yoke.
(j) Using SST, press the universal joint spider bearing into the universal joint yoke until the groove
can be seen.
SST : 09950-40011
Page 677
Power Door Lock Switch: Service and Repair Unlock Warning Switch
Components
DOOR LOCK: UNLOCK WARNING SWITCH: COMPONENTS
Removal
DOOR LOCK: UNLOCK WARNING SWITCH: REMOVAL
1. REMOVE LOWER STEERING COLUMN COVER (for Manual Tilt and Manual Telescopic
Steering Column) See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering
Column Assembly (for Manual Tilt and Manual
Page 4297
Parts Information
Required Tools & Equipment
Repair Procedure
1. Confirm the condition matches the Introduction.
Page 5546
Standard voltage:
(3) If the voltage is not as specified, replace the 4WD control ECU See: Relays and Modules Transmission and Drivetrain/Relays and
Modules - Transfer Case/Control Module/Service and Repair/Removal. If the voltage is normal,
replace the 4WD control switch.
Page 9362
Parts Information
Repair Procedure
1. Test-drive the vehicle and confirm the condition.
NOTE
Repeat remaining steps for both No.3 cab mounts.
2. Loosen the No.2 cab mount nuts (at front of cab) down to the last thread on the long bolt. This is
necessary to allow the cab to be raised to remove
the No.3 mount.
The cab mounts in the front are only loosened to allow the technician to raise the cab to install the
rear cab mounts. Not necessary to change.
Page 4144
Airbag Cut-OFF Switch
Air Bag Deactivation Switch: Service and Repair Airbag Cut-OFF Switch
Components
SUPPLEMENTAL RESTRAINT SYSTEM: AIRBAG CUT-OFF SWITCH: COMPONENTS
Removal
SUPPLEMENTAL RESTRAINT SYSTEM: AIRBAG CUT-OFF SWITCH: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY
(a) Remove the lower No. 2 instrument panel airbag assembly See: Air Bag Systems/Air
Bag/Service and Repair/Removal and
Replacement/Front Passenger Side Knee Airbag Assembly/Removal.
3. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and
Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument
Panel Safety Pad (for Column Shift Type)/Removal
4. REMOVE AIRBAG CUT-OFF SWITCH
(a) Detach the 2 claws to remove the switch.
Installation
SUPPLEMENTAL RESTRAINT SYSTEM: AIRBAG CUT-OFF SWITCH: INSTALLATION
1. INSTALL AIRBAG CUT-OFF SWITCH
(a) Attach the 2 claws to install the switch.
2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY See: Body and
Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Column Shift Type)/Installation
3. INSTALL LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY
(a) Install the lower No. 2 instrument panel airbag assembly See: Air Bag Systems/Air Bag/Service
and Repair/Removal and Replacement/Front
Passenger Side Knee Airbag Assembly/Installation.
4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Page 1395
Removal
SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for CrewMax): REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Disassembly
3. REMOVE FRONT UPPER ARMREST BASE PANEL LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Page 9084
Connectors Part 2
Page 6270
"Case1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (/\ Mark) and pull the terminal retainer
up to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Air Fuel Ratio Sensor
Oxygen Sensor: Diagrams Air Fuel Ratio Sensor
Page 8071
Removal
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift
Type): REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal
3. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding
/ Trim/Dashboard / Instrument
Page 6284
3. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE
HINT The diagnostic system in the TOYOTA TUNDRA has various functions.
* The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU
memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a
previous malfunction's DTC can be checked by a technician during troubleshooting.
* Another function is the Input Signal Check, which checks if the signals from various switches are
sent to the ECU correctly.
* By using these functions, the problem areas can be narrowed down and troubleshooting is more
effective. Diagnostic functions are incorporated in the following systems in the TOYOTA TUNDRA.
Page 2360
Page 6367
Engine Room Main Wire
Page 2000
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Page 1861
Step 6. Pull the filter out of the filter outlet.
Cleaning method.
Page 5814
Brake Fluid Pump Relay: Locations From 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Recall 11V185000 - TPMS Non-Compliance
Tire Pressure Module: All Technical Service Bulletins Recall 11V185000 - TPMS Non-Compliance
VEHICLE MAKE/MODEL: MODEL YEAR(S) Toyota/FJ Cruiser 2011
Toyota/Tundra 2009-2011
MANUFACTURER: Gulf States Toyota, Inc.
MFR'S REPORT DATE: March 16, 2011
NHTSA CAMPAIGN ID NUMBER: 11V185000
NHTSA ACTION NUMBER: N/A
COMPONENT: Tires: Pressure Monitoring and Regulating Systems
POTENTIAL NUMBER OF UNITS AFFECTED: 1,489
SUMMARY: Gulf States Toyota is recalling certain model year 2011 FJ Cruiser and model year
2009-2011 Tundra vehicles for failing to comply with the requirements of Federal Motor Vehicle
Safety Standard No. 138, "Tire Pressure Monitoring Systems." The TPMS on some vehicles may
not have been properly calibrated and as a result the low tire pressure warning lamp may not
illuminate should the inflation pressure in one or more of the vehicle's tires fall below the threshold
for when the low tire pressure warning lamp should illuminate.
CONSEQUENCE: Drivers will not receive a warning from the tire pressuring monitor that one or
more tires are underinflated increasing the risk that a vehicle will be driven with one or more
underinflated tires and increasing the risk of a tire failure that may lead to a crash.
REMEDY: Dealers will recalibrate the tire pressure monitoring system in accordance with the
regulation free of charge. The safety recall is expected to begin during April 2011. Owners may
contact Gulf State Toyota Customer Assistance Center toll free at 1-800-444-1074 Monday through
Thursday, 8:30 AM to 5:00 PM, or Friday 8:30 AM to 4:00 PM Central Standard Time.
NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle
Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov.
Page 6467
DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector.
Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
Page 7992
CAUTION: Wear protective gloves. Sharp areas on the seat frame and adjuster may injure your
hands.
1. INSTALL FRONT SEAT SIDE AIRBAG ASSEMBLY
CAUTION: *
The nuts must not be reused.
* Make sure that the seat frame assembly is not deformed. If it is, replace it with a new one.
(a) Install the front seat side airbag assembly with 2 new nuts.
Torque : 5.5 Nm (56 kgf-cm, 49 in-lbf)
(b) Connect the clamp.
2. INSTALL FRONT SEATBACK COVER WITH PAD RH See: Body and Frame/Seats/Service and
Repair/Overhaul/Front Seat Assembly (for
Fold Down Seat Type)/Reassembly
3. INSTALL FRONT SEATBACK LOCK SUB-ASSEMBLY RH See: Body and Frame/Seats/Service
and Repair/Overhaul/Front Seat Assembly
(for Fold Down Seat Type)/Reassembly
4. INSTALL FRONT SEATBACK LOCK HANDLE ROD See: Body and Frame/Seats/Service and
Repair/Overhaul/Front Seat Assembly (for
Fold Down Seat Type)/Reassembly
5. INSTALL FRONT SEATBACK LOCK SUB-ASSEMBLY LH See: Body and Frame/Seats/Service
and Repair/Overhaul/Front Seat Assembly
(for Fold Down Seat Type)/Reassembly
6. INSTALL FRONT SEATBACK BOARD See: Body and Frame/Seats/Service and
Repair/Overhaul/Front Seat Assembly (for Fold Down Seat
Type)/Reassembly
7. INSTALL FRONT SEATBACK ASSEMBLY RH
(a) Install the seatback with the 4 bolts.
Torque : 43 Nm (438 kgf-cm, 32 ft-lbf)
(b) Connect the 3 airbag wire harness clamps to under the seat.
Drivetrian - Rear End Howling/Growling Noises
Wheel Bearing: All Technical Service Bulletins Drivetrian - Rear End Howling/Growling Noises
T-SB-0151-10
June11, 2010
Rear Axle Bearing Abnormal Noise
Service Category Drivetrain
Section Axle/Differential
Market USA
Applicability
Introduction
Some 2007 - 2010 model year Tundra vehicles may exhibit a howling or growling noise from the
rear of the vehicle that increases with vehicle speed. Changes have been made to the rear axle
bearing to correct this condition. Follow the procedure in the bulletin to address customer concerns.
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60
months or 60,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Parts Information
Page 8818
Removal
AUDIO / VISUAL: FRONT DOOR SPEAKER (for Double Cab): REMOVAL
HINT *
Use the same procedures for the LH side and RH side.
* The procedures listed below are for the LH side.
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE FRONT LOWER DOOR FRAME BRACKET GARNISH LH See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Disassembly
3. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH See: Body and Frame/Doors,
Hood and Trunk/Doors/Front Door/Service and
Repair/Front Door (for Double Cab)/Disassembly
Components
Power Steering Pressure Switch: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: POWER STEERING OIL PRESSURE SWITCH:
COMPONENTS
Page 9119
when inserting and after full engagement.
NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal.
(d) REPAIR METHOD OF CONNECTOR TERMINAL
(1) If there is any foreign matter on the terminal, clean the contact point using an air gun or cloth.
Never rub the contact point using sandpaper
as the plating may come off.
(2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is
gold-plated (gold color), use a gold-plated female
terminal; if it is silver-plated (silver color), use a silver-plated female terminal.
(3) Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock
into the housing, the housing may have to be
replaced.
(e) HANDLING OF WIRE HARNESS
(1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be
restored in the same way.
(2) Never twist, pull or slacken the wire harness more than necessary.
(3) The wire harness should never come into contact with a high temperature part, or rotating,
moving, vibrating or sharp-edged parts. Avoid
contact with panel edges, screw tips and other sharp items.
(4) When installing parts, never pinch the wire harness.
(5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with
vinyl tape.
2. CHECK FOR OPEN CIRCUIT
Page 6615
Power Outlet Socket (115V)
Page 2260
(h) It is extremely dangerous to perform any work on a vehicle raised on a jack alone, even for
work that can be finished quickly. Safety stands
must be used to support the vehicle.
Page 4218
Accelerator Pedal: Testing and Inspection
1UR-FE ENGINE CONTROL SYSTEM: ACCELERATOR PEDAL: ON-VEHICLE INSPECTION
1. INSPECT ACCELERATOR PEDAL ROD ASSEMBLY
(a) Connect the Techstream to the DLC3.
(b) Turn the ignition switch to ON.
(c) Turn the Techstream main switch ON.
(d) Enter the following menus: Powertrain / Engine and ECT / Data List / ALL Date / Accel Sensor
Out No. 1 and Accel Sensor Out No. 2.
(e) Read the value displayed on the tester.
Standard Voltage:
Accel Sensor Out No. 1
Accel Sensor Out No. 2
(f) If the result is not as specified, check the accelerator pedal rod, wire harness or ECM.
Page 2981
Power Steering Pressure Switch: Diagrams Power Steering Oil Pressure Switch
Page 5066
Standard backlash:
0.1 to 0.25 mm (0.00394 to 0.00984 in.)
(2) If the backlash is not within the specification, install a side gear thrust washer with a different
thickness.
(d) Using a pin punch and hammer, tap in the straight pin through the differential case and hole of
the pinion shaft.
(e) Stake the differential case.
8. INSTALL DIFFERENTIAL RING GEAR
(a) Clean the contact surfaces of the differential case and ring gear.
(b) Heat the ring gear to about 100C (212F) in boiling water.
(c) Carefully take the ring gear out of the boiling water.
(d) After the moisture on the ring gear has completely evaporated, quickly set the ring gear onto the
differential case.
HINT *
Align the matchmarks on the ring gear and differential case.
* Temporarily install the 10 bolts so that the bolt holes in the ring gear and differential case are
aligned.
(e) After the ring gear cools down sufficiently, apply adhesive to the bolts and install them.
Torque : 137 Nm (1397 kgf-cm, 101 ft-lbf)
Adhesive:
Toyota Genuine Adhesive 1360K, Three Bond 1360K or equivalent
9. INSTALL FRONT DIFFERENTIAL CASE BEARING
(a) Using SST and a press, press in the 2 bearings (inner race).
SST : 09316-20011
SST : 09316-60011
09316-00041
Page 6476
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: ELECTRONIC
CIRCUIT INSPECTION PROCEDURE
1. BASIC INSPECTION
(a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS
(1) Unless otherwise stated, all resistance measurements should be made at an ambient
temperature of 20°C (68°F). Resistance measurements
may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been
running. Measurements should be made after the engine has cooled down.
(b) HANDLING CONNECTORS
(1) When disconnecting a connector, first squeeze the mating halves tightly together to release the
lock, and then press the lock claw and
separate the connector.
(2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly
and separate it.
(3) Before connecting a connector, check that there are no deformed, damaged, loose or missing
terminals.
(4) When connecting a connector, press firmly until it locks with a "click" sound.
(5) If checking a connector with a TOYOTA electrical tester, check the connector from the backside
(harness side) using a mini test lead.
NOTICE: *
As a waterproof connector cannot be checked from the backside, check it by connecting a
sub-harness.
* Do not damage the terminals by moving the inserted tester needle.
(c) CHECKING CONNECTORS
(1) Checking when a connector is connected: Squeeze the connectors together to confirm that they
are fully connected and locked.
(2) Checking when a connector is disconnected: Check by pulling the wire harness lightly from the
backside of the connector. Look for
unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for
corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or
deformed terminals.
(3) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a
female terminal, and check for ample tension
Page 3486
NG -- REPAIR OR REPLACE CAN BRANCH WIRE OR CONNECTOR (CENTER AIRBAG
SENSOR)
OK -- REPLACE CENTER AIRBAG SENSOR
12. CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (4WD CONTROL ECU)
NOTICE: For vehicles without 4WD, go to "CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH
WIRE (POWER STEERING ECU)".
(a) Disconnect the A25 4WD control ECU connector.
(b) Reconnect the cable to the negative (-) battery terminal.
(c) Select "CAN Bus Check" on the Techstream.
Result
B -- CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (POWER STEERING ECU) A -Continue to next step.
13. CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (4WD CONTROL ECU BRANCH
WIRE)
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE CAN BRANCH WIRE OR CONNECTOR (4WD CONTROL ECU)
OK -- REPLACE 4WD CONTROL ECU
14. CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (POWER STEERING ECU)
NOTICE: For vehicles without a power steering ECU, go to "CHECK FOR OPEN IN ONE SIDE OF
CAN BRANCH WIRE (AIR CONDITIONING AMPLIFIER BRANCH WIRE)".
(a) Disconnect the J101 power steering ECU connector.
Page 6192
Installation
OTHER SYSTEM: POWER OUTLET SOCKET (for CrewMax Column Shift Type): INSTALLATION
1. INSTALL REAR POWER POINT SOCKET (for AC Power Supply)
(a) Attach the 2 claws to install the power outlet socket.
2. INSTALL REAR POWER OUTLET SOCKET COVER (for Standard)
(a) Attach the 2 claws to install the power outlet socket cover.
3. INSTALL REAR POWER OUTLET SOCKET (for Standard)
(a) Attach the claw to install the power outlet socket.
4. INSTALL NO. 2 SEATBACK LOCK CONTROL BEZEL
Page 3536
INSPECTION PROCEDURE
HINT Operating the ignition switch, any switches or any doors triggers related ECU and sensor
communication with the CAN, which causes resistance variation.
PROCEDURE
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
(a) Disconnect the cable from the negative (-) battery terminal before measuring the resistances of
the main wire and the branch wire.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
NEXT -- Continue to next step.
2. CHECK FOR OPEN IN CAN BUS WIRE (AIR CONDITIONING AMPLIFIER BRANCH WIRE)
(a) Disconnect the J19 air conditioning amplifier connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE AIR CONDITIONING AMPLIFIER BRANCH WIRE OR
CONNECTOR (CANH, CANL)
Page 2135
Tire Pressure Module: Diagrams
Page 5800
Vacuum Brake Booster: Testing and Inspection
BRAKE: BRAKE BOOSTER: ON-VEHICLE INSPECTION
1. INSPECT BRAKE BOOSTER
(a) OPERATING CHECK
(1) Depress the brake pedal several times with the engine off and check that there is no change in
the pedal reserve distance.
(2) Depress the brake pedal and start the engine. If the pedal goes down slightly, operation is
normal.
(b) AIRTIGHTNESS CHECK
(1) Start the engine and stop it after 1 or 2 minutes. Depress the brake pedal several times slowly.
If the pedal goes down farthest the 1st time, but gradually rises after the 2nd or 3rd time, the
booster is airtight.
(2) Depress the brake pedal while the engine is running, and stop the engine with the pedal
depressed. If there is no change in the pedal reserve
travel after holding the pedal for 30 seconds, the booster is airtight.
2. CHECK BRAKE VACUUM CHECK VALVE ASSEMBLY
(a) Check the check valve.
(1) Slide the clip and disconnect the vacuum hose.
(2) Remove the check valve from the booster.
(3) Check that there is ventilation from the booster to the engine, and no ventilation from the engine
to the booster.
If the results are not as specified, replace the check valve assembly.
Page 8016
Removal
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift
Type): REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal
3. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding
/ Trim/Dashboard / Instrument
Page 5965
General Information
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: GENERAL
INFORMATION
* A large number of ECU controlled systems are used in the TOYOTA TUNDRA. In general, ECU
controlled systems are considered to be very intricate, requiring a high level of technical knowledge
to troubleshoot. However, most problem checking procedures only involve inspecting the ECU
controlled system's circuits one by one. An adequate understanding of the system and a basic
knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and
necessary repairs.
1. TROUBLESHOOTING PROCEDURES
* The troubleshooting procedures consist of diagnosis procedures for when a DTC is stored and
diagnosis procedures for when no DTC is stored. The basic idea is explained in the following table.
* Vehicle systems are complex and use many ECUs that are difficult to inspect independently.
Therefore, a process of elimination is used, where components that can be inspected individually
are inspected, and if no problems are found in these components, the related ECU is identified as
the problem and replaced.
* It is extremely important to ask the customer about the environment and the conditions present
when the problem occurred (Customer Problem Analysis). This makes it possible to simulate the
conditions and confirm the symptom. If the symptom cannot be confirmed or the DTC does not
recur, the malfunctioning part may not be identified using the troubleshooting procedure, and the
ECU for the related system may be replaced even though it is not defective. If this happens, the
original problem will not be solved.
* In order to prevent endless expansion of troubleshooting procedures, the troubleshooting
procedures are written with the assumption that multiple malfunctions do not occur simultaneously
for a single problem symptom.
* To identify the malfunctioning part, troubleshooting procedures narrow down the target by
separating components, ECUs and wire harnesses during the inspection. If the wire harness is
identified as the cause of the problem, it is necessary to inspect not only the connections to
components and ECUs but also all of the wire harness connectors between the component and the
ECU.
DIAGNOSTIC TESTER
2. DESCRIPTION
System data and the Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector
3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the Techstream* to
check for a malfunction and perform repairs.
HINT *: Techstream is the name for the diagnostic tester in North America.
3. DATA LINK CONNECTOR 3 (DLC3)
(a) The vehicle's ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of
the DLC3 complies with SAE J1962 and
matches the ISO 15765-4 format.
Page 8777
Rear Door Speaker
Woofer
Page 3420
2. CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (MAIN BODY ECU)
(a) Disconnect the J2 main body ECU connector.
(b) Reconnect the cable to the negative (-) battery terminal.
(c) Select "CAN Bus Check" on the Techstream.
Result
B -- CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (SKID CONTROL ECU WITH
ACTUATOR) A -- Continue to next step.
3. CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (MAIN BODY ECU BRANCH
WIRE)
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE CAN BRANCH WIRE OR CONNECTOR (MAIN BODY ECU)
OK -- REPLACE MAIN BODY ECU
4. CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (SKID CONTROL ECU WITH
ACTUATOR)
(a) Disconnect the A17 skid control ECU with actuator connector.
(b) Reconnect the cable to the negative (-) battery terminal.
(c) Select "CAN Bus Check" on the Techstream.
Result
B -- CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (STEERING ANGLE SENSOR)
Front Door Lock Switch
Power Door Lock Switch: Diagrams Front Door Lock Switch
Page 8154
2. INSTALL FRONT SEAT ASSEMBLY LH
(a) Install the front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Fold Down Seat
Type)/Installation.
3. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
Page 5274
(a) Align the matchmarks on the propeller shaft flange and differential flange.
(b) Install the propeller shaft to the differential side with the 4 bolts and 4 nuts.
Torque : 70 Nm (714 kgf-cm, 52 ft-lbf)
(c) Align the matchmarks on the propeller shaft flange and transfer flange.
(d) Install the propeller shaft to the transfer side with the 4 nuts.
Torque : 70 Nm (714 kgf-cm, 52 ft-lbf)
2. MEASURE TRANSFER AND DIFFERENTIAL FLANGE ANGLE (for 3 Joint Type)
NOTICE: *
Perform the inspection on a level surface.
* Perform the inspection with the vehicle empty.
* Perform the inspection with all wheels on the ground.
HINT As the transfer and rear differential flange angles are necessary when measuring the
installation angle of the propeller shaft, measure the angle of the transfer and rear differential
flange before installing the propeller shaft.
(a) Using SST, measure and record the angle of the transfer flange (A).
SST : 09370-50010
Page 5122
Production Change Information
This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown
below.
Parts Information
Required Tools & Equipment
Inspection Procedure
1. Test drive the vehicle and confirm the noise is only present in 4WD.
2. Place the vehicle on the lift and remove the left front wheel.
Page 8531
(a) for Regular Cab:
Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular Cab)/Removal.
(b) for Double Cab:
Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Removal.
(c) for CrewMax:
Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for CrewMax)/Removal.
2. REMOVE COWL SIDE TRIM BOARD LH
(a) for Regular Cab:
Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular Cab)/Removal.
(b) for Double Cab:
Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Removal.
(c) for CrewMax:
Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for CrewMax)/Removal.
3. REMOVE CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service
and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Removal
4. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal
5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Removal
6. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column
Shift Type)/Removal
7. REMOVE FRONT ASH RECEPTACLE BOX SUB-ASSEMBLY
8. REMOVE LOWER INSTRUMENT CLUSTER FINISH PANEL See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column
Shift Type)/Removal
9. REMOVE INSTRUMENT PANEL CUP HOLDER ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column
Shift Type)/Removal
10. REMOVE INTEGRATION CONTROL AND PANEL ASSEMBLY
Page 8788
1. INSPECT FRONT NO. 1 SPEAKER ASSEMBLY (for Standard)
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the speaker assembly.
2. INSPECT FRONT NO. 1 SPEAKER ASSEMBLY (for 10 Speakers)
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the speaker assembly.
3. INSPECT FRONT NO. 3 SPEAKER ASSEMBLY (for 10 Speakers)
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the speaker assembly.
Front Door Speaker (for Regular Cab)
Page 7216
6. REMOVE LOWER NO. 1 INSTRUMENT PANEL AIR BAG ASSEMBLY See: Restraint
Systems/Air Bag Systems/Air Bag/Service and
Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Removal
7. REMOVE NO. 1 AIR DUCT SUB-ASSEMBLY See: Steering Column/Service and
Repair/Removal and Replacement/Steering Column
Assembly (for Manual Tilt)/Removal
8. REMOVE MULTIPLEX TILT AND TELESCOPIC ECU
(a) Disconnect the 2 ECU connectors.
(b) Remove the 2 screws and ECU.
Page 6408
Page 1660
Washer Fluid Level Switch: Diagrams
Recall 10V017000: Accelerator Pedal Sticking
Accelerator Pedal Position Sensor: Recalls Recall 10V017000: Accelerator Pedal Sticking
VEHICLE MAKE/MODEL: MODEL YEAR(S): Toyota/Avalon 2005-2010 Toyota/Camry 2007-2010
Toyota/Corolla 2009-2010 Toyota/Corolla Matrix 2009-2010 Toyota/Highlander 2010 Toyota/ RAV4
2009-2010 Toyota/Sequoia 2008-2010 Toyota/Tundra 2007-2010 MANUFACTURER: Toyota
Motor North America, Inc.
MFR'S REPORT DATE: January 21, 2010
NHTSA CAMPAIGN ID NUMBER: 10V017000
NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Accelerator Assembly:
Pedal/Linkage
POTENTIAL NUMBER OF UNITS AFFECTED: ?
SUMMARY: Toyota is recalling certain model year 2005-2010 Avalon, model year 2007-2010
Camry, model year 2009-2010 Corolla, Corolla Matrix, RAV4, model year 2010 Highlander, model
year 2008-2010 Sequoia, and model year 2007-2010 Tundra. due to the manner in which the
friction lever interacts with the sliding surface of the accelerator pedal inside the pedal sensor
assembly, the sliding surface of the lever may become smooth during vehicle operation. In this
condition, if condensation occurs on the surface, as may occur from heater operation (without A/C)
when the pedal assembly is cold, the friction when the accelerator pedal is operated may increase,
which may result in the accelerator pedal becoming harder to depress, slower to return, or, in the
worst case, mechanically stuck in a partially depressed position.
CONSEQUENCE: The accelerator pedal may become hard to depress, slow to return to idle, or, in
the worst case, mechanically stuck in a partially depressed position, increasing the risk of a crash.
REMEDY: Toyota has not yet provided a remedy plan or an owner notification schedule. Owners
may contact Toyota at 1-800-331-4331.
NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle
Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov.
Page 2068
Push the secondary locking device or terminal retainer in to the full lock position.
CONNECT CONNECTOR
Voltage Check
VOLTAGE CHECK
Page 3577
Knock Sensor: Testing and Inspection
1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: INSPECTION
1. INSPECT KNOCK SENSOR
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) If the result is not as specified, replace the knock sensor.
Page 343
^ Calibration ID(s) [Refer to the Calibration Identification Chart for the NEW CALIBRATION ID]
^ Dealer Code
^ Repair Date
^ Change Authority [This TSB number]
B. Affix the Authorized Modifications Label to the vehicle at the location shown in Figure 1. The
Authorized Modifications Label is available
through the MDC P/N 00451-00001-LBL.
Front Power Seat Control System (w/ Memory)
Power Seat Switch: Locations Front Power Seat Control System (w/ Memory)
SEAT: FRONT POWER SEAT CONTROL SYSTEM (w/ Memory): PARTS LOCATION
Page 1631
Power Window Switch: Diagrams Power Window Regulator Switch (for Back Window)
Page 3619
5. REMOVE PROPELLER SHAFT HEAT INSULATOR (for 4WD) See: Transmission and
Drivetrain/Drive/Propeller Shafts, Bearings and
Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Front Propeller Shaft
Assembly/Removal
6. REMOVE FRONT NO. 2 EXHAUST PIPE ASSEMBLY (for 4WD)
(a) Disconnect the heated oxygen sensor connector.
(b) Disconnect the air fuel ratio sensor connector.
(c) Disconnect the front No. 2 exhaust pipe from the exhaust pipe support.
(d) Remove the 3 nuts, front No. 2 exhaust pipe and gasket from the exhaust manifold LH.
7. REMOVE AIR FUEL RATIO SENSOR (for Bank 1 Sensor 1)
(a) for 2WD:
Disconnect the air fuel ratio sensor connector.
(b) Using SST, remove the sensor.
SST : 09224-00010
Installation
1UR-FE ENGINE CONTROL SYSTEM: AIR FUEL RATIO SENSOR: INSTALLATION
1. INSTALL AIR FUEL RATIO SENSOR (for Bank 1 Sensor 1)
(a) Install the sensor to the exhaust pipe by hand.
(b) Using SST, tighten the sensor.
SST : 09224-00010
Page 5304
09951-04020
09952-04010
09953-04020
09954-04020
09955-04051
09957-04010
SST : 09950-60010
09951-00290
SST : 09336-16010
(k) Using needle-nose pliers, install the previously selected snap ring into the groove on the
universal joint yoke.
HINT Use the same installation procedure for the universal joint spider bearing on the opposite
side.
4. INSTALL PROPELLER SHAFT UNIVERSAL JOINT SPIDER BEARING
(a) Check the spider bearings for wear and damage.
(b) Measure each spider bearing's axial play by turning the yoke while holding the shaft tightly.
Maximum bearing axial play:
0.05 mm (0.00197 in.)
Page 6004
Parking and Paint Protection
^ Storage areas should be paved, well lit and secure. If your off-site storage lot is not paved,
spread gravel down to minimize mud and dust. Be sure vehicles are driven carefully when moving
them to or from a long-term lot. This will help minimize damage to the paint finish from road grit or
gravel.
^ Park vehicles from right to left at least three feet apart. Leave enough space front and rear to
easily walk between rows.
^ HVAC vent controls should be set to "Recirc" to minimize dust and odor intrusion.
^ Make sure the plastic door edge protectors are in place and fold in the side view mirror (if
applicable).
^ Anti-rust covers or anti-rust film should remain on vehicle during storage
1. Anti-Rust Covers (behind wheel) should be removed at PDS.
2. Anti-Rust Film (applied to wheel) should be removed just prior to customer delivery.
^ Wash vehicles frequently.
Battery
^ Turn off all electrical accessories, make sure windows and sunroof are closed and check that the
transmission is in "park" (first or reverse for manual transmission vehicles). Do not apply the
parking brake.
^ Test batteries monthly (more often in high heat or cold areas), using the Digital Battery System
^ Analyzer (P/N 00002-V8150-KIT). Refer to TSB PG001-06, "Battery Maintenance for In Stock
Vehicles and Pre-Delivery" for complete battery maintenance procedures.
^ To reduce battery drain during long-term storage, remove the battery ground (-) cable of each
vehicle and reinstall just before delivery to the customer. Locate the current PDS TSB on TIS for
complete details.
^ If a hybrid vehicle is put into storage, the state of charge (SOC) of it's battery and auxiliary battery
will gradually decrease. To prevent the auxiliary battery from becoming discharged during storage,
proper maintenance is necessary. Refer to TSB "Maintenance for HV & Auxiliary Batteries" for
procedure and additional information.
Tire Inflation Pressure
If the vehicle is parked for long periods without being moved, a flat spot may develop on each tire
surface in contact with the ground, even if the tires are inflated to specification. Tire inflation
pressure should be checked once a month.
Tire inflation pressure for storage only: 45 psi.
Parts Rust
If the vehicles in your storage area are exposed to a sea breeze and/or a significant precipitation
corrosion with rust in some parts may occur.
If rust is found remove it and treat it by applying rust inhibitor to prevent recurrence. Engine Starting
and Vehicle Movement
If the vehicle is stored over an extended period of time starting and running the engine periodically
will ensure smooth running operation.
1. Start and operate the engine at an engine speed under 1,500 RPM for 15 minutes or longer.
This also eliminates moisture in the exhaust system.
NOTE
Be sure to allow sufficient clearance at the rear of the vehicle to prevent other vehicles stored
behind from getting damaged by exhaust gas.
2. Move the vehicle at least 30 feet to lubricate the transmission and differential and prevent tire
flat-spot damage.
3. Raise engine speed above 3,000 RPM 10 times to eliminate moisture from the exhaust.
A/C Compressor Lubrication
To minimize the possibility of damage to the A/C compressor while storing a vehicle perform the
following recommended maintenance procedures at
Page 1225
Power Steering Pressure Switch: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: POWER STEERING OIL PRESSURE SWITCH:
INSTALLATION
1. INSTALL POWER STEERING OIL PRESSURE SWITCH
(a) Install a new O-ring to the power steering oil pressure switch.
(b) Apply a light coat of engine oil to the O-ring of the power steering oil pressure switch.
NOTICE: *
When reusing the power steering oil pressure switch, inspect the O-ring.
* If the O-ring has scratches or cuts, replace the power steering oil pressure switch.
(c) Using SST, install the power steering oil pressure switch.
SST : 09922-10010
without SST - Torque : 21 Nm (210 kgf-cm, 15 ft-lbf)
with SST - Torque : 15 Nm (148 kgf-cm, 11 ft-lbf)
HINT *
Use a torque wrench with a fulcrum length of 30 cm (11.8 in.). When using a torque wrench with a
fulcrum length that is not 30 cm (11.8 in.), calculate the torque specification for the torque wrench
and SST based on the "without SST" torque specification See: Service Precautions
* Make sure SST and the torque wrench are connected in a straight line.
(d) Connect the oil pressure switch connector.
2. INSTALL FAN AND GENERATOR V BELT
(a) Install the fan and generator V belt See: Engine, Cooling and Exhaust/Engine/Drive Belts,
Mounts, Brackets and Accessories/Drive
Belt/Service and Repair/Installation.
3. ADD POWER STEERING FLUID
4. BLEED POWER STEERING FLUID See: Steering and Suspension/Steering/Testing and
Inspection/Component Tests and General
Diagnostics/Power Steering System/On-Vehicle Inspection
5. INSPECT FOR POWER STEERING FLUID LEAK
6. CHECK FLUID LEVEL See: Steering and Suspension/Steering/Testing and
Inspection/Component Tests and General Diagnostics/Power
Steering System/On-Vehicle Inspection
7. INSTALL FRONT FENDER APRON SEAL RH See: Engine, Cooling and Exhaust/Exhaust
System/Exhaust Manifold/Service and
Repair/Installation
8. INSTALL FRONT WHEEL See: Steering and Suspension/Suspension/Suspension Strut / Shock
Absorber/Service and Repair/Removal and
Replacement/Front Shock Absorber/Installation
Page 9085
Connectors Part 3
Page 1368
(b) Detach the 2 claws and remove the switch.
Installation
SUPPLEMENTAL RESTRAINT SYSTEM: CURTAIN SHIELD AIRBAG CUTOFF SWITCH:
INSTALLATION
1. INSTALL CURTAIN SHIELD AIRBAG CUTOFF SWITCH
(a) Attach the 2 claws to install the switch.
(b) Connect the connector.
2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Installation
3. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
4. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Installation
5. INSTALL FRONT DOOR SCUFF PLATE LH (for Double Cab, CrewMax) See: Body and
Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Installation
6. INSTALL FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Installation
7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
8. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
Page 987
Page 7037
for Regular Cab of Long Deck
for Double Cab of Standard Deck
Page 2998
Page 9303
Page 1953
* Do not operate the cooler compressor before charging refrigerant as the cooler compressor will
not work properly without any refrigerant, and will overheat.
* Approximately 200 g (7.05 oz.) of refrigerant may need to be charged after bubbles disappear.
The refrigerant amount should be checked by measuring its quantity, and not with the sight glass.
3. WARM UP ENGINE
(a) Warm up the engine at less than 1500 rpm for 1 minute or more after charging the refrigerant.
NOTICE: Be sure to warm up the compressor when turning the A/C switch ON after removing and
installing the cooler refrigerant lines (including the compressor), to prevent damage to the
compressor.
4. CHECK FOR REFRIGERANT GAS LEAK
(a) After recharging the refrigerant gas, check for refrigerant gas leakage using a halogen leak
detector.
(b) Perform the operation under the following conditions:
* The ignition switch is OFF.
* The vehicle is in a place with good air ventilation and without any volatile gases, such as
evaporated gasoline or exhaust gas. The detector is very sensitive to volatile gases.
* Some refrigerant is remaining in the refrigerant system.
* The compressor is off and its pressure is approximately 392 to 588 kPa (4.0 to 6.0 kgf/cm2, 57 to
85 psi).
(c) Using a halogen leak detector, check the refrigerant line for leakage.
(d) If a gas leak is not detected on the drain hose, remove the blower motor control (blower
resistor) from the cooling unit. Insert the halogen leak
detector sensor into the unit and perform the test.
(e) Disconnect the connector and wait for approximately 20 minutes. Bring the halogen leak
detector close to the pressure switch and perform the
test.
Page 7040
*: for 5 leaf spring
Page 1739
This TSB applies to all Sequoia and Tundra vehicles equipped with lUR-FE (4.6L) 2UZ-FE (4.7L)
and 3UR-FE/FBE (5.7L) engines produced BEFORE the Production Change Effective VINs shown.
Repair Procedure
1. Remove and replace the air cleaner lid.
2. Remove and replace the front right hand (RH) fender liner.
Components
Crankshaft Position Sensor: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: CRANKSHAFT POSITION SENSOR: COMPONENTS
Page 6741
J/B No.4 - Instrument Panel Center
Page 4087
EGR Valve: Testing and Inspection
1UR-FE EMISSION CONTROL: EGR VALVE: INSPECTION
1. INSPECT EGR VALVE ASSEMBLY
(a) Check the resistance of the EGR valve.
(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(2) If the result is not as specified, replace the EGR valve.
Page 2056
Relay Box: Diagnostic Aids
Continuity and Resistance Check
CONTINUITY AND RESISTANCE CHECK
Disconnect the battery terminal or wire so there is no voltage between the check points.
Contact the two leads of an ohmmeter to each of the check points.
Page 7576
Inspection
Air Flow Meter/Sensor: Testing and Inspection Inspection
1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: INSPECTION
1. INSPECT MASS AIR FLOW METER
(a) Check the output voltage.
(1) Apply battery voltage across terminals 1 (+B) and 2 (E2G).
NOTICE: While using the battery during inspection, do not bring the positive and negative tester
probes too close to each other as a short circuit may occur.
(2) Using a voltmeter, connect the positive (+) tester probe to terminal 3 (VG), and negative (-)
tester probe to terminal 2 (E2G).
(3) Blow air into the MAF meter, and check that the voltage fluctuates.
If the result is not as specified, replace the MAF meter.
(b) Perform a visual check for any foreign matter on the platinum hot wire (heater) of the mass air
flow meter shown in the illustration.
OK:
There is no foreign material.
(c) If the result is not as specified, replace the mass air flow meter.
(d) Check the IAT sensor.
Component Tests and General Diagnostics
Acceleration/Deceleration Sensor: Component Tests and General Diagnostics
BRAKE CONTROL: YAW RATE AND DECELERATION SENSOR: INSPECTION
1. CHECK YAW RATE SENSOR
(a) Check the yaw rate sensor.
Under any of the following conditions, replace the sensor with a new one:
* The surface of the sensor is cracked, dented, or chipped.
* The connector is scratched, cracked, or damaged.
* The sensor has been dropped.
Page 8355
Impact Sensor: Service and Repair Side Airbag Sensor (for Double Cab)
Components
SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Double Cab):
COMPONENTS
Page 5655
Torque : 11 Nm (107 kgf-cm, 8 ft-lbf)
NOTICE: *
Make sure there are no pieces of iron or other foreign matter attached to the sensor tip part.
* While inserting the speed sensor into the knuckle hole, do not strike or damage the sensor tip
part.
* After installing the speed sensor, make sure there is no clearance or foreign matter between the
sensor stay part and the knuckle.
* Make sure there is no foreign matter attached to the magnetic rotor.
6. INSTALL FRONT SKID CONTROL SENSOR WIRE RH
(a) Install the skid control sensor clamp (labeled A) with the bolt (labeled B).
for Bolt B - Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)
(b) Install the connector (labeled C) with connect the connector (labeled C).
(c) Install the 2 harness clamps (labeled D) with the 2 bolts (labeled E).
for Bolt E - Torque : 13 Nm (127 kgf-cm, 9 ft-lbf)
NOTICE: *
When installing the clamps, do not twist the wire harness.
* For clamps with rotation stoppers, make sure the rotation stopper touches the installation
position.
(d) Install the harness clamp with the bolt (labeled E).
Torque : 13 Nm (127 kgf-cm, 9 ft-lbf)
NOTICE: *
When installing the clamp, do not twist the wire harness.
* Make sure the clamp's rotation stopper touches the installation position.
Page 385
(e) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR OK -- Continue to next step.
6. INSPECT IGNITION SWITCH See: Powertrain Management/Computers and Control
Systems/Testing and Inspection/Diagnostic Trouble
Code Tests and Associated Procedures/P Code Charts/P0617
NG -- REPLACE IGNITION SWITCH See: Powertrain Management/Ignition System/Sensors and
Switches - Ignition System/Ignition Switch/Service and Repair/Removal OK -- Continue to next
step.
7. CHECK HARNESS AND CONNECTOR (INTEGRATION RELAY - ECM, BATTERY AND BODY
GROUND)
(a) Disconnect the ECM connector.
(b) Disconnect the cable from the battery positive terminal.
(c) Remove the integration relay from the engine room relay block.
(d) Disconnect the integration relay connectors.
Page 6240
Engine Room R/B, J/B - Engine Compartment Left
Page 4362
Fuel Pressure Regulator: Service and Repair Removal
1UR-FE FUEL: FUEL PRESSURE REGULATOR: REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE See: Fuel Injector/Service and Repair/Removal
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
3. REMOVE V-BANK COVER See: Engine, Cooling and Exhaust/Engine/Service and
Repair/Removal and Replacement/Engine
Assembly/Removal
4. REMOVE AIR CLEANER HOSE ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Removal
5. REMOVE FUEL PRESSURE REGULATOR ASSEMBLY
(a) Disconnect the No. 2 fuel tube from the pressure regulator See: Service Precautions.
CAUTION: Put a cloth or equivalent under the pressure regulator.
(b) Disconnect the vacuum sensing hose from the pressure regulator.
(c) Remove the 2 bolts, and pull out the pressure regulator.
(d) Remove the O-ring from the pressure regulator.
Page 2866
Fuel Pump Relay: Testing and Inspection Fuel Pump Relay
1UR-FE ENGINE CONTROL SYSTEM: FUEL PUMP RELAY: ON-VEHICLE INSPECTION
1. REMOVE FUEL PUMP RELAY (F/PMP)
(a) Remove the fuel pump relay from the engine room relay block.
2. INSPECT FUEL PUMP RELAY
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) If the result is not as specified, replace the fuel pump relay.
3. INSTALL FUEL PUMP RELAY
(a) Install the fuel pump relay to the engine room relay block.
Page 6791
Push the terminal retainer down to the temporary lock position.
Locations
Door Switch: Locations
DOOR LOCK: KEY REMINDER WARNING SYSTEM: PARTS LOCATION
Page 334
Parts Information
Required Tools & Equipment
Repair Procedure
1. Confirm the condition matches the Introduction.
Page 8821
Repair/Front Door (for Double Cab)/Reassembly
8. INSTALL FRONT LOWER DOOR FRAME BRACKET GARNISH LH See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Reassembly
9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Components
AUDIO / VISUAL: FRONT DOOR SPEAKER (for Regular Cab): COMPONENTS
Emissions - MIL ON/Multiple Air Injection DTC's Set
Air Injection Pump: All Technical Service Bulletins Emissions - MIL ON/Multiple Air Injection DTC's
Set
T-SB-0350-09
Rev1
October 1, 2009
Air Injection Pump With Water Intrusion: MIL "ON" DTC P04181P0419 and/or P244 #
Service Category Engine/Hybrid System
Section Engine Control
Market USA
Applicability
TSB REVISION NOTICE
May 21, 2010 Rev1:
^ DTCs P0418 and P0419 have been added to the TSB.
^ The Applicable Warranty has been updated in the Warranty Information section. Any previous
printed versions of this service bulletin should be discarded.
Introduction
Some 2010 model year Tundra vehicles built in the Texas plant may exhibit a MIL "ON" condition
with Diagnostic Trouble Code (DTC) P0418, P0419, P2440, P2441, P2442, P2443, P2446, and/or
P2447. This concern may be caused by water intrusion into the air injection pump assembly. Use
the following procedure to address this condition.
Parts Information
Production Change Information
Page 5659
1. INSTALL SKID CONTROL SENSOR WIRE
(a) Install the sensor clamp with the nut (labeled A).
Torque : 13 Nm (127 kgf-cm, 9 ft-lbf)
NOTICE: Make sure the clamp's rotation stopper touches the installation position.
(b) Install the sensor clamp with the bolt (labeled B).
Torque : 13 Nm (127 kgf-cm, 9 ft-lbf)
NOTICE: When installing the clamp, do not twist the wire harness.
(c) Attach the 7 clips (labeled C).
NOTICE: *
When installing the clamps, do not twist the wire harness.
* When installing the clamps, securely insert them as shown in the illustration.
(d) Connect the sensor connector (labeled D).
NOTICE: Securely connect the connector.
2. INSTALL REAR SPEED SENSOR LH
(a) Install the speed sensor (labeled A) with the nut (labeled B).
Torque : 11 Nm (107 kgf-cm, 8 ft-lbf)
(b) Connect the speed sensor connector (labeled C).
NOTICE: Securely connect the connector.
3. INSTALL REAR SPEED SENSOR RH
(a) Install the speed sensor (labeled A) with the nut (labeled B).
Page 5367
Standard resistance:
(4) If the resistance is not as specified, repair or replace the harness or connector.
(c) Check the 4WD control switch.
(1) Turn the ignition switch OFF.
(2) Connect the L1 switch connector.
(3) Connect the A25 and A26 ECU connectors.
(4) Measure the voltage according to the value(s) in the table below.
Standard voltage:
(5) If the voltage is not as specified, check the 4WD control ECU.
(d) Check the 4WD control ECU.
(1) Disconnect the L1 switch connector.
(2) Measure the voltage according to the value(s) in the table below.
Page 2255
* The procedures listed below are for the LH side.
1. REMOVE REAR WHEEL LH
2. DISCONNECT REAR DISC BRAKE CYLINDER ASSEMBLY LH See: Brakes and Traction
Control/Parking Brake System/Service and
Repair/Disassembly
3. REMOVE REAR DISC LH See: Brakes and Traction Control/Disc Brake System/Service and
Repair/Removal and Replacement/Rear
Brake/Removal
4. REMOVE PARKING BRAKE SHOE RETURN TENSION SPRING LH See: Brakes and Traction
Control/Parking Brake System/Service and
Repair/Disassembly
5. REMOVE NO. 1 PARKING BRAKE SHOE ASSEMBLY LH See: Brakes and Traction
Control/Parking Brake System/Service and
Repair/Disassembly
6. REMOVE NO. 2 PARKING BRAKE SHOE ASSEMBLY LH See: Brakes and Traction
Control/Parking Brake System/Service and
Repair/Disassembly
7. REMOVE PARKING BRAKE SHOE LEVER SUB-ASSEMBLY LH See: Brakes and Traction
Control/Parking Brake System/Service and
Repair/Disassembly
8. REMOVE REAR AXLE LH HUB BOLT
(a) Using SST and a screwdriver or equivalent to hold the axle hub, remove the hub bolt.
SST : 09650-17011
9. INSTALL REAR AXLE LH HUB BOLT
(a) Temporarily install a washer and hub nut to a new hub bolt as shown in the illustration.
NOTICE: Install hub nuts to prevent damage to the hub bolts.
(b) Using a screwdriver or equivalent to hold the hub, turn the hub nut until the bottom surface of
the hub bolt head touches the axle hub.
(c) Remove the washer and hub nut.
NOTICE: Do not damage the threads of the hub bolts.
10. INSTALL PARKING BRAKE SHOE LEVER SUB-ASSEMBLY LH See: Brakes and Traction
Control/Parking Brake System/Service and
Repair/Reassembly
11. INSTALL NO. 2 PARKING BRAKE SHOE ASSEMBLY LH See: Brakes and Traction
Control/Parking Brake System/Service and
Repair/Reassembly
Page 2224
Tire Pressure Adjustment
Recommended Tire Pressure Adjustment:
NOTE
Use a high quality accurate tire pressure gauge, and check its accuracy regularly.
^ Consider the difference of the air temperature in the workshop and the lowest ambient
temperature that may be expected in the next few weeks (especially in winter).
^ Use the chart (Figure 1) to compensate for temperature of the tires when adjusting tire pressure.
Use temperature compensation Example 1 for the spare tire.
Example 1: Temperature Compensation - "Cold" Tires
^ The vehicle has been parked overnight outside shop (vehicle has "cold" tires) and tire pressures
are set to 31.9 psi.
^ Workshop temperature is 68°F and expected lowest ambient temperature in the local area is to
be 14°F.
^ Subtract the expected lowest temperature (14 F) from the workshop temperature (68°F) = 54°F.
^ Using the tire pressure chart (Figure 1) find the intersection of the cold tire line at the point
corresponding to 54°F and read oft the value on the tire pressure change axis. In this case it would
be about 4.9 psi.
^ The tires should be filled to:
31.9 + 4.9 psi = 36.8 psi
Example 2: Temperature Compensation - "Warm" Tires
^ The vehicle has been driven to the shop on surface streets for about 30 minutes (vehicle has
"warm" tires) and tire pressures are set to 31.9 psi.
^ Workshop temperature is 68 F and expected lowest ambient temperature in your area is to be
14°F.
Page 9180
5. REMOVE NO. 2 SIDE STEP BRACKET LH
(a) Remove the 2 bolts and side step bracket.
6. REMOVE NO. 3 SIDE STEP BRACKET LH
(a) Remove the 4 bolts and 2 side step brackets.
Reassembly
EXTERIOR: SIDE STEP: REASSEMBLY
1. INSTALL NO. 3 SIDE STEP BRACKET LH
(a) Install the 2 side step brackets with the 4 bolts.
Torque : 12 Nm (122 kgf-cm, 9 ft-lbf)
2. INSTALL NO. 2 SIDE STEP BRACKET LH
(a) Install the side step bracket with the 2 bolts.
Torque : 12 Nm (122 kgf-cm, 9 ft-lbf)
Page 4426
Fuel Pump Control Unit: Service and Repair Removal
1UR-FE FUEL: FUEL PUMP ECU: REMOVAL
1. REMOVE FUEL PUMP ECU
(a) Disconnect the 2 fuel pump ECU connectors.
(b) Remove the 2 bolts and fuel pump ECU.
NOTICE: Make sure the fuel pump ECU is not subjected to physical shocks such as being
dropped, etc.
Page 1042
Cargo Lamp Switch: Service and Repair Removal
LIGHTING: CARGO LIGHT SWITCH: REMOVAL
1. REMOVE FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Removal
2. REMOVE FRONT DOOR SCUFF PLATE LH (for Double Cab, CrewMax) See: Body and
Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Removal
3. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Removal
4. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal
5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Removal
6. REMOVE CARGO LIGHT SWITCH
(a) Detach the 2 claws and remove the light switch.
Page 2037
Junction Connector (CAN No.2) - Lower Finish Panel
Page 6721
when inserting and after full engagement.
NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal.
(d) REPAIR METHOD OF CONNECTOR TERMINAL
(1) If there is any foreign matter on the terminal, clean the contact point using an air gun or cloth.
Never rub the contact point using sandpaper
as the plating may come off.
(2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is
gold-plated (gold color), use a gold-plated female
terminal; if it is silver-plated (silver color), use a silver-plated female terminal.
(3) Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock
into the housing, the housing may have to be
replaced.
(e) HANDLING OF WIRE HARNESS
(1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be
restored in the same way.
(2) Never twist, pull or slacken the wire harness more than necessary.
(3) The wire harness should never come into contact with a high temperature part, or rotating,
moving, vibrating or sharp-edged parts. Avoid
contact with panel edges, screw tips and other sharp items.
(4) When installing parts, never pinch the wire harness.
(5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with
vinyl tape.
2. CHECK FOR OPEN CIRCUIT
Page 6975
Push the secondary locking device or terminal retainer in to the full lock position.
CONNECT CONNECTOR
Voltage Check
VOLTAGE CHECK
Page 2897
Air Flow Meter/Sensor: Diagrams
Page 8948
3. INSTALL FRONT BUMPER COVER (for Resin Type Bumper) See: Body and
Frame/Bumper/Front Bumper/Service and Repair/Removal and
Replacement/Front Bumper (for Resin Type Bumper)/Installation
4. INSTALL FRONT END PANEL LH (for Resin Type Bumper) See: Body and
Frame/Bumper/Front Bumper/Service and Repair/Removal and
Replacement/Front Bumper (for Resin Type Bumper)/Installation
5. INSTALL FRONT END PANEL RH (for Resin Type Bumper) See: Body and
Frame/Bumper/Front Bumper/Service and Repair/Removal and
Replacement/Front Bumper (for Resin Type Bumper)/Installation
6. INSTALL FRONT BUMPER BAR (for Steel Type Bumper) See: Body and Frame/Bumper/Front
Bumper/Service and Repair/Removal and
Replacement/Front Bumper (for Steel Type Bumper)/Installation
7. INSTALL FRONT LOWER BUMPER COVER (for Steel Type Bumper) See: Body and
Frame/Bumper/Front Bumper/Service and
Repair/Removal and Replacement/Front Bumper (for Steel Type Bumper)/Installation
8. INSTALL FRONT END PANEL LH (for Steel Type Bumper) See: Body and Frame/Bumper/Front
Bumper/Service and Repair/Removal and
Replacement/Front Bumper (for Resin Type Bumper)/Installation
9. INSTALL FRONT END PANEL RH (for Steel Type Bumper) See: Body and Frame/Bumper/Front
Bumper/Service and Repair/Removal and
Replacement/Front Bumper (for Resin Type Bumper)/Installation
10. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH (for Steel Type Bumper)
See: Body and Frame/Bumper/Front
Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Steel Type
Bumper)/Installation
11. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH (for Steel Type Bumper)
See: Body and Frame/Bumper/Front
Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Steel Type
Bumper)/Installation
12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
13. ADJUST FOG LIGHT
(a) Adjust the fog light See: Lighting and Horns/Fog/Driving Lamp/Adjustments.
Page 2716
Removal
1UR-FE EXHAUST: EXHAUST PIPE (except Regular Cab Standard Deck): REMOVAL
CAUTION: *
Wear protective gloves when removing the exhaust pipe.
* The exhaust pipe is extremely hot immediately after the engine has stopped.
* Confirm that the exhaust pipe has cooled down before removing it.
1. REMOVE TAILPIPE ASSEMBLY
(a) Remove the bolt, clamp and gasket.
(b) Disconnect the tailpipe from the exhaust pipe support.
2. REMOVE CENTER EXHAUST PIPE ASSEMBLY
(a) Remove the 4 bolts.
(b) Disconnect the center exhaust pipe from the 3 exhaust pipe supports.
(c) Remove the center exhaust pipe from the front exhaust pipe and front No. 2 exhaust pipe.
Page 6295
Driver Side J/B - Cowl Side Left
Page 2029
Engine Room R/B, J/B - Engine Compartment Left
Page 268
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION: Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC
terminals are touched, the IC may be destroyed by static electricity.)
When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact with the terminals of leads from the IC, etc. of the
replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown on the left.
DISCONNECT CONNECTOR
Page 5443
(4) If the resistance is not as specified, repair or replace the harness or connector.
(c) Check the 4WD control switch.
(1) Turn the ignition switch OFF.
(2) Connect the L1 switch connector.
(3) Connect the A25 and A26 ECU connectors.
(4) Measure the voltage according to the value(s) in the table below.
Standard voltage:
(5) If the voltage is not as specified, check the 4WD control ECU.
(d) Check the 4WD control ECU.
(1) Disconnect the L1 switch connector.
(2) Measure the voltage according to the value(s) in the table below.
Page 50
Cab)/Installation
7. INSTALL LUGGAGE COMPARTMENT SIDE COVER SUB-ASSEMBLY RH See: Body and
Frame/Seats/Service and Repair/Removal and
Replacement/Rear Seat Assembly (for Double Cab)/Installation
8. INSTALL LUGGAGE COMPARTMENT SIDE COVER SUB-ASSEMBLY LH See: Body and
Frame/Seats/Service and Repair/Removal and
Replacement/Rear Seat Assembly (for Double Cab)/Installation
Page 4633
Spark Plug: Service and Repair Installation
1UR-FE IGNITION: IGNITION COIL AND SPARK PLUG: INSTALLATION
1. INSTALL SPARK PLUG
(a) Using a 16 mm plug wrench, install the 8 spark plugs.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
2. INSTALL IGNITION COIL ASSEMBLY
(a) for Bank 1:
(1) Install the 4 ignition coils with the 4 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(2) Connect the 4 ignition coil connectors.
(3) Connect the 3 wire harness clamps.
(b) for Bank 2:
(1) Install the 4 ignition coils with the 4 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(2) Connect the 4 ignition coil connectors and 2 wire harness clamps.
(3) Connect the water by-pass pipe with the 2 bolts.
Torque : 18 Nm (184 kgf-cm, 13 ft-lbf)
Specifications
Spark Plug: Specifications
SPARK PLUG
Using a 16 mm plug wrench, install the 8 spark plugs.
Torque..................................................................................................................................................
.....................................21 Nm (214 kgf-cm, 15 ft-lbf)
GAP
Page 990
Door Switch: Service and Repair Rear Door Courtesy Switch
Components
LIGHTING: REAR DOOR COURTESY SWITCH: COMPONENTS
Page 3290
Mongoose MFC Software and Driver MUST be installed before Mongoose MFC selection will be
available.
See TIS - Diagnostics - Scantool page for additional information.
^ If using TIS Techstream select TIS Techstream VIM (this is the default).
4. Click OK.
Operation Procedure
1. Verify the vehicle's applicability for recalibration and locate desired calibration file.
A. Connect Techstream and establish a vehicle connection.
B. Click the Health Check button on the System Select tab.
Page 8699
Seat Memory Switch: Testing and Inspection
SEAT: SEAT MEMORY SWITCH (w/ Seat Position Memory System): INSPECTION
1. INSPECT SEAT MEMORY SWITCH
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the switch.
Page 7080
(a) Attach the claw to install the upper steering column cover.
(b) Attach the 4 clips to install the upper steering cover onto the instrument panel cluster finish
panel.
(c) Install the 2 screws.
Torque : 2.0 Nm (20 kgf-cm, 18 in-lbf)
HINT Turn the steering wheel to the right and left as necessary to install the 2 screws.
8. INSPECT SRS WARNING LIGHT
(a) Inspect the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
9. CONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
Page 4819
Page 4941
Torque : 14 Nm (143 kgf-cm, 10 ft-lbf)
NOTICE: When connecting the cable to the transmission control shaft lever, make sure the L
bracket of the cable faces the inside of the vehicle.
(g) Connect the transmission control cable support with the nut.
Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)
2. ADJUST SHIFT LEVER POSITION See: Shifter A/T/Adjustments/SHIFT LEVER ASSEMBLY
(for Floor Shift Type)
3. INSPECT SHIFT LEVER POSITION See: Shifter A/T/Adjustments/SHIFT LEVER ASSEMBLY
(for Floor Shift Type)
4. INSTALL FRONT CONSOLE BOX See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal
and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation
5. INSTALL REAR CONSOLE BOX ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation
6. INSTALL CONSOLE BOX CARPET
7. INSTALL REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
8. INSTALL REAR UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
9. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding
/ Trim/Dashboard / Instrument Panel/Service
and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
10. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Floor Shift Type)/Installation
11. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Installation
12. INSTALL FRONT DOOR SCUFF PLATE LH (for Double Cab, CrewMax) See: Body and
Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Installation
13. INSTALL FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Installation
Page 1696
*: for 5 leaf spring
Page 2223
Introduction
The purpose of this bulletin is to provide a procedure to adjust tire pressure correctly when outside
temperature is significantly colder or warmer than shop temperature.
Seasonal temperature change can dramatically alter tire pressure, which can cause the tire
pressure warning lamp to illuminate.
NOTE
This bulletin applies to some 2004 - 2007 model year Toyota vehicles with direct TPWS and all
2008 and newer model year Toyota vehicles.
Warranty Information
Tire Pressure vs. Tire Temperature
Tire temperature is dependent on "cold" tire pressure, driving distance and speed, ambient
temperature and road surface temperature. As the temperature of the tire changes, air in the tire
expands and contracts, changing the tire's air pressure. The cold tire pressure for all Toyota
models will vary and will need to be adjusted accordingly.
"Cold" tire pressure, as shown on the tire pressure label on our vehicles, is generally considered to
be the pressure in a tire that has not been driven in the past 4 hours and has been parked
outdoors.
The TPWS MUST be initialized with the tire pressure marked on the vehicle placard. Tires are then
adjusted according to the information in this bulletin to ensure that the TPWS light does not
illuminate unnecessarily.
Locations
Power Distribution Relay: Locations
Instrument Panel (Floor Shift)
Instrument Panel (Column Shift)
Page 6581
Symbols Used Within Diagrams
Symbols Used Within Diagrams
Page 8575
3. INSTALL FRONT BUMPER COVER (for Resin Type Bumper) See: Body and
Frame/Bumper/Front Bumper/Service and Repair/Removal and
Replacement/Front Bumper (for Resin Type Bumper)/Installation
4. INSTALL FRONT END PANEL LH (for Resin Type Bumper) See: Body and
Frame/Bumper/Front Bumper/Service and Repair/Removal and
Replacement/Front Bumper (for Resin Type Bumper)/Installation
5. INSTALL FRONT END PANEL RH (for Resin Type Bumper) See: Body and
Frame/Bumper/Front Bumper/Service and Repair/Removal and
Replacement/Front Bumper (for Resin Type Bumper)/Installation
6. INSTALL FRONT BUMPER BAR (for Steel Type Bumper) See: Body and Frame/Bumper/Front
Bumper/Service and Repair/Removal and
Replacement/Front Bumper (for Steel Type Bumper)/Installation
7. INSTALL FRONT LOWER BUMPER COVER (for Steel Type Bumper) See: Body and
Frame/Bumper/Front Bumper/Service and
Repair/Removal and Replacement/Front Bumper (for Steel Type Bumper)/Installation
8. INSTALL FRONT END PANEL LH (for Steel Type Bumper) See: Body and Frame/Bumper/Front
Bumper/Service and Repair/Removal and
Replacement/Front Bumper (for Resin Type Bumper)/Installation
9. INSTALL FRONT END PANEL RH (for Steel Type Bumper) See: Body and Frame/Bumper/Front
Bumper/Service and Repair/Removal and
Replacement/Front Bumper (for Resin Type Bumper)/Installation
10. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH (for Steel Type Bumper)
See: Body and Frame/Bumper/Front
Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Steel Type
Bumper)/Installation
11. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH (for Steel Type Bumper)
See: Body and Frame/Bumper/Front
Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Steel Type
Bumper)/Installation
12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
13. ADJUST FOG LIGHT
(a) Adjust the fog light See: Lighting and Horns/Fog/Driving Lamp/Adjustments.
Page 1650
HINT Tape the screwdriver tip before use.
(b) Disconnect the master switch connector.
2. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY
(a) Remove the 3 screws and master switch.
Installation
WINDSHIELD / WINDOWGLASS: POWER WINDOW MASTER SWITCH: INSTALLATION
1. INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY
(a) Install the master switch with the 3 screws.
Page 7797
Refrigerant Pressure Sensor / Switch: Diagrams
Page 6389
Page 3478
2. CLEAR DTC
(a) Connect the Techstream to the DLC3.
(b) Turn the ignition switch ON.
(c) Turn the Techstream on.
(d) Enter the following menus: Body Electrical / Main Body / Trouble Codes.
(e) Clear the DTCs.
Problem Symptoms Table
MULTIPLEX COMMUNICATION: LIN COMMUNICATION SYSTEM: PROBLEM SYMPTOMS
TABLE
HINT *
Use the table below to help determine the cause of the problem symptom. The potential causes of
the symptoms are listed in order of probability in the "Suspected Area" column of the table. Check
each symptom by checking the suspected areas in the order they are listed. Replace parts as
necessary.
* Inspect the fuses and relays related to the system before inspecting the suspected areas below.
Integration Control and Panel Assembly Communication Error
MULTIPLEX COMMUNICATION: LIN COMMUNICATION SYSTEM: Integration Control and Panel
Assembly Communication Error - Integration Control and Panel Assembly Communication Error
DESCRIPTION
The LIN communication of the components related to the mirror heater occurs between the air
conditioning amplifier assembly (A/C ECU) and integration control and panel assembly.
WIRING DIAGRAM
INSPECTION PROCEDURE
NOTICE: When using the Techstream with the ignition switch OFF to troubleshoot:
Components
Camshaft Position Sensor: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT POSITION SENSOR: COMPONENTS
Locations
Throttle Position Sensor: Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 6563
J/B No.3 Inner Circuit
J/B No.4 Inner Circuit
J/B No.5 Inner Circuit
Page 3732
(c) WAVEFORM 2:
HINT The wavelength varies in accordance with the engine operating conditions.
(d) WAVEFORM 3:
HINT In the Data List, item O2S B1 S2 and O2S B2 S2 shows the ECM input values from the
heated oxygen sensor.
(e) WAVEFORM 4:
Page 8797
Speaker: Service and Repair Floor Speaker (for Double Cab)
Components
AUDIO / VISUAL: FLOOR SPEAKER (for Double Cab): COMPONENTS
Removal
AUDIO / VISUAL: FLOOR SPEAKER (for Double Cab): REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
Page 733
Seat Heater Switch: Testing and Inspection
SEAT: SEAT HEATER SWITCH (w/ Seat Heater System or Climate Control Seat System):
INSPECTION
1. INSPECT SEAT HEATER SWITCH LH (w/ Seat Heater System)
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
HINT As the dial is being turned, the resistance changes gradually.
(b) If the result is not as specified, replace the switch.
(c) Apply battery voltage to the switch connector, and check that the seat heater switch illuminates.
OK:
(d) If the result is not as specified, replace the switch.
(e) Apply battery voltage to the switch connector, and check that the seat heater switch illuminates.
OK:
Removal and Replacement
Housing Assembly HVAC: Removal and Replacement
Components
AIR CONDITIONING: AIR CONDITIONING UNIT: COMPONENTS
Page 7639
"Case2" Open the secondary locking device.
[B] For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray
Gray or White : Black
Center Airbag Sensor Assembly (for Column Shift Type)
Impact Sensor: Testing and Inspection Center Airbag Sensor Assembly (for Column Shift Type)
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Column
Shift Type): ON-VEHICLE INSPECTION
1. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION)
(a) Perform a diagnostic system check See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
2. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND
AIRBAG HAS NOT DEPLOYED)
(a) Perform a diagnostic system check See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
3. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND
AIRBAG IS DEPLOYED)
(a) Replace the center airbag sensor.
CAUTION: For removal and installation procedures of the center airbag sensor, be sure to follow
the correct procedure.
HINT The center airbag sensor should be replaced after any of the airbags has deployed, as it has
been subjected to the impact.
Page 5709
Brake Bleeding: Service and Repair Replacement
BRAKE: BRAKE FLUID: REPLACEMENT
NOTICE: *
Perform fluid replacement with the parking brake applied.
* Perform fluid replacement while maintaining the brake fluid level between the MIN/MAX level on
the brake fluid reservoir.
* Do not allow brake fluid to contact the vehicle's paint surfaces. If contact occurs, clean it off
immediately.
* Add fluid to the brake fluid reservoir as necessary so that the fluid does not decrease below the
MIN level.
1. REPLACE BRAKE FLUID
(a) Replace the brake fluid.
(1) Remove the brake master cylinder reservoir filler cap assembly.
(2) Add brake fluid into the reservoir between MAX and MIN level on the brake fluid reservoir.
Brake fluid:
SAE J1703 or FMVSS No. 116 DOT3
(3) Connect a vinyl tube to the bleeder plug of the front disc brake cylinder RH.
(4) Depress the brake pedal several times, and then loosen the bleeder plug with the pedal
depressed.*1
(5) When fluid stops coming out, tighten the bleeder plug, and then release the brake pedal.*2
(6) Repeat *1 and *2 until all the air in the brake fluid is completely bled out and the new brake fluid
comes out.
(7) Tighten the bleeder plug completely.
Torque : 11 Nm (110 kgf-cm, 8 ft-lbf)
(8) Replace the brake fluid from the front disc brake cylinder LH using the same procedure as for
RH.
(9) Connect a vinyl tube to the bleeder plug of the rear disc brake cylinder RH.
(10)Depress the brake pedal several times, and then loosen the bleeder plug with the pedal
depressed.*1
(11)When fluid stops coming out, tighten the bleeder plug, and then release the brake pedal.*2
(12)Repeat *1 and *2 until all the air in the brake fluid is completely bled out and the new brake
fluid comes out.
(13)Tighten the bleeder plug completely.
Torque : 11 Nm (110 kgf-cm, 8 ft-lbf)
(14)Replace the brake fluid from the rear disc brake cylinder LH using the same procedure as for
RH.
(b) Check and bleed brake system.
(1) If the following malfunction symptoms occur, air may have entered the brake fluid line. Perform
the following air bleed procedures.
* Low pedal or spongy pedal.
* Brake pedal is depressed firmly but braking is insufficient.
(c) Inspect for the brake fluid leak.
(d) Check and adjust brake fluid level in reservoir See: Brake Fluid/Testing and Inspection.
Page 7852
Compressor Speed Sensor: Locations Air Conditioning System (for Manual Air Conditioning
System)
AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Manual Air Conditioning System):
PARTS LOCATION
Page 6618
Power Outlet [12V]
Locations
Transmission Mode Switch: Locations
A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS
LOCATION
Page 6480
(2) Disconnect connector B and measure the resistance.
Standard resistance (Fig. 7):
* If the results match the examples above, a short circuit exists between terminal 1 of connector B2
and terminal 1 of connector C.
4. CHECK AND REPLACE ECU
NOTICE: *
The connector should not be disconnected from the ECU. Perform the inspection from the backside
of the connector on the wire harness side.
* When no measuring condition is specified, perform the inspection with the engine stopped and
the ignition switch ON.
* Check that the connectors are fully seated. Check for loose, corroded or broken wires.
(a) First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be
faulty. Temporarily replace the ECU with a
normally functioning one and check if the symptoms occur. If the trouble symptoms disappear,
replace the original ECU.
(1) Measure the resistance between the ECU ground terminal and body ground.
Standard resistance:
Below 1 Ohms
(2) Disconnect the ECU connector. Check the ground terminal on the ECU side and wire harness
side for bending, corrosion or foreign matter.
Lastly, check the contact pressure of the female terminals.
Page 3431
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- CHECK FOR SHORT IN CAN BUS WIRES (SKID CONTROL ECU WITH ACTUATOR) OK
-- Continue to next step.
10. CHECK FOR SHORT IN CAN BUS WIRES (NO. 1 JUNCTION CONNECTOR - STEERING
ANGLE SENSOR)
(a) Disconnect the J87 No. 1 junction connector connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- CHECK FOR SHORT IN CAN BUS WIRES (STEERING ANGLE SENSOR) OK -- Continue
to next step.
11. CHECK FOR SHORT IN CAN BUS WIRES (NO. 1 JUNCTION CONNECTOR - POWER
STEERING ECU)
NOTICE: For vehicles without a power steering ECU, go to "CHECK FOR SHORT IN CAN BUS
WIRES (NO. 1 JUNCTION CONNECTOR - CENTER AIRBAG SENSOR)".
(a) Disconnect the J115 No. 1 junction connector connector.
Up to 11/2009
Steering Angle Sensor: Locations Up to 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 2159
No further tightening is required once the nut is tightened with the specified torque.
2. INSTALL WHEEL
for Aluminum Wheel - Torque : 131 Nm (1336 kgf-cm, 97 ft-lbf)
for Steel Wheel - Torque : 209 Nm (2131 kgf-cm, 154 ft-lbf)
3. INSPECT TIRE
(a) Inspect the tire See: Testing and Inspection/Component Tests and General Diagnostics.
4. REGISTRATION OF TRANSMITTER ID
(a) Register the transmitter ID See: Tire Monitoring System/Testing and Inspection/Programming
and Relearning/Registration.
5. PERFORM INITIALIZATION
(a) Perform initialization See: Tire Monitoring System/Testing and Inspection/Programming and
Relearning/Initialization.
NOTICE: Be sure to inflate all tires to the proper inflation pressure before initialization.
6. CHECK TIRE PRESSURE AFTER REPAIRS
(a) After repairs, confirm that the actual tire pressures are displayed in the DATA LIST See: Tire
Monitoring System/Testing and
Inspection/Scan Tool Testing and Procedures/Data List / Active Test.
Page 1449
Seat Occupant Sensor: Diagrams Rear Occupant Classification Sensor
Page 399
(q) WAVEFORM 16:
HINT The wavelength changes when the air injection control driver detects malfunctions in the air
injection system See: Powertrain Management/Computers and Control Systems/Testing and
Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0412
(r) WAVEFORM 17:
HINT The wavelength becomes shorter as engine rpm increases.
(s) WAVEFORM 18:
Page 2581
Fuel Pressure: Testing and Inspection
1UR-FE FUEL: FUEL SYSTEM: ON-VEHICLE INSPECTION
1. CHECK FUEL PUMP OPERATION AND FOR FUEL LEAK
(a) Connect the Techstream to the DLC3.
(b) Turn the ignition switch to ON.
NOTICE: Do not start the engine.
(c) Turn the Techstream main switch ON.
(d) Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump /
Speed.
(e) Check the fuel pump operation.
(1) Check for pressure in the fuel inlet tube from the fuel line. Check that the sound of fuel flowing
in the fuel tank can be heard.
If there is no sound, check the integration relay, fuel pump, ECM and wiring connector.
(f) Check for fuel leak.
(1) Check that there are no fuel leaks after performing maintenance anywhere on the system.
If there are fuel leaks, repair or replace parts as necessary.
2. CHECK FUEL PRESSURE
(a) Check that the battery voltage is 11 to 14 V.
(b) Perform the "DISCHARGE FUEL SYSTEM PRESSURE" procedures See: Powertrain
Management/Fuel Delivery and Air
Induction/Service Precautions.
(c) Disconnect the cable from the negative (-) battery terminal.
(d) Remove the fuel pipe clamp from the fuel tube connector.
(e) Pinch and pull the fuel tube (fuel tube connector) to disconnect it.
CAUTION: *
Always read the precautions See: Powertrain Management/Fuel Delivery and Air Induction/Service
Precautions before disconnecting the fuel tube connector (quick type).
* The fuel tube may spray fuel as a result of pressure that remains in it. Do not allow fuel to be
sprayed in the engine compartment.
Page 5787
Parking Brake Warning Switch: Testing and Inspection
PARKING BRAKE: PARKING BRAKE SWITCH: ON-VEHICLE INSPECTION
1. REMOVE PARKING BRAKE SWITCH ASSEMBLY See: Parking Brake Pedal/Service and
Repair/Overhaul/Disassembly
2. CHECK PARKING BRAKE SWITCH ASSEMBLY
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the parking brake switch assembly.
3. INSTALL PARKING BRAKE SWITCH ASSEMBLY See: Parking Brake Pedal/Service and
Repair/Overhaul/Reassembly
Engine Control System - SFI System
Camshaft Position Sensor: Locations Engine Control System - SFI System
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 1854
J. When Cal 1 has completed the update process turn ignition OFF for a minimum of 10 seconds.
Then click Next.
K. Turn ignition to the ON position. Then click Start.
L. Do NOT disturb the vehicle during flash reprogramming.
Page 2024
If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness
or connector in that circuit in the past. Check the wire harness and connectors.
B -- SYSTEM NORMAL
A -- TROUBLESHOOTING OF EACH PROBLEM SYMPTOM
The problem is still occurring in a place other than the diagnostic circuit (the DTC displayed first is
either for a past problem or a secondary problem).
4. SYMPTOM SIMULATION
HINT The most difficult case in troubleshooting is when no problem symptoms occur. In such a
case, a thorough problem analysis must be carried out. A simulation of the same or similar
conditions and environment in which the problem occurred in the customer's vehicle should be
carried out. No matter how much skill or experience a technician has, troubleshooting without
confirming the problem symptoms will lead to important repairs being overlooked and mistakes or
delays.
For example:
With a problem that only occurs when the engine is cold or as a result of vibration caused by the
road during driving, the problem can never be determined if the symptoms are being checked on a
stationary vehicle or on a vehicle with a warmed-up engine. Vibration, heat or water penetration
(moisture) is difficult to reproduce. The symptom simulation tests below are effective substitutes for
the conditions and can be applied on a stationary vehicle.
Important points in the symptom simulation test:
In the symptom simulation test, the problem symptoms as well as the problem area or parts must
be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then,
connect the tester and carry out the symptom simulation test, judging whether the circuit being
tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the
problem symptoms table for each system to narrow down the possible causes.
To reproduce DTCs, it is necessary to satisfy the respective DTC detection conditions.
(a) VIBRATION METHOD:
When a malfunction seems to occur as a result of vibration.
(1) PART AND SENSOR
Apply slight vibration with a finger to the part of the sensor suspected to be the cause of the
problem, and check whether or not the malfunction occurs.
NOTICE: Applying strong vibration to relays may open them.
Page 4609
Ignition Switch: Connector Views
Locations
Trailer Lighting Relay: Locations
LIGHTING: LIGHTING SYSTEM: PARTS LOCATION
Page 6939
Driver Side J/B - Cowl Side Left
Page 2605
(4) for Fuel Pipe Clamp Type:
Install the fuel pipe clamp to the connector.
(5) for Fuel Hose Connector Cover Type:
Attach the lock claw to the connector by pushing down on the cover, as shown in the illustration.
(6) Check that there is no fuel leakage.
3. CHECK FOR FUEL LEAK
(a) Check that there are no fuel leaks after performing maintenance anywhere on the fuel system
See: Powertrain Management/Fuel Delivery and
Air Induction/Testing and Inspection.
Page 1329
Page 3914
Variable Valve Timing Actuator: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT OIL CONTROL VALVE: REMOVAL
1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Removal
2. REMOVE AIR CLEANER HOSE ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Removal
3. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side of Bank
1)
(a) Disconnect the oil control valve connector.
(b) Remove the bolt and oil control valve.
(c) Remove the O-ring from the oil control valve.
4. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side of Bank 1)
(a) Disconnect the oil control valve connector.
(b) Remove the bolt and oil control valve.
(c) Remove the O-ring from the oil control valve.
5. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side of Bank 2)
(a) Disconnect the oil control valve connector.
(b) Remove the bolt and oil control valve.
(c) Remove the O-ring from the oil control valve.
6. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side of Bank
2)
(a) Disconnect the oil control valve connector.
(b) Remove the bolt and oil control valve.
Page 8440
Antenna, Radio: Service and Repair Radio Antenna Pole
Components
AUDIO / VISUAL: RADIO ANTENNA POLE: COMPONENTS
Removal
AUDIO / VISUAL: RADIO ANTENNA POLE: REMOVAL
1. REMOVE PULL TOP ANTENNA POLE SUB-ASSEMBLY
Page 5531
Transmission Speed Sensor: Service and Repair Installation
A760F AUTOMATIC TRANSMISSION: SPEED SENSOR: INSTALLATION
1. INSTALL SPEED SENSOR SP2
(a) Coat a new O-ring with ATF and install it to the sensor.
(b) Install the sensor with the bolt.
Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)
(c) Connect the sensor connector.
2. INSTALL SPEED SENSOR NT
(a) Coat a new O-ring with ATF and install it to the sensor.
(b) Install the sensor with the bolt.
Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)
(c) Connect the sensor connector.
Page 6333
Components
Fuel Pump Control Unit: Service and Repair Components
1UR-FE FUEL: FUEL PUMP ECU: COMPONENTS
Page 4862
Transmission Mode Switch: Diagrams Tow/Haul Pattern Select Switch
Page 3819
Knock Sensor: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: INSTALLATION
1. INSTALL KNOCK SENSOR
(a) Install the 4 sensors with the 4 bolts so that the sensors are angled as shown in the illustration.
Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)
NOTICE: The acceptable installation angle of the sensor is between 10° upward and downward
from the horizontal position.
(b) Connect the 4 sensor connectors.
2. INSTALL SEPARATOR CASE
(a) Install the separator case with the 4 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
3. INSTALL INTAKE MANIFOLD
(a) Install the intake manifold See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service
and Repair/Installation.
Page 444
Ignition Relay: Testing and Inspection
1UR-FE ENGINE CONTROL SYSTEM: IGNITION RELAY NO. 2: ON-VEHICLE INSPECTION
1. REMOVE INTEGRATION RELAY
(a) Remove the engine room relay block cover.
(b) Using a screwdriver, detach the 2 claws and remove the integration relay from the engine room
relay block.
HINT Tape the screwdriver tip before use.
(c) Disconnect the 3 connectors.
2. INSPECT INTEGRATION RELAY (IG2)
NOTICE: *
Some relays are built into the integration relay. The integration relay cannot be disassembled. If
there is a malfunction in the circuit of the integration relay, replace the integration relay.
* The internal circuit of the integration relay is as shown in the illustration below. Inspect the
integration relay using the following procedures.
(a) Measure the resistance of the IG2 MAIN fuse.
(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(2) If the result is not as specified, replace the IG2 MAIN fuse.
(b) Measure the resistance of the ignition relay No. 2 (IG2).
Page 3905
Parts Information
Required Tools & Equipment
Additional TIS Techstream units may be ordered by calling Approved Dealer Equipment (ADE).
TSB Overview
1. Confirm that DTC P0012 and/or P0022 is stored in the ECM.
2. Diagnose the Oil Control Valves (OCVs) for proper operation.
3. If the OCVs operate correctly replace both intake VVTi gear assemblies following the Repair
Manual.
Diagnostic Procedure
1. Using TIS Techstream confirm that DTC P0012 and/or P0022 is stored in the ECM.
2. Remove the affected Oil Control Valve (OCV) and inspect for debris in the valve or evidence that
the valve is stuck.
3. Check valve operation by applying positive (+) battery voltage to terminal 1 and negative (-)
battery voltage to terminal 2. Valve should move
quickly when voltage is applied. If NOT valve should be replaced.
4. Reinstall the OCVs warm up the engine to over 167°F (75°C) and perform an Active Test using
Tech stream.
Powertrain / Engine and ECT / Active Test / Control the WT System (Bank 1) or (Bank 2)
5. If there is NO debris and the OCV moves with battery voltage and Active Test functions Replace both intake VVTi gears following the repair
procedure below.
Repair Procedure
1. Replace both intake VVTi gears.
Page 1423
9. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH (for Rear Side)
10. INSTALL REAR DOOR SCUFF PLATE LH (for Rear Side) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and Repair/Roof
Headlining (For Double Cab)/Installation
11. INSTALL REAR SEAT ASSEMBLY (for Rear Side)
(a) Install the rear seat assembly See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Rear Seat Assembly (for Double
Cab)/Installation.
12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
13. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
Components
SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Regular Cab):
COMPONENTS
Page 5670
Page 6488
(2) CONNECTORS
Slightly shake the connector vertically and horizontally.
(3) WIRE HARNESS
Slightly shake the wire harness vertically and horizontally.
HINT The connector joint and fulcrum of the vibration are the major areas that should be checked
thoroughly.
(b) HEAT METHOD:
When a malfunction seems to occur when the area in question is heated.
(1) Heat the component that is the possible cause of the malfunction with a hair dryer or similar
device. Check if the malfunction occurs.
NOTICE: *
Do not heat to more than 60°C (140°F). Exceeding this temperature may damage components.
* Do not apply heat directly to the parts in the ECU.
(c) WATER SPRINKLING METHOD:
When a malfunction seems to occur on a rainy day or in high-humidity.
(1) Sprinkle water onto the vehicle and check if the malfunction occurs.
NOTICE: *
Never sprinkle water directly into the engine compartment. Indirectly change the temperature and
humidity by spraying water onto the front of the radiator.
* Never apply water directly onto the electronic components.
HINT If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU
or connections. Look for evidence of corrosion or short circuits. Proceed with caution during water
tests.
(d) HIGH ELECTRICAL LOAD METHOD:
When a malfunction seems to occur when the electrical load is excessive.
(1) Turn on the heater blower, headlights, rear window defogger and all other electrical loads.
Check if the malfunction reoccurs.
5. DIAGNOSTIC TROUBLE CODE CHART
Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate
section's Diagnostic Trouble Code Chart. Use the chart to determine the trouble area and the
proper inspection procedure. A description of each of the chart's columns is below.
Page 6628
2. REMOVE CONSOLE BOX BEZEL
(a) Disconnect the connector.
(b) Using a screwdriver, detach the 5 claws and remove the console box bezel.
HINT Tape the screwdriver tip before use.
3. REMOVE POWER OUTLET SOCKET ASSEMBLY
(a) Using a screwdriver, detach the claw and remove the power outlet socket.
HINT Tape the screwdriver tip before use.
4. REMOVE POWER OUTLET SOCKET COVER
(a) Detach the 2 claws and remove the power outlet socket cover.
5. REMOVE REAR CONSOLE END PANEL SUB-ASSEMBLY (for Double Cab) See: Body and
Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Floor Shift Type)/Removal
6. REMOVE REAR POWER OUTLET SOCKET ASSEMBLY (for Double Cab)
(a) Using a screwdriver, detach the claw and remove the power outlet socket.
Page 4342
Page 6930
* In the DTC check, it is very important to determine whether the problem indicated by the DTC is
either: 1) still occurring; or 2) occurred in the past but has since returned to normal. In addition, the
DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs
should be checked before and after confirmation of symptoms (i.e., whether or not problem
symptoms exist) to determine current system conditions, as shown in the flowchart below.
* Never skip the DTC check. Failing to check DTCs may, depending on the case, result in
unnecessary troubleshooting for systems operating normally or lead to repairs not related to the
problem. Follow the procedures listed in the flowchart in the correct order.
* The following flowchart shows how to proceed with troubleshooting using the DTC check.
Directions from the flowchart will indicate how to proceed either to DTC troubleshooting or to the
troubleshooting of each problem symptom.
1. DTC CHECK
NEXT -- Continue to next step.
2. MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR MEMORY
NEXT -- Continue to next step.
3. SYMPTOM CONFIRMATION
B -- Go to step 5 A -- Continue to next step.
4. SIMULATION TEST USING SYMPTOM SIMULATION METHODS
NEXT -- Continue to next step.
5. DTC CHECK
B -- TROUBLESHOOTING OF PROBLEM INDICATED BY DTC A -- Continue to next step.
6. SYMPTOM CONFIRMATION
Page 179
Use a volt/ohmmeter with high impedance (10 kohms/V minimum) for troubleshooting of the
electrical circuit.
Disconnection of Male and Female Connectors
DISCONNECTION OF MALE AND FEMALE CONNECTORS
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Finding A Short Circuit
FINDING A SHORT CIRCUIT
Page 7039
for CrewMax of standard deck
Page 6634
Auxiliary Power Outlet: Service and Repair Power Outlet Socket (for Crewmax Column Shift Type)
Components
OTHER SYSTEM: POWER OUTLET SOCKET (for CrewMax Column Shift Type): COMPONENTS
Removal
OTHER SYSTEM: POWER OUTLET SOCKET (for CrewMax Column Shift Type): REMOVAL
1. REMOVE CENTER SEATBACK PANEL See: Body and Frame/Seats/Service and
Repair/Overhaul/Front Seat Assembly (for Center
Seat)/Disassembly
Page 4114
(4) for Fuel Pipe Clamp Type:
Install the fuel pipe clamp to the connector.
(5) for Fuel Hose Connector Cover Type:
Attach the lock claw to the connector by pushing down on the cover, as shown in the illustration.
(6) Check that there is no fuel leakage.
3. CHECK FOR FUEL LEAK
(a) Check that there are no fuel leaks after performing maintenance anywhere on the fuel system
See: Testing and Inspection.
Occupant Classification System
Air Bag Control Module: Locations Occupant Classification System
SUPPLEMENTAL RESTRAINT SYSTEM: OCCUPANT CLASSIFICATION SYSTEM: PARTS
LOCATION
Page 8400
Seat Occupant Sensor: Locations Seat Belt Warning System
SEAT BELT: SEAT BELT WARNING SYSTEM: PARTS LOCATION
Page 8351
Removal
SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for CrewMax): REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Disassembly
3. REMOVE FRONT UPPER ARMREST BASE PANEL LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Page 8013
Removal
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Column
Shift Type): REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service
and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Removal
3. REMOVE CENTER AIRBAG SENSOR ASSEMBLY
Page 3537
OK -- Continue to next step.
3. CHECK HARNESS AND CONNECTOR (AIR CONDITIONING AMPLIFIER - BATTERY AND
BODY GROUND)
(a) Reconnect the cable to the negative (-) battery terminal before measuring the resistances of the
main wire and the branch wire.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(c) Measure the voltage according to the value(s) in the table below.
Standard voltage:
NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- REPLACE AIR CONDITIONING AMPLIFIER ASSEMBLY
Bus Buffer ECU Communication Stop Mode
CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: Bus Buffer ECU Communication
Stop Mode - Bus Buffer ECU Communication Stop Mode
DESCRIPTION
WIRING DIAGRAM
Page 7198
(c) Install the rear housing with the 4 bolts.
Torque : 22 Nm (224 kgf-cm, 16 ft-lbf)
8. INSPECT TOTAL PRELOAD See: Testing and Inspection
9. INSTALL POWER STEERING SUCTION PORT UNION
(a) Coat a new O-ring with power steering fluid and install it to the suction port union.
(b) Install the suction port union to the vane pump with the bolt.
Torque : 12 Nm (122 kgf-cm, 9 ft-lbf)
Page 3411
Page 6107
(2) If the result is not as specified, replace the starter armature assembly.
(d) Using a vernier caliper, measure the commutator diameter.
Standard diameter:
35.0 mm (1.38 in.)
Minimum diameter:
34.0 mm (1.34 in.)
(e) If the diameter is less than the minimum, replace the starter armature assembly.
(f) Using a dial gauge, measure the commutator runout.
Maximum commutator runout:
0.05 mm (0.00197 in.)
(g) If the commutator runout is more than the maximum, correct it using a lathe.
(h) Measure the undercut depth of the commutator.
Standard undercut depth:
0.7 mm (0.0276 in.)
Minimum undercut depth:
0.2 mm (0.00787 in.)
Page 6017
1UR-FE CHARGING: GENERATOR: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE FAN AND GENERATOR V BELT
(a) Remove the fan and generator V belt See: Engine, Cooling and Exhaust/Engine/Drive Belts,
Mounts, Brackets and Accessories/Drive
Belt/Service and Repair/Removal.
3. REMOVE AIR CLEANER ASSEMBLY See: Powertrain Management/Ignition System/Ignition
Coil/Service and Repair/Removal
4. REMOVE FRONT FENDER APRON SEAL RH See: Engine, Cooling and Exhaust/Exhaust
System/Exhaust Manifold/Service and
Repair/Removal
5. DISCONNECT POWER STEERING OIL PRESSURE SWITCH CONNECTOR See: Steering
and Suspension/Steering/Power Steering/Power
Steering Pump/Service and Repair/Removal and Replacement/Removal
6. DISCONNECT SOLENOID VALVE CONNECTOR See: Steering and
Suspension/Steering/Power Steering/Power Steering Pump/Service and
Repair/Removal and Replacement/Removal
7. DISCONNECT VANE PUMP ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Engine
Lubrication/Oil Pump/Service and
Repair/Removal and Replacement/Removal
8. DISCONNECT OIL COOLER TUBE SUB-ASSEMBLY (w/ Trailer Towing System) See: Engine,
Cooling and Exhaust/Engine/Service and
Repair/Removal and Replacement/Engine Assembly/Removal
9. REMOVE GENERATOR ASSEMBLY
(a) Remove the terminal cap.
(b) Disconnect the generator connector.
(c) Remove the nut and disconnect the generator wire.
(d) Remove the bolt and disconnect the wire harness bracket from the generator.
(e) Remove the 3 bolts, nut and generator.
Installation
1UR-FE CHARGING: GENERATOR: INSTALLATION
1. INSTALL GENERATOR ASSEMBLY
(a) Install the generator with the 3 bolts and nut.
Page 3376
Establish conditions in which voltage is present at the check point.
Example:
- [A] - Ignition SW on
- [B] - Ignition SW and SW1 on
- [C] - Ignition SW, SW1 and Relay on (SW2 off)
Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or component terminal.
This check can be done with a test light instead of a voltmeter.
Electronic Circuit Inspection Procedure
Page 3590
(a) Disconnect the ECM connector.
(b) Disconnect the combination meter connector.
(c) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- REPLACE COMBINATION METER ASSEMBLY See: Instrument Panel, Gauges and
Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Combination Meter/Removal
5. CHECK THAT MIL IS ILLUMINATED
(a) Check if the MIL is illuminated when the ignition switch is turned to ON.
OK:
MIL should be illuminated.
NG -- CHECK THAT ENGINE STARTS
OK -- END
6. CHECK THAT ENGINE STARTS
(a) Turn the ignition switch to ON.
(b) Start the engine.
Result
HINT *: The Techstream cannot communicate with the ECM.
Page 8018
(e) Connect the holder (with connectors).
(f) Check that the waterproof sheet is properly set.
2. INSTALL FRONT CONSOLE BOX See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal
and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation
3. INSTALL REAR CONSOLE BOX ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation
4. INSTALL CONSOLE BOX CARPET
5. INSTALL REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
6. INSTALL UPPER CONSOLE REAR PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
7. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding
/ Trim/Dashboard / Instrument Panel/Service
and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
8. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation
9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
10. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
Components
Knock Sensor: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: COMPONENTS
Page 5777
(b) Remove the clip.
(c) Using a screwdriver, slowly bend up the claw.
NOTICE: Be careful not to damage the No. 1 parking brake cable or claw.
(d) Disconnect the parking brake cable from the parking brake control pedal.
7. REMOVE PARKING BRAKE CONTROL PEDAL ASSEMBLY
(a) Disconnect the connector.
(b) Detach the wire harness clamp from the control pedal.
(c) Remove the 3 nuts and parking brake control pedal from the body.
Page 830
Page 4602
4. SYMPTOM CONFIRMATION AND DTC (INCLUDING FREEZE FRAME DATA) CHECK
(a) Visually check the wire harnesses, connectors and fuses for open and short circuits.
(b) Warm up the engine to the normal operating temperature.
(c) Confirm the problem symptoms and conditions, and check for DTCs.
B -- Go to step 6 A -- Continue to next step.
5. DTC CHART
(a) Check the results obtained in the DTC check. Then find the output DTC in the DTC chart. Look
at the "Trouble Area" column for a list of
potentially malfunctioning circuits and / or parts.
NEXT -- Go to step 7
6. PROBLEM SYMPTOMS TABLE
(a) Check the results obtained in the symptom confirmation. Then find the problem symptoms in
the problem symptoms table. Look at the
"Suspected Area" column for a list of potentially malfunctioning circuits and / or parts.
NEXT -- Continue to next step.
7. CIRCUIT INSPECTION OR PARTS INSPECTION
(a) Confirm the malfunctioning circuit or part.
NEXT -- Continue to next step.
8. ADJUST, REPAIR OR REPLACE
(a) Adjust, repair or replace the malfunctioning circuit or parts.
NEXT -- Continue to next step.
9. CONFIRMATION TEST
(a) After the adjustment, repairs or replacement, confirm that the malfunction no longer exists. If the
malfunction does not reoccur, perform a
confirmation test under the same conditions and in the same environment as when the malfunction
occurred the first time.
NEXT -- END
2. CUSTOMER PROBLEM ANALYSIS
HINT *
In troubleshooting, confirm that the problem symptoms have been accurately identified.
Preconceptions should be discarded in order to make an accurate judgment. To clearly understand
what the problem symptoms are, it is extremely important to ask the customer about the problem
and the conditions at the time the malfunction occurred.
* Gather as much information as possible for reference. Past problems that seem unrelated may
also help in some cases.
* The following 5 questions are important points in the problem analysis:
Page 3524
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO MAIN BODY ECU (CANH,
CANL)
OK -- REPLACE MAIN BODY ECU
15. CHECK FOR SHORT TO GND IN CAN BUS WIRE (SKID CONTROL ECU WITH ACTUATOR)
(a) Disconnect the A17 skid control ECU with actuator connector.
Page 8045
(3) After setting the spiral cable to the center position, rotate the spiral cable 2.5 times clockwise.
Then while rotating the spiral cable 5 times
counterclockwise, measure the resistance according to the U4 (uecs) in the table below.
Standard resistance:
NOTICE: As the spiral cable may break, do not rotate the spiral cable more than the specified
amount.
Page 3541
NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- REPLACE CENTER AIRBAG SENSOR
Combination Meter ECU Communication Stop Mode
CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: Combination Meter ECU
Communication Stop Mode - Combination Meter ECU Communication Stop Mode
DESCRIPTION
WIRING DIAGRAM
INSPECTION PROCEDURE
PROCEDURE
1. CHECK HARNESS AND CONNECTOR (COMBINATION METER ECU - BATTERY AND BODY
GROUND)
(a) Disconnect the J28 combination meter ECU connector.
Page 8476
Alarm System Transponder: Service and Repair Removal
ENGINE IMMOBILISER: TRANSPONDER KEY AMPLIFIER: REMOVAL
1. REMOVE LOWER STEERING COLUMN COVER
(a) While turning the steering wheel to the right and left, remove the 2 screws.
(b) Detach the 2 claws and remove the lower steering column cover.
2. REMOVE TRANSPONDER KEY AMPLIFIER
(a) Using a screwdriver, widen the claws attached to the upper bracket by approximately 1 mm
(0.0394 in.).
(b) Pull out the transponder key amplifier with the claws open.
NOTICE: Take care not to apply excessive force to prevent the case from being damaged.
Page 5481
Actuator: Service and Repair Removal
DIFFERENTIAL: AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR (for 4WD):
REMOVAL
1. REMOVE NO. 1 ENGINE UNDER COVER See: Engine, Cooling and Exhaust/Engine/Drive
Belts, Mounts, Brackets and Accessories/Drive
Belt/Service and Repair/Removal
2. REMOVE AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR
(a) Disconnect the actuator hose.
(b) Disconnect the actuator connector.
(c) Remove the 4 bolts and actuator.
Page 5687
Brake Pedal Assy: Service and Repair Removal
BRAKE: BRAKE PEDAL: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to disable the SRS system.
2. REMOVE FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Removal
3. REMOVE FRONT DOOR SCUFF PLATE LH (for Double Cab, CrewMax) See: Body and
Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Removal
4. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Removal
5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Removal
6. REMOVE LOWER NO. 1 INSTRUMENT PANEL AIR BAG ASSEMBLY See: Restraint
Systems/Air Bag Systems/Air Bag/Service and
Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Removal
7. REMOVE NO. 1 AIR DUCT SUB-ASSEMBLY
(a) Remove the bolt and air duct.
8. REMOVE PUSH ROD PIN
(a) Remove the clip and push rod pin from the brake pedal lever.
9. REMOVE STOP LIGHT SWITCH ASSEMBLY
(a) Disconnect the stop light switch connector.
(b) Remove the stop light switch See: Lighting and Horns/Brake Light Switch/Service and
Repair/Removal.
(c) Detach the harness clip.
10. REMOVE STOP LIGHT SWITCH MOUNTING ADJUSTER
(a) Remove the stop light switch mounting adjuster See: Lighting and Horns/Brake Light
Switch/Service and Repair/Removal.
11. REMOVE BRAKE PEDAL SUPPORT SUB-ASSEMBLY
(a) Remove the brake pedal return spring.
Page 6798
(1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be
checked by conducting a voltage check.
With each connector still connected, measure the voltage between the body ground and these
terminals (in this order): 1) terminal 1 of connector A; 2) terminal 1 of connector B; and 3) terminal
1 of connector C.
Standard voltage (Fig. 4):
* If the results match the examples above, an open circuit exists in the wire harness between
terminal 1 of connector B and terminal 1 of connector C.
3. CHECK FOR SHORT CIRCUIT
(a) If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance
check with the body ground (below).
(b) Check the resistance with the body ground.
(1) Disconnect connectors A and C and measure the resistance.
Standard resistance (Fig. 6):
HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally.
If your results match the examples above, a short circuit exists between terminal 1 of connector A
and terminal 1 of connector C.
Page 1446
Page 5944
Page 1181
Knock Sensor: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: REMOVAL
1. REMOVE INTAKE MANIFOLD
(a) Remove the intake manifold See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service
and Repair/Removal.
2. REMOVE SEPARATOR CASE
(a) Remove the 4 bolts and separator case.
3. REMOVE KNOCK SENSOR
(a) Disconnect the 4 knock sensor connectors.
(b) Remove the 4 bolts and 4 knock sensors.
Page 4922
2. REMOVE SHIFT LOCK RELEASE BUTTON
(a) Detach the 4 claws and remove the position indicator housing from the floor shift.
(b) Detach the 2 claws and remove the button.
3. REMOVE SHIFT LOCK CONTROL ECU
(a) Disconnect the shift lock solenoid connector.
(b) Detach the 3 claws and remove the ECU.
Reassembly
A760F AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY (for Floor Shift Type):
REASSEMBLY
1. INSTALL SHIFT LOCK CONTROL ECU
Page 4353
NOTICE:
For reinstallation, attach a tag or label to the injector shaft.
(b) Remove the O-ring from the fuel injector.
(c) Detach the 3 clamps and then remove the No. 6 wire harness from the delivery pipe RH.
(d) Detach the 3 clamps and then remove the No. 7 wire harness from the delivery pipe LH.
Page 6019
Alternator: Overhaul
Disassembly
1UR-FE CHARGING: GENERATOR: DISASSEMBLY
1. REMOVE GENERATOR PULLEY
SST : 09820-63011
09820-06010
09820-06021
HINT
(a) Clamp the generator housing stay in a vise.
(b) Install SST 1-A to the pulley shaft.
(c) Install SST 1-B to SST 1-A.
(d) Hold SST 1-A with a torque wrench, and tighten SST 1-B clockwise to the specified torque.
Torque : 39 Nm (398 kgf-cm, 29 ft-lbf)
NOTICE: Check that SST is secured on the rotor shaft.
(e) Insert SST 2, and attach the pulley nut to SST 2.
(f) To loosen the pulley nut, turn SST 1-A in the direction shown in the illustration.
Page 403
Engine Control Module: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: ECM: REMOVAL
1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Removal
2. REMOVE AIR CLEANER ASSEMBLY See: Powertrain Management/Ignition System/Ignition
Coil/Service and Repair/Removal
3. DISCONNECT CONNECTOR HOLDER BLOCK
(a) Remove the connector holder block cover.
(b) Remove the 3 bolts and move the connector holder block so that the ECM can be removed in
the next step.
4. REMOVE ECM
(a) Disconnect the wire harness clamp.
(b) Raise the 2 levers while pushing the locks on the 2 levers shown in the illustration.
NOTICE: Make sure that the lock lever is raised 90° as shown in the illustration before
disconnecting the connectors. Failure to do this may cause the connectors to break.
(c) Disconnect the 2 connectors.
(d) Remove the 4 bolts and ECM.
5. REMOVE GASKET
(a) Peel off the rubber part of the gasket.
Page 8578
4. REMOVE LICENSE PLATE LIGHT ASSEMBLY RH (for Resin Type Bumper) See: Body and
Frame/Bumper/Rear Bumper/Service and
Repair/Removal and Replacement/Rear Bumper (for Resin Type Bumper)/Removal
5. REMOVE LICENSE PLATE LIGHT ASSEMBLY RH (for Steel Type Bumper) See: Body and
Frame/Bumper/Rear Bumper/Service and
Repair/Removal and Replacement/Rear Bumper (for Steel Type Bumper)/Removal
6. REMOVE REAR BUMPER PAD SUB-ASSEMBLY (for Steel Type Bumper) See: Body and
Frame/Bumper/Rear Bumper/Service and
Repair/Removal and Replacement/Rear Bumper (for Steel Type Bumper)/Removal
7. REMOVE REAR BUMPER PLATE LH (for Steel Type Bumper) See: Body and
Frame/Bumper/Rear Bumper/Service and Repair/Removal and
Replacement/Rear Bumper (for Steel Type Bumper)/Removal
8. REMOVE REAR BUMPER PLATE RH (for Steel Type Bumper) See: Body and
Frame/Bumper/Rear Bumper/Service and Repair/Removal and
Replacement/Rear Bumper (for Steel Type Bumper)/Removal
9. REMOVE REAR BUMPER COVER (for Resin Type Bumper) See: Body and
Frame/Bumper/Rear Bumper/Service and Repair/Removal and
Replacement/Rear Bumper (for Resin Type Bumper)/Removal
10. REMOVE REAR BUMPER BAR (for Steel Type Bumper) See: Body and Frame/Bumper/Rear
Bumper/Service and Repair/Removal and
Replacement/Rear Bumper (for Steel Type Bumper)/Removal
11. REMOVE NO. 1 ULTRASONIC SENSOR
(a) While pushing down on the lever with a finger to release the one claw, detach the claw on the
other side to remove the ultrasonic sensor.
HINT The type of claw on the top and bottom of the sensor are different. Observe the claws
carefully before removing the sensor.
12. REMOVE NO. 1 ULTRASONIC SENSOR RETAINER
(a) Detach the 2 claws and remove the sensor retainer from the rear bumper.
13. REMOVE NO. 2 ULTRASONIC SENSOR
(a) While pushing down on the lever with a finger to release the one claw, detach the claw on the
other side to remove the ultrasonic sensor.
Page 5653
2. INSTALL FRONT SPEED SENSOR LH
(a) Install the speed sensor (labeled D) with the hexagon socket head cap bolt (labeled E).
Torque : 11 Nm (107 kgf-cm, 8 ft-lbf)
NOTICE: *
Make sure there are no pieces of iron or other foreign matter attached to the sensor tip part.
* While inserting the speed sensor into the knuckle hole, do not strike or damage the sensor tip
part.
* After installing the speed sensor, make sure there is no clearance or foreign matter between the
sensor stay part and the knuckle.
* Make sure there is no foreign matter attached to the magnetic rotor.
3. INSTALL FRONT SKID CONTROL SENSOR WIRE LH
(a) Connect the connector (labeled A).
(b) Install the 3 harness clamps (labeled B) with the 3 bolts (labeled C).
Torque : 13 Nm (127 kgf-cm, 9 ft-lbf)
NOTICE: *
When installing the clamps, do not twist the wire harness.
* For clamps with rotation stoppers, make sure the rotation stopper touches the installation
position.
(c) Install the harness clamp with the bolt (labeled D).
Page 8901
Cab)/Installation
7. INSTALL LUGGAGE COMPARTMENT SIDE COVER SUB-ASSEMBLY RH See: Body and
Frame/Seats/Service and Repair/Removal and
Replacement/Rear Seat Assembly (for Double Cab)/Installation
8. INSTALL LUGGAGE COMPARTMENT SIDE COVER SUB-ASSEMBLY LH See: Body and
Frame/Seats/Service and Repair/Removal and
Replacement/Rear Seat Assembly (for Double Cab)/Installation
Page 7603
If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness
or connector in that circuit in the past. Check the wire harness and connectors.
B -- SYSTEM NORMAL
A -- TROUBLESHOOTING OF EACH PROBLEM SYMPTOM
The problem is still occurring in a place other than the diagnostic circuit (the DTC displayed first is
either for a past problem or a secondary problem).
4. SYMPTOM SIMULATION
HINT The most difficult case in troubleshooting is when no problem symptoms occur. In such a
case, a thorough problem analysis must be carried out. A simulation of the same or similar
conditions and environment in which the problem occurred in the customer's vehicle should be
carried out. No matter how much skill or experience a technician has, troubleshooting without
confirming the problem symptoms will lead to important repairs being overlooked and mistakes or
delays.
For example:
With a problem that only occurs when the engine is cold or as a result of vibration caused by the
road during driving, the problem can never be determined if the symptoms are being checked on a
stationary vehicle or on a vehicle with a warmed-up engine. Vibration, heat or water penetration
(moisture) is difficult to reproduce. The symptom simulation tests below are effective substitutes for
the conditions and can be applied on a stationary vehicle.
Important points in the symptom simulation test:
In the symptom simulation test, the problem symptoms as well as the problem area or parts must
be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then,
connect the tester and carry out the symptom simulation test, judging whether the circuit being
tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the
problem symptoms table for each system to narrow down the possible causes.
To reproduce DTCs, it is necessary to satisfy the respective DTC detection conditions.
(a) VIBRATION METHOD:
When a malfunction seems to occur as a result of vibration.
(1) PART AND SENSOR
Apply slight vibration with a finger to the part of the sensor suspected to be the cause of the
problem, and check whether or not the malfunction occurs.
NOTICE: Applying strong vibration to relays may open them.
Page 3410
HINT *
o: DTC is memorized.
* *1: Only during failure status.
Page 3851
(b) Using SST, remove the sensor.
SST : 09224-00010
Installation
1UR-FE ENGINE CONTROL SYSTEM: HEATED OXYGEN SENSOR: INSTALLATION
1. INSTALL HEATED OXYGEN SENSOR (for Bank 2 Sensor 2)
(a) Install the sensor to the exhaust pipe by hand.
(b) Using SST, tighten the sensor.
SST : 09224-00010
without SST - Torque : 44 Nm (449 kgf-cm, 32 ft-lbf)
with SST - Torque : 40 Nm (408 kgf-cm, 30 ft-lbf)
HINT *
Use a torque wrench with a fulcrum length of 30 cm (11.8 in.). When using a torque wrench with a
fulcrum length that is not 30 cm (11.8 in.), calculate the torque specification for the torque wrench
and SST based on the "without SST" torque specification See: Service Precautions
* Make sure SST and the wrench are connected in a straight line.
2. INSTALL HEATED OXYGEN SENSOR (for Bank 1 Sensor 2)
(a) Install the sensor to the exhaust pipe by hand.
(b) Using SST, tighten the sensor.
Page 7
Accessory Relay: Diagrams
Page 3069
Use a volt/ohmmeter with high impedance (10 kohms/V minimum) for troubleshooting of the
electrical circuit.
Disconnection of Male and Female Connectors
DISCONNECTION OF MALE AND FEMALE CONNECTORS
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Finding A Short Circuit
FINDING A SHORT CIRCUIT
Diagrams
Shift Interlock Solenoid: Diagrams
Page 7831
Ambient Temperature Sensor / Switch HVAC: Diagrams
Page 4625
Knock Sensor: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: INSTALLATION
1. INSTALL KNOCK SENSOR
(a) Install the 4 sensors with the 4 bolts so that the sensors are angled as shown in the illustration.
Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)
NOTICE: The acceptable installation angle of the sensor is between 10° upward and downward
from the horizontal position.
(b) Connect the 4 sensor connectors.
2. INSTALL SEPARATOR CASE
(a) Install the separator case with the 4 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
3. INSTALL INTAKE MANIFOLD
(a) Install the intake manifold See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service
and Repair/Installation.
Specifications
Fuel Pressure: Specifications
FUEL PRESSURE
Page 270
[A] For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
"Case1" Raise the terminal retainer up to the temporary lock position.
Locations
Starter Relay: Locations
1UR-FE STARTING: STARTING SYSTEM: PARTS LOCATION
Locations
Steering Control Module: Locations
Instrument Panel (Floor Shift)
Instrument Panel (Column Shift)
Page 275
Release the locking lug from terminal and pull the terminal out from rear.
INSTALL TERMINAL TO CONNECTOR
Insert the terminal.
HINT: Make sure the terminal is positioned correctly.
Insert the terminal until the locking lug locks firmly.
Insert the terminal with terminal retainer in the temporary lock position.
Page 8608
Refer to the Technical Information System (TIS) applicable model and model year Repair Manual:
5. Verify normal USB operation after repair.
Page 9054
Remove the blown fuse and disconnect all loads of the fuse.
Connect a test light in place of the fuse.
Establish conditions in which the test light comes on.
Example:
- [A] - Ignition SW on
- [B] - Ignition SW and SW1 on
- [C] - Ignition SW, SW1 and Relay on (Connect the Relay) and SW2 off (or Disconnect SW2)
Disconnect and reconnect the connectors while watching the test light.
Page 4604
Page 9226
pretensioner activation.
2. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH
(a) Using a screwdriver, detach the 4 claws and remove the inside handle bezel.
HINT Tape the screwdriver tip before use.
3. REMOVE FRONT UPPER ARMREST BASE PANEL LH (w/ Power Window)
(a) Using a screwdriver, detach the 2 clips and front upper armrest base panel.
HINT Tape the screwdriver tip before use.
(b) Disconnect the connectors.
4. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY (w/ Power Window)
(a) Remove the 3 screws and power window regulator master switch.
5. REMOVE FRONT DOOR WINDOW REGULATOR HANDLE ASSEMBLY (w/o Power Window)
(a) Insert a clip remover between the plate and trim.
(b) Turn the handle clockwise to remove the handle.
Page 3101
Ignition Switch: Service and Repair Installation
1UR-FE STARTING: IGNITION SWITCH: INSTALLATION
1. INSTALL IGNITION SWITCH ASSEMBLY
(a) Attach the 2 claws to install the ignition switch to the steering lock.
2. INSTALL UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Manual Tilt)
See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering Column Assembly
(for Manual Tilt)/Reassembly
3. INSTALL UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Manual Tilt
and Manual Telescopic Steering Column)
See: Steering and Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering
Column Assembly (for Manual Tilt and Manual Telescopic Steering Column)/Reassembly
4. INSTALL UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Power Tilt
and Power Telescopic Steering Column)
See: Steering and Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering
Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Reassembly
5. INSTALL STEERING COLUMN ASSEMBLY
(a) for Manual Tilt:
Install the steering column See: Steering and Suspension/Steering/Steering Column/Service and
Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Installation.
(b) for Manual Tilt and Manual Telescopic Steering Column:
Install the steering column See: Steering and Suspension/Steering/Steering Column/Service and
Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt and Manual
Telescopic Steering Column)/Installation.
(c) for Power Tilt and Power Telescopic Steering Column:
Install the steering column See: Steering and Suspension/Steering/Steering Column/Service and
Repair/Removal and Replacement/Steering Column Assembly (for Power Tilt and Power
Telescopic Steering Column)/Installation.
6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Drivetrain - Front Driveshaft Ticking Noise In 4WD
Drive/Propeller Shaft: All Technical Service Bulletins Drivetrain - Front Driveshaft Ticking Noise In
4WD
T-SB-0045-10
January 27, 2010
Front Propeller Shaft Parts Label Delaminating - Ticking Noise
Service Category Drivetrain
Section Drive Shaft/Propeller Shaft
Market USA
Applicability
Introduction
Some 2008 - 2010 model year 4WD Sequoia and 2007 - 2010 model year 4WD Tundra vehicles
may have a ticking noise present only when in 4WD. Production changes have been made to
correct this condition. Follow the procedure in this bulletin to address this condition.
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60
months or 60,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Repair Procedure
1. Confirm there is a ticking noise only present in 4WD.
Page 8891
Entertainment System Control Module: Diagrams
Components
Control Module: Service and Repair Components
JF1A TRANSFER: 4WD CONTROL ECU: COMPONENTS
Locations
Accessory Relay: Locations
Instrument Panel (Floor Shift)
Instrument Panel (Column Shift)
Page 5109
Actuator: Service and Repair Removal
DIFFERENTIAL: AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR (for 4WD):
REMOVAL
1. REMOVE NO. 1 ENGINE UNDER COVER See: Engine, Cooling and Exhaust/Engine/Drive
Belts, Mounts, Brackets and Accessories/Drive
Belt/Service and Repair/Removal
2. REMOVE AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR
(a) Disconnect the actuator hose.
(b) Disconnect the actuator connector.
(c) Remove the 4 bolts and actuator.
Back Power Window Switch
Power Window Switch: Service and Repair Back Power Window Switch
Components
WINDSHIELD / WINDOWGLASS: BACK POWER WINDOW SWITCH: COMPONENTS
Removal
WINDSHIELD / WINDOWGLASS: BACK POWER WINDOW SWITCH: REMOVAL
1. REMOVE FRONT DOOR SCUFF PLATE LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining
(for CrewMax)/Removal
2. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for
CrewMax)/Removal
3. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal
4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Removal
5. REMOVE POWER WINDOW REGULATOR SWITCH ASSEMBLY
(a) Using a screwdriver, detach the 2 claws.
HINT
Page 9050
Page 3377
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: ELECTRONIC
CIRCUIT INSPECTION PROCEDURE
1. BASIC INSPECTION
(a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS
(1) Unless otherwise stated, all resistance measurements should be made at an ambient
temperature of 20°C (68°F). Resistance measurements
may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been
running. Measurements should be made after the engine has cooled down.
(b) HANDLING CONNECTORS
(1) When disconnecting a connector, first squeeze the mating halves tightly together to release the
lock, and then press the lock claw and
separate the connector.
(2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly
and separate it.
(3) Before connecting a connector, check that there are no deformed, damaged, loose or missing
terminals.
(4) When connecting a connector, press firmly until it locks with a "click" sound.
(5) If checking a connector with a TOYOTA electrical tester, check the connector from the backside
(harness side) using a mini test lead.
NOTICE: *
As a waterproof connector cannot be checked from the backside, check it by connecting a
sub-harness.
* Do not damage the terminals by moving the inserted tester needle.
(c) CHECKING CONNECTORS
(1) Checking when a connector is connected: Squeeze the connectors together to confirm that they
are fully connected and locked.
(2) Checking when a connector is disconnected: Check by pulling the wire harness lightly from the
backside of the connector. Look for
unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for
corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or
deformed terminals.
(3) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a
female terminal, and check for ample tension
Page 4957
* Make sure the paint marks and pinching portion of each clip are facing the directions shown in the
illustration.
5. INSTALL TRANSMISSION OIL COOLER ASSEMBLY (w/ Trailer Towing System)
(a) Coat 2 new O-rings with ATF and install them to the grooves of the transmission oil cooler.
(b) Install the oil cooler to the transmission oil thermostat with the 3 bolts.
Torque : 14 Nm (143 kgf-cm, 10 ft-lbf)
(c) Install the 2 No. 1 transmission oil cooler hoses to the transmission oil thermostat.
NOTICE: Make sure the pinching portion of each clip is facing the direction shown in the
illustration.
(d) Connect the 2 No. 1 transmission oil cooler hoses to the transmission.
NOTICE: Make sure the pinching portion of each clip is facing the direction shown in the
illustration.
(e) Temporarily install the transmission oil cooler together with the transmission oil thermostat with
bolt C. Temporarily install bolt A and bolt B.
Tighten the bolts in alphabetical order.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
(f) Connect the No. 2 transmission oil cooler inlet hose and No. 2 transmission oil cooler outlet
hose to the oil cooler tube.
NOTICE: *
When connecting the hoses to the tube, support the tube by hand and be careful to prevent the
tube from being deformed.
* Make sure the paint marks and pinching portion of each clip are facing the directions shown in the
illustration.
(g) Install the No. 2 transmission oil cooler inlet hose and No. 2 transmission oil cooler outlet hose
to the transmission oil thermostat.
NOTICE: Make sure the paint marks and pinching portion of each clip are facing the directions
shown in the illustration.
6. INSTALL TRANSMISSION OIL COOLER ASSEMBLY (w/o Trailer Towing System)
Page 4696
Transmission Speed Sensor: Diagrams
Page 5275
(b) Using SST, measure and record the angle of the rear differential flange (B).
SST : 09370-50010
3. TEMPORARILY INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for 3
Joint Type)
HINT When replacing the spider bearing, make sure that the grease fitting assembly hole is facing
in the direction shown in the illustration.
(a) w/o Bearing Washer:
Page 53
(a) Remove the front door scuff plate See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Removal.
HINT The procedures listed below are for the LH side.
5. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP RH
6. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY RH See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Removal
7. REMOVE FRONT QUARTER TRIM PANEL ASSEMBLY RH See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Removal
8. REMOVE DOOR CONTROL RECEIVER
(a) Disconnect the door control receiver connector.
(b) Remove the bolt and receiver.
Installation
DOOR LOCK: DOOR CONTROL RECEIVER (for Regular Cab): INSTALLATION
1. INSTALL DOOR CONTROL RECEIVER
(a) Install the receiver with the bolt.
(b) Connect the door control receiver connector.
2. INSTALL FRONT QUARTER TRIM PANEL ASSEMBLY RH See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Installation
3. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY RH See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Installation
4. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH
5. INSTALL FRONT DOOR SCUFF PLATE RH
(a) Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular
Cab)/Installation.
HINT The procedures listed below are for the LH side.
Page 8415
2. INSTALL FRONT SEAT ASSEMBLY LH
(a) Install the front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Fold Down Seat
Type)/Installation.
3. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Air Bag Systems/Testing and Inspection/Initial Inspection
and Diagnostic Overview/Diagnosis System.
Page 4904
(d) Using a T30 "TORX" wrench, remove the 3 bolts and column shift.
Installation
A760F AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY (for Column Shift Type):
INSTALLATION
1. INSTALL COLUMN SHIFT ASSEMBLY
(a) Using a T30 "TORX" wrench, install the column shift with the 3 bolts.
Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf)
(b) Connect the connector and attach the harness clamp.
(c) Connect the column shift transmission control cable end to the column shift.
NOTICE: Make sure to connect the cable end so that the inner cable is not twisted. Confirm that
the ridged side of the cable end is facing upward.
2. ADJUST SHIFT LEVER POSITION See: Adjustments/SHIFT LEVER ASSEMBLY (for Column
Shift Type)
Page 3397
HINT The ECM uses the CAN communication system to perform DTC communication instead of
the conventional communication line (SIL).
CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: SYSTEM DESCRIPTION
1. BRIEF DESCRIPTION
(a) The CAN (Controller Area Network) is a serial data communication system for real time
application. It is a vehicle multiplex communication
system which has a high communication speed (500 kbps, 250 kbps) and the ability to detect
malfunctions.
(b) By pairing the CANH and CANL bus lines, the CAN performs communication based on
differential voltages.
(c) Many ECUs (sensors) installed on the vehicle operate by sharing information and
communicating with each other.
(d) The CAN has 2 resistors of 120 Ohms which are necessary to communicate with the main wire.
2. DEFINITION OF TERMS
(a) Main wire
(1) The main wire is a wire harness between the 2 termination circuits on the bus (communication
line). This is the main bus in the CAN
communication system.
(b) Branch wire
Page 1913
Fluid - A/T: Service and Repair
A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION FLUID: ADJUSTMENT
NOTICE: *
This transmission requires Toyota Genuine ATF WS.
* After servicing the transmission, you must follow the ATF adjustment procedure.
* Maintain the vehicle in a horizontal position while adjusting the fluid level.
1. PRELIMINARY PROCEDURES
(a) w/ Trailer Towing System (with transmission oil thermostat):
(1) Using compressed air, etc., blow dust off the thermostat cap to clean it.
(2) Using a screwdriver, push in the shaft of the thermostat.
HINT *
Distance pushed: 5.5 to 7.0 mm (0.217 to 0.276 in.)
* Push the shaft until the screwdriver contacts the step inside the cap.
(3) With the shaft of the thermostat pressed, push a pin into a hole in the side of the thermostat
cap. Insert the pin until it passes through the
hole in the other side of the thermostat cap to fix the shaft in place.
HINT Pin diameter: 1.0 to 1.8 mm (0.0394 to 0.0709 in.)
2. BEFORE FILLING TRANSMISSION
* When you have replaced the entire transmission, transmission pan, drain plug, valve body and/or
torque converter, proceed to the "Transmission Fill" procedures.
Page 5181
Axle Shaft Assembly: Component Tests and General Diagnostics
Front Drive Shaft Assembly
DRIVE SHAFT: FRONT DRIVE SHAFT ASSEMBLY (for 4WD): INSPECTION
1. INSPECT FRONT DRIVE SHAFT ASSEMBLY
NOTICE: Move the drive shaft while keeping it level.
(a) Check if there is excessive play in the outboard joint.
(b) Check if the inboard joint shaft slides smoothly in the thrust direction.
(c) Check if there is excessive play in the radial direction of the inboard joint shaft.
(d) Check the boots for damage.
Rear Axle Shaft
AXLE: REAR AXLE SHAFT: INSPECTION
1. INSPECT REAR AXLE SHAFT
(a) Using a dial indicator, measure the rear axle shaft runout and flange runout.
Maximum runout:
Shaft runout 1.50 mm (0.0591 in.)
Flange runout 0.05 mm (0.00197 in.)
(b) If the rear axle shaft or flange is damaged or worn, or if the runout is greater than the maximum,
replace the rear axle shaft.
Page 6761
JJ1-JL1
Components
Tire Pressure Module: Service and Repair Components
TIRE AND WHEEL: TIRE PRESSURE WARNING ECU: COMPONENTS
Page 7641
"Case2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 8072
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
4. REMOVE UPPER CONSOLE REAR PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
5. REMOVE REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
6. REMOVE CONSOLE BOX CARPET
7. REMOVE REAR CONSOLE BOX ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal
8. REMOVE FRONT CONSOLE BOX See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal
and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal
9. REMOVE CENTER AIRBAG SENSOR ASSEMBLY
(a) Disconnect the holder (with connectors).
(b) Remove the 3 bolts and airbag sensor.
Installation
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift
Type): INSTALLATION
1. INSTALL CENTER AIRBAG SENSOR ASSEMBLY
(a) Check that the ignition switch is OFF.
(b) Check that the cable is disconnected from the battery negative (-) terminal.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
(c) Install the airbag sensor with the 3 bolts.
Torque : 18 Nm (184 kgf-cm, 13 ft-lbf)
NOTICE: *
If the center airbag sensor has been dropped, or there are any cracks, dents or other defects in the
case, bracket or connector, replace it with a new one.
* When installing the center airbag sensor, be careful that the SRS wiring does not interfere with
other parts and that it is not pinched between other parts.
(d) Check that there is no looseness in the installation parts of the center airbag sensor.
Page 6190
Auxiliary Power Outlet: Service and Repair Power Outlet Socket (for Crewmax Column Shift Type)
Components
OTHER SYSTEM: POWER OUTLET SOCKET (for CrewMax Column Shift Type): COMPONENTS
Removal
OTHER SYSTEM: POWER OUTLET SOCKET (for CrewMax Column Shift Type): REMOVAL
1. REMOVE CENTER SEATBACK PANEL See: Body and Frame/Seats/Service and
Repair/Overhaul/Front Seat Assembly (for Center
Seat)/Disassembly
Page 6837
Locations
Ignition Switch: Locations
1UR-FE STARTING: STARTING SYSTEM: PARTS LOCATION
Page 295
Driver Side J/B - Cowl Side Left
Page 6672
Diode: Diagrams Diode (Rear Door Courtesy Light)
Page 9267
Hood Latch Release Cable: Service and Repair Removal
ENGINE HOOD / DOOR: HOOD LOCK CONTROL CABLE ASSEMBLY: REMOVAL
1. REMOVE HOOD LOCK CONTROL CABLE COVER
(a) Remove the screw.
(b) Remove the cap and nut.
(c) Detach the clamp and remove the cable cover.
2. REMOVE HOOD LOCK ASSEMBLY
(a) Remove the cap.
(b) Remove the 2 bolts and nut.
(c) Remove the hood lock.
(d) w/ Theft Deterrent System:
(1) Disconnect the hood lock control cable.
3. REMOVE HOOD LOCK CONTROL LEVER SUB-ASSEMBLY
(a) Detach the 2 claws.
(b) Disconnect the hood lock control cable and remove the hood lock lever.
4. REMOVE HOOD LOCK CONTROL CABLE ASSEMBLY
Page 9255
2. REMOVE REAR UPPER DOOR ARMREST BASE PANEL LH
(a) Using a screwdriver, detach the 2 clips and rear upper door armrest base panel. Then
disconnect the connector.
HINT Tape the screwdriver tip before use.
3. REMOVE REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY
(a) Detach the 4 claws and remove the power window regulator switch.
4. REMOVE REAR DOOR FRAME GARNISH LH
(a) Detach the 4 clips and remove the rear door frame garnish.
5. REMOVE REAR DOOR ARMREST COVER LH
6. REMOVE REAR DOOR TRIM BOARD SUB-ASSEMBLY LH
(a) Remove the 2 screws.
(b) Using a clip remover, remove the clip.
(c) Detach the 9 clips and remove the trim cover. Then disconnect the connector.
(d) Disconnect the 2 cables from the inside handle.
Page 6913
"Case2" Open the secondary locking device.
[B] For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray
Gray or White : Black
Page 9147
Body Control Module: Locations LIN Communication System
MULTIPLEX COMMUNICATION: LIN COMMUNICATION SYSTEM: PARTS LOCATION
Drivetrain - Rear Differential Growl/Whine While Driving
Differential Case: All Technical Service Bulletins Drivetrain - Rear Differential Growl/Whine While
Driving
T-SB-0297-10
November 2, 2010
Rear Differential Housing Oil Baffle Growl/Whine Noise
Service Category Drivetrain
Section Axle/Differential
Market USA
Applicability
Introduction
Some vehicles may exhibit a growl or whine noise from the rear when the vehicle is in motion.
Production changes have been made to prevent this noise. Follow the procedure in the bulletin to
address this noise condition.
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60
months or 60,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Production Change Information
Page 9223
Components
Brake Light Switch: Service and Repair Components
LIGHTING: STOP LIGHT SWITCH: COMPONENTS
Page 6851
Console Box Wire
Engine Wire
Components
Spark Plug: Service and Repair Components
1UR-FE IGNITION: IGNITION COIL AND SPARK PLUG: COMPONENTS
Page 6677
Page 8104
Removal
SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Double Cab): REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Disassembly
3. REMOVE FRONT ARMREST BASE PANEL UPPER LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Page 5024
3. DRAIN DIFFERENTIAL OIL See: Fluid - Differential/Service and Repair
4. REMOVE REAR AXLE SHAFT LH
(a) Remove the rear axle shaft LH See: Drive Axles, Bearings and Joints/Axle Shaft
Assembly/Service and Repair/Removal and
Replacement/Rear Axle Shaft/Removal.
5. REMOVE REAR AXLE SHAFT RH
HINT Use the same procedures described for the LH side.
6. REMOVE REAR DIFFERENTIAL CARRIER ASSEMBLY
(a) Remove the 10 nuts, 10 washers and differential carrier.
NOTICE: Be careful not to damage the contact surfaces of the differential carrier and rear axle
housing.
(b) Remove the gasket.
Installation
DIFFERENTIAL: DIFFERENTIAL CARRIER ASSEMBLY (for 1GR-FE, 1UR-FE): INSTALLATION
1. INSTALL REAR DIFFERENTIAL CARRIER ASSEMBLY
(a) Clean the contact surfaces of the rear differential carrier and the rear axle housing.
(b) Install a new rear differential carrier gasket and the differential carrier with the 10 washers and
10 nuts.
Torque : 72 Nm (734 kgf-cm, 53 ft-lbf)
NOTICE: Be careful not to damage the installation surface.
2. INSTALL REAR AXLE SHAFT LH
(a) Install the rear axle shaft LH See: Drive Axles, Bearings and Joints/Axle Shaft
Assembly/Service and Repair/Removal and
Replacement/Rear Axle Shaft/Installation.
3. INSTALL REAR AXLE SHAFT RH
HINT Use the same procedures described for the LH side.
Page 7124
Power Steering Pressure Switch: Diagrams Power Steering Oil Pressure Switch
Page 7775
(a) Install the heater radiator unit.
(b) Attach the 3 claws to install the heater clamp.
(c) Install the plate with the 3 screws.
5. INSTALL COOLING UNIT DAMPER SERVO SUB-ASSEMBLY (for Automatic Air Conditioning
System)
(a) Install the damper servo with the 3 screws, as shown in the illustration.
(b) Connect the connector.
6. INSTALL BLOWER DAMPER SERVO SUB-ASSEMBLY
(a) Install the damper servo with the 3 screws.
(b) Connect the connector.
Page 2491
Front Crankshaft Seal: Service and Repair Installation
1UR-FE ENGINE MECHANICAL: FRONT CRANKSHAFT OIL SEAL: INSTALLATION
1. INSTALL FRONT CRANKSHAFT OIL SEAL
(a) Apply MP grease to the lip of a new oil seal.
(b) Using SST and a hammer, tap in the oil seal to a depth between 0 to 1.0 mm (0 to 0.0394 in.)
from the timing chain cover edge.
SST : 09223-22010
SST : 09506-35010
NOTICE: *
Keep the lip free from foreign matter.
* Do not tap the oil seal at an angle.
2. INSTALL CRANKSHAFT TIMING GEAR KEY
(a) Install the crankshaft timing gear key.
3. INSTALL CRANKSHAFT PULLEY See: Engine Lubrication/Oil Pump/Service and
Repair/Removal and Replacement/Installation
4. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY See: Engine Lubrication/Oil Cooler/Service
and Repair/Removal and
Replacement/Installation
5. INSTALL NO. 1 OIL COOLER BRACKET (w/ Oil Cooler) See: Engine Lubrication/Oil
Cooler/Service and Repair/Removal and
Replacement/Installation
6. INSTALL WATER BY-PASS PIPE (w/ Oil Cooler) See: Water Pump/Service and
Repair/Installation
7. INSTALL OIL PRESSURE SENDER GAUGE ASSEMBLY See: Engine Lubrication/Oil Pressure
Sender/Service and Repair/Installation
8. CONNECT COOLER COMPRESSOR ASSEMBLY See: Engine Lubrication/Oil Pump/Service
and Repair/Removal and
Replacement/Installation
9. CONNECT FRONT STABILIZER BAR
(a) Connect the stabilizer bar and install the 2 stabilizer bushes and 2 stabilizer brackets with the 4
bolts.
Torque : 69 Nm (704 kgf-cm, 51 ft-lbf)
Page 6790
"Case2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 2808
Engine Control Module: Locations
Engine Compartment
Page 9057
[A] For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
"Case1" Raise the terminal retainer up to the temporary lock position.
Wire and Wire In Engine Compartment
Multiple Junction Connector: Locations Wire and Wire In Engine Compartment
AB1-RA3
Page 6987
* In the DTC check, it is very important to determine whether the problem indicated by the DTC is
either: 1) still occurring; or 2) occurred in the past but has since returned to normal. In addition, the
DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs
should be checked before and after confirmation of symptoms (i.e., whether or not problem
symptoms exist) to determine current system conditions, as shown in the flowchart below.
* Never skip the DTC check. Failing to check DTCs may, depending on the case, result in
unnecessary troubleshooting for systems operating normally or lead to repairs not related to the
problem. Follow the procedures listed in the flowchart in the correct order.
* The following flowchart shows how to proceed with troubleshooting using the DTC check.
Directions from the flowchart will indicate how to proceed either to DTC troubleshooting or to the
troubleshooting of each problem symptom.
1. DTC CHECK
NEXT -- Continue to next step.
2. MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR MEMORY
NEXT -- Continue to next step.
3. SYMPTOM CONFIRMATION
B -- Go to step 5 A -- Continue to next step.
4. SIMULATION TEST USING SYMPTOM SIMULATION METHODS
NEXT -- Continue to next step.
5. DTC CHECK
B -- TROUBLESHOOTING OF PROBLEM INDICATED BY DTC A -- Continue to next step.
6. SYMPTOM CONFIRMATION
Page 6089
Page 1698
Standard vehicle height (unloaded vehicle):
for Regular Cab of Long Deck
Standard vehicle height (unloaded vehicle):
for Double Cab of Standard Deck
Locations
Main Relay (Computer/Fuel System): Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 5496
Shift Interlock Control Module: Diagrams
Components
Ignition Switch: Service and Repair Components
1UR-FE STARTING: IGNITION SWITCH: COMPONENTS
Page 9116
Push the secondary locking device or terminal retainer in to the full lock position.
CONNECT CONNECTOR
Voltage Check
VOLTAGE CHECK
Page 3079
Push the secondary locking device or terminal retainer in to the full lock position.
CONNECT CONNECTOR
Voltage Check
VOLTAGE CHECK
Components
Throttle Body: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: THROTTLE BODY: COMPONENTS
Components
Parking Brake Cable: Service and Repair Components
PARKING BRAKE: PARKING BRAKE CABLE: COMPONENTS
Power Steering Oil Pressure Sensor
Power Steering Pressure Switch: Diagrams Power Steering Oil Pressure Sensor
Page 2035
J/B No.5 - Instrument Panel Center
Page 4506
Camshaft Position Sensor: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT POSITION SENSOR: REMOVAL
1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Removal
2. REMOVE CAMSHAFT POSITION SENSOR
(a) Disconnect the sensor connector.
(b) Remove the bolt and sensor.
Components
Seat Position Sensor: Service and Repair Components
SUPPLEMENTAL RESTRAINT SYSTEM: SEAT POSITION SENSOR: COMPONENTS
Page 7637
DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector.
Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
Page 5688
(b) Remove the bolt from the No. 3 brake pedal bracket.
(c) Remove the bolt, nut and No. 3 brake pedal bracket from the brake pedal support.
(d) Remove the 4 nuts and brake pedal support.
12. REMOVE BRAKE PEDAL PAD
(a) Remove the brake pedal pad.
Page 1730
(m)Measure the fuel pressure.
Standard fuel pressure:
281 to 287 kPa (2.87 to 2.93 kgf/cm2, 41 to 42 psi)
(n) If the pressure is not as specified, check the fuel pump, pressure regulator and/or injectors.
(o) Stop the engine.
(p) Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped.
Standard fuel pressure:
147 kPa (1.5 kgf/cm2, 21 psi) or higher
(q) If the pressure is not as specified, check the fuel pump, pressure regulator and/or injectors.
(r) After checking the fuel pressure, disconnect the cable from the negative (-) battery terminal and
carefully remove SST and the fuel tube
connector to prevent gasoline from spraying.
(s) Reconnect the fuel tube (fuel tube connector).
(t) Check for fuel leak.
(1) Check that there are no fuel leaks after performing maintenance anywhere on the system.
If there are fuel leaks, repair or replace parts as necessary.
Locations
Power Seat Control Module: Locations
Seat (Separate Seat)
Page 7595
(1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be
checked by conducting a voltage check.
With each connector still connected, measure the voltage between the body ground and these
terminals (in this order): 1) terminal 1 of connector A; 2) terminal 1 of connector B; and 3) terminal
1 of connector C.
Standard voltage (Fig. 4):
* If the results match the examples above, an open circuit exists in the wire harness between
terminal 1 of connector B and terminal 1 of connector C.
3. CHECK FOR SHORT CIRCUIT
(a) If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance
check with the body ground (below).
(b) Check the resistance with the body ground.
(1) Disconnect connectors A and C and measure the resistance.
Standard resistance (Fig. 6):
HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally.
If your results match the examples above, a short circuit exists between terminal 1 of connector A
and terminal 1 of connector C.
Testing and Inspection
Malfunction Indicator Lamp: Testing and Inspection
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: MIL Circuit - MIL Circuit
DESCRIPTION
The MIL (Malfunction Indicator Lamp) is used to indicate vehicle malfunction detections by the
ECM. When the ignition switch is turned to ON, power is supplied to the MIL circuit, and the ECM
provides the circuit ground which illuminates the MIL.
The MIL operation can be checked visually: When the ignition switch is first turned to ON, the MIL
should be illuminated and should then turn off when the engine is started. If the MIL remains
illuminated or is not illuminated, conduct the following troubleshooting procedure using the
Techstream.
WIRING DIAGRAM
INSPECTION PROCEDURE
PROCEDURE
1. CHECK THAT MIL IS ILLUMINATED
(a) Perform troubleshooting in accordance with the table below.
Result
B -- CHECK THAT MIL IS ILLUMINATED A -- Continue to next step.
2. CHECK WHETHER MIL TURNS OFF
(a) Connect the Techstream to the DLC3.
(b) Turn the ignition switch to ON.
(c) Turn the Techstream on.
Diagram Information and Instructions
Multiple Junction Connector: Diagram Information and Instructions
Wiring Color Codes
Abbreviations Used Within Diagrams
Abbreviations Used Within Diagrams
Page 6312
AB1-DF1
Page 5202
HINT Align the 2 oil drain holes.
(b) Temporarily install a washer and nut to 5 new hub bolts as shown in the illustration.
(c) Install the hub bolts by tightening each nut.
(d) Removed the washer and nut from each hub bolt.
2. INSTALL REAR AXLE HUB AND BEARING ASSEMBLY
(a) Position the parking brake plate on a new rear axle hub and bearing.
NOTICE: Make sure to securely fit the bearing to the parking brake plate.
(b) Using 2 socket wrenches and a press, press in the 4 housing bolts.
3. INSTALL REAR AXLE SHAFT
(a) Install the washer and a new retainer to the axle hub as shown in the illustration.
Page 8123
Seat Occupant Classification Module - Air Bag: Locations Occupant Classification System
SUPPLEMENTAL RESTRAINT SYSTEM: OCCUPANT CLASSIFICATION SYSTEM: PARTS
LOCATION
Page 2478
(a) Uniformly loosen and remove the 2 bolts in the sequence shown in the illustration.
(b) Using a 10 mm bi-hexagon wrench, uniformly loosen the 10 cylinder head bolts in the sequence
shown in the illustration. Remove the 10
cylinder head bolts and plate washers.
HINT Be sure to arrange the removed parts for each installation position separately.
NOTICE: *
Be careful not to drop washers into the cylinder head.
* Head warpage or cracking could result from removing bolts in an incorrect order.
7. REMOVE CYLINDER HEAD GASKET LH
Installation
1UR-FE ENGINE MECHANICAL: CYLINDER HEAD GASKET (for Bank 1): INSTALLATION
1. INSPECT CYLINDER HEAD SET BOLT See: Testing and Inspection/Engine Unit
2. INSPECT CYLINDER HEAD SUB-ASSEMBLY LH See: Cylinder Head Assembly/Testing and
Inspection
3. INSTALL CYLINDER HEAD GASKET LH
(a) Check the piston protrusions for each cylinder.
(1) Clean the cylinder block with solvent.
(2) Set the piston of the cylinder to be measured to slightly ATDC.
(b) Place the cylinder head gasket on the cylinder block surface with the front face of the Lot No.
stamp upward.
NOTICE: *
Be careful of the installation direction.
* Make sure that no oil is on the front end (indicated by the arrows) of the cylinder head gasket.
4. INSTALL CYLINDER HEAD SUB-ASSEMBLY LH
(a) Place the cylinder head on the cylinder block.
Page 6570
Auxiliary Power Outlet Switch: Service and Repair Removal
OTHER SYSTEM: INVERTER MAIN SWITCH (for CrewMax): REMOVAL
1. REMOVE FRONT DOOR SCUFF PLATE LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining
(For Double Cab)/Removal
2. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for
CrewMax)/Removal
3. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal
4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Floor Shift Type)/Removal
5. REMOVE INVERTER MAIN SWITCH
(a) Detach the 2 claws and remove the main switch.
Page 4213
Page 1527
Power Steering Pressure Switch: Testing and Inspection
1UR-FE ENGINE CONTROL SYSTEM: POWER STEERING OIL PRESSURE SWITCH:
ON-VEHICLE INSPECTION
1. INSPECT POWER STEERING OIL PRESSURE SWITCH
(a) Check the oil pressure switch.
(1) Connect the Techstream to the DLC3.
(2) Turn the ignition switch to ON.
(3) Turn the Techstream main switch on.
(4) Enter the following menus: Powertrain / Engine and ECT / Data List / All Data / Power Steering
pressure.
(5) Start the engine.
(6) Operate the steering wheel while idling, and read the value on the Techstream.
Standard:
(7) If not as specified, check for DTCs See: Powertrain Management/Computers and Control
Systems/Testing and Inspection/Reading and
Clearing Diagnostic Trouble Codes/DTC Check / Clear. If the power steering system inspection
results are normal and a DTC is not output, replace the power steering oil pressure switch.
Inspect the power steering system See: Steering and Suspension/Steering/Testing and
Inspection/Component Tests and General Diagnostics/Power Steering System/On-Vehicle
Inspection. If the power steering system inspection results are normal and a DTC is not output,
replace the power steering oil pressure switch.
Page 4503
Camshaft Position Sensor: Diagrams
Page 3504
NG -- REPAIR OR REPLACE CAN MAIN WIRE OR CONNECTOR (NO. 1 JUNCTION
CONNECTOR - NO. 2 JUNCTION CONNECTOR) OK -- Continue to next step.
6. CONNECT CONNECTOR
(a) Reconnect the J94 No. 1 junction connector connector.
(b) Reconnect the J113 No. 2 junction connector connector.
NEXT -- Continue to next step.
7. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (NO. 1 JUNCTION CONNECTOR COMBINATION METER ECU)
(a) Disconnect the J84 No. 1 junction connector connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- CHECK FOR SHORT TO B+ IN CAN BUS WIRE (COMBINATION METER ECU) OK -Continue to next step.
8. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (NO. 1 JUNCTION CONNECTOR - MAIN
BODY ECU)
(a) Disconnect the J96 No. 1 junction connector connector.
Page 3393
(b) Use a repair wire to check the connector if it is impossible to check resistance from the rear of
the connector.
Page 7429
Tire Pressure Module: Service and Repair Removal
TIRE AND WHEEL: TIRE PRESSURE WARNING ECU: REMOVAL
NOTICE: *
It is necessary to perform initialization See: Tire Monitoring System/Testing and
Inspection/Programming and Relearning/Initialization after registration See: Tire Monitoring
System/Testing and Inspection/Programming and Relearning/Registration of the transmitter IDs
into the tire pressure warning ECU after the ECU has been replaced.
* When replacing the tire pressure warning ECU, read the transmitter IDs stored in the old ECU
using the intelligent tester or Techstream and write them down before removal.
1. REMOVE FRONT DOOR SCUFF PLATE RH (for Regular Cab)
(a) Remove the front door scuff plate RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Removal.
HINT Use the same procedures described for the LH side.
2. REMOVE FRONT DOOR SCUFF PLATE RH (for Double Cab, for CrewMax)
(a) Remove the front door scuff plate RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Removal.
HINT Use the same procedures described for the LH side.
3. REMOVE COWL SIDE TRIM BOARD RH
(a) Remove the cowl side trim board RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Removal.
HINT Use the same procedures described for the LH side.
4. REMOVE INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal
5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and
Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument
Panel Safety Pad (for Column Shift Type)/Removal
6. REMOVE TIRE PRESSURE WARNING ECU
(a) Disconnect the ECU connector.
(b) Remove the 2 nuts and ECU.
Diagram Information and Instructions
Relay Box: Diagram Information and Instructions
Wiring Color Codes
Abbreviations Used Within Diagrams
Abbreviations Used Within Diagrams
Page 5955
"Case2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Body - Bumper Component Repair
Rear Bumper Reinforcement: Technical Service Bulletins Body - Bumper Component Repair
COLLISION REPAIR INFORMATION FOR THE COLLISION REPAIR PROFESSIONAL
TITLE: BUMPER COMPONENT REPAIR
SECTION: EXTERIOR BULLETIN # 172
MODELS: ALL TOYOTA LEXUS and SCION
DATE: MARCH 2009
While it may seem cost effective to repair damaged bumper components specifically impact energy
absorbers and reinforcements there is no way to certify that a repaired part will function as
originally intended under all future operating conditions and subsequent collisions. Original
Equipment bumper components comply with Federal Motor Vehicle Safety Standards established
under the National Highway Traffic Safety Administration Title 49 Part 581. Therefore it is
recommended to replace damaged bumper impact energy absorbers and reinforcements with
genuine new original equipment replacement parts only.
For more information on collision damage repair topics please refer to Collision Repair Information
Bulletin # 161 Collision Damage Repair Precautions and plan to attend Toyota Collision Repair &
Refinish Training. Visit www.crrtraining.com for training information.
Components
Vacuum Brake Booster: Service and Repair Components
BRAKE: BRAKE BOOSTER: COMPONENTS
Locations
Central Control Module: Locations
NAVIGATION: NAVIGATION SYSTEM (w/ USB Audio System): PARTS LOCATION
m
Page 2809
Engine Control Module: Diagrams
Page 1003
Fuel Gauge Sender: Service and Repair Fuel Sending Unit Cover
Fuel Sending Unit Upper Cover Installation
Introduction
A Fuel Sending Unit Upper Cover has been developed as a separate service part for 2007-2010
MY Tundra vehicles to allow for individual replacement. This bulletin supplements the Repair
Manual by providing the installation procedures and part number details for this component.
Vehicles produced after the production change below utilize this replaceable Fuel Sending Unit
Upper Cover.
Production Change Information
This information applies to vehicles produced BEFORE the Production Change Effective VINs
shown below.
Production Change Information (Continued)
Parts Information
Warranty Information
Page 6205
(a) Attach the claw to install the power outlet socket.
3. INSTALL LOWER INSTRUMENT CLUSTER FINISH PANEL See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column
Shift Type)/Installation
4. INSTALL FRONT ASH RECEPTACLE BOX SUB-ASSEMBLY
5. INSTALL CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service
and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
6. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Installation
7. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
8. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Installation
9. INSTALL FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Installation
10. INSTALL FRONT DOOR SCUFF PLATE LH (for Double Cab)
Components
OTHER SYSTEM: POWER OUTLET SOCKET (for CrewMax Column Shift Type): COMPONENTS
Page 6946
Engine Room R/B And Engine Room J/B Inner Circuit
Page 3427
HINT *
*1: w/ Power Steering ECU
* *2: w/ 4WD
* *3: w/ Bus Buffer ECU
Short in CAN Bus Lines
CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: Short in CAN Bus Lines - Short in
CAN Bus Lines
DESCRIPTION
There may be a short circuit between the CAN bus lines when the resistance between terminals 6
(CANH) and 14 (CANL) of the DLC3 is below 54 Ohms.
HINT *
*1: w/ Bus Buffer ECU
* *2: w/ 4WD
* *3: w/ Power Steering ECU
WIRING DIAGRAM
Page 1996
Components
Variable Valve Timing Actuator Position Sensor: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: VVT SENSOR: COMPONENTS
Page 6060
3. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE
HINT The diagnostic system in the TOYOTA TUNDRA has various functions.
* The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU
memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a
previous malfunction's DTC can be checked by a technician during troubleshooting.
* Another function is the Input Signal Check, which checks if the signals from various switches are
sent to the ECU correctly.
* By using these functions, the problem areas can be narrowed down and troubleshooting is more
effective. Diagnostic functions are incorporated in the following systems in the TOYOTA TUNDRA.
Page 6838
Page 1472
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Page 781
Brake Fluid Pressure Sensor/Switch: Locations From 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Components
Yaw Rate Sensor: Service and Repair Components
BRAKE CONTROL: YAW RATE AND DECELERATION SENSOR: COMPONENTS
Page 5830
Traction Control Relay: Locations From 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 1290
Crankshaft Position Sensor: Locations Ignition System
1UR-FE IGNITION: IGNITION SYSTEM: PARTS LOCATION
Page 919
Cab)/Installation.
(b) for Double Cab:
Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Installation.
(c) for CrewMax:
Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for CrewMax)/Installation.
Page 2782
^ Calibration ID(s) [Refer to the Calibration Identification Chart for the NEW CALIBRATION ID]
^ Dealer Code
^ Repair Date
^ Change Authority [This TSB number]
B. Affix the Authorized Modifications Label to the vehicle at the location shown in Figure 1. The
Authorized Modifications Label is available
through the MDC P/N 00451-00001-LBL.
Components
Seat Position Sensor: Service and Repair Components
SUPPLEMENTAL RESTRAINT SYSTEM: SEAT POSITION SENSOR: COMPONENTS
Page 722
Power Seat Switch: Service and Repair Front Power Seat Lumbar Switch (for Manual Seat)
Components
SEAT: FRONT POWER SEAT LUMBAR SWITCH (for Manual Seat): COMPONENTS
Locations
Shift Interlock Control Module: Locations
Instrument Panel (Floor Shift)
Instrument Panel (Column Shift)
Page 8828
(a) Using a screwdriver, detach the 4 clips and claw.
HINT Tape the screwdriver tip before use.
(b) Remove the speaker panel.
5. REMOVE NO. 2 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY
(a) Using a screwdriver, detach the 4 clips and claw.
HINT Tape the screwdriver tip before use.
(b) Remove the speaker panel.
6. REMOVE FRONT NO. 2 SPEAKER ASSEMBLY LH
(a) Remove the 2 bolts.
(b) Remove the speaker and disconnect the connector.
Page 7964
Width 185 mm (7.28 in.)
Inner diameter 360 mm (1.18 ft.)
(2) Tie the curtain shield airbag to the tire with several wire harnesses.
CAUTION: Make sure that the wire harnesses are tight. If there is slack in the wire harnesses, the
curtain shield airbag may become loose due to the shock when the airbag is deployed.
NOTICE: As the tires may be damaged by the airbag deployment, use a tire that you are planning
to throw away.
(e) Install SST.
(1) After connecting SST each other, connect them to the curtain shield airbag.
SST : 09082-00802
09082-10801
09082-40800
(f) Place the tires.
NOTICE: Do not place the deployment direction of the curtain shield airbag facing the ground.
(1) Place at least 2 tires under the tire which the curtain shield airbag is tied to.
(2) Place at least 2 tires over the tire which the curtain shield airbag is tied to. The top tire should
have the disc wheel installed.
NOTICE: *
Do not place SST connector under the tire because it could be damaged.
* As the disc wheel may be damaged by the airbag deployment, use a disc wheel that you are
planning to throw away.
* As the tires may be damaged by the airbag deployment, use a tire that you are planning to throw
away.
(3) Tie the tires together with 2 wire harnesses.
Page 6247
Fuse Block Location - Under The Instrument Panel
Fuse Location - Under The Instrument Panel
Page 6023
Torque : 2.3 Nm (23 kgf-cm, 20 in-lbf)
2. INSTALL GENERATOR ROTOR ASSEMBLY
(a) Place the drive end frame on the pulley.
(b) Install the rotor to the drive end frame.
3. INSTALL GENERATOR COIL ASSEMBLY
(a) Place the generator washer on the rotor.
(b) Using SST and a press, slowly press in the coil assembly.
SST : 09285-76010
(c) Install the 4 bolts.
Page 6464
Use a volt/ohmmeter with high impedance (10 kohms/V minimum) for troubleshooting of the
electrical circuit.
Disconnection of Male and Female Connectors
DISCONNECTION OF MALE AND FEMALE CONNECTORS
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Finding A Short Circuit
FINDING A SHORT CIRCUIT
Page 2653
Engine Temperature Sensor: Testing and Inspection
1UR-FE ENGINE CONTROL SYSTEM: ENGINE COOLANT TEMPERATURE SENSOR:
INSPECTION
1. INSPECT ENGINE COOLANT TEMPERATURE SENSOR
(a) Partially immerse the sensor in water and warm up the water.
(b) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(c) If the result is not as specified, replace the engine coolant temperature sensor.
NOTICE: When checking the sensor in water, keep the terminals dry. After the check, wipe the
sensor dry.
HINT If the result is as specified, do not replace the engine coolant temperature sensor.
Page 8811
Removal
AUDIO / VISUAL: FLOOR SPEAKER (for Double Cab): REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE NO. 1 BOX SPEAKER ASSEMBLY
Audio System - Satellite Radio Inop. Until Key Is Cycled
Radio Receiver: All Technical Service Bulletins Audio System - Satellite Radio Inop. Until Key Is
Cycled
T-SB-0271-09
Rev1
August 11, 2009
XM Satellite Radio Inoperative Until Ignition Key Is Cycled
Service Category
Audio/Visual/Telematics
Section Audio/Video
Market USA
Applicability
March 30, 2010 Rev1:
TSB REVISION NOTICE
^ Applicability has been updated to include additional 2010 - 2011 model year Toyota vehicles.
Any previous printed versions of this service bulletin should be discarded.
Introduction
Some vehicles equipped with a PPO/DIO accessory XM Satellite Radio Receiver (P/N
86180-0W030 or 86180-0W031) may exhibit one or more of the following conditions:
^ XM Satellite Radio becomes non-operational or locked while in use.
^ Sound output becomes sporadic or non-existent.
When either of these conditions occur cycling the ignition from "ON"-"OFF"-"ON" restores normal
operation.
Improved XM Satellite Radio Receiver exchange units are available to correct this condition.
NOTE
Page 7676
Compressor Clutch Relay: Locations Air Conditioning System (for Manual Air Conditioning System)
AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Manual Air Conditioning System):
PARTS LOCATION
Page 3580
Knock Sensor: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: REMOVAL
1. REMOVE INTAKE MANIFOLD
(a) Remove the intake manifold See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service
and Repair/Removal.
2. REMOVE SEPARATOR CASE
(a) Remove the 4 bolts and separator case.
3. REMOVE KNOCK SENSOR
(a) Disconnect the 4 knock sensor connectors.
(b) Remove the 4 bolts and 4 knock sensors.
Page 736
(f) If the result is not as specified, replace the switch.
4. INSPECT SEAT HEATER SWITCH RH (w/ Climate Control Seat System)
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance (for Heater):
Standard Resistance (for Blower):
HINT As the dial is being turned, the resistance changes gradually.
(b) If the result is not as specified, replace the switch.
(c) Apply battery voltage to the switch connector, and check that the seat heater switch illuminates.
OK:
(d) If the result is not as specified, replace the switch.
(e) Apply battery voltage to the switch connector, and check that the seat heater switch illuminates.
OK:
Page 6886
Power Distribution Module: Service and Repair Removal
OTHER SYSTEM: VOLTAGE INVERTER (for CrewMax): REMOVAL
1. REMOVE BACK PANEL TRIM LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for
CrewMax)/Removal
2. REMOVE BACK PANEL TRIM RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for
CrewMax)/Removal
3. REMOVE REAR DOOR SCUFF PLATE LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining
(for CrewMax)/Removal
4. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH
5. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY LH See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (for CrewMax)/Removal
6. REMOVE VOLTAGE INVERTER ASSEMBLY
(a) Remove the 2 bolts.
(b) Disconnect the voltage inverter connector and removal the voltage inverter.
Page 6612
(2) CONNECTORS
Slightly shake the connector vertically and horizontally.
(3) WIRE HARNESS
Slightly shake the wire harness vertically and horizontally.
HINT The connector joint and fulcrum of the vibration are the major areas that should be checked
thoroughly.
(b) HEAT METHOD:
When a malfunction seems to occur when the area in question is heated.
(1) Heat the component that is the possible cause of the malfunction with a hair dryer or similar
device. Check if the malfunction occurs.
NOTICE: *
Do not heat to more than 60°C (140°F). Exceeding this temperature may damage components.
* Do not apply heat directly to the parts in the ECU.
(c) WATER SPRINKLING METHOD:
When a malfunction seems to occur on a rainy day or in high-humidity.
(1) Sprinkle water onto the vehicle and check if the malfunction occurs.
NOTICE: *
Never sprinkle water directly into the engine compartment. Indirectly change the temperature and
humidity by spraying water onto the front of the radiator.
* Never apply water directly onto the electronic components.
HINT If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU
or connections. Look for evidence of corrosion or short circuits. Proceed with caution during water
tests.
(d) HIGH ELECTRICAL LOAD METHOD:
When a malfunction seems to occur when the electrical load is excessive.
(1) Turn on the heater blower, headlights, rear window defogger and all other electrical loads.
Check if the malfunction reoccurs.
5. DIAGNOSTIC TROUBLE CODE CHART
Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate
section's Diagnostic Trouble Code Chart. Use the chart to determine the trouble area and the
proper inspection procedure. A description of each of the chart's columns is below.
Page 3689
load while reprogramming.
^ Confirm the hood is open and ensure under hood temperature does NOT exceed 158°F (70°C).
^ Confirm cable connections between the vehicle and Techstream are secure.
^ Do NOT disconnect or turn off Techstream or vehicle ignition during reprogramming.
^ Set parking brake.
^ Complete ALL flash calibration updates provided for each ECU.
^ If the battery's state of charge or capacity are in question, test with SST. No. 00002-8150-KIT
"Digital Battery Analyze," and follow TSB No. PG001-06, "Battery Maintenance for In-Stock
Vehicles & Pre-Delivery" or the appropriate "Maintenance for HV & Auxiliary Batteries" service
bulletin.
^ The GR8 Battery Diagnostic Station MUST be used in Power Supply Mode to maintain battery
voltage at 13.5 volts while flash reprogramming the vehicle. For details on how to use the GR8
Battery Diagnostic Station, refer to the GR8 Instruction Manual located on TIS, Diagnostics - Tools
& Equipment - Battery Diagnostics.
3C. Click Next to start the calibration update process.
D. When using TIS Techstream select Techstream VIM as the desired programming device. Then
click Next.
Page 5221
Wheel Bearing: Tools and Equipment
Wheel Bearing Nut Socket
AST tool# TOY 185
For R and R of wheel bearing nut located on inboard side of wheel hub. Applicable: Newer Toyota
trucks and SUV's (2wd only).
- Made in USA
Contact AST for pricing.
Assenmacher Specialty Tools 1-800-525-2943
Components
Tire Pressure Monitor Receiver / Transponder: Service and Repair Components
TIRE AND WHEEL: TIRE PRESSURE WARNING RECEIVER: COMPONENTS
Air Switching Valve (for Bank 1)
Air Injection Control Valve: Service and Repair Air Switching Valve (for Bank 1)
Components
1UR-FE EMISSION CONTROL: AIR SWITCHING VALVE (for Bank 1): COMPONENTS
Removal
1UR-FE EMISSION CONTROL: AIR SWITCHING VALVE (for Bank 1): REMOVAL
1. DISCONNECT NO. 2 AIR HOSE
(a) Disconnect the No. 2 air hose and connector.
2. REMOVE AIR SWITCHING VALVE ASSEMBLY
(a) Remove the bolt and disconnect the wire harness clamp bracket.
Page 176
Page 5212
Required Tools & Equipment
Repair Procedure Overview
^ Confirm noise is coming from the rear of the vehicle and changes with vehicle speed.
^ Install ChaSSiSEAR(TM) (or equivalent) and isolate the noise to the rear wheel bearing.
^ Remove the rear axle shaft assembly.
^ Install new rear wheel bearing brake caliper bracket and seals.
^ Reinstall rear axle shaft assembly and confirm the noise is no longer present.
Repair Procedure
1. Test drive the vehicle and confirm the customer complaint.
Does the noise increase and decrease with vehicle speed?
^ YES - Go to step 2.
^ NO - This TSB does NOT apply. Refer to the Repair Manual for further diagnosis.
Page 5078
(a) Using a chisel and hammer, stake the nut.
42. INSTALL DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL
(a) Using SST and a plastic-faced hammer, tap in a new oil seal until its surface is flush with the
differential carrier end.
SST : 09608-32010
(b) Coat the lip of the oil seal with MP grease.
Standard oil seal depth:
-0.45 to 0.45 mm (-0.0177 to 0.0177 in.)
43. INSTALL DIFFERENTIAL SIDE GEAR INTER SHAFT SUB-ASSEMBLY
(a) Install a new snap ring onto the side gear inter shaft.
(b) Using a plastic-faced hammer, install the side gear inter shaft onto the differential case.
(c) Check that there is 2 to 3 mm (0.0788 to 0.118 in.) of play in the axial direction.
(d) Check that the side gear inter shaft does not come out when trying to pull it out by hand.
44. INSTALL FRONT DIFFERENTIAL TUBE ASSEMBLY
(a) Remove any old FIPG material and be careful not to drop oil on the contact surfaces of the
differential tube and bearing retainer.
Components
Power Distribution Module: Service and Repair Components
OTHER SYSTEM: VOLTAGE INVERTER (for CrewMax): COMPONENTS
Inspection
Air Flow Meter/Sensor: Testing and Inspection Inspection
1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: INSPECTION
1. INSPECT MASS AIR FLOW METER
(a) Check the output voltage.
(1) Apply battery voltage across terminals 1 (+B) and 2 (E2G).
NOTICE: While using the battery during inspection, do not bring the positive and negative tester
probes too close to each other as a short circuit may occur.
(2) Using a voltmeter, connect the positive (+) tester probe to terminal 3 (VG), and negative (-)
tester probe to terminal 2 (E2G).
(3) Blow air into the MAF meter, and check that the voltage fluctuates.
If the result is not as specified, replace the MAF meter.
(b) Perform a visual check for any foreign matter on the platinum hot wire (heater) of the mass air
flow meter shown in the illustration.
OK:
There is no foreign material.
(c) If the result is not as specified, replace the mass air flow meter.
(d) Check the IAT sensor.
Page 8272
(a) Pass the seat belt through the seatback hole.
3. INSTALL REAR SEAT REAR CUSHION MOULDING RH See: Body and Frame/Seats/Service
and Repair/Overhaul/Rear Seat Assembly (for
Crewmax LH Side)/Reassembly
4. INSTALL SEPARATE TYPE REAR SEAT CUSHION COVER LH See: Body and
Frame/Seats/Service and Repair/Overhaul/Rear Seat
Assembly (for Crewmax LH Side)/Reassembly
5. INSTALL REAR SEAT ASSEMBLY LH
(a) Install the seat with the 4 bolts.
Torque : 37 Nm (377 kgf-cm, 27 ft-lbf)
6. CONNECT REAR SEAT INNER BELT ASSEMBLY
Page 9384
6. Remove the cab mount bolts by pulling them through the hole and discard. New bolts will be
used in their place
7. Raise the back of the cab from the pinch welds high enough to remove the No.3 cab mounts
(see Figures 8 and 9).
Page 6940
J/B No.3 - Instrument Panel Right
Page 4735
Parts Information
Calibration Information
Required Tools & Equipment
Repair Procedure
Page 7489
Tire Pressure Monitor Receiver / Transponder: Service and Repair Installation
TIRE AND WHEEL: TIRE PRESSURE WARNING RECEIVER: INSTALLATION
1. INSTALL TIRE PRESSURE WARNING ANTENNA AND RECEIVER
(a) Install the receiver with the bolt.
Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
(b) Connect the receiver connector.
2. INSTALL ROOF HEADLINING ASSEMBLY
(a) for Regular Cab:
Install the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Installation.
(b) for Double Cab:
Install the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Double Cab)/Installation.
(c) for CrewMax:
Install the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (for CrewMax)/Installation.
Page 3908
Page 2109
(d) Enter the following menus: Powertrain / Engine and ECT / Trouble Codes.
(e) Check if any DTCs have been stored. Note down any DTCs.
(f) Clear DTCs See: Powertrain Management/Computers and Control Systems/Testing and
Inspection/Reading and Clearing Diagnostic
Trouble Codes/DTC Check / Clear.
(g) Check if the MIL goes off.
OK:
MIL goes off.
NG -- CHECK HARNESS AND CONNECTOR (CHECK FOR SHORT IN WIRE HARNESS)
OK -- REPAIR CIRCUITS INDICATED BY OUTPUT DTCS See: Powertrain
Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code
Descriptions/Engine Control System - SFI System
3. CHECK HARNESS AND CONNECTOR (CHECK FOR SHORT IN WIRE HARNESS)
(a) Disconnect the ECM connector.
(b) Turn the ignition switch to ON.
(c) Check that the MIL is not illuminated.
OK:
MIL is not illuminated.
NG -- CHECK HARNESS AND CONNECTOR (COMBINATION METER - ECM)
OK -- REPLACE ECM See: Powertrain Management/Computers and Control Systems/Engine
Control Module/Service and Repair/Removal
4. CHECK HARNESS AND CONNECTOR (COMBINATION METER - ECM)
Page 7554
Air Door Actuator / Motor: Locations Air Conditioning System (for Manual Air Conditioning System)
AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Manual Air Conditioning System):
PARTS LOCATION
Page 3638
Power Steering Pressure Switch: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: POWER STEERING OIL PRESSURE SWITCH:
REMOVAL
1. REMOVE FAN AND GENERATOR V BELT
(a) Remove the fan and generator V belt See: Engine, Cooling and Exhaust/Engine/Drive Belts,
Mounts, Brackets and Accessories/Drive
Belt/Service and Repair/Removal.
2. REMOVE FRONT WHEEL
3. REMOVE FRONT FENDER APRON SEAL RH See: Engine, Cooling and Exhaust/Exhaust
System/Exhaust Manifold/Service and
Repair/Removal
4. DRAIN POWER STEERING FLUID
5. REMOVE POWER STEERING OIL PRESSURE SWITCH
(a) Disconnect the power steering oil pressure switch connector.
(b) Remove the power steering oil pressure switch.
(c) Remove the O-ring.
Page 4811
Actuator: Service and Repair Removal
DIFFERENTIAL: AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR (for 4WD):
REMOVAL
1. REMOVE NO. 1 ENGINE UNDER COVER See: Engine, Cooling and Exhaust/Engine/Drive
Belts, Mounts, Brackets and Accessories/Drive
Belt/Service and Repair/Removal
2. REMOVE AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR
(a) Disconnect the actuator hose.
(b) Disconnect the actuator connector.
(c) Remove the 4 bolts and actuator.
Page 3813
Knock Sensor: Diagrams
Page 9366
12. Torque the NEW nuts to the specified torque range on the No.2 mounts.
Torque: 54 N*m (551 kgf*cm, 40 ft*lbf)
13. Reinstall the body plugs for the cab mount bolt holes and then restore the carpet to its original
position.
14. Test drive vehicle to confirm the condition has been improved.
Page 3925
Variable Valve Timing Actuator Position Sensor: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: VVT SENSOR: INSTALLATION
1. INSTALL VVT SENSOR
(a) Install the 4 sensors with the 4 bolts.
Page 4538
Page 4522
Page 1308
Use a volt/ohmmeter with high impedance (10 kohms/V minimum) for troubleshooting of the
electrical circuit.
Disconnection of Male and Female Connectors
DISCONNECTION OF MALE AND FEMALE CONNECTORS
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Finding A Short Circuit
FINDING A SHORT CIRCUIT
Page 6078
If the customer has experienced a RES malfunction above -22 F (-30 C) proceed with diagnosis
referencing the applicable troubleshooting guide in the Technical Information System (TIS)
Accessory tab Accessory Diagnostic Guide:
For 2007 Camry, Camry HV; Tundra, and 2006 - 2007 RAV4:
Refer also to TSB T-SB-0070-08, "Remote Engine Starter (RES) Cold Temperature Operation".
Page 8361
Impact Sensor: Service and Repair
Components
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift
Type): COMPONENTS
Testing and Inspection
Evaporative Emission Control Canister: Testing and Inspection
1UR-FE EMISSION CONTROL: CANISTER: INSPECTION
1. INSPECT CANISTER ASSEMBLY
(a) Visually check the canister assembly for cracks or damage.
(b) If cracks or damage are found, replace the canister assembly.
(c) Check for the canister operation.
(1) With the purge port closed, blow 1.67 kPa (20 gf/cm2, 0.24 psi) of air into the vent port, and
check that air flows from the air inlet port.
If the result is not as specified, replace the canister assembly.
(2) With the vent port closed, blow 1.06 kPa (10 gf/cm2, 0.15 psi) of air inlet port, and check that air
flows from the purge port.
(3) If the result is not as specified, replace the canister assembly.
(d) Check for air leak.
Page 8300
Front Seat Belt Extender Applications
Page 1428
between other parts.
(d) Check that there is no looseness in the installation parts of the side airbag sensor.
(e) Connect the connector.
9. INSTALL FRONT DOOR SCUFF PLATE LH (for Rear Side) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Installation
10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
11. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
Components
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Column
Shift Type): COMPONENTS
Page 8626
(a) Attach the 2 claws to install the adapter.
2. INSTALL INTEGRATION CONTROL AND PANEL ASSEMBLY (for Manual Air Conditioning
System) See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and
Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation
3. INSTALL INTEGRATION CONTROL AND PANEL ASSEMBLY (for Automatic Air Conditioning
System) See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and
Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation
4. INSTALL INSTRUMENT PANEL CUP HOLDER ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column
Shift Type)/Installation
5. INSTALL LOWER INSTRUMENT CLUSTER FINISH PANEL See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column
Shift Type)/Installation
6. INSTALL FRONT ASH RECEPTACLE BOX SUB-ASSEMBLY
7. INSTALL CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service
and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
8. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column
Shift Type)/Installation
9. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Installation
10. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
11. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Installation
12. INSTALL FRONT DOOR SCUFF PLATE LH
(a) for Double Cab:
Install the front door scuff plate LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation.
(b) for Regular Cab:
Install the front door scuff plate LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation.
(c) for CrewMax:
Install the front door scuff plate LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation.
13. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Page 3703
4. Attach the Authorized Vehicle Modification Label.
Modifications to ECU calibrations MUST be recorded and properly displayed on the vehicle using
the Authorized Modification Label.
Techstream Preparation
Selecting the TIS Techstream VIM or the Mongoose MFC VIM.
Techstream software requires a VIM selection before you can use the Mongoose MFC VIM.
If using TIS Techstream no changes are needed.
Perform the following:
1. Select Setup from the Techstream Main Menu screen.
2. Select VIM Select from the Setup drop down menu.
3. Select the correct Interface Setup from the drop down list.
^ If using Techstream Lite select Mongoose MFC.
NOTE
Page 6990
6. PROBLEM SYMPTOMS TABLE
When a "Normal" code is output during a DTC check but the problem is still occurring, use the
Problem Symptoms Table. The suspected areas (circuits or parts) for each problem symptom are
in the table. The suspected areas are listed in order of probability. A description of each of the
chart's columns is below.
HINT In some cases, the problem is not detected by the diagnostic system even though a problem
symptom is present. It is possible that the problem is occurring outside the detection range of the
diagnostic system, or that the problem is occurring in a completely different system.
7. CIRCUIT INSPECTION
A description of the main areas of each circuit inspection is below.
Page 6683
Engine Room R/B, J/B - Engine Compartment Left
Page 4131
Page 3926
ERROR: undefined
OFFENDING COMMAND: f‘~
STACK:
Page 3419
INSPECTION PROCEDURE
HINT *
Perform the following inspection for the ECUs (sensors) which are not displayed on the
Techstream. If a malfunction cannot be identified, perform the following inspections for the ECUs
(sensors) connected to the CAN communication system.
* Do not remove the combination meter and ECM, as they are the end parts of the circuit. If
removed, CAN communication will not be possible.
* The open circuit confirmation of the combination meter, ECM and main wire is performed in the
CHECK CAN BUS LINE procedure of "HOW TO PROCEED WITH TROUBLESHOOTING". This
inspection only has procedures for checking for an open circuit on one side of the CAN branch
wire.
PROCEDURE
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
(a) Disconnect the cable from the negative (-) battery terminal before measuring the resistances of
the main wire and the branch wire.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
NEXT -- Continue to next step.
Components
Evaporator Temperature Sensor / Switch: Service and Repair Components
AIR CONDITIONING: FRONT EVAPORATOR TEMPERATURE SENSOR: COMPONENTS
Page 8694
Integrated Accessory Switch Assembly: Service and Repair Installation
METER: DRIVE MONITOR SWITCH: INSTALLATION
1. INSTALL DRIVE MONITOR SWITCH
(a) Attach the 2 claws to install the monitor switch.
2. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Panel,
Gauges and Warning Indicators/Instrument Cluster
/ Carrier/Service and Repair/Combination Meter/Installation
Center Airbag Sensor Assembly (for Column Shift Type)
Air Bag Control Module: Service and Repair Center Airbag Sensor Assembly (for Column Shift
Type)
Components
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Column
Shift Type): COMPONENTS
Page 7920
Air Bag: Testing and Inspection Curtain Shield Airbag Assembly
SUPPLEMENTAL RESTRAINT SYSTEM: CURTAIN SHIELD AIRBAG ASSEMBLY: ON-VEHICLE
INSPECTION
1. CHECK CURTAIN SHIELD AIRBAG ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION)
(a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnosis System.
(b) With the curtain shield airbag installed on the vehicle, perform a visual check. If any of the
defects mentioned below are present, replace the
curtain shield airbag with a new one:
Cuts, minute cracks or marked discoloration on the curtain shield airbag.
2. CHECK CURTAIN SHIELD AIRBAG ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND
AIRBAG HAS NOT DEPLOYED)
(a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnosis System.
(b) With the curtain shield airbag removed from the vehicle, perform a visual check. If there are any
defects as mentioned below, replace the
curtain shield airbag with a new one:
* Cuts, minute cracks or marked discoloration on the curtain shield airbag.
* Cracks or other damage to the connectors.
CAUTION: For removal and installation procedures of the curtain shield airbag, be sure to follow
the correct procedure.
Locations
Ignition Switch: Locations
1UR-FE STARTING: STARTING SYSTEM: PARTS LOCATION
Page 49
Double Cab)/Removal
5. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH
6. REMOVE REAR DOOR SCUFF PLATE RH
(a) Remove the front door scuff plate See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Removal.
HINT The procedures listed below are for the LH side.
7. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY RH See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Double Cab)/Removal
8. REMOVE DOOR CONTROL RECEIVER
(a) Disconnect the door control receiver connector.
(b) Remove the bolt and receiver.
Installation
DOOR LOCK: DOOR CONTROL RECEIVER (for Double Cab): INSTALLATION
1. INSTALL DOOR CONTROL RECEIVER
(a) Install the receiver with the bolt.
(b) Connect the door control receiver connector.
2. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY RH
3. INSTALL REAR DOOR SCUFF PLATE RH
(a) Install rear door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double
Cab)/Installation.
HINT The procedures listed below are for the LH side.
4. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH
5. INSTALL REAR SEAT ASSEMBLY See: Body and Frame/Seats/Service and Repair/Removal
and Replacement/Rear Seat Assembly (for
Double Cab)/Installation
6. INSTALL SEAT FLOOR BOX See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Rear Seat Assembly (for Double
Page 4579
Locations
Accessory Relay: Locations
Instrument Panel (Floor Shift)
Instrument Panel (Column Shift)
Page 472
Page 2794
^ Engine Control Module (ECM)
^ Transmission Control Module (TCM)
^ Or any other Toyota specific control unit
Warranty Information
Parts Information
Required Tools & Equipment
NOTE
Additional SSTs may be ordered by calling 1-800-933-8335.
Process Overview
Techstream ECU flash reprogramming is a 4-step process:
1. Verify the vehicle's applicability for recalibration and locate desired calibration file by performing
the Techstream Health Check function.
NOTE
Techstream will automatically search TIS for the appropriate service bulletin using the current
Calibration ID from the vehicle. Calibration file links can be found embedded in the corresponding
service bulletin.
2. Connect the GR8 Battery Diagnostic Station using "Power Supply Mode" only.
The GR8 Battery Diagnostic Station includes a Power Supply Mode to help maintain battery
voltage at 13.5 volts during ECU reprogramming.
ECU damage may occur if the correct battery charger mode setting is NOT used.
3. Locate appropriate calibration ID and reprogram the vehicle ECU with Techstream.
Techstream uses the Calibration Update Wizard (CUW) application to open calibration files and
facilitate the ECU flash reprogramming process.
Page 786
Braking Sensor/Switch: Locations From 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Components
Crankshaft Position Sensor: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: CRANKSHAFT POSITION SENSOR: COMPONENTS
Page 5054
09952-04010
09953-04020
09954-04010
09955-04011
09957-04010
09958-04011
(b) Remove the snap ring from the side gear inter shaft.
5. REMOVE FRONT DRIVE PINION COMPANION FLANGE FRONT NUT
(a) Using SST and a hammer, unstake the nut.
SST : 09930-00010
(b) Using SST to hold the companion, remove the nut.
SST : 09330-00021
09330-00030
6. REMOVE FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY
(a) Using SST, remove the companion flange from the differential carrier.
SST : 09950-30012
09951-03010
09953-03010
Page 4787
load while reprogramming.
^ Confirm the hood is open and ensure under hood temperature does NOT exceed 158°F (70°C).
^ Confirm cable connections between the vehicle and Techstream are secure.
^ Do NOT disconnect or turn off Techstream or vehicle ignition during reprogramming.
^ Set parking brake.
^ Complete ALL flash calibration updates provided for each ECU.
^ If the battery's state of charge or capacity are in question, test with SST. No. 00002-8150-KIT
"Digital Battery Analyze," and follow TSB No. PG001-06, "Battery Maintenance for In-Stock
Vehicles & Pre-Delivery" or the appropriate "Maintenance for HV & Auxiliary Batteries" service
bulletin.
^ The GR8 Battery Diagnostic Station MUST be used in Power Supply Mode to maintain battery
voltage at 13.5 volts while flash reprogramming the vehicle. For details on how to use the GR8
Battery Diagnostic Station, refer to the GR8 Instruction Manual located on TIS, Diagnostics - Tools
& Equipment - Battery Diagnostics.
3C. Click Next to start the calibration update process.
D. When using TIS Techstream select Techstream VIM as the desired programming device. Then
click Next.
Page 4038
Air Injection Pump: Testing and Inspection
1UR-FE EMISSION CONTROL: AIR PUMP: ON-VEHICLE INSPECTION
1. INSPECT AIR PUMP ASSEMBLY
(a) Start the engine and warm it up.
(b) Turn the ignition switch off.
(c) Connect the 400 A probe of an ammeter to the (+) wire of the air pump.
(d) Connect the Techstream to the DLC3.
(e) Turn the ignition switch to ON and turn the Techstream ON.
(f) Enter the following menus: Powertrain / Engine and ECT / Utility / Air Injection Check / Manual
Mode / AIR PUMP 1: ON, ASV1: OPEN,
AIR PUMP 2: ON, ASV2: OPEN.
HINT When Manual Mode is selected, the Techstream initialization (atmospheric pressure
measurement) is performed automatically. The initialization takes 10 seconds. After the
initialization, AIR PUMP and ASV operation can be selected.
(g) Measure the current while the air pump is turning.
Standard Current:
(h) If the result is not as specified, replace the air pump.
(i) Turn the ignition switch to OFF.
NOTICE: *
This Air Injection Check only allows technicians to operate the AIR system for a maximum of 5
seconds.
* Furthermore, the check can only be performed up to 4 times per trip. If the test is repeated,
intervals of at least 30 seconds are required between checks.
* While AIR system operation using the Techstream is prohibited, the Techstream display indicates
the prohibition (WAIT or ERROR).
* If an ERROR is displayed on the Techstream during the test, stop the engine for 10 minutes, and
then try again.
* Performing the Air Injection Check repeatedly may cause damage to the AIR system. If
necessary, leave an interval of several minutes between Air Injection Check operations to prevent
the system from overheating.
* When performing the Air Injection Check operation after the battery cable has been reconnected,
wait for 7 minutes with the ignition switch turned to ON or the engine running.
* Turn the ignition switch off when the Air Injection Check operation finishes.
Page 1062
(b) Disconnect the connector and remove the courtesy switch.
Installation
LIGHTING: FRONT DOOR COURTESY SWITCH: INSTALLATION
HINT *
Use the same procedures for the RH and LH side.
* The procedures listed below are for the LH side.
* A bolt without a torque specification is shown in the standard bolt chart See:
Specifications/Mechanical Specifications/Standard Bolt - Specified Torque For Standard Bolts
1. INSTALL FRONT DOOR COURTESY SWITCH
(a) Connect the connector.
(b) Install the courtesy switch with the bolt.
Page 5933
Yaw Rate Sensor: Service and Repair Installation
BRAKE CONTROL: YAW RATE AND DECELERATION SENSOR: INSTALLATION
1. INSTALL YAW RATE SENSOR
(a) Connect the sensor connector (labeled A), and then attach the clamp (labeled B) to the hole of
the sensor bracket.
(b) Install the yaw rate sensor with the 2 nuts (labeled C).
Torque : 13 Nm (127 kgf-cm, 9 ft-lbf)
NOTICE: *
Make sure that the sensor is oriented correctly.
* If the sensor is dropped, replace it.
* Securely connect the connector.
* When installing the sensor, make sure to avoid impacts to the sensor.
2. INSTALL CENTER FRONT SEAT (for Center Seat) See: Body and Frame/Seats/Service and
Repair/Removal and Replacement/Front Seat
Assembly (for Center Seat)/Installation
3. INSTALL CONSOLE BOX ASSEMBLY (for Separate Seat Type)
(a) Install the console box See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and
Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation.
4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
5. PERFORM YAW RATE SENSOR ZERO POINT CALIBRATION
(a) Perform the yaw rate sensor zero point calibration See: Antilock Brakes / Traction Control
Systems/Testing and Inspection/Programming
and Relearning.
6. CHECK YAW RATE SENSOR SIGNAL
(a) Check the yaw rate sensor signal See: Antilock Brakes / Traction Control Systems/Testing and
Inspection/Scan Tool Testing and
Procedures/Test Mode Procedure.
Page 3977
6. In some instances where water has entered the system DTCs P2440/P2441/P2442/P2443 may
set.
Refer to TIS 2010 model year Tundra Repair Manual to diagnose and inspect the emission control
valves if necessary:
7. If there is NO liquid found in the air pump assemblies or the DTC is still present after
replacement inspect the air injection system.
Refer to TIS 2010 model year Tundra Repair Manual:
8. Clear the DTC and road test the vehicle to confirm the condition has been corrected.
Components
Seat Memory Switch: Service and Repair Components
SEAT: SEAT MEMORY SWITCH (w/ Seat Position Memory System): COMPONENTS
Page 2156
Tire Pressure Sensor: Service and Repair Removal
TIRE AND WHEEL: TIRE PRESSURE WARNING VALVE AND TRANSMITTER: REMOVAL
1. REMOVE TIRE
2. REMOVE TIRE PRESSURE WARNING VALVE AND TRANSMITTER
(a) Remove the valve core and cap, and release the air from the tire.
(b) After ensuring that a sufficient amount of air has been released, remove the nut and washer
that is used to secure the tire pressure warning
valve and transmitter. Then drop the tire pressure warning valve and transmitter inside the tire.
HINT Keep the removed cap, valve core, nut and washer.
(c) Disengage the bead using the shoe of a tire remover.
NOTICE: Be careful as the tire pressure warning valve and transmitter may become damaged due
to interference between the sensor and tire bead.
(d) Remove the bead on the upper side.
(e) Take out the tire pressure warning valve and transmitter from the tire, then remove the bead on
the lower side.
HINT *
The grommet is a non-reusable part.
* Check that there are no cracks or damage on the grommet. If any damage is found, replace the
washer and nut.
Page 4577
Page 4956
Transmission Cooler: Service and Repair Installation
A760F AUTOMATIC TRANSMISSION: OIL COOLER: INSTALLATION
1. INSTALL OIL COOLER TUBE (w/ Trailer Towing System)
(a) Temporarily install the oil cooler tube to the engine with bolt A. Install bolt B and tighten it to the
specified torque. Then tighten bolt A to the
specified torque.
Torque : 14 Nm (143 kgf-cm, 10 ft-lbf)
2. INSTALL NO. 2 OIL COOLER TUBE (w/ Trailer Towing System)
(a) Install the No. 4 oil cooler inlet hose and No. 4 oil cooler outlet hose to the No. 2 oil cooler tube.
NOTICE: Make sure the paint marks and pinching portion of each clip are facing the directions
shown in the illustration.
(b) Install the No. 2 oil cooler tube together with the 2 oil cooler hoses with the bolt.
Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)
(c) Connect the No. 4 oil cooler inlet hose and No. 4 oil cooler outlet hose to the cooler condenser.
NOTICE: *
Make sure the paint marks are facing the directions shown in the illustration.
* Make sure the pinching portion of each clip is not in the hatched areas shown in the illustration.
3. INSTALL COOLER CONDENSER ASSEMBLY (AIR COOLED OIL COOLER) (w/ Trailer Towing
System)
(a) Install the cooler condenser See: Heating and Air Conditioning/Condenser HVAC/Service and
Repair/Installation.
4. INSTALL OIL COOLER ACCESSORY ASSEMBLY (w/ Trailer Towing System)
(a) Install the oil cooler accessory assembly to the oil cooler tube, and then pass the 2 hoses
through the No. 1 flexible hose clamp and close the
clamp as shown in the illustration.
(b) Connect the 2 hoses to the No. 2 oil cooler tube.
NOTICE: *
When connecting the hoses to the tube, support the tube by hand and be careful to prevent the
tube from being deformed.
Page 2556
Required Tools & Equipment
Repair Procedure Overview
^ Confirm noise is coming from the rear of the vehicle and changes with vehicle speed.
^ Install ChaSSiSEAR(TM) (or equivalent) and isolate the noise to the rear wheel bearing.
^ Remove the rear axle shaft assembly.
^ Install new rear wheel bearing brake caliper bracket and seals.
^ Reinstall rear axle shaft assembly and confirm the noise is no longer present.
Repair Procedure
1. Test drive the vehicle and confirm the customer complaint.
Does the noise increase and decrease with vehicle speed?
^ YES - Go to step 2.
^ NO - This TSB does NOT apply. Refer to the Repair Manual for further diagnosis.
Page 6943
J/B No.6 Assembly - Instrument Panel Center
Page 9051
Trailer Lamps: Diagnostic Aids
Continuity and Resistance Check
CONTINUITY AND RESISTANCE CHECK
Disconnect the battery terminal or wire so there is no voltage between the check points.
Contact the two leads of an ohmmeter to each of the check points.
Air Conditioning System (for Automatic Air Conditioning
System)
Refrigerant Pressure Sensor / Switch: Locations Air Conditioning System (for Automatic Air
Conditioning System)
AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Automatic Air Conditioning System):
PARTS LOCATION
Page 4196
Page 2511
Variable Valve Timing Actuator Position Sensor: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: VVT SENSOR: INSTALLATION
1. INSTALL VVT SENSOR
(a) Install the 4 sensors with the 4 bolts.
Page 1190
Manifold Pressure/Vacuum Sensor: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: MANIFOLD ABSOLUTE PRESSURE SENSOR:
REMOVAL
1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Removal
2. REMOVE MANIFOLD ABSOLUTE PRESSURE SENSOR
(a) Disconnect the manifold absolute pressure sensor connector.
(b) Remove the screw and manifold absolute pressure sensor.
(c) Remove the O-ring from the manifold absolute pressure sensor.
Page 5034
7. REMOVE REAR DRIVE PINION NUT
(a) Using SST and a hammer, unstake the nut.
SST : 09930-00010
(b) Using SST to hold the companion flange, remove the nut.
SST : 09330-00021
09330-00030
8. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY
(a) Using SST, remove the companion flange.
SST : 09950-30012
09951-03010
09953-03010
09954-03010
09956-03030
SST : 09955-03050
9. REMOVE REAR DIFFERENTIAL DUST DEFLECTOR
(a) Using SST, a steel plate and press, press out the dust deflector.
Page 3200
Camshaft Position Sensor: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT POSITION SENSOR: INSTALLATION
1. INSTALL CAMSHAFT POSITION SENSOR
(a) Install the sensor with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(b) Connect the sensor connector.
2. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Installation
Page 5035
SST : 09950-00020
NOTICE: Do not drop the companion flange.
10. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL
(a) Using SST, remove the oil seal.
SST : 09308-10010
11. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
12. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
(a) Using SST, remove the bearing (inner race).
SST : 09556-22010
(b) Remove the bearing spacer.
13. REMOVE REAR DIFFERENTIAL BEARING ADJUSTING NUT LOCK
(a) Remove the 2 bolts and 2 nut locks.
14. REMOVE REAR DIFFERENTIAL CASE ASSEMBLY
Page 3027
Air Flow Meter/Sensor: Testing and Inspection On-Vehicle Inspection
1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: ON-VEHICLE INSPECTION
1. CHECK MASS AIR FLOW METER
(a) Check the mass air flow value.
(1) Connect the Techstream to the DLC3.
(2) Turn the ignition switch to ON.
(3) Turn the Techstream main switch ON.
(4) Enter the following menus: Powertrain / Engine / Data List / All Data / MAF.
(5) Blow air into the MAF meter, and check that the MAF value fluctuates.
(6) If the result is not as specified, check the MAF meter See: Inspection, or wiring and ECM See:
Computers and Control Systems/Testing
and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0102.
Page 5713
Brake Fluid: Testing and Inspection
BRAKE: BRAKE FLUID: ON-VEHICLE INSPECTION
1. CHECK BRAKE FLUID LEVEL IN RESERVOIR
(a) Check the fluid level and add fluid if necessary.
Fluid:
SAE J1703 or FMVSS No. 116 DOT3
HINT The brake fluid level must always be adjust to the MAX line.
Page 1762
(4) Remove the 2 bolts and disconnect the water by-pass pipe.
(5) Remove the 4 bolts and 4 ignition coils.
4. REMOVE SPARK PLUG
(a) Using a 16 mm plug wrench, remove the 8 spark plugs.
Page 6927
4. SYMPTOM CONFIRMATION AND DTC (INCLUDING FREEZE FRAME DATA) CHECK
(a) Visually check the wire harnesses, connectors and fuses for open and short circuits.
(b) Warm up the engine to the normal operating temperature.
(c) Confirm the problem symptoms and conditions, and check for DTCs.
B -- Go to step 6 A -- Continue to next step.
5. DTC CHART
(a) Check the results obtained in the DTC check. Then find the output DTC in the DTC chart. Look
at the "Trouble Area" column for a list of
potentially malfunctioning circuits and / or parts.
NEXT -- Go to step 7
6. PROBLEM SYMPTOMS TABLE
(a) Check the results obtained in the symptom confirmation. Then find the problem symptoms in
the problem symptoms table. Look at the
"Suspected Area" column for a list of potentially malfunctioning circuits and / or parts.
NEXT -- Continue to next step.
7. CIRCUIT INSPECTION OR PARTS INSPECTION
(a) Confirm the malfunctioning circuit or part.
NEXT -- Continue to next step.
8. ADJUST, REPAIR OR REPLACE
(a) Adjust, repair or replace the malfunctioning circuit or parts.
NEXT -- Continue to next step.
9. CONFIRMATION TEST
(a) After the adjustment, repairs or replacement, confirm that the malfunction no longer exists. If the
malfunction does not reoccur, perform a
confirmation test under the same conditions and in the same environment as when the malfunction
occurred the first time.
NEXT -- END
2. CUSTOMER PROBLEM ANALYSIS
HINT *
In troubleshooting, confirm that the problem symptoms have been accurately identified.
Preconceptions should be discarded in order to make an accurate judgment. To clearly understand
what the problem symptoms are, it is extremely important to ask the customer about the problem
and the conditions at the time the malfunction occurred.
* Gather as much information as possible for reference. Past problems that seem unrelated may
also help in some cases.
* The following 5 questions are important points in the problem analysis:
Page 9394
7. Raise the back of the cab from the pinch welds high enough to remove the No.3 cab mounts.
8. With the cab still raised install the new No.3 cab mounts.
9. Install the two bolts on top that were previously removed from the No.3 cab mount and torque to
specification.
Torque: 61 N*m (622 kgf*cm, 45 ft*lbf)
Page 6489
6. PROBLEM SYMPTOMS TABLE
When a "Normal" code is output during a DTC check but the problem is still occurring, use the
Problem Symptoms Table. The suspected areas (circuits or parts) for each problem symptom are
in the table. The suspected areas are listed in order of probability. A description of each of the
chart's columns is below.
HINT In some cases, the problem is not detected by the diagnostic system even though a problem
symptom is present. It is possible that the problem is occurring outside the detection range of the
diagnostic system, or that the problem is occurring in a completely different system.
7. CIRCUIT INSPECTION
A description of the main areas of each circuit inspection is below.
Page 8251
(a) Align the vehicle's claws with the seat belt retractor positioning holes.
(b) Install the seat belt with the 2 bolts.
HINT First install the bolt A, and then install bolt B.
for bolt A - Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
for bolt B - Torque : 42 Nm (428 kgf-cm, 31 ft-lbf)
(c) Connect the pretensioner connector as shown in the illustration.
(d) Install the shoulder anchor to the shoulder belt anchor adjuster with the nut.
Torque : 42 Nm (428 kgf-cm, 31 ft-lbf)
2. INSTALL CENTER PILLAR GARNISH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Installation
3. INSTALL LOWER CENTER PILLAR GARNISH
Page 2208
No further tightening is required once the nut is tightened with the specified torque.
2. INSTALL WHEEL
for Aluminum Wheel - Torque : 131 Nm (1336 kgf-cm, 97 ft-lbf)
for Steel Wheel - Torque : 209 Nm (2131 kgf-cm, 154 ft-lbf)
3. INSPECT TIRE
(a) Inspect the tire See: Testing and Inspection/Component Tests and General Diagnostics.
4. REGISTRATION OF TRANSMITTER ID
(a) Register the transmitter ID See: Testing and Inspection/Programming and
Relearning/Registration.
5. PERFORM INITIALIZATION
(a) Perform initialization See: Testing and Inspection/Programming and Relearning/Initialization.
NOTICE: Be sure to inflate all tires to the proper inflation pressure before initialization.
6. CHECK TIRE PRESSURE AFTER REPAIRS
(a) After repairs, confirm that the actual tire pressures are displayed in the DATA LIST See: Testing
and Inspection/Scan Tool Testing and
Procedures/Data List / Active Test.
Page 8060
Impact Sensor: Diagrams Front Airbag Sensor
Locations
Transmission Speed Sensor: Locations
A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS
LOCATION
Page 7193
HINT Tape the screwdriver tip before use.
4. REMOVE VANE PUMP SHAFT SUB-ASSEMBLY WITH PULLEY
(a) Using 2 screwdrivers, remove the snap ring from the vane pump shaft.
(b) Remove the vane pump shaft sub-assembly with pulley.
NOTICE: Be careful not to drop or damage the vane pump shaft sub-assembly with pulley. If it is
damaged, replace the vane pump assembly.
5. REMOVE VANE PUMP ROTOR
(a) Remove the 10 vane plates.
NOTICE: Take care not to drop the vane plate.
(b) Remove the vane pump rotor.
6. REMOVE VANE PUMP CAM RING
(a) Remove the cam ring from the front housing.
7. REMOVE VANE PUMP FRONT SIDE PLATE
Page 6504
Driver Side J/B Inner Circuit
Page 5150
Replacement
DIFFERENTIAL: FRONT DIFFERENTIAL CARRIER OIL SEAL (for 4WD): REPLACEMENT
1. DRAIN DIFFERENTIAL OIL See: Fluid - Differential/Service and Repair
2. REMOVE FRONT DIFFERENTIAL CARRIER ASSEMBLY
(a) Remove the differential carrier See: Differential Carrier/Service and Repair/Removal and
Replacement/Front Differential Carrier
Assembly/Removal.
3. REMOVE FRONT DIFFERENTIAL TUBE ASSEMBLY See: Differential Carrier/Service and
Repair/Overhaul/Front Differential Carrier
Assembly/Disassembly
Page 9005
Trailer Connector: Diagnostic Aids
Continuity and Resistance Check
CONTINUITY AND RESISTANCE CHECK
Disconnect the battery terminal or wire so there is no voltage between the check points.
Contact the two leads of an ohmmeter to each of the check points.
Page 6061
Recall 10V017000: Accelerator Pedal Sticking
Accelerator Pedal Position Sensor: All Technical Service Bulletins Recall 10V017000: Accelerator
Pedal Sticking
VEHICLE MAKE/MODEL: MODEL YEAR(S): Toyota/Avalon 2005-2010 Toyota/Camry 2007-2010
Toyota/Corolla 2009-2010 Toyota/Corolla Matrix 2009-2010 Toyota/Highlander 2010 Toyota/ RAV4
2009-2010 Toyota/Sequoia 2008-2010 Toyota/Tundra 2007-2010 MANUFACTURER: Toyota
Motor North America, Inc.
MFR'S REPORT DATE: January 21, 2010
NHTSA CAMPAIGN ID NUMBER: 10V017000
NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Accelerator Assembly:
Pedal/Linkage
POTENTIAL NUMBER OF UNITS AFFECTED: ?
SUMMARY: Toyota is recalling certain model year 2005-2010 Avalon, model year 2007-2010
Camry, model year 2009-2010 Corolla, Corolla Matrix, RAV4, model year 2010 Highlander, model
year 2008-2010 Sequoia, and model year 2007-2010 Tundra. due to the manner in which the
friction lever interacts with the sliding surface of the accelerator pedal inside the pedal sensor
assembly, the sliding surface of the lever may become smooth during vehicle operation. In this
condition, if condensation occurs on the surface, as may occur from heater operation (without A/C)
when the pedal assembly is cold, the friction when the accelerator pedal is operated may increase,
which may result in the accelerator pedal becoming harder to depress, slower to return, or, in the
worst case, mechanically stuck in a partially depressed position.
CONSEQUENCE: The accelerator pedal may become hard to depress, slow to return to idle, or, in
the worst case, mechanically stuck in a partially depressed position, increasing the risk of a crash.
REMEDY: Toyota has not yet provided a remedy plan or an owner notification schedule. Owners
may contact Toyota at 1-800-331-4331.
NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle
Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov.
Page 8280
(d) for RH Side:
Detach the 3 clips and remove the lower quarter trim panel.
7. REMOVE FRONT QUARTER TRIM PANEL ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and Repair/Roof
Headlining (For Double Cab)/Removal
8. REMOVE REAR SEAT OUTER BELT ASSEMBLY
(a) Remove the nut and disconnect the seat belt's shoulder anchor.
(b) Remove the 2 bolts and seat belt.
9. REMOVE REAR SHOULDER BELT ANCHOR ADJUSTER ASSEMBLY
(a) Remove the 2 bolts and adjuster.
Installation
SEAT BELT: REAR SEAT OUTER BELT ASSEMBLY (for CrewMax): INSTALLATION
HINT
Page 5502
Control Module: Locations JF1A Transfer Case
JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION
Page 8563
Parking Assist Control Module: Service and Repair Removal
PARK ASSIST / MONITORING: CLEARANCE WARNING ECU: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to disable the SRS system.
2. REMOVE INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal
3. REMOVE NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY See: Body and
Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Column Shift Type)/Removal
4. REMOVE LOWER INSTRUMENT PANEL See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal
5. REMOVE LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY See: Restraint
Systems/Air Bag Systems/Air Bag/Service and
Repair/Removal and Replacement/Front Passenger Side Knee Airbag Assembly/Removal
6. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and
Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument
Panel Safety Pad (for Column Shift Type)/Removal
7. REMOVE CLEARANCE WARNING ECU WITH BRACKET
(a) Disconnect the ECU connectors and detach the harness clamp.
NOTICE: Do not apply excessive force to the wire harnesses.
(b) Remove the bolt, nut and ECU with bracket.
8. REMOVE CLEARANCE WARNING ECU ASSEMBLY
(a) Remove the 2 nuts and clearance warning ECU from the bracket.
NOTICE: *
Avoid any impact to the clearance warning ECU.
* Do not drop the ECU. If it is dropped, replace it with a new one.
Page 2770
^ Figure 17 shows an example of the update procedure for a two-processor ECU.
G. Turn ignition OFF. Then click Next.
H. Confirm the following:
^ Ignition is ON and engine is OFF or "READY" OFF (hybrid vehicles).
^ Hood is open.
^ All accessories are OFF.
^ Battery voltage is above 11.4 volts.
NOTICE
Verify the vehicle is connected to a battery charger before continuing - If battery voltage falls below
11.4 volts, ECU damage may occur.
Page 6665
Auxiliary Power Outlet Switch: Service and Repair Removal
OTHER SYSTEM: INVERTER MAIN SWITCH (for CrewMax): REMOVAL
1. REMOVE FRONT DOOR SCUFF PLATE LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining
(For Double Cab)/Removal
2. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for
CrewMax)/Removal
3. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal
4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Floor Shift Type)/Removal
5. REMOVE INVERTER MAIN SWITCH
(a) Detach the 2 claws and remove the main switch.
Components
Alarm System Transponder: Service and Repair Components
ENGINE IMMOBILISER: TRANSPONDER KEY AMPLIFIER: COMPONENTS
Page 277
Establish conditions in which voltage is present at the check point.
Example:
- [A] - Ignition SW on
- [B] - Ignition SW and SW1 on
- [C] - Ignition SW, SW1 and Relay on (SW2 off)
Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or component terminal.
This check can be done with a test light instead of a voltmeter.
Electronic Circuit Inspection Procedure
Page 6374
Page 818
Traction Control Switch: Testing and Inspection
BRAKE CONTROL: VSC OFF SWITCH: INSPECTION
1. INSPECT VSC OFF SWITCH
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the VSC OFF switch.
Removal and Replacement
Drive/Propeller Shaft: Removal and Replacement
Components
PROPELLER SHAFT: PROPELLER SHAFT ASSEMBLY (for 4WD): COMPONENTS
Page 175
Page 3127
This TSB applies to all Sequoia and Tundra vehicles equipped with lUR-FE (4.6L) 2UZ-FE (4.7L)
and 3UR-FE/FBE (5.7L) engines produced BEFORE the Production Change Effective VINs shown.
Repair Procedure
1. Remove and replace the air cleaner lid.
2. Remove and replace the front right hand (RH) fender liner.
Page 6036
Page 6643
Removal
OTHER SYSTEM: CENTER POWER OUTLET SOCKET (for Floor Shift Type): REMOVAL
1. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding
/ Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
2. REMOVE CONSOLE BOX BEZEL
Page 7824
Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular Cab)/Installation.
(b) for Double Cab:
Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Installation.
(c) for CrewMax:
Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for CrewMax)/Installation.
10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
11. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Reading and Clearing Diagnostic Trouble
Codes/Check Mode Procedure.
Page 2510
Variable Valve Timing Actuator Position Sensor: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: VVT SENSOR: REMOVAL
1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Service and Repair/Removal and
Replacement/Engine Assembly/Removal
2. REMOVE AIR CLEANER HOSE ASSEMBLY See: Service and Repair/Removal and
Replacement/Engine Assembly/Removal
3. REMOVE VVT SENSOR
(a) Disconnect the 4 sensor connectors.
(b) Remove the 4 bolts and 4 sensors.
Locations
Knock Sensor: Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Components
Spark Plug: Service and Repair Components
1UR-FE IGNITION: IGNITION COIL AND SPARK PLUG: COMPONENTS
SHIFT LEVER ASSEMBLY (for Column Shift Type)
Shifter A/T: Adjustments SHIFT LEVER ASSEMBLY (for Column Shift Type)
A760F AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY (for Column Shift Type):
ADJUSTMENT
1. INSPECT SHIFT LEVER POSITION
(a) When moving the shift lever from N to other positions, check that the lever can be moved
smoothly and accurately to each position and that the
position indicator comes on in accordance with the shift lever position.
If the indicator and shift lever position do not match, carry out the following adjustment procedures.
2. ADJUST SHIFT LEVER POSITION
(a) Move the shift lever to N.
(b) Fold back the transmission control cable adjust case cover. Then while sliding the slider toward
the cable end side, press out the lock piece
from the back side to release the lock.
(c) Check that the spring of the adjust case is applying enough tension to the shift control cable.
Then press in the lock piece to set the lock.
NOTICE: *
Use your hand to push in the lock piece. Do not use any tools.
* Securely push in the lock piece so that the protrusion of the slider is above the lock piece.
(d) Return the cover of the adjust case to its original position.
(e) Inspect the shift lever operation after the adjustment.
Page 7062
Standard steering axis inclination (unloaded vehicle):
for Double Cab of Long Deck
Components
Traction Control Switch: Service and Repair Components
BRAKE CONTROL: VSC OFF SWITCH: COMPONENTS
Page 2190
(a) After repairs, confirm that the actual tire pressures are displayed in the DATA LIST See: Testing
and Inspection/Scan Tool Testing and
Procedures/Data List / Active Test.
Occupant Classification System
Air Bag Control Module: Locations Occupant Classification System
SUPPLEMENTAL RESTRAINT SYSTEM: OCCUPANT CLASSIFICATION SYSTEM: PARTS
LOCATION
Page 4356
(a) Install the 2 delivery pipe spacers and 4 insulators to the cylinder head RH.
(b) Install the delivery pipe (with injectors) to the cylinder head RH.
(c) Install the 2 bolts.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
NOTICE:
Make sure that the part of the injector labeled B is between the parts of the delivery pipe labeled A.
(d) Connect the No. 6 wire harness connector.
4. CONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY
(a) Connect the No. 1 fuel pipe to the fuel delivery pipe LH See: Service Precautions.
5. CONNECT FUEL TUBE SUB-ASSEMBLY
(a) Connect the fuel tube to the delivery pipe LH See: Service Precautions.
(b) Connect the fuel tube to the delivery pipe RH See: Service Precautions.
6. CONNECT NO. 2 FUEL TUBE SUB-ASSEMBLY
(a) Connect the No. 2 fuel tube to the fuel pressure regulator See: Service Precautions.
Locations
Shift Solenoid: Locations
A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS
LOCATION
Page 6067
Ignition Switch: Testing and Inspection
1UR-FE STARTING: IGNITION SWITCH: INSPECTION
1. INSPECT IGNITION SWITCH ASSEMBLY
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) If the result is not as specified, replace the ignition switch assembly.
Page 2287
Variable Valve Timing Actuator: Testing and Inspection On-Vehicle Inspection
1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT OIL CONTROL VALVE: ON-VEHICLE
INSPECTION
1. INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
(a) Connect the Techstream to the DLC3.
(b) Start the engine and turn the tester ON.
(c) Warm up the engine.
(d) Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the VVT Linear
(Bank 1) or Control the VVT Linear (Bank
2) or Control the VVT System (Bank 1) or Control the VVT System (Bank 2) or Control the VVT
Exhaust Linear (Bank 1) or Control the VVT Exhaust Linear (Bank 2).
(e) Check the engine speed while operating the Oil Control Valve (OCV) using the tester.
OK:
(f) If the result is not as specified, check the oil control valve, wiring and camshaft timing gear.
HINT *
Control the VVT Linear (Bank 1): Command to activate exhaust and intake side oil control valves of
bank 1 (Control range: Between -128 to 127%).
* Control the VVT Linear (Bank 2): Command to activate exhaust and intake side oil control valves
of bank 2 (Control range: Between -128 to 127%).
* Control VVT System (Bank 1): Command to activate oil control valve of bank 1 (Control range:
ON/OFF).
* Control VVT System (Bank 2): Command to activate oil control valve of bank 2 (Control range:
ON/OFF).
* Control the VVT Exhaust Linear (Bank 1): Command to activate exhaust side oil control valve of
bank 1 (Control range: Between -128 to 127%).
* Control the VVT Exhaust Linear (Bank 2): Command to activate exhaust side oil control valve of
bank 2 (Control range: Between -128 to 127%).
Page 7777
(1) Insert the pin into the plate groove.
(2) Attach the claw to install the main plate.
(3) Install the 2 screws.
(c) Set the damper servo so that the cutout part engages with the tooth of the gear, and attach the
claw to install the damper servo.
(d) Install the 4 screws and connect the 2 connectors.
10. INSTALL AIR DUCT
Page 4016
1UR-FE EMISSION CONTROL: AIR SWITCHING VALVE (for Bank 2): REMOVAL
1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Removal
2. REMOVE AIR CLEANER HOSE ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Removal
3. DISCONNECT NO. 3 VENTILATION HOSE
(a) Disconnect the No. 3 ventilation hose.
4. DISCONNECT NO. 1 AIR HOSE
(a) Disconnect the No. 1 air hose.
5. REMOVE AIR SWITCHING VALVE ASSEMBLY
(a) Disconnect the connector and clamp.
(b) Remove the bolt and disconnect the wire harness clamp bracket.
(c) Remove the 2 bolts.
(d) Remove the 3 bolts, air switching valve and gasket.
NOTICE: Be careful not to damage the installation surface of the gaskets.
Installation
1UR-FE EMISSION CONTROL: AIR SWITCHING VALVE (for Bank 2): INSTALLATION
1. INSTALL AIR SWITCHING VALVE ASSEMBLY
Page 1390
Impact Sensor: Service and Repair Front Airbag Sensor
Components
SUPPLEMENTAL RESTRAINT SYSTEM: FRONT AIRBAG SENSOR: COMPONENTS
Removal
SUPPLEMENTAL RESTRAINT SYSTEM: FRONT AIRBAG SENSOR: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
Engine Control System - SFI System
Crankshaft Position Sensor: Locations Engine Control System - SFI System
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 3527
NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO CENTER AIRBAG
SENSOR (CANH, CANL)
OK -- REPLACE CENTER AIRBAG SENSOR
19. CHECK FOR SHORT TO GND IN CAN BUS WIRE (NO. 2 JUNCTION CONNECTOR - AIR
CONDITIONING AMPLIFIER)
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- CHECK FOR SHORT TO GND IN CAN BUS WIRE (AIR CONDITIONING AMPLIFIER) OK
-- Continue to next step.
20. CHECK FOR SHORT TO GND IN CAN BUS WIRE (NO. 2 JUNCTION CONNECTOR - BUS
BUFFER ECU)
NOTICE: For vehicles without a bus buffer ECU, go to "CHECK FOR SHORT TO GND IN CAN
BUS WIRE (NO. 2 JUNCTION CONNECTOR - 4WD CONTROL ECU)".
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- CHECK FOR SHORT TO GND IN CAN BUS WIRE (BUS BUFFER ECU) OK -- Continue to
next step.
21. CHECK FOR SHORT TO GND IN CAN BUS WIRE (NO. 2 JUNCTION CONNECTOR - 4WD
CONTROL ECU)
Page 8109
Removal
SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Regular Cab): REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Regular Cab)/Disassembly
3. REMOVE FRONT ARMREST BASE PANEL UPPER LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Page 7703
Removal
AIR CONDITIONING: AIR CONDITIONING PANEL (for Floor Shift Type): REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION:
Page 1301
Symbols Used Within Diagrams
Symbols Used Within Diagrams
Locations
Knock Sensor: Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 6499
J/B No.6 Assembly - Instrument Panel Center
Page 6894
Power Distribution Relay: Testing and Inspection ACC Relay
1UR-FE STARTING: ACC RELAY: ON-VEHICLE INSPECTION
1. INSPECT MAIN BODY ECU (ACC RELAY)
(a) Measure the resistance of the ACC relay circuit.
(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(2) If the result is not as specified, replace the main body ECU.
Page 4053
Canister Purge Control Valve: Service and Repair Removal
1UR-FE EMISSION CONTROL: PURGE VALVE: REMOVAL
1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Removal
2. DISCONNECT PURGE LINE HOSE
(a) Disconnect the 2 purge line hoses.
3. REMOVE PURGE VSV
(a) Disconnect the connector.
(b) Remove the bolt and purge VSV.
Page 4310
When using Techstream Lite, select Generic J2534 Interface. Then click Next.
E. Confirm the following:
^ PC is connected to VIM.
^ VIM is connected to DLC3 connector.
^ Ignition is ON and engine is OFF or "READY" OFF (hybrid vehicles).
Specifications
Axle Nut: Specifications
FRONT AXLE HUB NUT LH (for 4WD)
Using a 39 mm socket wrench, install the hub nut.
Torque..................................................................................................................................................
...............................338 Nm (3446 kgf-cm, 249 ft-lbf)
Page 7286
NOTICE: Be careful not to damage the No. 2 steering rack boot.
6. REMOVE NO. 2 STEERING RACK BOOT
7. REMOVE NO. 1 STEERING RACK BOOT
8. REMOVE STEERING RACK END SUB-ASSEMBLY
(a) Using a screwdriver and hammer, stake back the washer.
NOTICE: Do not strike the steering rack.
(b) Using a wrench, hold the steering rack (LH side).
(c) Using SST, remove the steering rack end (LH side) from the power steering rack.
SST : 09922-10010
NOTICE: Rotate SST in the direction shown in the illustration.
(d) Using SST, remove the steering rack end (RH side) from the power steering rack.
SST : 09922-10010
NOTICE: Rotate SST in the direction shown in the illustration.
(e) Remove the 2 claw washers.
9. REMOVE STEERING GEAR RACK GUIDE
(a) Using SST, remove the steering rack guide spring cap nut.
SST : 09922-10010
NOTICE: Rotate SST in the direction shown in the illustration.
Page 1397
(b) Check that the cable is disconnected from the battery negative (-) terminal.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
(c) Install the door airbag sensor with the screw.
Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)
NOTICE: *
If the door airbag sensor has been dropped, or there are any cracks, dents or other defects in the
case, bracket or connector, replace it with a new one.
* When installing the door airbag sensor, be careful that the SRS wiring does not interfere with
other parts and that it is not pinched between other parts.
(d) Check that there is no looseness in the installation parts of the door airbag sensor.
(e) Connect the connector.
2. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Reassembly
3. INSTALL COURTESY LIGHT ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood
and Trunk/Doors/Front Door/Service and
Repair/Front Door (for Double Cab)/Reassembly
4. INSTALL FRONT LOWER DOOR FRAME BRACKET GARNISH LH (for Front Side) See: Body
and Frame/Doors, Hood and
Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly
5. INSTALL FRONT UPPER ARMREST BASE PANEL LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Reassembly
6. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Reassembly
7. INSTALL REAR SIDE AIRBAG SENSOR
(a) Check that the ignition switch is OFF.
(b) Check that the cable is disconnected from the battery negative (-) terminal.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
(c) Install the side airbag sensor with the bolt.
Page 9292
Page 4346
Fuel Injector: Testing and Inspection
1UR-FE FUEL: FUEL INJECTOR: INSPECTION
1. INSPECT FUEL INJECTOR ASSEMBLY
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) If the result is not as specified, replace the injector assembly.
(c) Inspect the injection volume.
CAUTION: This test involves high-pressure fuel and electricity. Take all precautions regarding safe
handling of both the fuel and the electricity. Perform this test in a safe area, and avoid any sparks
or flames. Do not smoke.
(1) Remove the fuel pipe clamp.
(2) Disconnect the fuel tube.
(3) Connect SST to the fuel pipe (the vehicle side).
Page 2318
(a) Move the stopper plate upward to release the lock, and push the plunger deep into the
tensioner.
(b) Move the stopper plate downward to set the lock, and insert a hexagon wrench into the hole of
the stopper plate.
(c) Install the chain tensioner with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(d) Remove the hexagon wrench from the chain tensioner.
8. INSTALL NO. 1 CHAIN SUB-ASSEMBLY LH See: Camshaft (for Bank 1)/Installation
9. INSTALL NO. 1 CHAIN TENSIONER SLIPPER LH See: Camshaft (for Bank 1)/Installation
10. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY LH See: Camshaft (for Bank 1)/Installation
11. INSTALL NO. 1 CHAIN VIBRATION DAMPER LH See: Camshaft (for Bank 1)/Installation
12. TIGHTEN CAMSHAFT TIMING GEAR
(a) LH:
(1) Using a wrench to hold the hexagonal portion of the No. 3 camshaft, tighten the camshaft timing
gear with the bolt.
Torque : 100 Nm (1020 kgf-cm, 74 ft-lbf)
(2) Using a wrench to hold the hexagonal portion of the No. 4 camshaft, tighten the camshaft timing
exhaust gear with the bolt.
Torque : 100 Nm (1020 kgf-cm, 74 ft-lbf)
Page 2750
^ Calibration ID(s) [Refer to the Calibration Identification Chart for the NEW CALIBRATION ID]
^ Dealer Code
^ Repair Date
^ Change Authority [This TSB number]
B. Affix the Authorized Modifications Label to the vehicle at the location shown in Figure 1. The
Authorized Modifications Label is available
through the MDC P/N 00451-00001-LBL.
Page 5031
Torque : 120 Nm (1224 kgf-cm, 89 ft-lbf)
(f) Tighten the D and E bolts.
Torque : 120 Nm (1224 kgf-cm, 89 ft-lbf)
(g) Connect the automatic disconnecting differential actuator hose.
(h) Connect the automatic disconnecting differential actuator connector.
2. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH
(a) Install the front drive shaft See: Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service
and Repair/Removal and Replacement/Front
Drive Shaft Assembly/Installation.
3. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH
HINT Use the same procedure as the LH side.
4. INSTALL FRONT PROPELLER SHAFT ASSEMBLY
(a) Install the front propeller shaft See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller
Shaft/Service and Repair/Removal and
Replacement/Front Propeller Shaft Assembly/Installation.
5. ADD DIFFERENTIAL OIL See: Fluid - Differential/Service and Repair
6. INSTALL NO. 1 ENGINE UNDER COVER See: Engine, Cooling and Exhaust/Engine/Drive
Belts, Mounts, Brackets and Accessories/Drive
Belt/Service and Repair/Installation
7. INSTALL FRONT WHEEL
(a) Install the front wheels.
for aluminum wheel - Torque : 131 Nm (1336 kgf-cm, 97 ft-lbf)
for steel wheel - Torque : 209 Nm (2131 kgf-cm, 154 ft-lbf)
8. INSPECT AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR
(a) Inspect the automatic disconnecting differential actuator See: Transfer Case/Testing and
Inspection/Component Tests and General
Diagnostics/Touch Select 2-4 and High-Low System.
Page 6703
Page 8080
Door/Service and Repair/Front Door (for Double Cab)/Disassembly
4. REMOVE FRONT LOWER DOOR FRAME BRACKET GARNISH LH (for Front Side) See: Body
and Frame/Doors, Hood and
Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly
5. REMOVE COURTESY LIGHT ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood
and Trunk/Doors/Front Door/Service and
Repair/Front Door (for Double Cab)/Disassembly
6. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Disassembly
7. REMOVE FRONT SIDE AIRBAG SENSOR
(a) Disconnect the connector.
(b) Remove the screw and side airbag sensor.
8. REMOVE REAR SEAT ASSEMBLY (for Rear Side)
(a) Remove the rear seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Rear Seat Assembly (for Double
Cab)/Removal.
9. REMOVE REAR DOOR SCUFF PLATE LH (for Rear Side) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and Repair/Roof
Headlining (For Double Cab)/Removal
10. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH (for Rear Side)
11. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY LH (for Rear Side) See: Body and
Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal
12. REMOVE REAR SIDE AIRBAG SENSOR
(a) Remove the bolt and side airbag sensor.
(b) Disconnect the connector.
Installation
SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for CrewMax):
INSTALLATION
1. INSTALL FRONT SIDE AIRBAG SENSOR
(a) Check that the ignition switch is OFF.
Page 7801
Refrigerant Pressure Sensor / Switch: Service and Repair Installation
AIR CONDITIONING: PRESSURE SWITCH: INSTALLATION
1. INSTALL PRESSURE SWITCH
(a) Sufficiently apply compressor oil to a new O-ring and the fitting surface of the pressure switch.
Compressor oil:
ND-OIL 8 or equivalent
(b) Install the O-ring on the pressure switch.
(c) Install the switch.
Torque : 10.8 Nm (110 kgf-cm, 8 ft-lbf)
(d) Connect the connector.
2. CHARGE REFRIGERANT See: Service and Repair
3. WARM UP ENGINE See: Service and Repair
4. CHECK FOR LEAKAGE OF REFRIGERANT See: Service and Repair
Page 8056
Airbag System
Air Bag Deactivation Switch: Locations Airbag System
SUPPLEMENTAL RESTRAINT SYSTEM: AIRBAG SYSTEM: PARTS LOCATION
Page 9010
DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector.
Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
Page 8079
Removal
SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for CrewMax): REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Disassembly
3. REMOVE FRONT UPPER ARMREST BASE PANEL LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Page 8219
(1) Wind the seat belt with the retractor.
(2) When the seat belt is sufficiently wound, cut the seat belt approximately 100 mm (3.94 in.) from
the retractor, as shown in the illustration.
HINT The seat belt is designed so that winding the seat belt before pretensioner activation will
decrease the pulling power of the seat belt during pretensioner activation.
(b) Check if SST is functioning properly.
SST : 09082-00700
SST : 09082-00770
CAUTION: When activating a seat belt pretensioner, always use the specified SST.
(c) Prepare SST for activation of the seat belt pretensioner.
(1) Connect SST (A) to SST (B). Then connect SST (B)'s connector to the seat belt pretensioner.
NOTICE: To avoid damaging SST connector and wire harness, do not lock the secondary lock of
the twin lock.
(2) Place the front seat outer belt on the ground and cover it with a tire (with wheel).
NOTICE: Set up the front seat outer belt as shown in the illustration.
Page 209
Headlamp Dimmer Relay: Testing and Inspection
LIGHTING: HEADLIGHT DIMMER RELAY: ON-VEHICLE INSPECTION
1. REMOVE HEADLIGHT DIMMER RELAY (DIM)
(a) Remove the dimmer relay from the engine room relay box.
2. INSPECT HEADLIGHT DIMMER RELAY
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the relay.
3. INSTALL HEADLIGHT DIMMER RELAY
Page 6114
ERROR: stackunderflow
OFFENDING COMMAND: ~
STACK:
Engine - Controls - Non-Linear Acceleration From A Stop
PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine - Controls Non-Linear Acceleration From A Stop
T-SB-0273-10
September 28, 2010
Non-Linear Acceleration from a Stop
Service Category Engine/Hybrid System
Section Engine Control
Market USA
Applicability
Introduction
Some 2010 model year Tundra vehicles with the 1UR-FE (4.6 L) engine may exhibit non-linear
acceleration from a stop under certain conditions of low engine rpm with high engine load. The
Engine Control Module/ECM (SAE term: Powertrain Control Module/PCM) logic has been revised
to address this condition. Use the following repair procedure to recalibrate the ECM (PCM).
Calibration Information
Warranty Information
Applicable Warranty
^ This repair is covered under the Toyota Federal Emission Warranty. This warranty is in effect for
96 months or 80,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Page 7153
No further tightening is required once the nut is tightened with the specified torque.
2. INSTALL WHEEL
for Aluminum Wheel - Torque : 131 Nm (1336 kgf-cm, 97 ft-lbf)
for Steel Wheel - Torque : 209 Nm (2131 kgf-cm, 154 ft-lbf)
3. INSPECT TIRE
(a) Inspect the tire See: Wheels and Tires/Testing and Inspection/Component Tests and General
Diagnostics.
4. REGISTRATION OF TRANSMITTER ID
(a) Register the transmitter ID See: Wheels and Tires/Tire Monitoring System/Testing and
Inspection/Programming and Relearning/Registration
.
5. PERFORM INITIALIZATION
(a) Perform initialization See: Wheels and Tires/Tire Monitoring System/Testing and
Inspection/Programming and Relearning/Initialization.
NOTICE: Be sure to inflate all tires to the proper inflation pressure before initialization.
6. CHECK TIRE PRESSURE AFTER REPAIRS
(a) After repairs, confirm that the actual tire pressures are displayed in the DATA LIST See: Wheels
and Tires/Tire Monitoring System/Testing
and Inspection/Scan Tool Testing and Procedures/Data List / Active Test.
Components
Parking Assist Switch: Service and Repair Components
PARK ASSIST / MONITORING: CLEARANCE SONAR MAIN SWITCH: COMPONENTS
Locations
Four Wheel Drive Selector Switch: Locations
JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION
Page 131
Compressor Clutch Relay: Testing and Inspection
AIR CONDITIONING: MAGNETIC CLUTCH RELAY: ON-VEHICLE INSPECTION
1. INSPECT MAGNETIC CLUTCH RELAY (MG CLT)
(a) Remove the magnetic clutch relay from the engine room relay block.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
* If the result is not as specified, replace the relay.
(c) Install the magnetic clutch relay.
Components
Power Steering Pressure Switch: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: POWER STEERING OIL PRESSURE SWITCH:
COMPONENTS
Page 5193
(b) Using union nut wrench, connect the flexible hose to the brake tube while holding the flexible
hose with a wrench.
without union nut wrench - Torque : 15 Nm (155 kgf-cm, 11 ft-lbf)
with union nut wrench - Torque : 14 Nm (145 kgf-cm, 10 ft-lbf)
HINT Use a torque wrench with a fulcrum length of 30 cm (11.8 in.).
NOTICE: *
Do not bend or damage the brake tube.
* Do not allow any foreign matter such as dirt and dust to enter the brake tube from the connecting
point.
14. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
15. FILL RESERVOIR WITH BRAKE FLUID
(a) Fill the brake fluid See: Brakes and Traction Control/Brake Bleeding/Service and
Repair/Replacement.
16. BLEED BRAKE LINE See: Brakes and Traction Control/Brake Bleeding/Service and
Repair/Bleeding
17. CHECK BRAKE FLUID LEVEL IN RESERVOIR See: Brakes and Traction Control/Hydraulic
System/Brake Fluid/Testing and Inspection
18. CHECK FOR BRAKE FLUID LEAKS
19. INSTALL REAR WHEEL LH
for Aluminum Wheel - Torque : 131 Nm (1336 kgf-cm, 97 ft-lbf)
for Steel Wheel - Torque : 209 Nm (2131 kgf-cm, 154 ft-lbf)
20. INSPECT DIFFERENTIAL OIL See: Differential Assembly/Fluid - Differential/Service and
Repair
21. INSPECT FOR DIFFERENTIAL OIL LEAK
22. CHECK PARKING BRAKE PEDAL TRAVEL See: Brakes and Traction Control/Parking Brake
System/Adjustments
23. ADJUST PARKING BRAKE PEDAL TRAVEL See: Brakes and Traction Control/Parking Brake
System/Adjustments
24. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
25. CHECK SPEED SENSOR SIGNAL
(a) Check the speed sensor signal See: Brakes and Traction Control/Antilock Brakes / Traction
Control Systems/Testing and Inspection/Scan
Tool Testing and Procedures/Test Mode Procedure.
Page 693
Power Mirror Switch: Service and Repair Removal
MIRROR: OUTER MIRROR SWITCH: REMOVAL
1. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column
Shift Type)/Removal
2. REMOVE OUTER MIRROR SWITCH ASSEMBLY
(a) Using a screwdriver, detach the 2 claws.
HINT Tape the screwdriver tip before use.
(b) Remove the outer mirror switch.
Page 5545
Standard resistance:
(4) If the resistance is not as specified, repair or replace the harness or connector.
(c) Check the 4WD control switch.
(1) Turn the ignition switch OFF.
(2) Connect the L1 switch connector.
(3) Connect the A25 and A26 ECU connectors.
(4) Measure the voltage according to the value(s) in the table below.
Standard voltage:
(5) If the voltage is not as specified, check the 4WD control ECU.
(d) Check the 4WD control ECU.
(1) Disconnect the L1 switch connector.
(2) Measure the voltage according to the value(s) in the table below.
Page 4185
Page 7722
Install the lower instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Column Shift Type)/Installation.
for Floor Shift Type:
Install the lower instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Floor Shift Type)/Installation.
5. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH
(a) for Column Shift Type:
Install the instrument panel finish panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Column Shift Type)/Installation.
(b) for Floor Shift Type:
Install the instrument panel finish panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Floor Shift Type)/Installation.
6. INSTALL NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY
(a) for Column Shift Type:
Install the No. 2 instrument panel under cover sub-assembly See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and
Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation.
(b) for Floor Shift Type:
Install the No. 2 instrument panel under cover sub-assembly See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and
Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation.
7. INSTALL INSTRUMENT SIDE PANEL RH
(a) for Column Shift Type:
Install the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Column Shift Type)/Installation.
(b) for Floor Shift Type:
Install the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Floor Shift Type)/Installation.
8. INSTALL COWL SIDE TRIM BOARD RH
(a) for Regular Cab:
Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular Cab)/Installation.
(b) for Double Cab:
Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Installation.
(c) for CrewMax:
Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for CrewMax)/Installation.
9. INSTALL FRONT DOOR SCUFF PLATE RH
(a) for Regular Cab:
Page 1914
* When you have replaced the transmission hose and/or output shaft oil seal, proceed to the "Fluid
Temperature Check" procedures.
3. TRANSMISSION FILL
(a) Remove the refill plug and overflow plug.
(b) Fill the transmission through the refill hole until fluid begins to trickle out of the overflow tube.
(c) Reinstall the overflow plug.
(d) Fill the transmission with the amount of fluid listed in the table below.
Reference Capacity:
(e) Install the refill plug.
HINT If you cannot fill the listed amount of fluid, perform the following:
(1) Start the engine and idle it.
NOTICE: Check that electrical systems such as the air conditioning system, audio system and
lighting system are off.
(2) Move the shift lever through the entire gear range to circulate the fluid.
(3) Wait for 30 seconds with the engine idling.
(4) Stop the engine.
(5) Remove the refill plug.
(6) Fill the transmission with the remaining fluid until the amount in the table has been filled.
(7) Install the refill plug.
4. FLUID TEMPERATURE CHECK
Engine - MIL ON/DTC's P0012/P0022 Set
Variable Valve Timing Actuator: Customer Interest Engine - MIL ON/DTC's P0012/P0022 Set
T-SB-0019-10
January 20, 2010
MIL "ON" DTC P0012 and/or P0022
Service Category Engine/Hybrid System
Section Engine Control
Market USA
Applicability
Introduction
Some 2010 model year Sequoia and Tundra vehicles may exhibit a MIL "ON" condition for
Diagnostic Trouble Code (DTC) P0012 and/or P0022 ( Camshaft Position "A" - Timing
Over-Retarded Bank 1/2).
Please refer to the following repair procedure to address this condition.
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60
months or 60,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Production Change Information
Page 3455
CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: Bus Buffer ECU Communication
Stop Mode - Bus Buffer ECU Communication Stop Mode
DESCRIPTION
WIRING DIAGRAM
INSPECTION PROCEDURE
HINT Operating the ignition switch, any switches or any doors triggers related ECU and sensor
communication with the CAN, which causes resistance variation.
PROCEDURE
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
(a) Disconnect the cable from the negative (-) battery terminal before measuring the resistances of
the main wire and the branch wire.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
NEXT -- Continue to next step.
2. CHECK FOR OPEN IN CAN BUS WIRE (BUS BUFFER ECU BRANCH WIRE)
(a) Disconnect the J59 bus buffer ECU connector.
(b) Measure the resistance according to the value(s) in the table below.
Page 2695
Water Pump: Service and Repair Installation
1UR-FE COOLING: WATER PUMP: INSTALLATION
1. INSTALL WATER PUMP ASSEMBLY
(a) Install a new gasket and the water pump with the 8 bolts shown in the illustration.
for bolt A - Torque : 47 Nm (479 kgf-cm, 35 ft-lbf)
for bolt B - Torque : 23 Nm (235 kgf-cm, 17 ft-lbf)
for bolt C - Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)
2. INSTALL WATER PUMP PULLEY
(a) Temporarily install the pulley with the 4 bolts.
(b) Using SST, hold the pulley and tighten the 4 bolts.
SST : 09960-10010
09962-01000
09963-01000
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
3. INSTALL WATER INLET HOUSING
(a) Install a new gasket to the water pump.
(b) Install the water inlet housing with the 3 bolts.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
4. CONNECT NO. 5 WATER BY-PASS HOSE
(a) Connect the water by-pass hose.
Transmission Control Switch
Transmission Mode Switch: Diagrams Transmission Control Switch
Page 4648
Actuator: Diagrams
Page 8238
Page 9257
(b) Attach the claw to install the courtesy light.
4. INSTALL REAR DOOR FRAME GARNISH LH
(a) Attach the 4 clips to install the rear door frame garnish.
5. INSTALL REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY
(a) Attach the 4 claws to install the control switch.
6. INSTALL REAR UPPER DOOR ARMREST BASE PANEL LH
(a) Connect the connector.
(b) Attach the 2 clips to install the rear upper door armrest base panel.
7. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG LH
(a) Attach the 4 claws to install the bezel plug.
Page 748
Seat Memory Switch: Service and Repair Removal
SEAT: SEAT MEMORY SWITCH (w/ Seat Position Memory System): REMOVAL
1. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH See: Body and Frame/Doors,
Hood and Trunk/Doors/Front Door/Service and
Repair/Front Door (for Double Cab)/Disassembly
2. REMOVE FRONT ARMREST UPPER BASE PANEL LH See: Body and Frame/Doors, Hood
and Trunk/Doors/Front Door/Service and
Repair/Front Door (for Double Cab)/Disassembly
3. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Disassembly
4. REMOVE COURTESY LIGHT ASSEMBLY See: Body and Frame/Doors, Hood and
Trunk/Doors/Front Door/Service and Repair/Front Door
(for Double Cab)/Disassembly
5. REMOVE FRONT DOOR ARMREST COVER LH
6. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH See: Body and Frame/Doors,
Hood and Trunk/Doors/Front Door/Service and
Repair/Front Door (for Double Cab)/Disassembly
7. REMOVE SEAT MEMORY SWITCH
(a) Remove the 2 screws and seat memory switch.
Locations
Headlamp Dimmer Switch: Locations
LIGHTING: LIGHTING SYSTEM: PARTS LOCATION
Page 4985
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) Apply 12 V battery voltage to the shift solenoid valve and check that the valve moves and
makes an operating noise.
OK:
(c) If the result is not as specified, replace the solenoid valve.
3. INSPECT SHIFT SOLENOID VALVE S2
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) Apply 12 V battery voltage to the shift solenoid valve and check that the valve moves and
makes an operating noise.
OK:
(c) If the result is not as specified, replace the solenoid valve.
4. INSPECT SHIFT SOLENOID VALVE S3
Page 1171
Engine Temperature Sensor: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: ENGINE COOLANT TEMPERATURE SENSOR:
REMOVAL
1. REMOVE NO. 1 ENGINE UNDER COVER See: Engine, Cooling and Exhaust/Engine/Engine
Lubrication/Engine Oil/Service and
Repair/Replacement
2. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Removal
3. DRAIN ENGINE COOLANT See: Engine, Cooling and Exhaust/Cooling System/Coolant/Service
and Repair
4. REMOVE ENGINE COOLANT TEMPERATURE SENSOR
(a) Disconnect the sensor connector.
(b) Using a 19 mm ball joint lock nut wrench, remove the sensor.
(c) Remove the gasket from the sensor.
Page 597
Specifications
Compression Check: Specifications
COMPRESSION
Page 8402
Page 2820
Page 9115
Release the locking lug from terminal and pull the terminal out from rear.
INSTALL TERMINAL TO CONNECTOR
Insert the terminal.
HINT: Make sure the terminal is positioned correctly.
Insert the terminal until the locking lug locks firmly.
Insert the terminal with terminal retainer in the temporary lock position.
Page 8386
Removal
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Column
Shift Type): REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service
and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Removal
3. REMOVE CENTER AIRBAG SENSOR ASSEMBLY
Page 8274
Removal
SEAT BELT: REAR SEAT INNER BELT ASSEMBLY (for Double Cab): REMOVAL
1. REMOVE REAR SEAT ASSEMBLY
(a) Remove the rear seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Rear Seat Assembly (for Double
Cab)/Removal.
2. REMOVE REAR NO. 1 SEAT INNER BELT ASSEMBLY RH
Page 3385
3. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE
HINT The diagnostic system in the TOYOTA TUNDRA has various functions.
* The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU
memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a
previous malfunction's DTC can be checked by a technician during troubleshooting.
* Another function is the Input Signal Check, which checks if the signals from various switches are
sent to the ECU correctly.
* By using these functions, the problem areas can be narrowed down and troubleshooting is more
effective. Diagnostic functions are incorporated in the following systems in the TOYOTA TUNDRA.
Page 6816
Components
Crankshaft Position Sensor: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: CRANKSHAFT POSITION SENSOR: COMPONENTS
Testing and Inspection
Drive Belt: Testing and Inspection
1UR-FE ENGINE MECHANICAL: DRIVE BELT: ON-VEHICLE INSPECTION
1. INSPECT FAN AND GENERATOR V BELT
(a) Check the belt for wear, cracks or other signs of damage.
(b) If any of the following defects is found, replace the fan and generator V belt.
* The belt is cracked.
* The belt is worn out to the extent that the cords are exposed.
* The belt has chunks missing from the ribs.
(c) Check that the belt fits properly in the ribbed grooves.
HINT Check with your hand to confirm that the belt has not slipped out of the grooves on the
bottom of the pulley. If it has slipped out, replace the fan and generator V belt. Install a new fan and
generator V belt correctly.
2. INSPECT V-RIBBED BELT TENSIONER ASSEMBLY
(a) Check that nothing gets caught in the tensioner by turning it clockwise and counterclockwise.
If the result is not as specified, replace the tensioner.
Page 5055
09954-03010
09955-03030
09956-03020
7. REMOVE FRONT DIFFERENTIAL CARRIER OIL SEAL
(a) Using SST, remove the oil seal.
SST : 09308-10010
8. REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER
9. REMOVE FRONT DIFFERENTIAL CROSS SHAFT BEARING RETAINER
(a) Remove the bolts B and front differential front support assembly LH.
(b) Remove the bolts A.
(c) Using a plastic-faced hammer, tap out the bearing retainer.
10. REMOVE DIFFERENTIAL CASE ASSEMBLY
(a) Remove the differential case from the differential carrier.
11. REMOVE DIFFERENTIAL DRIVE PINION
(a) Set the differential carrier to an overhaul stand as shown in the illustration.
Page 2339
Variable Valve Timing Actuator: Diagrams
Page 7822
Control Module HVAC: Service and Repair Installation
AIR CONDITIONING: AIR CONDITIONING AMPLIFIER: INSTALLATION
1. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY
(a) Install the amplifier with the 2 screws.
(b) for Manual Air Conditioning System:
Connect the 2 connectors.
(c) for Automatic Air Conditioning System:
Connect the 3 connectors.
2. INSTALL NO. 2 AIR DUCT SUB-ASSEMBLY
(a) Install the duct with the screw.
3. INSTALL LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY
for Column Shift Type:
Install the lower No. 2 instrument panel airbag assembly See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument
Panel Safety Pad (for Column Shift Type)/Installation.
for Floor Shift Type:
Install the lower No. 2 instrument panel airbag assembly See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument
Panel Safety Pad (for Floor Shift Type)/Installation.
4. INSTALL LOWER INSTRUMENT PANEL
for Column Shift Type:
Page 3460
INSPECTION PROCEDURE
PROCEDURE
1. CHECK HARNESS AND CONNECTOR (ECM - BATTERY AND BODY GROUND)
(a) Disconnect the A24 and D74 ECM connectors.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(c) Measure the voltage according to the value(s) in the table below.
Standard voltage:
Page 4933
NOTICE: Make sure to connect the cable end so that the inner cable is not twisted. Confirm that
the ridged side of the cable end is facing upward.
(d) Connect the 2 cable clamps with the 2 bolts.
Torque : 5.5 Nm (56 kgf-cm, 49 in-lbf)
(e) Return the floor carpet to its original position.
(f) Move the shift lever to N.
(g) Turn the control shaft lever counterclockwise until it stops, and then turn it clockwise 2 notches
to set it to the N position.
(h) Connect the control cable with a new clip and the nut.
Torque : 14 Nm (143 kgf-cm, 10 ft-lbf)
Page 1997
Page 5665
Yaw Rate Sensor: Locations From 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 3220
Page 9269
Hood Latch Release Cable: Service and Repair Installation
ENGINE HOOD / DOOR: HOOD LOCK CONTROL CABLE ASSEMBLY: INSTALLATION
HINT A bolt without a torque specification is shown in the standard bolt chart See:
Specifications/Mechanical Specifications/Standard Bolt - Specified Torque For Standard Bolts
1. INSTALL HOOD LOCK CONTROL CABLE ASSEMBLY
(a) Pass the cable into the engine room.
(b) Pass the cable rear side through the grommet until the cable stopper is attached to the
grommet.
(c) Pass the cable front side through the upper radiator support.
(d) Attach the cable to the clamps as shown in the illustration.
2. INSTALL HOOD LOCK CONTROL LEVER SUB-ASSEMBLY
(a) Connect the hood lock control cable to the hood lock lever.
(b) Attach the 2 claws to install the hood lock lever
3. INSTALL HOOD LOCK ASSEMBLY
(a) Apply MP grease to the sliding areas of the lock.
Page 6624
3. REMOVE FRONT SEAT ASSEMBLY LH (for Power Seat)
(a) Remove the front seat LH See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Power
Seat)/Removal.
4. REMOVE FRONT SEAT ASSEMBLY RH (for Power Seat)
HINT Use the same procedures described for the LH side.
5. REMOVE CENTER FRONT SEAT ASSEMBLY
(a) Remove the center front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Center
Seat)/Removal.
6. REMOVE POWER OUTLET SOCKET ASSEMBLY
(a) Disconnect the power outlet socket connector.
(b) Using a screwdriver, detach the claw and remove the power outlet socket.
HINT Tape the screwdriver tip before use.
7. REMOVE POWER OUTLET SOCKET COVER
(a) Detach the 2 claws and remove the power outlet socket cover.
8. REMOVE CENTER SEATBACK PANEL (for Double Cab) See: Body and Frame/Seats/Service
and Repair/Overhaul/Front Seat Assembly (for
Center Seat)/Disassembly
9. REMOVE REAR POWER OUTLET SOCKET ASSEMBLY (for Double Cab)
(a) Using a screwdriver, detach the claw and remove the power outlet socket.
Page 7488
Tire Pressure Monitor Receiver / Transponder: Service and Repair Removal
TIRE AND WHEEL: TIRE PRESSURE WARNING RECEIVER: REMOVAL
1. REMOVE ROOF HEADLINING ASSEMBLY
(a) for Regular Cab:
Remove the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Removal.
(b) for Double Cab:
Remove the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Double Cab)/Removal.
(c) for CrewMax:
Remove the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (for CrewMax)/Removal.
2. REMOVE TIRE PRESSURE WARNING ANTENNA AND RECEIVER
(a) Disconnect the receiver connector.
(b) Remove the bolt and receiver.
Page 5309
^ Torque the bolts to the specification found in the applicable Repair Manual.
NOTE
In most applications there will be 1 black torque converter bolt, be sure to install this bolt first to aid
in aligning the torque converter to the flywheel assembly.
Page 2503
Oil Pressure Sender: Service and Repair Installation
1UR-FE LUBRICATION: OIL PRESSURE SWITCH: INSTALLATION
1. INSTALL OIL PRESSURE SENDER GAUGE ASSEMBLY
(a) Apply adhesive to 2 or 3 threads of the oil pressure sender gauge.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
(b) Install the oil pressure sender gauge.
Torque : 15 Nm (153 kgf-cm, 11 ft-lbf)
NOTICE: Do not start the engine within 1 hour after installation.
(c) Connect the sender gauge connector.
2. INSPECT ENGINE OIL LEVEL See: Engine Lubrication/Testing and Inspection
3. INSPECT FOR OIL LEAK See: Engine Lubrication/Engine Oil/Service and Repair/Replacement
4. INSTALL NO. 1 ENGINE UNDER COVER See: Engine Lubrication/Engine Oil/Service and
Repair/Replacement
Page 5013
Actuator: Diagrams
Up to 11/2009
Traction Control Relay: Locations Up to 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 298
J/B No.3 - Instrument Panel Right
Page 7648
(a) For an open circuit in the wire harness in Fig. 1, check the resistance or voltage, as described
below.
(b) Check the resistance.
(1) Disconnect connectors A and C and measure the resistance between them.
Standard resistance (Fig. 2):
HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally.
If the results match the examples above, an open circuit exists between terminal 1 of connector A
and terminal 1 of connector C.
(2) Disconnect connector B and measure the resistance between the connectors.
Standard resistance (Fig. 3):
* If the results match the examples above, an open circuit exists between terminal 1 of connector
B2 and terminal 1 of connector C.
(c) Check the voltage.
Page 6291
Engine Room R/B, J/B - Engine Compartment Left
Page 6158
(a) For an open circuit in the wire harness in Fig. 1, check the resistance or voltage, as described
below.
(b) Check the resistance.
(1) Disconnect connectors A and C and measure the resistance between them.
Standard resistance (Fig. 2):
HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally.
If the results match the examples above, an open circuit exists between terminal 1 of connector A
and terminal 1 of connector C.
(2) Disconnect connector B and measure the resistance between the connectors.
Standard resistance (Fig. 3):
* If the results match the examples above, an open circuit exists between terminal 1 of connector
B2 and terminal 1 of connector C.
(c) Check the voltage.
Page 8728
^ This condition is NOT reception related. Switching modes will not correct the condition.
^ This condition affects XM ONLY - AM/FM reception is normal when this condition occurs. If
cycling the ignition key does NOT restore normal operation, this TSB does NOT apply.
Warranty Information
APPLICABLE WARRANTY
^ Toyota-supplied satellite radio component systems installed as original equipment are warranted
for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Toyota-supplied satellite radio components installed by a Toyota dealer are warranted for 12
months, regardless of mileage from the date of installation on the vehicle, or the remainder of the
applicable New Vehicle Limited Warranty for 36 months or 36,000 miles, whichever provides the
greater coverage.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Parts Information
Order parts through the Pioneer exchange program.
Service Exchange Part Identification
Countermeasure parts have a "P" marking on the parts label following the Toyota part number (see
Figure 1).
Required Tools & Equipment
NOTE
Page 6397
Page 1338
Page 6391
Page 8664
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION: Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC
terminals are touched, the IC may be destroyed by static electricity.)
When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact with the terminals of leads from the IC, etc. of the
replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown on the left.
DISCONNECT CONNECTOR
Page 6101
(1) Connect the field coil lead wire to terminal C.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(2) Mount the starter in a vise between aluminum plates.
(3) Connect the battery and ammeter to the starter as shown in the illustration.
(4) Check that the starter rotates smoothly and steadily while the pinion gear is moving outward.
Then measure the current.
Standard current:
90 A or less at 11.5 V
(5) If the result is not as specified, replace the starter assembly.
2. INSPECT MAGNET STARTER SWITCH ASSEMBLY
(a) Check the plunger.
(1) Push in the plunger and check that it returns quickly to its original position.
(2) If the result is not as specified, replace the magnet starter switch assembly.
(b) Check if the pull-in coil has an open circuit.
(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(2) If the result is not as specified, replace the magnet starter switch assembly.
(c) Check if the holding coil has an open circuit.
Page 6153
Release the locking lug from terminal and pull the terminal out from rear.
INSTALL TERMINAL TO CONNECTOR
Insert the terminal.
HINT: Make sure the terminal is positioned correctly.
Insert the terminal until the locking lug locks firmly.
Insert the terminal with terminal retainer in the temporary lock position.
Page 8789
AUDIO / VISUAL: FRONT DOOR SPEAKER (for Regular Cab): INSPECTION
1. INSPECT FRONT NO. 1 SPEAKER ASSEMBLY
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the speaker assembly.
Instrument Panel Speaker (for CrewMax)
AUDIO / VISUAL: INSTRUMENT PANEL SPEAKER (for CrewMax): INSPECTION
1. INSPECT FRONT NO. 2 SPEAKER ASSEMBLY (for Standard)
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the speaker assembly.
2. INSPECT FRONT NO. 2 SPEAKER ASSEMBLY (for 12 Speakers)
(a) Measure the resistance according to the value(s) in the table below.
Page 197
NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do
not operate the ignition switch, any other switches, or the doors.
(a) If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the
harness and connector.
(b) Connect the cable of the Techstream to the DLC3, turn the ignition switch ON and attempt to
use the tester. If the display indicates that a
communication error has occurred, there is a problem either with the vehicle or with the tester.
HINT *
If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of
the original vehicle.
* If communication is still not possible when the tester is connected to another vehicle, the problem
may be in the tester itself. Consult the Service Department listed in the tester's instruction manual.
How To Proceed With Troubleshooting
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: HOW TO
PROCEED WITH TROUBLESHOOTING
1. OPERATION FLOW
HINT Perform troubleshooting in accordance with the procedures below. The following is an outline
of basic troubleshooting procedures. Confirm the troubleshooting procedures for the circuit you are
working on before beginning troubleshooting.
1. VEHICLE BROUGHT TO WORKSHOP
NEXT -- Continue to next step.
2. CUSTOMER PROBLEM ANALYSIS
(a) Ask the customer about the conditions and environment when the problem occurred.
NEXT -- Continue to next step.
3. INSPECT BATTERY VOLTAGE
Standard voltage:
11 to 14 V
If the voltage is below 11 V, recharge or replace the battery before proceeding.
NEXT -- Continue to next step.
Page 1648
Power Window Switch: Service and Repair Power Window Master Switch
Components
WINDSHIELD / WINDOWGLASS: POWER WINDOW MASTER SWITCH: COMPONENTS
Page 6722
(a) For an open circuit in the wire harness in Fig. 1, check the resistance or voltage, as described
below.
(b) Check the resistance.
(1) Disconnect connectors A and C and measure the resistance between them.
Standard resistance (Fig. 2):
HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally.
If the results match the examples above, an open circuit exists between terminal 1 of connector A
and terminal 1 of connector C.
(2) Disconnect connector B and measure the resistance between the connectors.
Standard resistance (Fig. 3):
* If the results match the examples above, an open circuit exists between terminal 1 of connector
B2 and terminal 1 of connector C.
(c) Check the voltage.
Page 6604
(2) Disconnect connector B and measure the resistance.
Standard resistance (Fig. 7):
* If the results match the examples above, a short circuit exists between terminal 1 of connector B2
and terminal 1 of connector C.
4. CHECK AND REPLACE ECU
NOTICE: *
The connector should not be disconnected from the ECU. Perform the inspection from the backside
of the connector on the wire harness side.
* When no measuring condition is specified, perform the inspection with the engine stopped and
the ignition switch ON.
* Check that the connectors are fully seated. Check for loose, corroded or broken wires.
(a) First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be
faulty. Temporarily replace the ECU with a
normally functioning one and check if the symptoms occur. If the trouble symptoms disappear,
replace the original ECU.
(1) Measure the resistance between the ECU ground terminal and body ground.
Standard resistance:
Below 1 Ohms
(2) Disconnect the ECU connector. Check the ground terminal on the ECU side and wire harness
side for bending, corrosion or foreign matter.
Lastly, check the contact pressure of the female terminals.
Diagrams
Rear Vision Camera: Diagrams
Page 2411
Oil Cooler: Overhaul
Disassembly
1UR-FE LUBRICATION: ENGINE OIL COOLER: DISASSEMBLY
1. REMOVE OIL PUMP RELIEF VALVE
(a) Remove the relief valve plug and gasket.
(b) Remove the valve spring and oil pump relief valve.
Reassembly
1UR-FE LUBRICATION: ENGINE OIL COOLER: REASSEMBLY
1. INSTALL OIL PUMP RELIEF VALVE
(a) Coat the oil pump relief valve with engine oil.
(b) Install the relief valve and valve spring into the oil pump cover hole.
(c) Install a new gasket and the plug.
Torque : 37 Nm (375 kgf-cm, 27 ft-lbf)
Page 2574
Variable Valve Timing Actuator Position Sensor: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: VVT SENSOR: REMOVAL
1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Service and Repair/Removal and
Replacement/Engine Assembly/Removal
2. REMOVE AIR CLEANER HOSE ASSEMBLY See: Service and Repair/Removal and
Replacement/Engine Assembly/Removal
3. REMOVE VVT SENSOR
(a) Disconnect the 4 sensor connectors.
(b) Remove the 4 bolts and 4 sensors.
Page 6655
(a) for AC Power Supply:
Disconnect the clamp.
(b) Remove the 3 screws and bezel.
3. REMOVE REAR POWER OUTLET SOCKET (for Standard)
(a) Detach the claw and remove the power outlet socket.
4. REMOVE REAR POWER OUTLET SOCKET COVER (for Standard)
(a) Detach the 2 claws and remove the power outlet socket cover.
5. REMOVE REAR POWER POINT SOCKET (for AC Power Supply)
(a) Detach the 2 claws and remove the power outlet socket.
Page 7295
10. ADJUST TOTAL PRELOAD
(a) To prevent the steering rack teeth from damaging the oil seal lip, provisionally install the RH
and LH steering rack end.
(b) Using 32 mm hexagon wrench, torque the rack guide spring cap.
Torque : 30 Nm (306 kgf-cm, 22 ft-lbf)
(c) Using 32 mm hexagon wrench, loosen the rack guide spring cap.
(d) Using SST, turn the control valve to the right and left once or twice.
SST : 09616-00011
(e) Using SST, loosen the rack guide spring cap until the rack guide spring ceases to function.
(f) Using SST, a torque wrench and 32 mm hexagon wrench, tighten the cap until the preload is
within the specification.
SST : 09616-00011
Preload (turning):
1.9 to 2.7 N*m (19.4 to 27.5 kgf*cm, 16.8 to 23.9 in.*lbf)
(g) Apply adhesive to 2 or 3 threads of the rack guide spring cap nut.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
(h) Provisionally install the rack guide spring cap nut.
(i) Using SST, hold the rack guide spring cap and using 32 mm hexagon wrench, torque the rack
guide spring cap nut.
SST : 09922-10010
without SST - Torque : 85 Nm (867 kgf-cm, 63 ft-lbf)
Page 47
Keyless Entry Module: Service and Repair Door Control Receiver (for Double Cab)
Components
DOOR LOCK: DOOR CONTROL RECEIVER (for Double Cab): COMPONENTS
Page 6299
J/B No.6 Assembly - Instrument Panel Center
Page 882
Oil Pressure Sender: Diagrams Oil Pressure Switch
Page 7448
Tire Pressure Sensor: Service and Repair Installation
TIRE AND WHEEL: TIRE PRESSURE WARNING VALVE AND TRANSMITTER: INSTALLATION
1. INSTALL TIRE PRESSURE WARNING VALVE AND TRANSMITTER
(a) Insert the tire pressure warning valve into the valve installation hole from the inside of the rim so
that the print surface can be seen.
NOTICE: *
Check that there is no visible deformation, damage or other abnormalities on the tire pressure
warning valve and transmitter.
* Check that there is no foreign matter on the inner grommet and around the rim hole.
* If the tire pressure warning valve and transmitter is installed in the reverse direction, it may be
damaged or fail to transmit signals when running at a high speed.
* If installing a new tire pressure warning valve and transmitter, write down the transmitter ID before
installation.
* The transmitter ID registration must be performed for all tire pressure warning valve and
transmitters, regardless of the number of tire pressure warning valve and transmitters replaced. If
all of the tire pressure warning valve and transmitters do not need to be replaced, check the DATA
LIST and write down the transmitter IDs of the tire pressure warning valve and transmitters that do
not need to be replaced before performing the transmitter ID registration See: Tire Monitoring
System/Testing and Inspection/Programming and Relearning/Registration
* It is necessary to perform initialization See: Tire Monitoring System/Testing and
Inspection/Programming and Relearning/Initialization after registration See: Tire Monitoring
System/Testing and Inspection/Programming and Relearning/Registration of the transmitter IDs
into the tire pressure warning ECU after the tire pressure warning valve and transmitter has been
replaced.
(b) If reusing the tire pressure warning valve and transmitter:
Install a new grommet.
HINT A new tire pressure warning valve and transmitter is supplied with a grommet.
(c) Install the washer on the tire pressure warning valve from the rim side and tighten the nut.
Page 678
Telescopic Steering Column)/Removal
2. REMOVE LOWER STEERING COLUMN COVER (for Power Tilt and Power Telescopic Steering
Column) See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering
Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Removal
3. REMOVE UNLOCK WARNING SWITCH ASSEMBLY
(a) Disconnect the unlock warning switch connector.
(b) Detach the 3 claws and remove the cover.
(c) Remove the contact pin cap.
(d) Remove the unlock warning switch.
Installation
DOOR LOCK: UNLOCK WARNING SWITCH: INSTALLATION
1. INSTALL UNLOCK WARNING SWITCH ASSEMBLY
(a) If reusing unlock warning switch assembly:
(1) Temporarily install the unlock warning switch.
(2) Install the contact pin cap.
(3) Attach the 3 claws to install the cover.
Page 273
"Case2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 2063
"Case2" Open the secondary locking device.
[B] For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray
Gray or White : Black
Page 6792
Release the locking lug from terminal and pull the terminal out from rear.
INSTALL TERMINAL TO CONNECTOR
Insert the terminal.
HINT: Make sure the terminal is positioned correctly.
Insert the terminal until the locking lug locks firmly.
Insert the terminal with terminal retainer in the temporary lock position.
Page 7615
Cabin Temperature Sensor / Switch: Diagrams
Page 6713
"Case2" Open the secondary locking device.
[B] For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray
Gray or White : Black
Page 3023
Air Flow Meter/Sensor: Diagrams
Page 6963
Relay Box: Diagnostic Aids
Continuity and Resistance Check
CONTINUITY AND RESISTANCE CHECK
Disconnect the battery terminal or wire so there is no voltage between the check points.
Contact the two leads of an ohmmeter to each of the check points.
Page 396
HINT The wavelength becomes shorter as engine rpm increases.
(i) WAVEFORM 8:
HINT If the waveform is not similar to the illustration, check the waveform again after idling for 10
minutes or more.
(j) WAVEFORM 9:
Page 7333
(c) Using SST, disconnect the upper ball joint from the steering knuckle.
SST : 09628-62011
(d) Remove the steering knuckle.
7. REMOVE KNUCKLE GREASE RETAINER CAP LH (for 2WD)
(a) Using a screwdriver and hammer, tap out the retainer cap.
8. REMOVE STEERING KNUCKLE OIL SEAL LH (for 4WD)
(a) Using a screwdriver and hammer, tap out the oil seal.
Page 7580
Use a volt/ohmmeter with high impedance (10 kohms/V minimum) for troubleshooting of the
electrical circuit.
Disconnection of Male and Female Connectors
DISCONNECTION OF MALE AND FEMALE CONNECTORS
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Finding A Short Circuit
FINDING A SHORT CIRCUIT
Page 7456
Tire Pressure Warning Reset Switch: Testing and Inspection
TIRE AND WHEEL: TIRE PRESSURE WARNING RESET SWITCH: INSPECTION
1. CHECK TIRE PRESSURE WARNING RESET SWITCH
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the switch.
Component Tests and General Diagnostics
Engine Control Module: Component Tests and General Diagnostics
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: ECM Power Source Circuit - ECM Power
Source Circuit
DESCRIPTION
When the ignition switch is turned to ON, the battery voltage is applied to the IGSW terminal of the
ECM. The output signal from the MREL terminal of the ECM causes a current to flow to the coil,
closing the contacts of the integration relay (EFI relay) and supplying power to terminals +B and
+B2 of the ECM.
WIRING DIAGRAM
INSPECTION PROCEDURE
PROCEDURE
1. INSPECT FUSES (AM2, IG2 MAIN, EFI NO. 1, IGN)
Page 5281
*1: for 5 leaf spring
*2: includes Off road package
* If the measured angle is not within the specification, adjust it with the bearing washer (See
"Adjust Propeller Shaft Angle").
(c) Measure the No. 3 joint angle.
(1) Subtract the angle of the rear differential flange (B) measured before installing the propeller
shaft from the angle of the propeller shaft (D)
to calculate the No. 3 joint angle.
No. 3 joint angle:
Angle of propeller shaft (D) - Angle of rear differential flange (B)
Measured Value (Reference):
Page 1580
Transmission Position Switch/Sensor: Diagrams
Page 121
Traction Control Relay: Testing and Inspection
BRAKE CONTROL: STOP LIGHT CONTROL RELAY: ON-VEHICLE INSPECTION
1. CHECK STOP LIGHT CONTROL RELAY
(a) Remove the stop light control relay from the engine room relay block.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(c) If the result is not as specified, replace the relay.
(d) Install the stop light control relay.
Page 8162
Air Bag Control Module: Locations Seat Belt Warning System
SEAT BELT: SEAT BELT WARNING SYSTEM: PARTS LOCATION
Locations
Shift Solenoid: Locations
A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS
LOCATION
Page 1413
Page 6228
Diode: Diagrams Diode (Rear Door Courtesy Light)
Ultrasonic Sensor (for Front Side)
Parking Assist Distance Sensor: Service and Repair Ultrasonic Sensor (for Front Side)
Components
PARK ASSIST / MONITORING: ULTRASONIC SENSOR (for Front Side): COMPONENTS
Page 8644
2. REMOVE CENTER SEAT BACK PANEL See: Body and Frame/Seats/Service and
Repair/Overhaul/Front Seat Assembly (for Center
Seat)/Disassembly
3. REMOVE NO. 1 CONSOLE BOX REGISTER ASSEMBLY See: Body and Frame/Seats/Service
and Repair/Overhaul/Front Seat Assembly (for
Center Seat)/Disassembly
4. REMOVE NO. 2 CONSOLE BOX REGISTER ASSEMBLY See: Body and Frame/Seats/Service
and Repair/Overhaul/Front Seat Assembly (for
Center Seat)/Disassembly
5. REMOVE VIDEO TERMINAL
(a) Detach the clamp from the back panel.
(b) Detach the 4 claws and remove the video terminal.
Installation
AUDIO / VISUAL: VIDEO TERMINAL (for Bench Seat Type): INSTALLATION
1. INSTALL VIDEO TERMINAL
(a) Attach the 4 claws to install the video terminal.
(b) Attach the clamp to the back panel.
Page 2075
General Information
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: GENERAL
INFORMATION
* A large number of ECU controlled systems are used in the TOYOTA TUNDRA. In general, ECU
controlled systems are considered to be very intricate, requiring a high level of technical knowledge
to troubleshoot. However, most problem checking procedures only involve inspecting the ECU
controlled system's circuits one by one. An adequate understanding of the system and a basic
knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and
necessary repairs.
1. TROUBLESHOOTING PROCEDURES
* The troubleshooting procedures consist of diagnosis procedures for when a DTC is stored and
diagnosis procedures for when no DTC is stored. The basic idea is explained in the following table.
* Vehicle systems are complex and use many ECUs that are difficult to inspect independently.
Therefore, a process of elimination is used, where components that can be inspected individually
are inspected, and if no problems are found in these components, the related ECU is identified as
the problem and replaced.
* It is extremely important to ask the customer about the environment and the conditions present
when the problem occurred (Customer Problem Analysis). This makes it possible to simulate the
conditions and confirm the symptom. If the symptom cannot be confirmed or the DTC does not
recur, the malfunctioning part may not be identified using the troubleshooting procedure, and the
ECU for the related system may be replaced even though it is not defective. If this happens, the
original problem will not be solved.
* In order to prevent endless expansion of troubleshooting procedures, the troubleshooting
procedures are written with the assumption that multiple malfunctions do not occur simultaneously
for a single problem symptom.
* To identify the malfunctioning part, troubleshooting procedures narrow down the target by
separating components, ECUs and wire harnesses during the inspection. If the wire harness is
identified as the cause of the problem, it is necessary to inspect not only the connections to
components and ECUs but also all of the wire harness connectors between the component and the
ECU.
DIAGNOSTIC TESTER
2. DESCRIPTION
System data and the Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector
3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the Techstream* to
check for a malfunction and perform repairs.
HINT *: Techstream is the name for the diagnostic tester in North America.
3. DATA LINK CONNECTOR 3 (DLC3)
(a) The vehicle's ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of
the DLC3 complies with SAE J1962 and
matches the ISO 15765-4 format.
Page 8709
Page 4344
Center Airbag Sensor Assembly (for Floor Shift Type)
Impact Sensor: Service and Repair Center Airbag Sensor Assembly (for Floor Shift Type)
Components
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift
Type): COMPONENTS
Page 4377
Fuel Pump Control Unit: Locations Crew Max
Body
Page 8379
9. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH (for Rear Side)
10. INSTALL REAR DOOR SCUFF PLATE LH (for Rear Side) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and Repair/Roof
Headlining (For Double Cab)/Installation
11. INSTALL REAR SEAT ASSEMBLY (for Rear Side)
(a) Install the rear seat assembly See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Rear Seat Assembly (for Double
Cab)/Installation.
12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
13. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Air Bag Systems/Testing and Inspection/Initial Inspection
and Diagnostic Overview/Diagnosis System.
Components
SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Regular Cab):
COMPONENTS
Components
Ignition Switch: Service and Repair Components
1UR-FE STARTING: IGNITION SWITCH: COMPONENTS
Page 1588
Transmission Speed Sensor: Service and Repair Removal
A760F AUTOMATIC TRANSMISSION: SPEED SENSOR: REMOVAL
1. REMOVE SPEED SENSOR NT
(a) Disconnect the sensor connector.
(b) Remove the bolt and sensor.
(c) Remove the O-ring from the sensor.
2. REMOVE SPEED SENSOR SP2
(a) Disconnect the sensor connector.
(b) Remove the bolt and sensor.
(c) Remove the O-ring from the sensor.
Page 7932
(1) Place at least 2 tires under the tire which the lower No. 2 instrument panel airbag is tied to.
(2) Place at least 2 tires over the tire which the lower No. 2 instrument panel airbag is tied to. The
top tire should have a disc wheel installed.
NOTICE: *
Do not place SST connector under the tires because it could be damaged.
* As the disc wheel may be damaged by the airbag deployment, use a disc wheel that you are
planning to throw away.
* As the tires may be damaged by the airbag deployment, use tires that you are planning to throw
away.
(3) Tie the tires together with 2 wire harnesses.
CAUTION: Make sure that the wire harnesses are tight. Looseness in the wire harnesses results in
the tires coming free due to the shock when the airbag is deployed.
(f) Connect SST connector.
SST : 09082-00700
NOTICE: To avoid damaging SST connector and wire harness, do not lock the secondary lock of
the twin lock. Also, secure some slack for SST wire harness inside the tires.
(g) Deploy the airbag.
(1) Connect the red clip of SST to the positive (+) battery terminal and the black clip of SST to the
negative (-) battery terminal.
(2) Check that no one is within a 10 m (32.8 ft.) radius of the tire which the lower No. 2 instrument
panel airbag is tied to.
(3) Press SST activation switch to deploy the airbag.
CAUTION: When deploying the airbag, make sure that no one is near the tires.
HINT The airbag is deployed as the LED of SST activation switch comes on.
(h) Dispose of the lower No. 2 instrument panel airbag.
Page 5679
2. Loosen the bleeder plug.
3. Using the Techstream, operate the brake actuator, completely depress the brake pedal and hold
it there.
HINT The operation stops automatically after 4 seconds. When performing this procedure
continuously, set an interval of at least 20 seconds.
NOTICE: *
During this procedure, the pedal will feel heavy, but completely depress it so that the brake fluid
comes out of the bleeder plug.
* Depress and hold the brake pedal. Do not depress and release the pedal repeatedly.
(10)4. Tighten the bleeder plug, and then release the brake pedal.
5. Repeat the 3 previous steps until all air in the fluid is completely bled out.
6. Tighten the bleeder plug.
Torque : 11 Nm (110 kgf-cm, 8 ft-lbf)
(11)7. Repeat all of the above procedures for the other wheels to bleed the air out of the pressure
reduction line.
(12)Clear the DTCs See: Antilock Brakes / Traction Control Systems/Testing and
Inspection/Reading and Clearing Diagnostic Trouble
Codes.
(13)Inspect for brake fluid leak.
(14)Check and adjust brake fluid level in reservoir See: Hydraulic System/Brake Fluid/Testing and
Inspection.
(15)If any DTC is set, perform the troubleshooting for the DTC
(16)Check the DTC See: Antilock Brakes / Traction Control Systems/Testing and
Inspection/Reading and Clearing Diagnostic Trouble
Codes.
Page 4600
General Information
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: GENERAL
INFORMATION
* A large number of ECU controlled systems are used in the TOYOTA TUNDRA. In general, ECU
controlled systems are considered to be very intricate, requiring a high level of technical knowledge
to troubleshoot. However, most problem checking procedures only involve inspecting the ECU
controlled system's circuits one by one. An adequate understanding of the system and a basic
knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and
necessary repairs.
1. TROUBLESHOOTING PROCEDURES
* The troubleshooting procedures consist of diagnosis procedures for when a DTC is stored and
diagnosis procedures for when no DTC is stored. The basic idea is explained in the following table.
* Vehicle systems are complex and use many ECUs that are difficult to inspect independently.
Therefore, a process of elimination is used, where components that can be inspected individually
are inspected, and if no problems are found in these components, the related ECU is identified as
the problem and replaced.
* It is extremely important to ask the customer about the environment and the conditions present
when the problem occurred (Customer Problem Analysis). This makes it possible to simulate the
conditions and confirm the symptom. If the symptom cannot be confirmed or the DTC does not
recur, the malfunctioning part may not be identified using the troubleshooting procedure, and the
ECU for the related system may be replaced even though it is not defective. If this happens, the
original problem will not be solved.
* In order to prevent endless expansion of troubleshooting procedures, the troubleshooting
procedures are written with the assumption that multiple malfunctions do not occur simultaneously
for a single problem symptom.
* To identify the malfunctioning part, troubleshooting procedures narrow down the target by
separating components, ECUs and wire harnesses during the inspection. If the wire harness is
identified as the cause of the problem, it is necessary to inspect not only the connections to
components and ECUs but also all of the wire harness connectors between the component and the
ECU.
DIAGNOSTIC TESTER
2. DESCRIPTION
System data and the Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector
3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the Techstream* to
check for a malfunction and perform repairs.
HINT *: Techstream is the name for the diagnostic tester in North America.
3. DATA LINK CONNECTOR 3 (DLC3)
(a) The vehicle's ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of
the DLC3 complies with SAE J1962 and
matches the ISO 15765-4 format.
Page 2771
Then click Start.
I. Do NOT disturb the vehicle during flash reprogramming.
NOTE
^ ECU flash reprogramming may take anywhere from 3 - 30 minutes per calibration file.
^ Reprogramming time will vary depending on model and ECU communication protocol. Vehicles
using CAN communication protocol will reprogram much faster (2 - 7 minutes).
NOTE
^ If vehicle requires only ONE calibration update, then proceed to step N in this bulletin.
^ If vehicle requires a SECOND calibration update, then continue as follows:
^ For serial communication vehicles, go to step J.
^ For CAN communication vehicles, go to step L.
Page 6716
Push the terminal retainer down to the temporary lock position.
Page 8804
Speaker: Service and Repair Front Door Speaker (for Double Cab)
Components
AUDIO / VISUAL: FRONT DOOR SPEAKER (for Double Cab): COMPONENTS
Diagrams
Electronic Noise Suppressor: Diagrams
Page 8087
Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to
prevent airbag and seat belt pretensioner activation.
(c) Install the door airbag sensor with the screw.
Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)
NOTICE: *
If the door airbag sensor has been dropped, or there are any cracks, dents or other defects in the
case, bracket or connector, replace it with a new one.
* When installing the door airbag sensor, be careful that the SRS wiring does not interfere with
other parts and that it is not pinched between other parts.
(d) Check that there is no looseness in the installation parts of the door airbag sensor.
(e) Connect the connector.
2. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Reassembly
3. INSTALL COURTESY LIGHT ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood
and Trunk/Doors/Front Door/Service and
Repair/Front Door (for Double Cab)/Reassembly
4. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH LH (for Front Side) See: Body
and Frame/Doors, Hood and
Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly
5. INSTALL FRONT ARMREST BASE PANEL UPPER LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Reassembly
6. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Reassembly
7. INSTALL REAR SIDE AIRBAG SENSOR
(a) Check that the ignition switch is OFF.
(b) Check that the cable is disconnected from the battery negative (-) terminal.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
(c) Install the side airbag sensor with the bolt.
Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)
NOTICE: *
If the side airbag sensor has been dropped, or there are any cracks, dents or other defects in the
case, bracket or connector, replace it with a new one.
* When installing the side airbag sensor, be careful that the SRS wiring does not interfere with
other parts and that it is not pinched between other parts.
(d) Check that there is no looseness in the installation parts of the side airbag sensor.
(e) Connect the connector.
8. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY LH (for Rear Side) See: Body and
Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation
Page 2031
Driver Side J/B - Cowl Side Left
Page 8875
Alarm Module: Service and Repair Installation
THEFT DETERRENT: THEFT WARNING ECU: INSTALLATION
1. INSTALL GLASS BREAKAGE SENSOR ECU
(a) Install the ECU with the nut.
(b) Install the junction block with the 2 nuts.
(c) Connect the connectors.
2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH
(a) for Column Shift Type:
Remove the instrument panel finish panel See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument
Panel Safety Pad (for Column Shift Type)/Installation.
(b) for Floor Shift Type:
Remove the instrument panel finish panel See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument
Panel Safety Pad (for Floor Shift Type)/Installation.
3. INSTALL INSTRUMENT SIDE PANEL LH
Page 7298
SST : 09521-24010
Clearance:
3.0 mm (0.118 in.) or less
NOTICE: Be careful not to damage the rack boot No. 1.
16. INSTALL STEERING RACK BOOT NO. 2 CLAMP
HINT The installation procedure for the No. 2 side is the same as that for the No. 1 side.
17. INSTALL STEERING RACK BOOT CLIP
(a) Using pliers, install the 2 rack boot clips.
NOTICE: Make sure that each clip's claws are positioned within the area shown in the illustration.
18. INSTALL TIE ROD END SUB-ASSEMBLY LH
(a) Align the matchmarks of the tie rod and rack end and temporarily install the tie rod with the lock
nut.
(b) After adjusting toe-in, torque the nut.
Torque : 82 Nm (836 kgf-cm, 60 ft-lbf)
19. INSTALL TIE ROD END SUB-ASSEMBLY RH
HINT The installation procedure for the RH side is the same as that for the LH side.
20. INSTALL STEERING TURN PRESSURE TUBE
(a) Coat 4 new O-rings with power steering fluid and install them onto the pressure tubes.
(b) Using union nut wrench, install the 2 pressure tubes.
Page 1266
Air Flow Meter/Sensor: Testing and Inspection On-Vehicle Inspection
1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: ON-VEHICLE INSPECTION
1. CHECK MASS AIR FLOW METER
(a) Check the mass air flow value.
(1) Connect the Techstream to the DLC3.
(2) Turn the ignition switch to ON.
(3) Turn the Techstream main switch ON.
(4) Enter the following menus: Powertrain / Engine / Data List / All Data / MAF.
(5) Blow air into the MAF meter, and check that the MAF value fluctuates.
(6) If the result is not as specified, check the MAF meter See: Inspection, or wiring and ECM See:
Powertrain Management/Computers and
Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated
Procedures/P Code Charts/P0102.
Page 1556
Tire Pressure Sensor: Service and Repair Disposal
TIRE AND WHEEL: TIRE PRESSURE WARNING VALVE AND TRANSMITTER: DISPOSAL
HINT The tire pressure warning valve is powered by a lithium battery. When disposing of the tire
pressure warning valve and transmitter, remove the battery and dispose of it correctly.
1. DISPOSE OF TIRE PRESSURE WARNING VALVE AND TRANSMITTER
(a) Use the tip of a screwdriver to pry off the back cover.
(b) The battery and base board are exposed. While taking out the battery, cut the 2 terminals that
connect the battery to the base board.
Page 265
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Page 4566
Crankshaft Position Sensor: Diagrams
Page 1057
Door Switch: Testing and Inspection Rear Door Courtesy Switch
LIGHTING: REAR DOOR COURTESY SWITCH: INSPECTION
1. INSPECT REAR DOOR COURTESY SWITCH
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the switch.
Page 1484
Establish conditions in which voltage is present at the check point.
Example:
- [A] - Ignition SW on
- [B] - Ignition SW and SW1 on
- [C] - Ignition SW, SW1 and Relay on (SW2 off)
Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or component terminal.
This check can be done with a test light instead of a voltmeter.
Electronic Circuit Inspection Procedure
Components
Neutral Safety Switch: Service and Repair Components
A760F AUTOMATIC TRANSMISSION: PARK / NEUTRAL POSITION SWITCH: COMPONENTS
Page 9047
Page 8101
Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)
NOTICE: *
If the side airbag sensor has been dropped, or there are any cracks, dents or other defects in the
case, bracket or connector, replace it with a new one.
* When installing the side airbag sensor, be careful that the SRS wiring does not interfere with
other parts and that it is not pinched between other parts.
(d) Check that there is no looseness in the installation parts of the side airbag sensor.
(e) Connect the connector.
8. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY LH (for Rear Side) See: Body and
Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation
9. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH (for Rear Side)
10. INSTALL REAR DOOR SCUFF PLATE LH (for Rear Side) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and Repair/Roof
Headlining (For Double Cab)/Installation
11. INSTALL REAR SEAT ASSEMBLY (for Rear Side)
(a) Install the rear seat assembly See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Rear Seat Assembly (for Double
Cab)/Installation.
12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
13. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
Components
SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Double Cab):
COMPONENTS
Locations
Transmission Position Switch/Sensor: Locations
A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS
LOCATION
A760F Automatic Transmission System
Transfer Case Actuator: Locations A760F Automatic Transmission System
A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS
LOCATION
Page 1340
Ignition Switch: Service and Repair Installation
1UR-FE STARTING: IGNITION SWITCH: INSTALLATION
1. INSTALL IGNITION SWITCH ASSEMBLY
(a) Attach the 2 claws to install the ignition switch to the steering lock.
2. INSTALL UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Manual Tilt)
See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering Column Assembly
(for Manual Tilt)/Reassembly
3. INSTALL UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Manual Tilt
and Manual Telescopic Steering Column)
See: Steering and Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering
Column Assembly (for Manual Tilt and Manual Telescopic Steering Column)/Reassembly
4. INSTALL UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Power Tilt
and Power Telescopic Steering Column)
See: Steering and Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering
Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Reassembly
5. INSTALL STEERING COLUMN ASSEMBLY
(a) for Manual Tilt:
Install the steering column See: Steering and Suspension/Steering/Steering Column/Service and
Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Installation.
(b) for Manual Tilt and Manual Telescopic Steering Column:
Install the steering column See: Steering and Suspension/Steering/Steering Column/Service and
Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt and Manual
Telescopic Steering Column)/Installation.
(c) for Power Tilt and Power Telescopic Steering Column:
Install the steering column See: Steering and Suspension/Steering/Steering Column/Service and
Repair/Removal and Replacement/Steering Column Assembly (for Power Tilt and Power
Telescopic Steering Column)/Installation.
6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Locations
Tire Pressure Monitor Receiver / Transponder: Locations
TIRE AND WHEEL: TIRE PRESSURE WARNING SYSTEM: PARTS LOCATION
Page 6627
Auxiliary Power Outlet: Service and Repair Center Power Outlet Socket (for Floor Shift Type)
Components
OTHER SYSTEM: CENTER POWER OUTLET SOCKET (for Floor Shift Type): COMPONENTS
Removal
OTHER SYSTEM: CENTER POWER OUTLET SOCKET (for Floor Shift Type): REMOVAL
1. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding
/ Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
Page 6693
Page 6820
Floor Wire
Page 6766
AJ1-AJ8
Page 6557
Junction Connector (CAN No.2) - Lower Finish Panel
Page 6800
General Information
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: GENERAL
INFORMATION
* A large number of ECU controlled systems are used in the TOYOTA TUNDRA. In general, ECU
controlled systems are considered to be very intricate, requiring a high level of technical knowledge
to troubleshoot. However, most problem checking procedures only involve inspecting the ECU
controlled system's circuits one by one. An adequate understanding of the system and a basic
knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and
necessary repairs.
1. TROUBLESHOOTING PROCEDURES
* The troubleshooting procedures consist of diagnosis procedures for when a DTC is stored and
diagnosis procedures for when no DTC is stored. The basic idea is explained in the following table.
* Vehicle systems are complex and use many ECUs that are difficult to inspect independently.
Therefore, a process of elimination is used, where components that can be inspected individually
are inspected, and if no problems are found in these components, the related ECU is identified as
the problem and replaced.
* It is extremely important to ask the customer about the environment and the conditions present
when the problem occurred (Customer Problem Analysis). This makes it possible to simulate the
conditions and confirm the symptom. If the symptom cannot be confirmed or the DTC does not
recur, the malfunctioning part may not be identified using the troubleshooting procedure, and the
ECU for the related system may be replaced even though it is not defective. If this happens, the
original problem will not be solved.
* In order to prevent endless expansion of troubleshooting procedures, the troubleshooting
procedures are written with the assumption that multiple malfunctions do not occur simultaneously
for a single problem symptom.
* To identify the malfunctioning part, troubleshooting procedures narrow down the target by
separating components, ECUs and wire harnesses during the inspection. If the wire harness is
identified as the cause of the problem, it is necessary to inspect not only the connections to
components and ECUs but also all of the wire harness connectors between the component and the
ECU.
DIAGNOSTIC TESTER
2. DESCRIPTION
System data and the Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector
3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the Techstream* to
check for a malfunction and perform repairs.
HINT *: Techstream is the name for the diagnostic tester in North America.
3. DATA LINK CONNECTOR 3 (DLC3)
(a) The vehicle's ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of
the DLC3 complies with SAE J1962 and
matches the ISO 15765-4 format.
Page 173
Page 4465
Air Flow Meter/Sensor: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: REMOVAL
1. REMOVE MASS AIR FLOW METER
(a) Disconnect the MAF connector.
(b) Remove the 2 screws and MAF meter.
Capacity Specifications
Refrigerant Oil: Capacity Specifications
COMPRESSOR OIL
Standard
(Oil capacity inside the new compressor and magnetic clutch: 120 + 15 cc (4.1 + 0.51 fl.oz.)) (Remaining oil amount in the removed compressor and magnetic clutch) = (Oil amount to be
removed from the new compressor when replacing)
Page 5410
(4) If the resistance is not as specified, repair or replace the harness or connector.
(c) Check the 4WD control switch.
(1) Turn the ignition switch OFF.
(2) Connect the L1 switch connector.
(3) Connect the A25 and A26 ECU connectors.
(4) Measure the voltage according to the value(s) in the table below.
Standard voltage:
(5) If the voltage is not as specified, check the 4WD control ECU.
(d) Check the 4WD control ECU.
(1) Disconnect the L1 switch connector.
(2) Measure the voltage according to the value(s) in the table below.
Page 1707
Standard wheel angle (unloaded vehicle):
for CrewMax of standard deck
Page 439
Main Relay (Computer/Fuel System): Testing and Inspection
1UR-FE ENGINE CONTROL SYSTEM: CIRCUIT OPENING RELAY: ON-VEHICLE INSPECTION
1. REMOVE CIRCUIT OPENING RELAY (C/OPN)
(a) Remove the circuit opening relay from the engine room relay block.
2. INSPECT CIRCUIT OPENING RELAY
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) If the result is not as specified, replace the circuit opening relay.
3. INSTALL CIRCUIT OPENING RELAY
(a) Install the circuit opening relay to the engine room relay block.
Page 177
Headlamp Alignment Control Module: Diagnostic Aids
Continuity and Resistance Check
CONTINUITY AND RESISTANCE CHECK
Disconnect the battery terminal or wire so there is no voltage between the check points.
Contact the two leads of an ohmmeter to each of the check points.
Page 8620
Auxiliary Input / Output Jack: Diagrams Stereo Jack Adapter
Locations
Shift Interlock Control Module: Locations
Instrument Panel (Floor Shift)
Instrument Panel (Column Shift)
Page 2774
NOTE
On some models, DTCs may set as a result of reprogramming. If DTCs are present, clear codes
and run the Health Check again. Troubleshoot any remaining Current, Pending, or History codes.
Permanent codes will not be cleared using Techstream. Permanent codes do not illuminate the MIL
and do not require troubleshooting. They will clear during normal driving once the Universal Trip
Drive Pattern is performed.
4. Attach the Authorized Modifications Label.
A. Using a permanent marker or ball point pen complete the Authorized Modifications Label and
attach to the vehicle. The Authorized
Modifications Label is available through the MDC P/N 00451-00001-LBL.
B. Attach the label under the hood in the location determined by the specific TSB or Campaign.
NOTE
Wait 60 - 90 seconds for ink to set before handling.
Components
Remote Switch: Service and Repair Components
AUDIO / VISUAL: STEERING PAD SWITCH: COMPONENTS
Page 1940
(b) Remove the oil filter drain plug.
(c) Install the pipe to the oil filter cap.
HINT Use a container to catch the draining oil.
NOTICE: If the O-ring is removed with the drain plug, install the O-ring together with the pipe.
(d) Check that oil is drained from the oil filter. Then disconnect the pipe and remove the O-ring, as
shown in the illustration.
(e) Using SST, remove the oil filter cap.
SST : 09228-06501
NOTICE: Do not remove the oil filter bracket clip.
Page 2904
Air Flow Meter/Sensor: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: REMOVAL
1. REMOVE MASS AIR FLOW METER
(a) Disconnect the MAF connector.
(b) Remove the 2 screws and MAF meter.
Specifications
Compression Check: Specifications
COMPRESSION
Page 7116
Tire Pressure Monitor Receiver / Transponder: Service and Repair Removal
TIRE AND WHEEL: TIRE PRESSURE WARNING RECEIVER: REMOVAL
1. REMOVE ROOF HEADLINING ASSEMBLY
(a) for Regular Cab:
Remove the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Removal.
(b) for Double Cab:
Remove the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Double Cab)/Removal.
(c) for CrewMax:
Remove the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (for CrewMax)/Removal.
2. REMOVE TIRE PRESSURE WARNING ANTENNA AND RECEIVER
(a) Disconnect the receiver connector.
(b) Remove the bolt and receiver.
Page 5604
HINT *
*1: FR RH
* *2: FR LH
* *3: RR RH
* *4: RR LH
* *5: FR Master Cylinder
* *6: RR Master Cylinder
(b) Using a union nut wrench, disconnect the 2 brake tubes from the VSC actuator.
(c) Using a union nut wrench, remove the 2 brake tubes from the brake master cylinder.
4. DISCONNECT BRAKE TUBE
(a) Using a union nut wrench, disconnect the 4 brake tubes from the VSC actuator.
(b) Remove the clamp from the VSC actuator bracket.
5. REMOVE VSC ACTUATOR WITH ACTUATOR BRACKET ASSEMBLY
(a) Remove the 3 nuts and VSC actuator with actuator bracket.
Installation
Page 1671
Wiper Switch: Service and Repair Installation
WIPER AND WASHER: WIPER SWITCH: INSTALLATION
1. INSTALL WINDSHIELD WIPER SWITCH ASSEMBLY
(a) Attach the claw to install the wiper switch.
(b) Connect the 2 connectors.
2. INSTALL UPPER STEERING COLUMN COVER
(a) Attach the 4 clips to install the upper steering column cover onto the instrument panel cluster
finish panel.
(b) Attach the claw to install the upper steering column cover.
3. INSTALL LOWER STEERING COLUMN COVER
(a) Attach the 2 claws to install the lower steering column cover.
NOTICE: Do not damage the tilt and telescopic switch.
(b) Using a screwdriver, while turning the steering wheel to the right and left, install the 2 screws
and lower steering column cover.
Page 6630
5. INSTALL POWER OUTLET SOCKET ASSEMBLY
(a) Attach the claw to install the power outlet socket.
6. INSTALL CONSOLE BOX BEZEL
(a) Attach the 5 claws to install the console box bezel.
(b) Connect the connector.
7. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding
/ Trim/Dashboard / Instrument Panel/Service
and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
Page 235
Accessory Relay: Diagrams
Recall 10V091000: Front Driveshaft Replacement
Drive/Propeller Shaft: Recalls Recall 10V091000: Front Driveshaft Replacement
VEHICLE MAKE/MODEL: MODEL YEAR(S): Toyota/Tundra 2010 MANUFACTURER: Toyota
Motor North America, Inc.
MFR'S REPORT DATE: March 09, 2010
NHTSA CAMPAIGN ID NUMBER: 10V091000
NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Axle Assembly: Axle Shaft
POTENTIAL NUMBER OF UNITS AFFECTED: 2
SUMMARY: Toyota is recalling certain model year 2010 Tundra vehicles with four wheel drive,
there is a possibility that an improper weld exists at the union of the propeller shaft and yoke. Due
to this improper weld, this joint may separate and the separated shaft may come into contact with
the road surface.
CONSEQUENCE: This may result in a loss of vehicle control increasing the risk of a crash.
REMEDY: Dealers will replace the front propeller shaft free of charge. The safety recall is expected
to begin during March 2010. Owners may contact Toyota at 1-800-331-4331.
NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle
Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov.
Page 2826
HINT The wavelength becomes shorter as engine rpm increases.
(i) WAVEFORM 8:
HINT If the waveform is not similar to the illustration, check the waveform again after idling for 10
minutes or more.
(j) WAVEFORM 9:
Page 5090
Parts Information
Required Tools & Equipment
Repair Procedure Overview
^ Confirm noise is coming from the rear of the vehicle when driving.
^ Install ChassisEAR(TM) (or equivalent) and isolate noise to the rear differential area.
^ Remove the rear differential and axle shafts.
Page 8904
(a) Remove the front door scuff plate See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Removal.
HINT The procedures listed below are for the LH side.
5. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP RH
6. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY RH See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Removal
7. REMOVE FRONT QUARTER TRIM PANEL ASSEMBLY RH See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Removal
8. REMOVE DOOR CONTROL RECEIVER
(a) Disconnect the door control receiver connector.
(b) Remove the bolt and receiver.
Installation
DOOR LOCK: DOOR CONTROL RECEIVER (for Regular Cab): INSTALLATION
1. INSTALL DOOR CONTROL RECEIVER
(a) Install the receiver with the bolt.
(b) Connect the door control receiver connector.
2. INSTALL FRONT QUARTER TRIM PANEL ASSEMBLY RH See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Installation
3. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY RH See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Installation
4. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH
5. INSTALL FRONT DOOR SCUFF PLATE RH
(a) Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular
Cab)/Installation.
HINT The procedures listed below are for the LH side.
Locations
Fuse Block: Locations
Engine Compartment
Page 6723
(1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be
checked by conducting a voltage check.
With each connector still connected, measure the voltage between the body ground and these
terminals (in this order): 1) terminal 1 of connector A; 2) terminal 1 of connector B; and 3) terminal
1 of connector C.
Standard voltage (Fig. 4):
* If the results match the examples above, an open circuit exists in the wire harness between
terminal 1 of connector B and terminal 1 of connector C.
3. CHECK FOR SHORT CIRCUIT
(a) If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance
check with the body ground (below).
(b) Check the resistance with the body ground.
(1) Disconnect connectors A and C and measure the resistance.
Standard resistance (Fig. 6):
HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally.
If your results match the examples above, a short circuit exists between terminal 1 of connector A
and terminal 1 of connector C.
Page 8809
Speaker: Service and Repair
Components
AUDIO / VISUAL: FLOOR SPEAKER (for CrewMax): COMPONENTS
Removal
AUDIO / VISUAL: FLOOR SPEAKER (for CrewMax): REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE BACK PANEL GARNISH RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for
Page 4266
2. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in
Figure 1. Confirm if the ECM (PCM) calibration has
been updated. If the calibration ID listed is NOT the latest ECM (PCM) calibration - go to step 3.
3. Flash reprogram the ECM (PCM).
NOTE
^ The GR8 Battery Diagnostic Station MUST be used in Power Supply Mode to maintain battery
voltage at 13.5 volts while flash reprogramming the vehicle.
^ For details on how to use the GR8 Battery Diagnostic Station, refer to the located on the
Technical Information System (TIS), Diagnostics - Battery
Follow the procedures outlined in TSB No. T-SB-0064-10, "Techstream ECU Flash
Reprogramming Procedure1⁄4 and flash the ECM (PCM) with the NEW calibration file update.
4. Install the Authorized Modifications Label.
A. Using a permanent marker enter the following information on the label:
^ ECM part number [Refer to the Parts Information section for the CURRENT PART NUMBER]
^ Calibration ID(s) [Refer to the Calibration Identification Chart for the NEW CALIBRATION ID]
^ Dealer Code
^ Repair Date
^ Change Authority [This TSB number]
B. Affix the Authorized Modifications Label to the vehicle at the location shown in Figure 1. The
Authorized Modifications Label is available
through the MDC P/N 00451-00001-LBL.
5. Test drive the vehicle to confirm proper vehicle operation.
Page 2044
J/B No.6 Assembly Inner Circuit
Engine - Controls - Non-Linear Acceleration From A Stop
PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine - Controls Non-Linear Acceleration From A Stop
T-SB-0273-10
September 28, 2010
Non-Linear Acceleration from a Stop
Service Category Engine/Hybrid System
Section Engine Control
Market USA
Applicability
Introduction
Some 2010 model year Tundra vehicles with the 1UR-FE (4.6 L) engine may exhibit non-linear
acceleration from a stop under certain conditions of low engine rpm with high engine load. The
Engine Control Module/ECM (SAE term: Powertrain Control Module/PCM) logic has been revised
to address this condition. Use the following repair procedure to recalibrate the ECM (PCM).
Calibration Information
Warranty Information
Applicable Warranty
^ This repair is covered under the Toyota Federal Emission Warranty. This warranty is in effect for
96 months or 80,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Page 6641
HINT Tape the screwdriver tip before use.
10. REMOVE REAR POWER OUTLET SOCKET COVER (for Double Cab)
(a) Detach the 2 claws and remove the power outlet socket cover.
Installation
OTHER SYSTEM: CENTER POWER OUTLET SOCKET (for Column Shift Type): INSTALLATION
1. INSTALL REAR POWER OUTLET SOCKET COVER (for Double Cab)
(a) Attach the 2 claws to install the power outlet socket cover.
2. INSTALL REAR POWER OUTLET SOCKET ASSEMBLY (for Double Cab)
(a) Attach the claw to install the power outlet socket.
3. INSTALL CENTER SEATBACK PANEL (for Double Cab) See: Body and Frame/Seats/Service
and Repair/Overhaul/Front Seat Assembly (for
Center Seat)/Reassembly
4. INSTALL POWER OUTLET SOCKET COVER
(a) Attach the 2 claws to install the power outlet socket cover.
5. INSTALL POWER OUTLET SOCKET ASSEMBLY
Adjustments
Brake Pedal Assy: Adjustments
BRAKE: BRAKE PEDAL: ADJUSTMENT
1. CHECK BRAKE PEDAL HEIGHT
(a) Check the brake pedal height.
(1) Turn back the carpet.
(2) Remove the tibia pad.
(3) Measure the shortest distance between the brake pedal surface and dash panel.
Standard pedal height from dash panel:
179.9 to 189.9 mm (7.08 to 7.48 in.)
NOTICE: Do not adjust the pedal height. Doing so by changing the push rod length will structurally
change the pedal ratio.
(4) If the pedal height is incorrect, check that there is no damage in the brake pedal, brake pedal
lever, brake pedal bracket and dash panel.
Even if there is damage, there is no problem if the reserve distance is within the standard value. If
necessary, replace them.
2. CHECK AND ADJUST STOP LIGHT SWITCH ASSEMBLY
HINT If the pedal height is incorrect, check and adjust the stop light switch clearance.
(a) Disconnect the stop light switch connector.
(b) Turn the stop light switch counterclockwise and remove it.
(c) Insert the stop light switch until the body hits the cushion.
NOTICE: When inserting the stop light switch, support the pedal from behind so that the pedal is
not pushed in.
(d) Make a quarter turn clockwise to install the stop light switch.
NOTICE: The turning torque for installing the stop light switch should be 1.5 N*m (15 kgf*cm, 13
in.*lbf) or less.
Page 6751
J/B No.6 Assembly Inner Circuit
Page 4338
(4) for Fuel Pipe Clamp Type:
Install the fuel pipe clamp to the connector.
(5) for Fuel Hose Connector Cover Type:
Attach the lock claw to the connector by pushing down on the cover, as shown in the illustration.
(6) Check that there is no fuel leakage.
3. CHECK FOR FUEL LEAK
(a) Check that there are no fuel leaks after performing maintenance anywhere on the fuel system
See: Testing and Inspection.
Page 1519
5. INSPECT PARK/NEUTRAL POSITION SWITCH ASSEMBLY
(a) Inspect the switch See: Testing and Inspection/Initial Inspection and Diagnostic Overview.
Page 2901
Air Flow Meter/Sensor: Testing and Inspection On-Vehicle Inspection
1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: ON-VEHICLE INSPECTION
1. CHECK MASS AIR FLOW METER
(a) Check the mass air flow value.
(1) Connect the Techstream to the DLC3.
(2) Turn the ignition switch to ON.
(3) Turn the Techstream main switch ON.
(4) Enter the following menus: Powertrain / Engine / Data List / All Data / MAF.
(5) Blow air into the MAF meter, and check that the MAF value fluctuates.
(6) If the result is not as specified, check the MAF meter See: Inspection, or wiring and ECM See:
Computers and Control Systems/Testing
and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0102.
Page 5032
Differential Carrier: Overhaul
Disassembly
DIFFERENTIAL: DIFFERENTIAL CARRIER ASSEMBLY (for 1GR-FE, 1UR-FE): DISASSEMBLY
1. INSPECT RUNOUT OF REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY
(a) Using a dial indicator, measure the runout of the companion flange vertically and laterally.
Maximum runout:
(b) If the runout is greater than the maximum, replace the companion flange.
2. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR
(a) Using a dial indicator, measure the runout of the ring gear.
Maximum runout:
0.05 mm (0.00197 in.)
(b) If the runout is greater than the maximum, replace the ring gear with a new one.
3. INSPECT DIFFERENTIAL RING GEAR BACKLASH
(a) Using a dial indicator, measure the backlash of the ring gear.
Standard backlash:
0.10 to 0.20 mm (0.00394 to 0.00788 in.)
Page 9128
* In the DTC check, it is very important to determine whether the problem indicated by the DTC is
either: 1) still occurring; or 2) occurred in the past but has since returned to normal. In addition, the
DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs
should be checked before and after confirmation of symptoms (i.e., whether or not problem
symptoms exist) to determine current system conditions, as shown in the flowchart below.
* Never skip the DTC check. Failing to check DTCs may, depending on the case, result in
unnecessary troubleshooting for systems operating normally or lead to repairs not related to the
problem. Follow the procedures listed in the flowchart in the correct order.
* The following flowchart shows how to proceed with troubleshooting using the DTC check.
Directions from the flowchart will indicate how to proceed either to DTC troubleshooting or to the
troubleshooting of each problem symptom.
1. DTC CHECK
NEXT -- Continue to next step.
2. MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR MEMORY
NEXT -- Continue to next step.
3. SYMPTOM CONFIRMATION
B -- Go to step 5 A -- Continue to next step.
4. SIMULATION TEST USING SYMPTOM SIMULATION METHODS
NEXT -- Continue to next step.
5. DTC CHECK
B -- TROUBLESHOOTING OF PROBLEM INDICATED BY DTC A -- Continue to next step.
6. SYMPTOM CONFIRMATION
Center Power Outlet Socket (for Column Shift Type)
Auxiliary Power Outlet: Service and Repair Center Power Outlet Socket (for Column Shift Type)
Components
OTHER SYSTEM: CENTER POWER OUTLET SOCKET (for Column Shift Type): COMPONENTS
Page 3518
(a) Reconnect the J86 No. 1 junction connector connector.
NEXT -- Continue to next step.
4. CHECK FOR SHORT TO GND IN CAN BUS WIRE (NO. 2 JUNCTION CONNECTOR SIDE)
(a) Disconnect the J113 No. 2 junction connector connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- CHECK FOR SHORT TO GND IN CAN BUS WIRE (NO. 2 JUNCTION CONNECTOR - AIR
CONDITIONING AMPLIFIER) OK -- Continue to next step.
5. CHECK FOR SHORT TO GND IN CAN BUS WIRE (NO. 1 JUNCTION CONNECTOR - NO. 2
JUNCTION CONNECTOR)
(a) Disconnect the J94 No. 1 junction connector connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
Page 9058
"Case2" Open the secondary locking device.
[B] For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray
Gray or White : Black
Page 6550
Driver Side J/B - Cowl Side Left
Page 6165
Page 2797
C. Choose desired ECU group(s) in the Health Check dialog box.
D. Click Next.
E. Click Continue to view Health Check results.
F. Available calibration updates are indicated by a link in the Cal. Update? column. Click the link to
access the appropriate service bulletin on TIS.
NOTE
^ Note any DTCs stored in Systems that will be flash reprogrammed.
^ Clicking the link will automatically launch TIS and perform a calibration search.
G. Log in to TIS. (If already logged in skip this step.)
H. To review the TSB and access the calibration file click the service bulletin link in the Document
Title column of the Calibration Search Result
portlet.
Page 5885
Page 6974
Release the locking lug from terminal and pull the terminal out from rear.
INSTALL TERMINAL TO CONNECTOR
Insert the terminal.
HINT: Make sure the terminal is positioned correctly.
Insert the terminal until the locking lug locks firmly.
Insert the terminal with terminal retainer in the temporary lock position.
Page 2976
SST : 09224-00010
without SST - Torque : 44 Nm (449 kgf-cm, 32 ft-lbf)
with SST - Torque : 40 Nm (408 kgf-cm, 30 ft-lbf)
HINT *
Use a torque wrench with a fulcrum length of 30 cm (11.8 in.). When using a torque wrench with a
fulcrum length that is not 30 cm (11.8 in.), calculate the torque specification for the torque wrench
and SST based on the "without SST" torque specification See: Service Precautions
* Make sure SST and the wrench are connected in a straight line.
3. INSTALL PROPELLER SHAFT HEAT INSULATOR (for 4WD) See: Transmission and
Drivetrain/Drive/Propeller Shafts, Bearings and
Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Front Propeller Shaft
Assembly/Installation
4. INSPECT FOR EXHAUST GAS LEAK See: Engine, Cooling and Exhaust/Exhaust
System/Exhaust Manifold/Service and Repair/Installation
Page 6707
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Page 735
OK:
(f) If the result is not as specified, replace the switch.
3. INSPECT SEAT HEATER SWITCH LH (w/ Climate Control Seat System)
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance (for Heater):
Standard Resistance (for Blower):
HINT As the dial is being turned, the resistance changes gradually.
(b) If the result is not as specified, replace the switch.
(c) Apply battery voltage to the switch connector, and check that the seat heater switch illuminates.
OK:
(d) If the result is not as specified, replace the switch.
(e) Apply battery voltage to the switch connector, and check that the seat heater switch illuminates.
OK:
Page 1492
4. SYMPTOM CONFIRMATION AND DTC (INCLUDING FREEZE FRAME DATA) CHECK
(a) Visually check the wire harnesses, connectors and fuses for open and short circuits.
(b) Warm up the engine to the normal operating temperature.
(c) Confirm the problem symptoms and conditions, and check for DTCs.
B -- Go to step 6 A -- Continue to next step.
5. DTC CHART
(a) Check the results obtained in the DTC check. Then find the output DTC in the DTC chart. Look
at the "Trouble Area" column for a list of
potentially malfunctioning circuits and / or parts.
NEXT -- Go to step 7
6. PROBLEM SYMPTOMS TABLE
(a) Check the results obtained in the symptom confirmation. Then find the problem symptoms in
the problem symptoms table. Look at the
"Suspected Area" column for a list of potentially malfunctioning circuits and / or parts.
NEXT -- Continue to next step.
7. CIRCUIT INSPECTION OR PARTS INSPECTION
(a) Confirm the malfunctioning circuit or part.
NEXT -- Continue to next step.
8. ADJUST, REPAIR OR REPLACE
(a) Adjust, repair or replace the malfunctioning circuit or parts.
NEXT -- Continue to next step.
9. CONFIRMATION TEST
(a) After the adjustment, repairs or replacement, confirm that the malfunction no longer exists. If the
malfunction does not reoccur, perform a
confirmation test under the same conditions and in the same environment as when the malfunction
occurred the first time.
NEXT -- END
2. CUSTOMER PROBLEM ANALYSIS
HINT *
In troubleshooting, confirm that the problem symptoms have been accurately identified.
Preconceptions should be discarded in order to make an accurate judgment. To clearly understand
what the problem symptoms are, it is extremely important to ask the customer about the problem
and the conditions at the time the malfunction occurred.
* Gather as much information as possible for reference. Past problems that seem unrelated may
also help in some cases.
* The following 5 questions are important points in the problem analysis:
Page 6138
Page 365
J. When Cal 1 has completed the update process turn ignition OFF for a minimum of 10 seconds.
Then click Next.
K. Turn ignition to the ON position. Then click Start.
L. Do NOT disturb the vehicle during flash reprogramming.
Locations
Oxygen Sensor Relay: Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 5077
Standard Drive Pinion Preload Plus:
39. INSPECT BACKLASH BETWEEN DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE
PINION
(a) Using SST and a dial indicator, measure the ring gear backlash.
SST : 09564-33010
Standard backlash:
0.17 to 0.27 mm (0.00670 to 0.0106 in.)
40. INSPECT RUNOUT OF FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY
(a) Using a dial indicator, measure the runout of the companion flange vertically and laterally.
Maximum runout:
(b) If the runout is greater than the maximum, replace the companion flange.
41. STAKE FRONT DRIVE PINION COMPANION FLANGE FRONT NUT
Components
Acceleration/Deceleration Sensor: Service and Repair Components
BRAKE CONTROL: YAW RATE AND DECELERATION SENSOR: COMPONENTS
Page 7940
NOTICE: Take care not to damage SST wire harness.
(5) Connect the red clip of SST to the battery positive (+) terminal and black clip of SST to the
battery negative (-) terminal.
(g) Deploy the airbag.
(1) Check that no one is inside the vehicle or within a 10 m (32.8 ft.) radius of the vehicle.
(2) Press the SST activation switch and deploy the airbag.
CAUTION: *
When deploying the airbag, make sure that no one is near the vehicle.
* The curtain shield airbag becomes extremely hot when the airbag is deployed, so do not touch it
for at least 30 minutes after deployment.
* Use gloves and safety glasses when handling a curtain shield airbag with a deployed airbag.
* Do not apply water to a curtain shield airbag with a deployed airbag.
* Always wash your hands with water after completing the operation.
HINT The airbag is deployed as the LED of SST activation switch comes on.
2. DISPOSE OF CURTAIN SHIELD AIRBAG ASSEMBLY (WHEN NOT INSTALLED IN VEHICLE)
CAUTION: Be sure to follow the procedure detailed below when deploying the airbag.
HINT Prepare a battery as the power source to deploy the airbag.
(a) Check the function of SST See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
(b) Remove the curtain shield airbag See: Removal and Replacement/Curtain Shield Airbag
Assembly/Removal.
(c) Cut off the deployment section of the curtain shield airbag.
(d) Using a service-purpose wire harness for the vehicle, tie down the curtain shield airbag to the
tire.
Components
Air Flow Meter/Sensor: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: COMPONENTS
Service and Repair
Air Bag(s) Arming and Disarming: Service and Repair
Air Bag(s) Arming and Disarming
Before starting work, wait at least 90 seconds after the ignition switch is turned OFF and after the
cable of the negative (-) battery terminal is disconnected. (SRS parts are equipped with a backup
power source. If work is started within 90 seconds of turning the ignition switch OFF and
disconnecting the cable from the negative (-) battery terminal, SRS parts may deploy.)
Page 9349
Rear Fender Liner: Service and Repair Removal
EXTERIOR: FENDER LINER (for Rear Side): REMOVAL
HINT *
Use the same procedures for the RH side and LH side.
* The procedures listed below are for the LH side.
1. REMOVE REAR WHEEL HOUSE LINER LH
(a) Remove the rear wheel house liner (center).
(1) Remove the 6 screws.
(2) Remove the 9 clips and rear wheel house liner.
(b) Remove the rear wheel house liner (front).
(1) Remove the 2 screws.
(2) Remove the 4 clips and rear wheel house liner.
Page 7197
HINT The vane pump rotor can be installed in both directions.
(b) Coat the 10 vane pump plates with power steering fluid.
(c) Install the vane pump plates with the round end facing outward.
NOTICE: Make sure that the vane pump plates are installed facing in the correct direction.
6. INSTALL VANE PUMP SHAFT SNAP RING
(a) Using a screwdriver and snap ring expander, install a new shaft snap ring onto the vane pump
shaft.
7. INSTALL VANE PUMP REAR HOUSING
(a) Coat a new O-ring and straight pin with power steering fluid and install it onto the rear housing.
(b) Align the straight pin of the rear housing with the notches of the cam ring, front side plate, and
front housing.
Components
Oil Pressure Sender: Service and Repair Components
1UR-FE LUBRICATION: OIL PRESSURE SWITCH: COMPONENTS
Page 8808
Repair/Front Door (for Double Cab)/Reassembly
8. INSTALL FRONT LOWER DOOR FRAME BRACKET GARNISH LH See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Reassembly
9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Power Steering Oil Pressure Sensor
Power Steering Pressure Switch: Diagrams Power Steering Oil Pressure Sensor
Page 2645
Radiator Cooling Fan: Service and Repair Removal
1UR-FE COOLING: FAN: REMOVAL
1. REMOVE NO. 1 ENGINE UNDER COVER See: Engine/Engine Lubrication/Engine Oil/Service
and Repair/Replacement
2. DRAIN ENGINE COOLANT See: Coolant/Service and Repair
3. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine/Service and Repair/Removal and
Replacement/Engine Assembly/Removal
4. REMOVE AIR CLEANER ASSEMBLY See: Powertrain Management/Ignition System/Ignition
Coil/Service and Repair/Removal
5. REMOVE INLET RADIATOR HOSE
(a) Remove the radiator hose.
6. REMOVE FAN SHROUD
(a) Loosen the 4 nuts holding the fluid coupling fan
(b) Remove the fan and generator V-belt See: Engine/Drive Belts, Mounts, Brackets and
Accessories/Drive Belt/Service and Repair/Removal.
(c) Disconnect the reservoir hose from the upper radiator tank.
(d) w/ Trailer Towing System:
Detach the claw to open the No. 1 flexible hose clamp.
(e) Remove the 2 bolts holding the fan shroud.
(f) Remove the 4 nuts of the fluid coupling fan, and then remove the shroud together with the fluid
coupling fan.
NOTICE:
Page 5786
Parking Brake Warning Switch: Diagrams
Emission Control System
Canister Purge Solenoid: Locations Emission Control System
1UR-FE EMISSION CONTROL: EMISSION CONTROL SYSTEM: PARTS LOCATION
Page 8772
Speaker: Diagrams Front Side Speaker
Page 6043
DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector.
Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
Page 6322
AJ1-AJ8
Page 8185
Seat Occupant Classification Module - Air Bag: Diagrams
Page 8364
(e) Connect the holder (with connectors).
(f) Check that the waterproof sheet is properly set.
2. INSTALL FRONT CONSOLE BOX See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal
and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation
3. INSTALL REAR CONSOLE BOX ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation
4. INSTALL CONSOLE BOX CARPET
5. INSTALL REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
6. INSTALL UPPER CONSOLE REAR PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
7. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding
/ Trim/Dashboard / Instrument Panel/Service
and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
8. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation
9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
10. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Air Bag Systems/Testing and Inspection/Initial Inspection
and Diagnostic Overview/Diagnosis System.
Components
SUPPLEMENTAL RESTRAINT SYSTEM: FRONT AIRBAG SENSOR: COMPONENTS
Components
Crankshaft Position Sensor: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: CRANKSHAFT POSITION SENSOR: COMPONENTS
Page 6241
Driver Side J/B - Cowl Side Left
Page 8259
9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Components
SEAT BELT: REAR CENTER SEAT OUTER BELT ASSEMBLY (for CrewMax): COMPONENTS
Engine Controls - A/F And O2 Sensor Identification
Oxygen Sensor: Technical Service Bulletins Engine Controls - A/F And O2 Sensor Identification
T-SB-0398-09
December 23, 2009
Engine Bank 1 and Bank 2 A/F and 02 Identification
Service Category Engine/Hybrid System
Section Engine Control
Market USA
Applicability
TSB SUPERSESSION NOTICE
The information contained in this TSB supersedes TSB No. EG034-07.
^ Applicability has been updated to include 2009 - 2010 model year vehicles and 2006 - 2010
model year Highlander HV.
TSB No. EG034-07 is Obsolete and any printed versions should be discarded. Be sure to review
the entire content of this service bulletin before proceeding.
Introduction
This service bulletin provides information on the proper identification of engine bank 1 and engine
bank 2 for correct A/F sensor and oxygen sensor replacement.
This bulletin contains information that identifies engine bank 1 and engine bank 2 on the following
engines: 1AZ-FE, 2AZ-FE, 2AZ-FE (PZEV), 1GR-FE, 2GR-FE, 2JZ-GE, 1MZ-FE, 3MZ-FE,
1UR-FE, 3UR-FE, 2UZ-FE 5VZ-FE and 1ZZ-FE.
^ Bank 1 (B1) refers to the bank that includes cylinder No. 1.
^ Bank 2 (B2) refers to the bank opposite bank 1.
^ Sensor 1 (S1) refers to the sensor that is located before the catalytic converters.
^ Sensor 2 (S2) refers to the sensor that is located after the catalytic converters.
Warranty Information
Page 831
Wheel Speed Sensor: Diagrams Rear Speed Sensor
Page 8812
(a) Disconnect the connector.
(b) Remove the 4 bolts and box speaker.
Installation
AUDIO / VISUAL: FLOOR SPEAKER (for Double Cab): INSTALLATION
1. INSTALL NO. 1 BOX SPEAKER ASSEMBLY
(a) Install the box speaker with the 4 bolts.
HINT Tighten the bolts in the order shown in the illustration.
(b) Connect the connector.
2. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Components
AUDIO / VISUAL: FRONT DOOR SPEAKER (for CrewMax): COMPONENTS
Page 1589
Transmission Speed Sensor: Service and Repair Installation
A760F AUTOMATIC TRANSMISSION: SPEED SENSOR: INSTALLATION
1. INSTALL SPEED SENSOR SP2
(a) Coat a new O-ring with ATF and install it to the sensor.
(b) Install the sensor with the bolt.
Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)
(c) Connect the sensor connector.
2. INSTALL SPEED SENSOR NT
(a) Coat a new O-ring with ATF and install it to the sensor.
(b) Install the sensor with the bolt.
Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)
(c) Connect the sensor connector.
A760F Automatic Transmission System
Transfer Case Actuator: Locations A760F Automatic Transmission System
A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS
LOCATION
Page 6012
Alternator: Testing and Inspection
1UR-FE CHARGING: GENERATOR: INSPECTION
1. INSPECT GENERATOR ROTOR ASSEMBLY
(a) Check the rotor for an open circuit.
(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(2) If the result is not as specified, replace the generator rotor assembly.
(b) Check if the rotor is grounded.
(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(2) If the result is not as specified, replace the generator rotor assembly.
(c) Check that the slip rings are not rough or scored.
If rough or scored, replace the generator rotor assembly.
(d) Using a vernier caliper, measure the slip ring diameter.
Page 2697
8. CONNECT COOLER COMPRESSOR ASSEMBLY (w/ Oil Cooler) See: Heating and Air
Conditioning/Compressor HVAC/Service and
Repair/Removal and Replacement/Installation
9. INSTALL FRONT FENDER APRON SEAL LH See: Exhaust System/Exhaust Manifold/Service
and Repair/Installation
10. INSTALL WATER INLET SUB-ASSEMBLY WITH THERMOSTAT
(a) Install the water inlet with thermostat See: Thermostat/Service and Repair/Installation.
11. INSTALL FAN SHROUD
(a) Install the fan shroud See: Radiator Cooling Fan/Service and Repair/Installation.
Page 998
Fuel Gauge Sender: Diagrams
Page 1823
M. Turn ignition OFF for a minimum of 10 seconds. Then click Next.
N. Turn ignition to the ON position. Then click Next.
0. Confirm all calibrations were updated as specified in the service bulletin. Then click Finish.
Drivetrian - Rear End Howling/Growling Noises
Wheel Bearing: Customer Interest Drivetrian - Rear End Howling/Growling Noises
T-SB-0151-10
June11, 2010
Rear Axle Bearing Abnormal Noise
Service Category Drivetrain
Section Axle/Differential
Market USA
Applicability
Introduction
Some 2007 - 2010 model year Tundra vehicles may exhibit a howling or growling noise from the
rear of the vehicle that increases with vehicle speed. Changes have been made to the rear axle
bearing to correct this condition. Follow the procedure in the bulletin to address customer concerns.
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60
months or 60,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Parts Information
Page 8678
(2) Disconnect connector B and measure the resistance.
Standard resistance (Fig. 7):
* If the results match the examples above, a short circuit exists between terminal 1 of connector B2
and terminal 1 of connector C.
4. CHECK AND REPLACE ECU
NOTICE: *
The connector should not be disconnected from the ECU. Perform the inspection from the backside
of the connector on the wire harness side.
* When no measuring condition is specified, perform the inspection with the engine stopped and
the ignition switch ON.
* Check that the connectors are fully seated. Check for loose, corroded or broken wires.
(a) First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be
faulty. Temporarily replace the ECU with a
normally functioning one and check if the symptoms occur. If the trouble symptoms disappear,
replace the original ECU.
(1) Measure the resistance between the ECU ground terminal and body ground.
Capacity Specifications
Coolant: Capacity Specifications
Cooling System Capacity
Without towing package ......................................................................................................................
.......................................................... 12.8 qt (12.1L) With towing package ........................................
.............................................................................................................................................. 13.9 qt
(13.2L)
Page 8088
9. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH (for Rear Side)
10. INSTALL REAR DOOR SCUFF PLATE LH (for Rear Side) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and Repair/Roof
Headlining (For Double Cab)/Installation
11. INSTALL REAR SEAT ASSEMBLY (for Rear Side)
(a) Install the rear seat assembly See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Rear Seat Assembly (for Double
Cab)/Installation.
12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
13. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
Page 734
(f) If the result is not as specified, replace the switch.
2. INSPECT SEAT HEATER SWITCH RH (w/ Seat Heater System)
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
HINT As the dial is being turned, the resistance changes gradually.
(b) If the result is not as specified, replace the switch.
(c) Apply battery voltage to the switch connector, and check that the seat heater switch illuminates.
OK:
(d) If the result is not as specified, replace the switch.
(e) Apply battery voltage to the switch connector, and check that the seat heater switch illuminates.
Page 3513
NOTICE: For vehicles without 4WD, go to "CHECK FOR SHORT TO B+ IN CAN BUS WIRE (NO.
2 JUNCTION CONNECTOR - ECM)".
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- CHECK FOR SHORT TO B+ IN CAN BUS WIRE (4WD CONTROL ECU) OK -- Continue to
next step.
22. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (NO. 2 JUNCTION CONNECTOR - ECM)
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- CHECK FOR SHORT TO B+ IN CAN BUS WIRE (ECM)
OK -- REPAIR OR REPLACE NO. 2 JUNCTION CONNECTOR
23. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (AIR CONDITIONING AMPLIFIER)
(a) Disconnect the J19 air conditioning amplifier connector.
Page 1670
(b) Detach the claw and remove the wiper switch.
NOTICE: Do not push the claw with excessive force as it may brake.
Components
Spark Plug: Service and Repair Components
1UR-FE IGNITION: IGNITION COIL AND SPARK PLUG: COMPONENTS
Page 6561
Driver Side J/B Inner Circuit
Page 5770
(e) Install the No. 1 parking brake cable and cable retainer with the bolt (labeled E).
Torque : 13 Nm (127 kgf-cm, 9 ft-lbf)
(f) Temporarily install the adjustment nut and lock nut (labeled F).
NOTICE: Do not bend and twist the parking brake cable.
HINT The nuts will be tightened to a torque specification in the "ADJUST PARKING BRAKE
PEDAL TRAVEL" procedure.
27. INSTALL NO. 1 PARKING BRAKE CABLE ASSEMBLY (for 4180 mm [13 ft. 8.6 in.] Wheelbase
Type)
(a) Install the No. 1 cable support bracket with the 3 bolts (labeled A).
Torque : 19 Nm (194 kgf-cm, 14 ft-lbf)
(b) Install the No. 1 parking brake cable to the inside of the vehicle with the 2 bolts (labeled B).
Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)
(c) Connect the 3 clamps (labeled C) to the No. 1 parking brake cable.
(d) Install the 3 clamps with the 3 nuts (labeled D).
Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)
(e) Install the No. 1 parking brake cable and cable retainer with the bolt (labeled E).
Torque : 13 Nm (127 kgf-cm, 9 ft-lbf)
(f) Temporarily install the adjustment nut and lock nut (labeled F).
NOTICE: Do not bend and twist the parking brake cable.
HINT The nuts will be tightened to a torque specification in the "ADJUST PARKING BRAKE
PEDAL TRAVEL" procedure.
Page 5184
Removal
DRIVE SHAFT: FRONT DRIVE SHAFT ASSEMBLY (for 4WD): REMOVAL
HINT *
Use the same procedures for the RH side and LH side.
* The procedures listed below are for the LH side.
1. REMOVE FRONT WHEEL
2. REMOVE NO. 1 ENGINE UNDER COVER See: Engine, Cooling and Exhaust/Engine/Drive
Belts, Mounts, Brackets and Accessories/Drive
Belt/Service and Repair/Removal
3. DRAIN DIFFERENTIAL OIL See: Differential Assembly/Fluid - Differential/Service and Repair
Page 1160
Crankshaft Position Sensor: Diagrams
Page 3706
NOTE
Only Toyota Certified Technicians and above may access calibration files.
2. Connect the GR8 Battery Diagnostic Station.
A. Connect the GR8 Battery Diagnostic Station to the vehicle and turn it ON.
B. Select Power Supply Mode by following the screen flow below.
NOTICE
^ ECU damage may occur if the correct battery charger and mode setting are NOT used.
A760F Automatic Transmission System
Transfer Case Actuator: Locations A760F Automatic Transmission System
A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS
LOCATION
Page 7579
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Page 2817
Engine Control Module: Pinout Values and Diagnostic Parameters
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: TERMINALS OF ECM
1. CHECK ECM
(a) Measure the voltage according to the value(s) in the table below.
HINT The standard voltage between each pair of ECM terminals is shown in the table below. The
appropriate conditions for checking each pair of terminals are also indicated. The result of checks
should be compared with the standard voltage for that pair of terminals, displayed in the Specified
Condition column. The illustration above can be used as a reference to identify the ECM terminal
locations.
Page 6250
Page 6053
when inserting and after full engagement.
NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal.
(d) REPAIR METHOD OF CONNECTOR TERMINAL
(1) If there is any foreign matter on the terminal, clean the contact point using an air gun or cloth.
Never rub the contact point using sandpaper
as the plating may come off.
(2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is
gold-plated (gold color), use a gold-plated female
terminal; if it is silver-plated (silver color), use a silver-plated female terminal.
(3) Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock
into the housing, the housing may have to be
replaced.
(e) HANDLING OF WIRE HARNESS
(1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be
restored in the same way.
(2) Never twist, pull or slacken the wire harness more than necessary.
(3) The wire harness should never come into contact with a high temperature part, or rotating,
moving, vibrating or sharp-edged parts. Avoid
contact with panel edges, screw tips and other sharp items.
(4) When installing parts, never pinch the wire harness.
(5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with
vinyl tape.
2. CHECK FOR OPEN CIRCUIT
Page 9301
Body Emblem: Service and Repair Name Plate Application Procedure
NAME PLATE APPLICATION PROCEDURE
Page 2502
Oil Pressure Sender: Service and Repair Removal
1UR-FE LUBRICATION: OIL PRESSURE SWITCH: REMOVAL
1. REMOVE NO. 1 ENGINE UNDER COVER See: Engine Lubrication/Engine Oil/Service and
Repair/Replacement
2. REMOVE OIL PRESSURE SENDER GAUGE ASSEMBLY
(a) Disconnect the sender gauge connector.
(b) Remove the oil pressure sender gauge.
Page 4182
Page 7970
CAUTION: Make sure that the wire harnesses are tight. Looseness in the wire harnesses results in
the tires coming free due to the shock when the airbag is deployed.
(f) Install SST.
(1) Connect SST connector.
SST : 09082-00700
NOTICE: To avoid damaging SST connector and wire harness, do not lock the secondary lock of
the twin lock. Also, secure some slack for SST wire harness inside the tire.
(g) Deploy the airbag.
(1) Connect the red clip of SST to the battery positive (+) terminal and the black clip of SST to the
battery negative (-) terminal.
(2) Check that no one is within a 10 m (32.8 ft.) radius of the tire which the front seat side airbag is
tied to.
(3) Press SST activation switch and deploy the airbag.
CAUTION: When deploying the airbag, make sure that no one is near the tire.
HINT The airbag is deployed as the LED of SST activation switch comes on.
(h) Dispose of the front seat side airbag.
CAUTION:
Page 3263
^ Calibration ID(s) [Refer to the Calibration Identification Chart for the NEW CALIBRATION ID]
^ Dealer Code
^ Repair Date
^ Change Authority [This TSB number]
B. Affix the Authorized Modifications Label to the vehicle at the location shown in Figure 1. The
Authorized Modifications Label is available
through the MDC P/N 00451-00001-LBL.
Components
Solar Sensor: Service and Repair Components
AIR CONDITIONING: SOLAR SENSOR (for Automatic Air Conditioning System): COMPONENTS
Page 349
2. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in
Figure 1. Confirm if the ECM (PCM) calibration has
been updated. If the calibration ID listed is NOT the latest ECM (PCM) calibration - go to step 3.
3. Flash reprogram the ECM (PCM).
NOTE
^ The GR8 Battery Diagnostic Station MUST be used in Power Supply Mode to maintain battery
voltage at 13.5 volts while flash reprogramming the vehicle.
^ For details on how to use the GR8 Battery Diagnostic Station, refer to the located on the
Technical Information System (TIS), Diagnostics - Battery
Follow the procedures outlined in TSB No. T-SB-0064-10, "Techstream ECU Flash
Reprogramming Procedure1⁄4 and flash the ECM (PCM) with the NEW calibration file update.
4. Install the Authorized Modifications Label.
A. Using a permanent marker enter the following information on the label:
^ ECM part number [Refer to the Parts Information section for the CURRENT PART NUMBER]
^ Calibration ID(s) [Refer to the Calibration Identification Chart for the NEW CALIBRATION ID]
^ Dealer Code
^ Repair Date
^ Change Authority [This TSB number]
B. Affix the Authorized Modifications Label to the vehicle at the location shown in Figure 1. The
Authorized Modifications Label is available
through the MDC P/N 00451-00001-LBL.
5. Test drive the vehicle to confirm proper vehicle operation.
Page 3428
INSPECTION PROCEDURE
HINT Operating the ignition switch, any switches or any doors triggers related ECU and sensor
communication with the CAN, which causes resistance variation.
PROCEDURE
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
(a) Disconnect the cable from the negative (-) battery terminal before measuring the resistances of
the main wire and the branch wire.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
NEXT -- Continue to next step.
2. CHECK FOR SHORT IN CAN BUS WIRES (DLC3 BRANCH WIRE)
(a) Disconnect the J86 No. 1 junction connector connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO DLC3 (CANH, CANL) OK -Continue to next step.
3. CONNECT CONNECTOR
Engine - MIL ON/DTC's P0012/P0022 Set
Variable Valve Timing Actuator: All Technical Service Bulletins Engine - MIL ON/DTC's
P0012/P0022 Set
T-SB-0019-10
January 20, 2010
MIL "ON" DTC P0012 and/or P0022
Service Category Engine/Hybrid System
Section Engine Control
Market USA
Applicability
Introduction
Some 2010 model year Sequoia and Tundra vehicles may exhibit a MIL "ON" condition for
Diagnostic Trouble Code (DTC) P0012 and/or P0022 ( Camshaft Position "A" - Timing
Over-Retarded Bank 1/2).
Please refer to the following repair procedure to address this condition.
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60
months or 60,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Production Change Information
Locations
Seat Position Sensor: Locations
SUPPLEMENTAL RESTRAINT SYSTEM: AIRBAG SYSTEM: PARTS LOCATION
Recall 11V185000 - TPMS Non-Compliance
Tire Pressure Module: Recalls Recall 11V185000 - TPMS Non-Compliance
VEHICLE MAKE/MODEL: MODEL YEAR(S) Toyota/FJ Cruiser 2011
Toyota/Tundra 2009-2011
MANUFACTURER: Gulf States Toyota, Inc.
MFR'S REPORT DATE: March 16, 2011
NHTSA CAMPAIGN ID NUMBER: 11V185000
NHTSA ACTION NUMBER: N/A
COMPONENT: Tires: Pressure Monitoring and Regulating Systems
POTENTIAL NUMBER OF UNITS AFFECTED: 1,489
SUMMARY: Gulf States Toyota is recalling certain model year 2011 FJ Cruiser and model year
2009-2011 Tundra vehicles for failing to comply with the requirements of Federal Motor Vehicle
Safety Standard No. 138, "Tire Pressure Monitoring Systems." The TPMS on some vehicles may
not have been properly calibrated and as a result the low tire pressure warning lamp may not
illuminate should the inflation pressure in one or more of the vehicle's tires fall below the threshold
for when the low tire pressure warning lamp should illuminate.
CONSEQUENCE: Drivers will not receive a warning from the tire pressuring monitor that one or
more tires are underinflated increasing the risk that a vehicle will be driven with one or more
underinflated tires and increasing the risk of a tire failure that may lead to a crash.
REMEDY: Dealers will recalibrate the tire pressure monitoring system in accordance with the
regulation free of charge. The safety recall is expected to begin during April 2011. Owners may
contact Gulf State Toyota Customer Assistance Center toll free at 1-800-444-1074 Monday through
Thursday, 8:30 AM to 5:00 PM, or Friday 8:30 AM to 4:00 PM Central Standard Time.
NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle
Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov.
Locations
Transmission Mode Switch: Locations
A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS
LOCATION
Page 7973
Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to
prevent airbag and seat belt pretensioner activation.
2. REMOVE ROOF HEADLINING ASSEMBLY
HINT Refer to the procedures up to "REMOVE ROOF HEADLINING ASSEMBLY" (for CrewMax)
See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (for
CrewMax)/Removal
3. REMOVE CURTAIN SHIELD AIRBAG ASSEMBLY
(a) Disconnect the connector.
NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness.
(b) Remove the 10 bolts and curtain shield airbag.
Installation
SUPPLEMENTAL RESTRAINT SYSTEM: CURTAIN SHIELD AIRBAG ASSEMBLY (for CrewMax):
INSTALLATION
1. INSTALL CURTAIN SHIELD AIRBAG ASSEMBLY
(a) Install the curtain shield airbag with the 10 bolts.
Torque : 11 Nm (110 kgf-cm, 8 ft-lbf)
NOTICE: Do not twist the curtain shield airbag when installing it.
(b) Connect the connector.
NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness.
Page 213
Page 773
Acceleration/Deceleration Sensor: Service and Repair Installation
BRAKE CONTROL: YAW RATE AND DECELERATION SENSOR: INSTALLATION
1. INSTALL YAW RATE SENSOR
(a) Connect the sensor connector (labeled A), and then attach the clamp (labeled B) to the hole of
the sensor bracket.
(b) Install the yaw rate sensor with the 2 nuts (labeled C).
Torque : 13 Nm (127 kgf-cm, 9 ft-lbf)
NOTICE: *
Make sure that the sensor is oriented correctly.
* If the sensor is dropped, replace it.
* Securely connect the connector.
* When installing the sensor, make sure to avoid impacts to the sensor.
2. INSTALL CENTER FRONT SEAT (for Center Seat) See: Body and Frame/Seats/Service and
Repair/Removal and Replacement/Front Seat
Assembly (for Center Seat)/Installation
3. INSTALL CONSOLE BOX ASSEMBLY (for Separate Seat Type)
(a) Install the console box See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and
Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation.
4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
5. PERFORM YAW RATE SENSOR ZERO POINT CALIBRATION
(a) Perform the yaw rate sensor zero point calibration See: Brakes and Traction Control/Antilock
Brakes / Traction Control Systems/Testing and
Inspection/Programming and Relearning.
6. CHECK YAW RATE SENSOR SIGNAL
(a) Check the yaw rate sensor signal See: Brakes and Traction Control/Antilock Brakes / Traction
Control Systems/Testing and Inspection/Scan
Tool Testing and Procedures/Test Mode Procedure.
Page 7007
J/B No.3 Inner Circuit
J/B No.4 Inner Circuit
J/B No.5 Inner Circuit
Page 6726
NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do
not operate the ignition switch, any other switches, or the doors.
(a) If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the
harness and connector.
(b) Connect the cable of the Techstream to the DLC3, turn the ignition switch ON and attempt to
use the tester. If the display indicates that a
communication error has occurred, there is a problem either with the vehicle or with the tester.
HINT *
If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of
the original vehicle.
* If communication is still not possible when the tester is connected to another vehicle, the problem
may be in the tester itself. Consult the Service Department listed in the tester's instruction manual.
How To Proceed With Troubleshooting
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: HOW TO
PROCEED WITH TROUBLESHOOTING
1. OPERATION FLOW
HINT Perform troubleshooting in accordance with the procedures below. The following is an outline
of basic troubleshooting procedures. Confirm the troubleshooting procedures for the circuit you are
working on before beginning troubleshooting.
1. VEHICLE BROUGHT TO WORKSHOP
NEXT -- Continue to next step.
2. CUSTOMER PROBLEM ANALYSIS
(a) Ask the customer about the conditions and environment when the problem occurred.
NEXT -- Continue to next step.
3. INSPECT BATTERY VOLTAGE
Standard voltage:
11 to 14 V
If the voltage is below 11 V, recharge or replace the battery before proceeding.
NEXT -- Continue to next step.
Page 9392
3. Loosen and remove the No.3 cab mount nut on the bottom of each cab mount.
4. Loosen and remove the two bolts on top of each of the cab mounts and save them for reuse.
Page 5879
Steering Angle Sensor: Locations From 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 8345
(e) Connect the holder (with connectors).
(f) Check that the waterproof sheet is properly set.
2. INSTALL FRONT CONSOLE BOX See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal
and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation
3. INSTALL REAR CONSOLE BOX ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation
4. INSTALL CONSOLE BOX CARPET
5. INSTALL REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
6. INSTALL UPPER CONSOLE REAR PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
7. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding
/ Trim/Dashboard / Instrument Panel/Service
and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
8. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation
9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
10. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Air Bag Systems/Testing and Inspection/Initial Inspection
and Diagnostic Overview/Diagnosis System.
Up to 11/2009
Traction Control Switch: Locations Up to 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 1303
Page 2761
^ Engine Control Module (ECM)
^ Transmission Control Module (TCM)
^ Or any other Toyota specific control unit
Warranty Information
Parts Information
Required Tools & Equipment
NOTE
Additional SSTs may be ordered by calling 1-800-933-8335.
Process Overview
Techstream ECU flash reprogramming is a 4-step process:
1. Verify the vehicle's applicability for recalibration and locate desired calibration file by performing
the Techstream Health Check function.
NOTE
Techstream will automatically search TIS for the appropriate service bulletin using the current
Calibration ID from the vehicle. Calibration file links can be found embedded in the corresponding
service bulletin.
2. Connect the GR8 Battery Diagnostic Station using "Power Supply Mode" only.
The GR8 Battery Diagnostic Station includes a Power Supply Mode to help maintain battery
voltage at 13.5 volts during ECU reprogramming.
ECU damage may occur if the correct battery charger mode setting is NOT used.
3. Locate appropriate calibration ID and reprogram the vehicle ECU with Techstream.
Techstream uses the Calibration Update Wizard (CUW) application to open calibration files and
facilitate the ECU flash reprogramming process.
Page 6379
Front Door Wire
Page 8796
2. REMOVE BACK PANEL GARNISH RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for
CrewMax)/Removal
3. REMOVE BACK PANEL GARNISH LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for
CrewMax)/Removal
4. REMOVE NO. 1 BOX SPEAKER ASSEMBLY
(a) Disconnect the connector.
(b) Remove the 3 bolts and box speaker.
Installation
AUDIO / VISUAL: FLOOR SPEAKER (for CrewMax): INSTALLATION
1. INSTALL NO. 1 BOX SPEAKER ASSEMBLY
(a) Install the box speaker with the 3 bolts.
(b) Connect the connector.
2. INSTALL BACK PANEL GARNISH LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for
CrewMax)/Installation
3. INSTALL BACK PANEL GARNISH RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for
CrewMax)/Installation
4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Page 4752
NOTE
Only Toyota Certified Technicians and above may access calibration files.
2. Connect the GR8 Battery Diagnostic Station.
A. Connect the GR8 Battery Diagnostic Station to the vehicle and turn it ON.
B. Select Power Supply Mode by following the screen flow below.
NOTICE
^ ECU damage may occur if the correct battery charger and mode setting are NOT used.
Page 6403
Page 7285
Steering Gear: Overhaul
Disassembly
POWER STEERING: STEERING GEAR: DISASSEMBLY
1. FIX POWER STEERING GEAR ASSEMBLY
(a) Using SST, secure the power steering gear.
SST : 09612-00012
HINT Tape SST before use.
NOTICE: When using a vise, do not overtighten it.
2. REMOVE TIE ROD END SUB-ASSEMBLY LH
(a) Put matchmarks on the tie rod end LH and steering rack end.
3. REMOVE TIE ROD END SUB-ASSEMBLY RH
HINT Use the same procedures described for the LH side.
4. REMOVE STEERING RACK BOOT CLIP
(a) Using pliers, remove the 2 steering rack boot clips.
5. REMOVE NO. 2 STEERING RACK BOOT CLAMP
(a) Using pliers, remove the 2 boot clamps as shown in the illustration.
Page 358
NOTE
Only Toyota Certified Technicians and above may access calibration files.
2. Connect the GR8 Battery Diagnostic Station.
A. Connect the GR8 Battery Diagnostic Station to the vehicle and turn it ON.
B. Select Power Supply Mode by following the screen flow below.
NOTICE
^ ECU damage may occur if the correct battery charger and mode setting are NOT used.
Page 4599
(2) Disconnect connector B and measure the resistance.
Standard resistance (Fig. 7):
* If the results match the examples above, a short circuit exists between terminal 1 of connector B2
and terminal 1 of connector C.
4. CHECK AND REPLACE ECU
NOTICE: *
The connector should not be disconnected from the ECU. Perform the inspection from the backside
of the connector on the wire harness side.
* When no measuring condition is specified, perform the inspection with the engine stopped and
the ignition switch ON.
* Check that the connectors are fully seated. Check for loose, corroded or broken wires.
(a) First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be
faulty. Temporarily replace the ECU with a
normally functioning one and check if the symptoms occur. If the trouble symptoms disappear,
replace the original ECU.
(1) Measure the resistance between the ECU ground terminal and body ground.
Standard resistance:
Below 1 Ohms
(2) Disconnect the ECU connector. Check the ground terminal on the ECU side and wire harness
side for bending, corrosion or foreign matter.
Lastly, check the contact pressure of the female terminals.
Locations
Accessory Relay: Locations
Instrument Panel (Floor Shift)
Instrument Panel (Column Shift)
Page 1487
(a) For an open circuit in the wire harness in Fig. 1, check the resistance or voltage, as described
below.
(b) Check the resistance.
(1) Disconnect connectors A and C and measure the resistance between them.
Standard resistance (Fig. 2):
HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally.
If the results match the examples above, an open circuit exists between terminal 1 of connector A
and terminal 1 of connector C.
(2) Disconnect connector B and measure the resistance between the connectors.
Standard resistance (Fig. 3):
* If the results match the examples above, an open circuit exists between terminal 1 of connector
B2 and terminal 1 of connector C.
(c) Check the voltage.
Page 1191
Manifold Pressure/Vacuum Sensor: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: MANIFOLD ABSOLUTE PRESSURE SENSOR:
INSTALLATION
1. INSTALL MANIFOLD ABSOLUTE PRESSURE SENSOR
(a) Install a new O-ring to the manifold absolute pressure sensor.
(b) Install the manifold absolute pressure sensor with the screw.
Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)
(c) Connect the manifold absolute pressure sensor connector.
2. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Installation
Page 8063
Impact Sensor: Testing and Inspection Center Airbag Sensor Assembly (for Floor Shift Type)
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift
Type): ON-VEHICLE INSPECTION
1. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION)
(a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnosis System.
2. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND
AIRBAG HAS NOT DEPLOYED)
(a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnosis System.
3. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND
AIRBAG IS DEPLOYED)
(a) Replace the center airbag sensor.
CAUTION: For removal and installation procedures of the center airbag sensor, be sure to follow
the correct procedure.
HINT The center airbag sensor should be replaced after any of the airbags has deployed, as it has
been subjected to the impact.
Components
Variable Valve Timing Actuator: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT OIL CONTROL VALVE: COMPONENTS
Page 2055
Locations
Central Control Module: Locations
NAVIGATION: NAVIGATION SYSTEM (w/ USB Audio System): PARTS LOCATION
m
Page 8170
(a) Disconnect the holder (with connectors).
(b) Remove the 3 bolts and airbag sensor.
Installation
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Column
Shift Type): INSTALLATION
1. INSTALL CENTER AIRBAG SENSOR ASSEMBLY
(a) Check that the ignition switch is OFF.
(b) Check that the cable is disconnected from the battery negative (-) terminal.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
(c) Install the airbag sensor with the 3 bolts.
Torque : 18 Nm (184 kgf-cm, 13 ft-lbf)
NOTICE: *
If the center airbag sensor has been dropped, or there are any cracks, dents or other defects in the
case, bracket or connector, replace it with a new one.
* When installing the center airbag sensor, be careful that the SRS wiring does not interfere with
other parts and that it is not pinched between other parts.
(d) Check that there is no looseness in the installation parts of the center airbag sensor.
(e) Connect the holder (with connectors).
(f) Check that the waterproof sheet is properly set.
2. INSTALL CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service
and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
NOTICE: Some systems need to be initialized after the cable is reconnected See: Testing and
Inspection/Programming and Relearning
4. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Air Bag Systems/Testing and Inspection/Initial Inspection
and Diagnostic Overview/Diagnosis System.
Components
Tire Pressure Warning Reset Switch: Service and Repair Components
TIRE AND WHEEL: TIRE PRESSURE WARNING RESET SWITCH: COMPONENTS
Page 1314
"Case1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (/\ Mark) and pull the terminal retainer
up to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Page 5931
Page 5408
Four Wheel Drive Selector Switch: Diagrams
Page 3404
(b) Wait 1 minute and then check the display of the connected ECUs and sensors.
NOTICE: ECUs and sensors that are not present will not be displayed. Be careful not to mistake
them for communication stop malfunctions.
HINT *
If the display of an ECU is intermittent during the check, one side of an ECU or sensor branch wire
is open. (The signal of the ECU is treated as noise, which affects the response and display of the
Techstream.)
* The main body ECU checks for proper ECU communication for ECUs that are connected to the
CAN MS bus circuit, and the results are displayed on the Techstream. If communication stops
between an ECU and the main body ECU for 10 seconds or more, the ECU disappears from the
Techstream display.
* For communication stop mode of ECUs connected to the CAN MS bus circuit, refer to the DTC
flowchart of the respective communication stop. B -- GO TO DTC U1002 FLOWCHART See:
Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/U Code
Charts/U1002
C -- GO TO MAIN BODY ECU COMMUNICATION STOP MODE FLOWCHART See: Component
Tests and General Diagnostics/Main Body ECU Communication Stop Mode
D -- GO TO PROBLEM SYMPTOMS TABLE See: Symptom Related Diagnostic Procedures/CAN
Communication System/Problem Symptoms Table
E -- GO TO OPEN IN ONE SIDE OF CAN BRANCH WIRE FLOWCHART
See: Symptom Related Diagnostic Procedures/CAN Communication System
A -- Continue to next step.
9. CHECK COMMUNICATION MALFUNCTION DTC (PAST DTC CHECK)*
(a) Select "CAN Bus Check" from the "System Select".
(b) Write down all of the DTCs stored in each ECU.
HINT *
If there are communication malfunction DTCs stored but the Techstream's "CAN Bus Check Communication Bus Check" screen displays all of the ECUs and sensors connected to the CAN
system, the communication malfunction DTCs may be past malfunctions that are no longer
present.
* For V bus main wire malfunctions, related ECUs are also detected. Therefore, determine the
malfunctioning area based on all of the DTCs that are output.
* For MS bus malfunctions, DTCs are output based on the detection of communication stop
malfunctions and network malfunctions of ECUs that are connected by the main body ECU.
B -- GO TO DTC U1002 FLOWCHART See: Testing and Inspection/Diagnostic Trouble Code
Tests and Associated Procedures/U Code Charts/U1002
Page 3454
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE AIR CONDITIONING AMPLIFIER BRANCH WIRE OR
CONNECTOR (CANH, CANL) OK -- Continue to next step.
3. CHECK HARNESS AND CONNECTOR (AIR CONDITIONING AMPLIFIER - BATTERY AND
BODY GROUND)
(a) Reconnect the cable to the negative (-) battery terminal before measuring the resistances of the
main wire and the branch wire.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(c) Measure the voltage according to the value(s) in the table below.
Standard voltage:
NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- REPLACE AIR CONDITIONING AMPLIFIER ASSEMBLY
Bus Buffer ECU Communication Stop Mode
Page 6539
NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do
not operate the ignition switch, any other switches, or the doors.
(a) If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the
harness and connector.
(b) Connect the cable of the Techstream to the DLC3, turn the ignition switch ON and attempt to
use the tester. If the display indicates that a
communication error has occurred, there is a problem either with the vehicle or with the tester.
HINT *
If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of
the original vehicle.
* If communication is still not possible when the tester is connected to another vehicle, the problem
may be in the tester itself. Consult the Service Department listed in the tester's instruction manual.
How To Proceed With Troubleshooting
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: HOW TO
PROCEED WITH TROUBLESHOOTING
1. OPERATION FLOW
HINT Perform troubleshooting in accordance with the procedures below. The following is an outline
of basic troubleshooting procedures. Confirm the troubleshooting procedures for the circuit you are
working on before beginning troubleshooting.
1. VEHICLE BROUGHT TO WORKSHOP
NEXT -- Continue to next step.
2. CUSTOMER PROBLEM ANALYSIS
(a) Ask the customer about the conditions and environment when the problem occurred.
NEXT -- Continue to next step.
3. INSPECT BATTERY VOLTAGE
Standard voltage:
11 to 14 V
If the voltage is below 11 V, recharge or replace the battery before proceeding.
NEXT -- Continue to next step.
Page 600
Page 6433
Accessory Relay: Diagrams
Page 7365
(b) Using a drill, make a hole in the cylinder between A and B shown in the illustration to discharge
the gas inside.
CAUTION: *
Be careful when drilling because shards of metal may fly about. Always use the proper safety
equipment.
* For off road type shock absorbers, be extremely careful when drilling it as its gas pressure is
much higher than the standard type.
NOTICE: The gas is colorless, odorless and nonpoisonous.
Components
SUSPENSION: REAR SHOCK ABSORBER: COMPONENTS
Component Tests and General Diagnostics
Engine Control Module: Component Tests and General Diagnostics
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: ECM Power Source Circuit - ECM Power
Source Circuit
DESCRIPTION
When the ignition switch is turned to ON, the battery voltage is applied to the IGSW terminal of the
ECM. The output signal from the MREL terminal of the ECM causes a current to flow to the coil,
closing the contacts of the integration relay (EFI relay) and supplying power to terminals +B and
+B2 of the ECM.
WIRING DIAGRAM
INSPECTION PROCEDURE
PROCEDURE
1. INSPECT FUSES (AM2, IG2 MAIN, EFI NO. 1, IGN)
Engine Control System - SFI System
Camshaft Position Sensor: Locations Engine Control System - SFI System
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Locations
Lock Cylinder Switch: Locations
THEFT DETERRENT: THEFT DETERRENT SYSTEM: PARTS LOCATION
Page 5069
15. INSTALL FRONT DIFFERENTIAL CASE
16. INSTALL FRONT DIFFERENTIAL CROSS SHAFT BEARING RETAINER
(a) Install the differential cross shaft bearing retainer and differential support with the 14 bolts.
for bolt A - Torque : 65 Nm (633 kgf-cm, 48 ft-lbf)
for bolt B - Torque : 155 Nm (1581 kgf-cm, 114 ft-lbf)
17. INSTALL FRONT DRIVE PINION FRONT RADIAL BALL BEARING
(a) Using SST and a hammer, lightly tap in the bearing (inner race) to install it.
SST : 09316-60011
09316-00041
18. INSTALL FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER
19. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD
(a) Using SST, install the companion flange.
SST : 09950-30012
09951-03010
09953-03010
Locations
Shift Solenoid: Locations
A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS
LOCATION
Locations
Shock Sensor: Locations
THEFT DETERRENT: THEFT DETERRENT SYSTEM: PARTS LOCATION
Components
Engine Temperature Sensor: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: ENGINE COOLANT TEMPERATURE SENSOR:
COMPONENTS
Page 1939
Engine Oil: Service and Repair Replacement
1UR-FE LUBRICATION: OIL AND OIL FILTER: REPLACEMENT
CAUTION: *
Prolonged and repeated contact with engine oil will result in the removal of natural oils from the
skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially
harmful contaminants which may cause skin cancer.
* Precautions should be taken when replacing engine oil to minimize the risk of your skin making
contact with used engine oil. Protective clothing and gloves that cannot be penetrated by oil should
be worn. The skin should be washed with soap and water, or use waterless hand cleaner, to
remove any used engine oil thoroughly. Do not use gasoline, thinners, or solvents.
* In order to protect the environment, used oil and used oil filters must be disposed of at designated
disposal sites.
1. DRAIN ENGINE OIL
(a) Remove the oil filler cap.
(b) Remove the oil pan drain plug and gasket, and drain the engine oil into a container.
(c) Install a new gasket and the oil pan drain plug.
Torque : 40 Nm (408 kgf-cm, 30 ft-lbf)
2. REMOVE NO. 1 ENGINE UNDER COVER
(a) Remove the 3 screws and 5 bolts.
(b) Unhook the engine under cover from the vehicle body as shown in the illustration.
3. REMOVE OIL FILTER ELEMENT
(a) Connect a hose with an inside diameter of 15 mm (0.591 in.) to the pipe.
Components
Control Module: Service and Repair Components
JF1A TRANSFER: 4WD CONTROL ECU: COMPONENTS
Body/Frame - Choppy Ride Under Various Conditions
Body / Frame Mount Bushing: All Technical Service Bulletins Body/Frame - Choppy Ride Under
Various Conditions
T-SB-0270-10
September 13, 2010
Choppy Ride
Service Category Vehicle Exterior
Section Frame/Unibody
Market USA
Applicability
Introduction
Some 2007 - 2010 Tundra vehicles may exhibit a body vibration when driving under certain road
conditions. A newly designed cab mount has been developed to improve this condition.
NOTE
The Tundra performs similarly to other long wheelbase trucks on choppy, broken concrete
surfaces. The enhanced cab mounts of this TSB reduce the amplitude of body vibrations caused by
uneven road surfaces, but they do NOT eliminate the sensation entirely. Customers should be
counseled that they will experience an improvement in the condition and their truck will perform
better than competitors in identical conditions, but some body
Page 3383
NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do
not operate the ignition switch, any other switches, or the doors.
(a) If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the
harness and connector.
(b) Connect the cable of the Techstream to the DLC3, turn the ignition switch ON and attempt to
use the tester. If the display indicates that a
communication error has occurred, there is a problem either with the vehicle or with the tester.
HINT *
If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of
the original vehicle.
* If communication is still not possible when the tester is connected to another vehicle, the problem
may be in the tester itself. Consult the Service Department listed in the tester's instruction manual.
How To Proceed With Troubleshooting
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: HOW TO
PROCEED WITH TROUBLESHOOTING
1. OPERATION FLOW
HINT Perform troubleshooting in accordance with the procedures below. The following is an outline
of basic troubleshooting procedures. Confirm the troubleshooting procedures for the circuit you are
working on before beginning troubleshooting.
1. VEHICLE BROUGHT TO WORKSHOP
NEXT -- Continue to next step.
2. CUSTOMER PROBLEM ANALYSIS
(a) Ask the customer about the conditions and environment when the problem occurred.
NEXT -- Continue to next step.
3. INSPECT BATTERY VOLTAGE
Standard voltage:
11 to 14 V
If the voltage is below 11 V, recharge or replace the battery before proceeding.
NEXT -- Continue to next step.
Engine Controls - A/F And O2 Sensor Identification
Oxygen Sensor: Technical Service Bulletins Engine Controls - A/F And O2 Sensor Identification
T-SB-0398-09
December 23, 2009
Engine Bank 1 and Bank 2 A/F and 02 Identification
Service Category Engine/Hybrid System
Section Engine Control
Market USA
Applicability
TSB SUPERSESSION NOTICE
The information contained in this TSB supersedes TSB No. EG034-07.
^ Applicability has been updated to include 2009 - 2010 model year vehicles and 2006 - 2010
model year Highlander HV.
TSB No. EG034-07 is Obsolete and any printed versions should be discarded. Be sure to review
the entire content of this service bulletin before proceeding.
Introduction
This service bulletin provides information on the proper identification of engine bank 1 and engine
bank 2 for correct A/F sensor and oxygen sensor replacement.
This bulletin contains information that identifies engine bank 1 and engine bank 2 on the following
engines: 1AZ-FE, 2AZ-FE, 2AZ-FE (PZEV), 1GR-FE, 2GR-FE, 2JZ-GE, 1MZ-FE, 3MZ-FE,
1UR-FE, 3UR-FE, 2UZ-FE 5VZ-FE and 1ZZ-FE.
^ Bank 1 (B1) refers to the bank that includes cylinder No. 1.
^ Bank 2 (B2) refers to the bank opposite bank 1.
^ Sensor 1 (S1) refers to the sensor that is located before the catalytic converters.
^ Sensor 2 (S2) refers to the sensor that is located after the catalytic converters.
Warranty Information
Center Airbag Sensor Assembly (for Column Shift Type)
Air Bag Control Module: Service and Repair Center Airbag Sensor Assembly (for Column Shift
Type)
Components
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Column
Shift Type): COMPONENTS
Page 9125
4. SYMPTOM CONFIRMATION AND DTC (INCLUDING FREEZE FRAME DATA) CHECK
(a) Visually check the wire harnesses, connectors and fuses for open and short circuits.
(b) Warm up the engine to the normal operating temperature.
(c) Confirm the problem symptoms and conditions, and check for DTCs.
B -- Go to step 6 A -- Continue to next step.
5. DTC CHART
(a) Check the results obtained in the DTC check. Then find the output DTC in the DTC chart. Look
at the "Trouble Area" column for a list of
potentially malfunctioning circuits and / or parts.
NEXT -- Go to step 7
6. PROBLEM SYMPTOMS TABLE
(a) Check the results obtained in the symptom confirmation. Then find the problem symptoms in
the problem symptoms table. Look at the
"Suspected Area" column for a list of potentially malfunctioning circuits and / or parts.
NEXT -- Continue to next step.
7. CIRCUIT INSPECTION OR PARTS INSPECTION
(a) Confirm the malfunctioning circuit or part.
NEXT -- Continue to next step.
8. ADJUST, REPAIR OR REPLACE
(a) Adjust, repair or replace the malfunctioning circuit or parts.
NEXT -- Continue to next step.
9. CONFIRMATION TEST
(a) After the adjustment, repairs or replacement, confirm that the malfunction no longer exists. If the
malfunction does not reoccur, perform a
confirmation test under the same conditions and in the same environment as when the malfunction
occurred the first time.
NEXT -- END
2. CUSTOMER PROBLEM ANALYSIS
HINT *
In troubleshooting, confirm that the problem symptoms have been accurately identified.
Preconceptions should be discarded in order to make an accurate judgment. To clearly understand
what the problem symptoms are, it is extremely important to ask the customer about the problem
and the conditions at the time the malfunction occurred.
* Gather as much information as possible for reference. Past problems that seem unrelated may
also help in some cases.
* The following 5 questions are important points in the problem analysis:
Page 5038
Maximum runout:
0.04 mm (0.00158 in.)
(c) Remove the differential case from the differential carrier.
22. REMOVE REAR DIFFERENTIAL CASE BEARING
(a) Using SST, remove the 2 bearings.
SST : 09950-40011
09951-04010
09952-04010
09953-04020
09954-04010
09955-04061
09957-04010
09958-04011
SST : 09950-60010
09951-00480
HINT Fix the claws of SST to the notches in the differential case.
23. DISASSEMBLE DIFFERENTIAL CASE
(a) Using a pin punch and hammer, tap out the straight pin.
(b) Remove the pinion shaft, 2 pinion gears, 2 pinion gear thrust washers, 2 side gears and 2 side
gear thrust washers.
24. REMOVE REAR DIFFERENTIAL DYNAMIC DAMPER (for Regular Cab Standard Deck)
(a) Remove the bolt, washer and dynamic damper.
Page 5490
Transfer Case Actuator: Diagrams
Page 3939
6. In some instances where water has entered the system DTCs P2440/P2441/P2442/P2443 may
set.
Refer to TIS 2010 model year Tundra Repair Manual to diagnose and inspect the emission control
valves if necessary:
7. If there is NO liquid found in the air pump assemblies or the DTC is still present after
replacement inspect the air injection system.
Refer to TIS 2010 model year Tundra Repair Manual:
8. Clear the DTC and road test the vehicle to confirm the condition has been corrected.
Page 6005
least once a month to lubricate the compressor.
1. Turn off A/C and blower switches prior to starting engine.
2. Start and warm up the engine until engine idle drops below 1,000 rpm.
3. Turn on the A/C system (including the rear A/C) using the following settings:
A. A/C Switch: On
B. Blower Speed: High
C. Engine Speed: Below 1,000 RPM
4. Keep A/C on with engine idling for at least one minute (in dual A/C vehicles leave on for two
minutes).
5. Turn off A/C system and stop engine.
Disk Brake Rotor Surface Rust Removal
The brake rotors are made of cast iron so they may show gradual build-up of surface rust during
long term storage. At least once every two months drive the vehicle and use the brakes normally
stopping from about 30 mph at least 20 times. This regular usage will help prevent severe rust build
up and the possibility of unwanted brake vibration concerns due to rust.
NOTE
^ If the brake vibration still occurs after the braking cycle, determine the root cause of the brake
vibration and repair.
^ Brake rotor resurfacing may be required if the rust was severe and resulted in excessive rotor
thickness variation.
Page 3077
Push the terminal retainer down to the temporary lock position.
Page 1143
Air Flow Meter/Sensor: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: REMOVAL
1. REMOVE MASS AIR FLOW METER
(a) Disconnect the MAF connector.
(b) Remove the 2 screws and MAF meter.
Page 7706
(a) Connect the connector.
(b) Attach the 4 clips to install the panel.
6. INSTALL CENTER LOWER INSTRUMENT PANEL FINISH PANEL See: Body and
Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
7. INSTALL FRONT CONSOLE BOX
8. INSTALL REAR CONSOLE BOX ASSEMBLY
9. INSTALL CONSOLE BOX CARPET
10. INSTALL REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
11. INSTALL UPPER REAR CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
12. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument Panel/Service
and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
13. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation
14. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
15. INSTALL LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY
16. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Floor Shift Type)/Installation
17. INSTALL FRONT PILLAR GARNISH LH
18. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH (for Regular Cab)
19. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH (for Double Cab, CrewMax)
20. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation
Page 3217
Page 8533
(a) Connect the connector.
(b) Attach the 4 clips to install the panel.
3. INSTALL INSTRUMENT PANEL CUP HOLDER ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column
Shift Type)/Installation
4. INSTALL LOWER INSTRUMENT CLUSTER FINISH PANEL See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column
Shift Type)/Installation
5. INSTALL FRONT ASH RECEPTACLE BOX SUB-ASSEMBLY
6. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column
Shift Type)/Installation
7. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Installation
8. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
9. INSTALL CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service
and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
10. INSTALL COWL SIDE TRIM BOARD LH
(a) for Regular Cab:
Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular Cab)/Installation.
(b) for Double Cab:
Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Installation.
(c) for CrewMax:
Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for CrewMax)/Installation.
Page 7967
(1) Disconnect the connector (yellow colored) from the front seat side airbag.
NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness.
(2) Connect SST connector to the front seat side airbag connector.
SST : 09082-00700
SST : 09082-00820
NOTICE: To avoid damaging SST connector and wire harness, do not lock the secondary lock of
the twin lock.
(3) Install the front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Fold Down
Seat Type)/Installation.
(4) Move SST at least 10 m (32.8 ft.) away from the vehicle front side window.
(5) Maintaining enough clearance for SST wire harness in the front side window, close all doors
and windows of the vehicle.
NOTICE: Take care not to damage SST wire harness.
(6) Connect the red clip of SST to the battery positive (+) terminal and the black clip of SST to the
battery negative (-) terminal.
(f) Deploy the airbag.
(1) Check that no one is inside the vehicle or within a 10 m (32.8 ft.) radius of the vehicle.
(2) Press SST activation switch and deploy the airbag.
CAUTION: *
When deploying the airbag, make sure that no one is near the vehicle.
* The front seat side airbag becomes extremely hot when the airbag is deployed, so do not touch it
for at least 30 minutes after deployment.
* Use gloves and safety glasses when handling a front seat side airbag with a deployed airbag.
* Do not apply water to a front seat side airbag with a deployed airbag.
* Always wash your hands with water after completing the operation.
HINT The airbag is deployed as the LED of SST activation switch comes on.
2. DISPOSE OF FRONT SEAT SIDE AIRBAG ASSEMBLY (WHEN NOT INSTALLED IN
VEHICLE)
NOTICE: Be sure to follow the procedure detailed below when deploying the airbag.
HINT Prepare a battery as the power source to deploy the airbag.
Page 8081
(b) Check that the cable is disconnected from the battery negative (-) terminal.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
(c) Install the door airbag sensor with the screw.
Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)
NOTICE: *
If the door airbag sensor has been dropped, or there are any cracks, dents or other defects in the
case, bracket or connector, replace it with a new one.
* When installing the door airbag sensor, be careful that the SRS wiring does not interfere with
other parts and that it is not pinched between other parts.
(d) Check that there is no looseness in the installation parts of the door airbag sensor.
(e) Connect the connector.
2. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Reassembly
3. INSTALL COURTESY LIGHT ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood
and Trunk/Doors/Front Door/Service and
Repair/Front Door (for Double Cab)/Reassembly
4. INSTALL FRONT LOWER DOOR FRAME BRACKET GARNISH LH (for Front Side) See: Body
and Frame/Doors, Hood and
Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly
5. INSTALL FRONT UPPER ARMREST BASE PANEL LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Reassembly
6. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Reassembly
7. INSTALL REAR SIDE AIRBAG SENSOR
(a) Check that the ignition switch is OFF.
(b) Check that the cable is disconnected from the battery negative (-) terminal.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
(c) Install the side airbag sensor with the bolt.
Page 1843
^ Engine Control Module (ECM)
^ Transmission Control Module (TCM)
^ Or any other Toyota specific control unit
Warranty Information
Parts Information
Required Tools & Equipment
NOTE
Additional SSTs may be ordered by calling 1-800-933-8335.
Process Overview
Techstream ECU flash reprogramming is a 4-step process:
1. Verify the vehicle's applicability for recalibration and locate desired calibration file by performing
the Techstream Health Check function.
NOTE
Techstream will automatically search TIS for the appropriate service bulletin using the current
Calibration ID from the vehicle. Calibration file links can be found embedded in the corresponding
service bulletin.
2. Connect the GR8 Battery Diagnostic Station using "Power Supply Mode" only.
The GR8 Battery Diagnostic Station includes a Power Supply Mode to help maintain battery
voltage at 13.5 volts during ECU reprogramming.
ECU damage may occur if the correct battery charger mode setting is NOT used.
3. Locate appropriate calibration ID and reprogram the vehicle ECU with Techstream.
Techstream uses the Calibration Update Wizard (CUW) application to open calibration files and
facilitate the ECU flash reprogramming process.
Page 6642
(a) Attach the claw to install the power outlet socket.
(b) Connect the power outlet socket connector.
6. INSTALL CENTER FRONT SEAT ASSEMBLY
(a) Install the center front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Center
Seat)/Installation.
7. INSTALL FRONT SEAT ASSEMBLY LH (for Power Seat)
(a) Install the front seat LH See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Power
Seat)/Installation.
8. INSTALL FRONT SEAT ASSEMBLY RH (for Power Seat)
HINT Use the same procedures described for the LH side.
9. INSTALL FRONT SEAT ASSEMBLY LH (for Manual Seat)
(a) Install the front seat LH See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Manual
Seat)/Installation.
10. INSTALL FRONT SEAT ASSEMBLY RH (for Manual Seat)
HINT Use the same procedures described for the LH side.
Components
OTHER SYSTEM: CENTER POWER OUTLET SOCKET (for Floor Shift Type): COMPONENTS
Page 3291
C. Choose desired ECU group(s) in the Health Check dialog box.
D. Click Next.
E. Click Continue to view Health Check results.
F. Available calibration updates are indicated by a link in the Cal. Update? column. Click the link to
access the appropriate service bulletin on TIS.
NOTE
^ Note any DTCs stored in Systems that will be flash reprogrammed.
^ Clicking the link will automatically launch TIS and perform a calibration search.
G. Log in to TIS. (If already logged in skip this step.)
H. To review the TSB and access the calibration file click the service bulletin link in the Document
Title column of the Calibration Search Result
portlet.
Page 2925
Crankshaft Position Sensor: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: CRANKSHAFT POSITION SENSOR: INSTALLATION
1. INSTALL CRANKSHAFT POSITION SENSOR
(a) Install the sensor with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(b) Connect the sensor connector.
2. INSTALL CRANKSHAFT POSITION SENSOR PROTECTOR
(a) Install the sensor protector with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
Page 40
Entertainment System Control Module: Diagrams
Page 8354
Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)
NOTICE: *
If the side airbag sensor has been dropped, or there are any cracks, dents or other defects in the
case, bracket or connector, replace it with a new one.
* When installing the side airbag sensor, be careful that the SRS wiring does not interfere with
other parts and that it is not pinched between other parts.
(d) Check that there is no looseness in the installation parts of the side airbag sensor.
(e) Connect the connector.
8. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY LH (for Rear Side) See: Body and
Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation
9. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH (for Rear Side)
10. INSTALL REAR DOOR SCUFF PLATE LH (for Rear Side) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and Repair/Roof
Headlining (For Double Cab)/Installation
11. INSTALL REAR SEAT ASSEMBLY (for Rear Side)
(a) Install the rear seat assembly See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Rear Seat Assembly (for Double
Cab)/Installation.
12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
13. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Air Bag Systems/Testing and Inspection/Initial Inspection
and Diagnostic Overview/Diagnosis System.
Components
Water Pump: Service and Repair Components
1UR-FE COOLING: WATER PUMP: COMPONENTS
Page 1689
for Regular Cab of Long Deck
for Double Cab of Standard Deck
Page 3289
4. Attach the Authorized Vehicle Modification Label.
Modifications to ECU calibrations MUST be recorded and properly displayed on the vehicle using
the Authorized Modification Label.
Techstream Preparation
Selecting the TIS Techstream VIM or the Mongoose MFC VIM.
Techstream software requires a VIM selection before you can use the Mongoose MFC VIM.
If using TIS Techstream no changes are needed.
Perform the following:
1. Select Setup from the Techstream Main Menu screen.
2. Select VIM Select from the Setup drop down menu.
3. Select the correct Interface Setup from the drop down list.
^ If using Techstream Lite select Mongoose MFC.
NOTE
A/T - Torque Converter Bolt Installation Precautions
Torque Converter: Technical Service Bulletins A/T - Torque Converter Bolt Installation Precautions
T-SB-0014-11
February 17, 2011
Torque Converter Bolt Installation
Service Category Drivetrain
Section Automatic Transmission/Transaxle
Market USA
Applicability
Introduction
The purpose of this TSB is to provide information regarding the installation of the correct torque
converter bolts during automatic transmission/transaxle assembly replacement. Incorrect torque
converter bolts or missing washers can cause damage to the torque converter assembly. Use the
information in this bulletin when installing an automatic transmission/transaxle assembly.
NOTE
Not all applications will use washers on the torque converter bolts.
Warranty Information
Installation Procedure
^ When removing torque converter bolts and washers take special care that the same bolts and
washers are used when installing the torque converter.
^ Using an incorrect size bolt or washer may cause damage to the torque converter assembly.
Page 3907
Variable Valve Timing Actuator: Diagrams
Locations
Alarm Horn Relay: Locations
THEFT DETERRENT: THEFT DETERRENT SYSTEM: PARTS LOCATION
Page 7296
with SST - Torque : 62 Nm (632 kgf-cm, 46 ft-lbf)
NOTICE: Turn SST 09922-10010 in the direction shown in the illustration.
HINT Use a torque wrench with a fulcrum length of 345 mm (13.58 in.).
(j) Recheck the total preload.
Preload (turning):
1.9 to 2.7 N*m (19.4 to 27.5 kgf*cm, 16.8 to 23.9 in.*lbf)
(k) Remove the RH and LH steering rack ends.
(l) Apply MP grease to the control valve as shown in the illustration.
(m)Wind vinyl tape around the serrated portion of the control valve.
(n) Install the dust cover onto the control valve housing.
11. INSTALL STEERING RACK END SUB-ASSEMBLY
(a) Install 2 new claw washers, and provisionally install the 2 steering rack ends.
Locations
Telescoping Wheel Switch: Locations
STEERING COLUMN: POWER TILT AND POWER TELESCOPIC STEERING COLUMN
SYSTEM: PARTS LOCATION
Components
Variable Valve Timing Actuator Position Sensor: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: VVT SENSOR: COMPONENTS
Page 6457
Symbols Used Within Diagrams
Symbols Used Within Diagrams
Page 6690
Page 6554
J/B No.4 - Instrument Panel Center
Page 3995
Required Tools & Equipment
Repair Procedure
1. Using TIS Techstream check if DTC P0418, P0419, P2440, P2441, P2442, P2443, P2446
and/or P2447 are present.
2. Using Techstream perform the manual Air Injection Test (options 1 and 2) to verify if the signal
from the air injection control driver is reaching the
air pumps.
^ The pumps should be heard turning on at this point and there should be battery voltage on pin 2
of the pumps during this test.
^ If there is NO voltage refer to the Repair Manual for air injection control driver diagnosis.
Refer to the Technical Information System (TIS) 2010 model year Tundra Repair Manual:
3. If during the test voltage is present at the pump and the pump is NOT running or the Air
Pressure (gauge) value did NOT increase from 0 to 1 psi on
TIS Techstream with the pump running remove the air pump assemblies for inspection.
Refer to TIS 2010 model year Tundra Repair Manual:
4. With the pumps removed from the vehicle verify if there is liquid or evidence that liquid entered
the pumps.
^ YES - If there is liquid evidence go to step 5.
^ NO - If there is NO evidence of liquid go to step 7.
5. If liquid is present replace the affected pump assembly.
Refer to TIS 2010 model year Tundra Repair Manual:
Page 7823
Install the lower instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Column Shift Type)/Installation.
for Floor Shift Type:
Install the lower instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Floor Shift Type)/Installation.
5. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH
(a) for Column Shift Type:
Install the instrument panel finish panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Column Shift Type)/Installation.
(b) for Floor Shift Type:
Install the instrument panel finish panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Floor Shift Type)/Installation.
6. INSTALL NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY
(a) for Column Shift Type:
Install the No. 2 instrument panel under cover sub-assembly See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and
Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation.
(b) for Floor Shift Type:
Install the No. 2 instrument panel under cover sub-assembly See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and
Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation.
7. INSTALL INSTRUMENT SIDE PANEL RH
(a) for Column Shift Type:
Install the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Column Shift Type)/Installation.
(b) for Floor Shift Type:
Install the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Floor Shift Type)/Installation.
8. INSTALL COWL SIDE TRIM BOARD RH
(a) for Regular Cab:
Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular Cab)/Installation.
(b) for Double Cab:
Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Installation.
(c) for CrewMax:
Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for CrewMax)/Installation.
9. INSTALL FRONT DOOR SCUFF PLATE RH
(a) for Regular Cab:
Locations
Main Relay (Computer/Fuel System): Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 5068
09951-00810
09951-00890
12. INSTALL FRONT DRIVE PINION REAR TAPERED ROLLER BEARING
(a) Using SST, install the washer and bearing (outer race).
SST : 09950-60020
09951-00890
09951-01030
HINT First, fit a washer of the same thickness as the removed washer, then after checking the
tooth contact pattern, replace the washer with one of a different thickness if necessary.
13. INSTALL FRONT DRIVE PINION REAR TAPERED ROLLER BEARING
(a) Using SST and a press, press in the bearing (inner race).
SST : 09506-35010
14. TEMPORARILY INSTALL DIFFERENTIAL DRIVE PINION
Page 7936
(2) Wind the wire harness around the stud bolts of the front seat side airbag as shown in the
illustration.
(3) Position the front seat side airbag inside the tire.
Tire size:
Must exceed the following dimensions
Width 185 mm (7.28 in.)
Inner diameter 360 mm (1.18 ft.)
CAUTION: *
Make sure that the wire harnesses are tight. If there is slack in the wire harnesses, the front seat
side airbag may become loose due to the shock when the airbag is deployed.
* Always tie down the front seat side airbag with the airbag deployment direction facing inside the
tire.
NOTICE: As the tires may be damaged by the airbag deployment, use a tire that you are planning
to throw away.
(d) Install SST.
(1) Connect SST connector to the front seat airbag connector.
SST : 09082-00820
(e) Place the tires.
Page 6137
Symbols Used Within Diagrams
Symbols Used Within Diagrams
Page 2821
Page 5073
(h) If the teeth are not engaged properly, use the following chart to select the appropriate washer
for correction.
Washer thickness:
23. REMOVE FRONT DRIVE PINION FRONT COMPANION FLANGE SUB-ASSEMBLY See:
Front Differential Carrier
Assembly/Disassembly
24. REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER
25. REMOVE FRONT DIFFERENTIAL CROSS SHAFT BEARING RETAINER See: Front
Differential Carrier Assembly/Disassembly
26. REMOVE FRONT DIFFERENTIAL CASE See: Front Differential Carrier
Assembly/Disassembly
27. REMOVE DIFFERENTIAL DRIVE PINION See: Front Differential Carrier
Assembly/Disassembly
28. REMOVE FRONT DRIVE PINION FRONT RADIAL BALL BEARING
29. INSTALL FRONT DIFFERENTIAL DRIVE PINION BEARING SPACER
(a) Install a new bearing spacer.
Page 5749
Brake Master Cylinder: Overhaul
Disassembly
BRAKE: BRAKE MASTER CYLINDER: DISASSEMBLY
1. REMOVE BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY
(a) Using a T25 "TORX" socket wrench, remove the screw and reservoir.
2. REMOVE MASTER CYLINDER RESERVOIR GROMMET
(b) Remove the 2 grommets.
Reassembly
BRAKE: BRAKE MASTER CYLINDER: REASSEMBLY
1. INSTALL MASTER CYLINDER RESERVOIR GROMMET
(a) Apply a light coat of lithium soap base glycol grease to 2 new grommets and install them onto
the master cylinder body.
2. INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY
(a) Install the master cylinder reservoir onto the master cylinder body.
(b) Using a T25 "TORX" socket wrench, install the screw.
Torque : 5.5 Nm (56 kgf-cm, 49 in-lbf)
Page 4502
Camshaft Position Sensor: Locations Ignition System
1UR-FE IGNITION: IGNITION SYSTEM: PARTS LOCATION
Page 8798
2. REMOVE NO. 1 BOX SPEAKER ASSEMBLY
(a) Disconnect the connector.
(b) Remove the 4 bolts and box speaker.
Installation
AUDIO / VISUAL: FLOOR SPEAKER (for Double Cab): INSTALLATION
1. INSTALL NO. 1 BOX SPEAKER ASSEMBLY
(a) Install the box speaker with the 4 bolts.
HINT Tighten the bolts in the order shown in the illustration.
(b) Connect the connector.
2. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Page 9140
Connectors Part 4
Locations: The locations of components, connectors, ground points, and splices referred to within
these diagrams can be found at Vehicle Locations. See: Locations
Page 7206
Steering Control Module: Service and Repair Installation
POWER STEERING: POWER STEERING ECU (for 1UR-FE): INSTALLATION
1. INSTALL POWER STEERING ECU ASSEMBLY
(a) Install the power steering ECU with the nut.
Torque : 8.5 Nm (87 kgf-cm, 75 in-lbf)
(b) Connect the power steering ECU connector.
2. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column
Shift Type)/Installation
3. INSTALL LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY See: Restraint
Systems/Air Bag Systems/Air Bag/Service and
Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Installation
4. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Installation
5. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
6. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Installation
7. INSTALL FRONT DOOR SCUFF PLATE LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining
(For Regular Cab)/Installation
Inspection
Air Flow Meter/Sensor: Testing and Inspection Inspection
1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: INSPECTION
1. INSPECT MASS AIR FLOW METER
(a) Check the output voltage.
(1) Apply battery voltage across terminals 1 (+B) and 2 (E2G).
NOTICE: While using the battery during inspection, do not bring the positive and negative tester
probes too close to each other as a short circuit may occur.
(2) Using a voltmeter, connect the positive (+) tester probe to terminal 3 (VG), and negative (-)
tester probe to terminal 2 (E2G).
(3) Blow air into the MAF meter, and check that the voltage fluctuates.
If the result is not as specified, replace the MAF meter.
(b) Perform a visual check for any foreign matter on the platinum hot wire (heater) of the mass air
flow meter shown in the illustration.
OK:
There is no foreign material.
(c) If the result is not as specified, replace the mass air flow meter.
(d) Check the IAT sensor.
Page 5006
Wiring Harness: Service and Repair Installation
A760F AUTOMATIC TRANSMISSION: TRANSMISSION WIRE: INSTALLATION
1. INSTALL TRANSMISSION WIRE
(a) Coat a new O-ring with ATF, and install it to the transmission wire connector.
(b) Install the transmission wire with the bolt.
Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)
(c) Connect the transmission wire connector.
HINT Push up the lever until the claw of the transmission wire connector makes a connection
sound.
2. CONNECT TRANSMISSION WIRE
(a) Connect the 9 solenoid valve connectors.
(b) Connect the 2 ATF temperature sensors with the 2 clamps and 2 bolts.
for bolt A - Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
for bolt B - Torque : 11 Nm (112 kgf-cm, 8 ft-lbf)
HINT Each bolt length is indicated below.
12 mm (0.472 in.) for bolt A
(b) 36 mm (1.41 in.) for bolt B
(c) Attach the wire harness to the 2 clamps.
3. INSTALL VALVE BODY OIL STRAINER ASSEMBLY
Page 4311
Then click Next.
F. Verify correct current calibration and new calibration information. Then click Next.
NOTE
^ The total number of calibration IDs in the calibration file corresponds to the number of
reprogrammable processors in the ECU.
^ Each calibration file may contain up to three separate calibrations.
Page 4376
Fuel Pump Control Unit: Locations Double Cab
Body
Page 8068
CAUTION: For removal and installation procedures of the side airbag sensor, be sure to follow the
correct procedure.
3. CHECK REAR AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS
DEPLOYED)
(a) Replace the side airbag sensor.
CAUTION: *
For removal and installation procedures of the side airbag sensor, be sure to follow the correct
procedure.
* If the airbags have deployed, replace the rear airbag sensor on the side in which the collision
occurred. Replace both if necessary.
Side Airbag Sensor (for Regular Cab)
SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Regular Cab):
ON-VEHICLE INSPECTION
1. CHECK SIDE AIRBAG SENSOR (VEHICLE NOT INVOLVED IN COLLISION)
(a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnosis System.
2. CHECK SIDE AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS
NOT DEPLOYED)
(a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnosis System.
(b) When the center pillar of the vehicle or its area is damaged, check if there is any damage to the
side airbag sensor. If there are any defects as
mentioned below, replace the side airbag sensor with a new one:
* Cracks, dents or chips on the sensor housing.
* Cracks or other damage to the connector.
* Peeling off of the label or damage to the serial number.
CAUTION: For removal and installation procedures of the side airbag sensor, be sure to follow the
correct procedure.
3. CHECK SIDE AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS
DEPLOYED)
(a) Replace the side airbag sensor.
CAUTION: *
For removal and installation procedures of the side airbag sensor, be sure to follow the correct
procedure.
* If the airbags have deployed, replace the side airbag sensor on the side in which the collision
occurred. Replace both if necessary.
Page 2001
Use a volt/ohmmeter with high impedance (10 kohms/V minimum) for troubleshooting of the
electrical circuit.
Disconnection of Male and Female Connectors
DISCONNECTION OF MALE AND FEMALE CONNECTORS
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Finding A Short Circuit
FINDING A SHORT CIRCUIT
Page 2241
Required Tools & Equipment
Repair Procedure Overview
^ Confirm noise is coming from the rear of the vehicle and changes with vehicle speed.
^ Install ChaSSiSEAR(TM) (or equivalent) and isolate the noise to the rear wheel bearing.
^ Remove the rear axle shaft assembly.
^ Install new rear wheel bearing brake caliper bracket and seals.
^ Reinstall rear axle shaft assembly and confirm the noise is no longer present.
Repair Procedure
1. Test drive the vehicle and confirm the customer complaint.
Does the noise increase and decrease with vehicle speed?
^ YES - Go to step 2.
^ NO - This TSB does NOT apply. Refer to the Repair Manual for further diagnosis.
Page 2805
J. When Cal 1 has completed the update process turn ignition OFF for a minimum of 10 seconds.
Then click Next.
K. Turn ignition to the ON position. Then click Start.
L. Do NOT disturb the vehicle during flash reprogramming.
Page 2077
4. SYMPTOM CONFIRMATION AND DTC (INCLUDING FREEZE FRAME DATA) CHECK
(a) Visually check the wire harnesses, connectors and fuses for open and short circuits.
(b) Warm up the engine to the normal operating temperature.
(c) Confirm the problem symptoms and conditions, and check for DTCs.
B -- Go to step 6 A -- Continue to next step.
5. DTC CHART
(a) Check the results obtained in the DTC check. Then find the output DTC in the DTC chart. Look
at the "Trouble Area" column for a list of
potentially malfunctioning circuits and / or parts.
NEXT -- Go to step 7
6. PROBLEM SYMPTOMS TABLE
(a) Check the results obtained in the symptom confirmation. Then find the problem symptoms in
the problem symptoms table. Look at the
"Suspected Area" column for a list of potentially malfunctioning circuits and / or parts.
NEXT -- Continue to next step.
7. CIRCUIT INSPECTION OR PARTS INSPECTION
(a) Confirm the malfunctioning circuit or part.
NEXT -- Continue to next step.
8. ADJUST, REPAIR OR REPLACE
(a) Adjust, repair or replace the malfunctioning circuit or parts.
NEXT -- Continue to next step.
9. CONFIRMATION TEST
(a) After the adjustment, repairs or replacement, confirm that the malfunction no longer exists. If the
malfunction does not reoccur, perform a
confirmation test under the same conditions and in the same environment as when the malfunction
occurred the first time.
NEXT -- END
2. CUSTOMER PROBLEM ANALYSIS
HINT *
In troubleshooting, confirm that the problem symptoms have been accurately identified.
Preconceptions should be discarded in order to make an accurate judgment. To clearly understand
what the problem symptoms are, it is extremely important to ask the customer about the problem
and the conditions at the time the malfunction occurred.
* Gather as much information as possible for reference. Past problems that seem unrelated may
also help in some cases.
* The following 5 questions are important points in the problem analysis:
Page 4923
(a) Attach the 3 claws to install the ECU to the floor shift.
(b) Connect the shift lock solenoid connector.
2. INSTALL SHIFT LOCK RELEASE BUTTON
(a) Attach the 2 claws to install the button.
(b) Attach the 4 claws to install the position indicator housing.
3. INSTALL INDICATOR LIGHT WIRE SUB-ASSEMBLY
(a) Align the wire with the key part of the transmission floor shift assembly, and install the wire.
Then rotate the wire clockwise until it locks.
(b) Securely connect the 2 wire terminals to terminal 4 (ILL+) and 8 (ILL-) of the transmission
control switch connector. Then push in the
connector housing retainer to lock it.
Page 4186
Page 9217
6. REMOVE FRONT NO. 3 SPEAKER ASSEMBLY (for 10 Speakers) See: Accessories and
Optional Equipment/Radio, Stereo, and Compact
Disc/Speaker/Service and Repair/Front Door Speaker (for Double Cab)/Removal
7. REMOVE COURTESY LIGHT ASSEMBLY
(a) Detach the claw and remove the courtesy light from the door trim board.
(b) Disconnect the connector.
8. REMOVE FRONT DOOR ARMREST COVER LH
9. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH
(a) Remove the 2 screws.
(b) Using a clip remover, remove the clip.
(c) Detach the 9 clips and remove the trim cover. Then disconnect the connector.
(d) Disconnect the 2 cables from the inside handle.
Page 2019
NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do
not operate the ignition switch, any other switches, or the doors.
(a) If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the
harness and connector.
(b) Connect the cable of the Techstream to the DLC3, turn the ignition switch ON and attempt to
use the tester. If the display indicates that a
communication error has occurred, there is a problem either with the vehicle or with the tester.
HINT *
If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of
the original vehicle.
* If communication is still not possible when the tester is connected to another vehicle, the problem
may be in the tester itself. Consult the Service Department listed in the tester's instruction manual.
How To Proceed With Troubleshooting
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: HOW TO
PROCEED WITH TROUBLESHOOTING
1. OPERATION FLOW
HINT Perform troubleshooting in accordance with the procedures below. The following is an outline
of basic troubleshooting procedures. Confirm the troubleshooting procedures for the circuit you are
working on before beginning troubleshooting.
1. VEHICLE BROUGHT TO WORKSHOP
NEXT -- Continue to next step.
2. CUSTOMER PROBLEM ANALYSIS
(a) Ask the customer about the conditions and environment when the problem occurred.
NEXT -- Continue to next step.
3. INSPECT BATTERY VOLTAGE
Standard voltage:
11 to 14 V
If the voltage is below 11 V, recharge or replace the battery before proceeding.
NEXT -- Continue to next step.
Page 1980
ACC Cut Relay
Power Distribution Relay: Testing and Inspection ACC Cut Relay
1UR-FE STARTING: ACC CUT RELAY: ON-VEHICLE INSPECTION
1. REMOVE ACC CUT RELAY
(a) Remove the clip.
(b) Detach the 2 clips and remove the cowl side trim board RH.
(c) Remove the relay.
2. INSPECT ACC CUT RELAY
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) If the result is not as specified, replace the relay.
3. INSTALL ACC CUT RELAY
(a) Install the relay.
(b) Attach the 2 clips to install the cowl side trim board RH.
(c) Install the clip.
Page 7949
SST : 09082-00700
SST : 09082-00780
NOTICE: To avoid damaging SST connector and wire harness, do not lock the secondary lock of
the twin lock.
(3) Move SST at least 10 m (32.8 ft.) away from the vehicle front side window.
(4) Maintaining enough clearance for SST wire harness in the front side window, close all doors
and windows of the vehicle.
NOTICE: Take care not to damage SST wire harness.
(5) Connect the red clip of SST to the battery positive (+) terminal and the black clip of SST to the
negative (-) terminal.
(f) Deploy the airbag.
(1) Check that no one is inside the vehicle or within a 10 m (32.8 ft.) radius of the vehicle.
(2) Press SST activation switch and deploy the airbag.
CAUTION: *
When deploying the airbag, make sure that no one is near the vehicle.
* The front passenger airbag becomes extremely hot when the airbag is deployed, so do not touch
it for at least 30 minutes after deployment.
* Use gloves and safety glasses when handling a front passenger airbag with a deployed airbag.
* Do not apply water to a front passenger airbag with a deployed airbag.
* Always wash your hands with water after completing the operation.
HINT The airbag is deployed as the LED of SST activation switch comes on.
2. DISPOSE OF FRONT PASSENGER AIRBAG ASSEMBLY (WHEN NOT INSTALLED IN
VEHICLE)
NOTICE: Be sure to follow the procedure detailed below when deploying the airbag.
HINT Prepare a battery as the power source to deploy the airbag.
(a) Check the function of SST See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
(b) Remove the front passenger airbag See: Removal and Replacement/Front Passenger Airbag
Assembly/Removal.
CAUTION:
Page 7485
Tire Pressure Monitor Receiver / Transponder: Diagrams
Page 6239
Engine Room R/B, J/B - Engine Compartment Left
Page 3824
Manifold Pressure/Vacuum Sensor: Testing and Inspection
1UR-FE ENGINE CONTROL SYSTEM: MANIFOLD ABSOLUTE PRESSURE SENSOR:
INSPECTION
1. INSPECT MANIFOLD ABSOLUTE PRESSURE SENSOR
(a) Check the resistance.
(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(2) If the result is not as specified, replace the manifold absolute pressure sensor.
Page 2138
Tire Pressure Module: Service and Repair Removal
TIRE AND WHEEL: TIRE PRESSURE WARNING ECU: REMOVAL
NOTICE: *
It is necessary to perform initialization See: Tire Monitoring System/Testing and
Inspection/Programming and Relearning/Initialization after registration See: Tire Monitoring
System/Testing and Inspection/Programming and Relearning/Registration of the transmitter IDs
into the tire pressure warning ECU after the ECU has been replaced.
* When replacing the tire pressure warning ECU, read the transmitter IDs stored in the old ECU
using the intelligent tester or Techstream and write them down before removal.
1. REMOVE FRONT DOOR SCUFF PLATE RH (for Regular Cab)
(a) Remove the front door scuff plate RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Removal.
HINT Use the same procedures described for the LH side.
2. REMOVE FRONT DOOR SCUFF PLATE RH (for Double Cab, for CrewMax)
(a) Remove the front door scuff plate RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Removal.
HINT Use the same procedures described for the LH side.
3. REMOVE COWL SIDE TRIM BOARD RH
(a) Remove the cowl side trim board RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Removal.
HINT Use the same procedures described for the LH side.
4. REMOVE INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal
5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and
Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument
Panel Safety Pad (for Column Shift Type)/Removal
6. REMOVE TIRE PRESSURE WARNING ECU
(a) Disconnect the ECU connector.
(b) Remove the 2 nuts and ECU.
Page 6300
Junction Connector (CAN No.2) - Lower Finish Panel
Page 2951
Manifold Pressure/Vacuum Sensor: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: MANIFOLD ABSOLUTE PRESSURE SENSOR:
REMOVAL
1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Removal
2. REMOVE MANIFOLD ABSOLUTE PRESSURE SENSOR
(a) Disconnect the manifold absolute pressure sensor connector.
(b) Remove the screw and manifold absolute pressure sensor.
(c) Remove the O-ring from the manifold absolute pressure sensor.
Page 5091
^ Inspect the axles and rear differential axle housing oil baffles.
^ Install new rear differential axle housing oil baffle(s).
^ Reinstall rear axle shaft and differential and confirm proper operation.
Repair Procedure
1. Test drive the vehicle and confirm the condition. Is the noise loudest from the rear of the vehicle?
^ YES - Go to step 2.
^ NO - This TSB does NOT apply. Refer to the Repair Manual for further diagnosis.
2. Install ChassisEAR(TM) (or equivalent) on the vehicle and attempt to isolate the source of the
noise. Is the noise loudest from the rear differential
area?
^ YES - Go to step 3.
^ NO - This TSB does NOT apply. Refer to the Repair Manual for further diagnosis.
3. Remove the rear axle shafts and rear differential.
Refer to the Technical Information System (TIS) applicable model year Tundra Repair Manual:
4. Inspect the rear axle housing oil baffles and axle shafts.
Are the rear axle housing baffle(s) deformed or are there wear marks on the axle shaft(s)
assembly? See Figures 1 and 2 for reference.
^ YES - Go to step 5.
^ NO - This TSB does NOT apply. Refer to the Repair Manual for further diagnosis.
Page 3313
Engine Control Module: Diagrams
Page 3964
This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown.
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60
months or 60,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Op Code EG9029 or EG9024: For California specification vehicles sold, registered, and operated
in California, Connecticut, Maine, Massachusetts, New Jersey, Oregon, Pennsylvania, Rhode
Island, Vermont, and Washington, this repair is covered under the California Emission Warranty.
This warranty is in effect for 84 months or 70,000 miles, whichever occurs first, from the vehicle's
in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Page 5667
Yaw Rate Sensor: Testing and Inspection
BRAKE CONTROL: YAW RATE AND DECELERATION SENSOR: INSPECTION
1. CHECK YAW RATE SENSOR
(a) Check the yaw rate sensor.
Under any of the following conditions, replace the sensor with a new one:
* The surface of the sensor is cracked, dented, or chipped.
* The connector is scratched, cracked, or damaged.
* The sensor has been dropped.
Page 6984
4. SYMPTOM CONFIRMATION AND DTC (INCLUDING FREEZE FRAME DATA) CHECK
(a) Visually check the wire harnesses, connectors and fuses for open and short circuits.
(b) Warm up the engine to the normal operating temperature.
(c) Confirm the problem symptoms and conditions, and check for DTCs.
B -- Go to step 6 A -- Continue to next step.
5. DTC CHART
(a) Check the results obtained in the DTC check. Then find the output DTC in the DTC chart. Look
at the "Trouble Area" column for a list of
potentially malfunctioning circuits and / or parts.
NEXT -- Go to step 7
6. PROBLEM SYMPTOMS TABLE
(a) Check the results obtained in the symptom confirmation. Then find the problem symptoms in
the problem symptoms table. Look at the
"Suspected Area" column for a list of potentially malfunctioning circuits and / or parts.
NEXT -- Continue to next step.
7. CIRCUIT INSPECTION OR PARTS INSPECTION
(a) Confirm the malfunctioning circuit or part.
NEXT -- Continue to next step.
8. ADJUST, REPAIR OR REPLACE
(a) Adjust, repair or replace the malfunctioning circuit or parts.
NEXT -- Continue to next step.
9. CONFIRMATION TEST
(a) After the adjustment, repairs or replacement, confirm that the malfunction no longer exists. If the
malfunction does not reoccur, perform a
confirmation test under the same conditions and in the same environment as when the malfunction
occurred the first time.
NEXT -- END
2. CUSTOMER PROBLEM ANALYSIS
HINT *
In troubleshooting, confirm that the problem symptoms have been accurately identified.
Preconceptions should be discarded in order to make an accurate judgment. To clearly understand
what the problem symptoms are, it is extremely important to ask the customer about the problem
and the conditions at the time the malfunction occurred.
* Gather as much information as possible for reference. Past problems that seem unrelated may
also help in some cases.
* The following 5 questions are important points in the problem analysis:
Page 7031
for CrewMax of standard deck
Components
Ignition Switch: Service and Repair Components
1UR-FE STARTING: IGNITION SWITCH: COMPONENTS
Page 6645
7. REMOVE REAR POWER OUTLET SOCKET COVER (for Double Cab)
(a) Detach the 2 claws and remove the power outlet socket cover.
Installation
OTHER SYSTEM: CENTER POWER OUTLET SOCKET (for Floor Shift Type): INSTALLATION
1. INSTALL REAR POWER OUTLET SOCKET COVER (for Double Cab)
(a) Attach the 2 claws to install the power outlet socket cover.
2. INSTALL REAR POWER OUTLET SOCKET ASSEMBLY (for Double Cab)
(a) Attach the claw to install the power outlet socket.
3. INSTALL REAR CONSOLE END PANEL SUB-ASSEMBLY (for Double Cab) See: Body and
Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Floor Shift Type)/Installation
4. INSTALL POWER OUTLET SOCKET COVER
(a) Attach the 2 claws to install the power outlet socket cover.
5. INSTALL POWER OUTLET SOCKET ASSEMBLY
Components
Front Crankshaft Seal: Service and Repair Components
1UR-FE ENGINE MECHANICAL: FRONT CRANKSHAFT OIL SEAL: COMPONENTS
Page 5689
Brake Pedal Assy: Service and Repair Installation
BRAKE: BRAKE PEDAL: INSTALLATION
1. INSTALL BRAKE PEDAL PAD
(a) Install the brake pedal pad onto the brake pedal.
2. INSTALL BRAKE PEDAL SUPPORT SUB-ASSEMBLY
(a) Install the brake pedal support with the 4 nuts.
Torque : 15 Nm (155 kgf-cm, 11 ft-lbf)
(b) Install the No. 3 brake pedal bracket to the brake pedal support.
(c) Temporarily install the brake pedal support, No. 3 brake pedal bracket and brake pedal lever
with the bolt and nut.
(d) Install the bolt to the No. 3 brake pedal bracket.
Torque : 18 Nm (184 kgf-cm, 13 ft-lbf)
(e) Apply a light coat of lithium soap base glycol grease to the inner surface of the hole on the
brake pedal and return spring mounting bracket of
the No. 3 brake pedal bracket.
(f) Install the brake pedal return spring.
(g) Tighten the bolt and nut.
Torque : 23 Nm (239 kgf-cm, 17 ft-lbf)
3. INSTALL PUSH ROD PIN
(a) Apply a light coat of lithium soap base glycol grease to the inner surface of the hole on the
brake pedal lever.
(b) Set the push rod clevis in place, insert the push rod pin from outside the vehicle and then install
a new clip.
NOTICE: After assembly, check that the pedal operates smoothly.
4. INSTALL STOP LIGHT SWITCH MOUNTING ADJUSTER
Page 3332
HINT The wavelength becomes shorter as the engine rpm increases.
(n) WAVEFORM 13:
HINT The waveform varies depending on the CAN communication signal.
(o) WAVEFORM 14:
HINT The waveform varies depending on the CAN communication signal.
(p) WAVEFORM 15:
HINT The wavelength becomes shorter as the engine rpm increases.
Page 1653
Removal
WINDSHIELD / WINDOWGLASS: REAR POWER WINDOW SWITCH: REMOVAL
HINT *
Use the same procedures for the LH side and RH side.
* The procedures listed below are for the LH side.
1. REMOVE REAR UPPER DOOR ARMREST BASE PANEL LH
(a) Using a screwdriver, detach the 2 clips and 5 claws, and remove the rear upper door armrest
base panel.
Page 8113
Diagrams
Trailer Brake Control Module: Diagrams
Engine Control System - SFI System
Camshaft Position Sensor: Locations Engine Control System - SFI System
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Locations
Gear Sensor/Switch: Locations
JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION
Page 1915
NOTICE: The ATF temperature can be confirmed by using the Techstream.
(a) Turn the ignition switch off.
(b) Connect the Techstream to the DLC3.
(c) Turn the ignition switch to ON.
(d) Enter the following menus: Powertrain / ECT / Data List / A/T Oil Temperature 1.
(e) Check the ATF temperature.
NOTICE: If the ATF temperature is higher than 59°C (138°F), turn the ignition switch off and wait
until the fluid temperature drops to between 53 and 59°C (127 and 138°F).
5. FLUID LEVEL CHECK
NOTICE: *
It is necessary to change to temperature detection mode in order to idle the vehicle appropriately.
* The ATF temperature must be between 53 and 59°C (127 and 138°F) to accurately check the
fluid level.
(a) When using the Techstream:
Enter the following menus: Powertrain / ECT / Active Test / Connect the TC and TE1.
Standard condition:
Indicator lights in the combination meter blink.
(b) When not using the Techstream:
Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3.
SST : 09843-18040
Standard condition:
Indicator lights in the combination meter blink.
(c) Start the engine and idle it.
NOTICE: Check that electrical systems such as the air conditioning system, audio system and
lighting system are off.
(d) Slowly move the shift lever from P to S, and then change the gear from 1st to 5th. Then return
the shift lever to P.
HINT Slowly move the shift lever to circulate the fluid through each part of the transmission.
(e) Move the shift lever to D, and quickly move it back and forth between N and D (once within 1.5
seconds) for at least 6 seconds. This will
activate the fluid temperature detection mode.
Page 3827
Manifold Pressure/Vacuum Sensor: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: MANIFOLD ABSOLUTE PRESSURE SENSOR:
REMOVAL
1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Removal
2. REMOVE MANIFOLD ABSOLUTE PRESSURE SENSOR
(a) Disconnect the manifold absolute pressure sensor connector.
(b) Remove the screw and manifold absolute pressure sensor.
(c) Remove the O-ring from the manifold absolute pressure sensor.
Page 5447
Four Wheel Drive Selector Switch: Service and Repair Removal
JF1A TRANSFER: 4WD CONTROL SWITCH: REMOVAL
1. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Panel,
Gauges and Warning Indicators/Instrument Cluster
/ Carrier/Service and Repair/Combination Meter/Removal
2. REMOVE 4WD CONTROL SWITCH
(a) Detach the 3 claws to remove the switch.
Page 6904
Page 2213
Tire Pressure Warning Reset Switch: Diagrams
Page 2676
Engine Temperature Sensor: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: ENGINE COOLANT TEMPERATURE SENSOR:
REMOVAL
1. REMOVE NO. 1 ENGINE UNDER COVER See: Engine/Engine Lubrication/Engine Oil/Service
and Repair/Replacement
2. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine/Service and Repair/Removal and
Replacement/Engine Assembly/Removal
3. DRAIN ENGINE COOLANT See: Coolant/Service and Repair
4. REMOVE ENGINE COOLANT TEMPERATURE SENSOR
(a) Disconnect the sensor connector.
(b) Using a 19 mm ball joint lock nut wrench, remove the sensor.
(c) Remove the gasket from the sensor.
Page 8674
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: ELECTRONIC
CIRCUIT INSPECTION PROCEDURE
1. BASIC INSPECTION
(a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS
(1) Unless otherwise stated, all resistance measurements should be made at an ambient
temperature of 20°C (68°F). Resistance measurements
may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been
running. Measurements should be made after the engine has cooled down.
(b) HANDLING CONNECTORS
(1) When disconnecting a connector, first squeeze the mating halves tightly together to release the
lock, and then press the lock claw and
separate the connector.
(2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly
and separate it.
(3) Before connecting a connector, check that there are no deformed, damaged, loose or missing
terminals.
(4) When connecting a connector, press firmly until it locks with a "click" sound.
(5) If checking a connector with a TOYOTA electrical tester, check the connector from the backside
(harness side) using a mini test lead.
NOTICE: *
As a waterproof connector cannot be checked from the backside, check it by connecting a
sub-harness.
* Do not damage the terminals by moving the inserted tester needle.
(c) CHECKING CONNECTORS
(1) Checking when a connector is connected: Squeeze the connectors together to confirm that they
are fully connected and locked.
(2) Checking when a connector is disconnected: Check by pulling the wire harness lightly from the
backside of the connector. Look for
unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for
corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or
deformed terminals.
(3) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a
female terminal, and check for ample tension
Page 8207
Seat Belt: Testing and Inspection Front Seat Outer Belt Assembly (for Center Seat)
SEAT BELT: FRONT SEAT OUTER BELT ASSEMBLY (for Center Seat): INSPECTION
1. INSPECT CENTER FRONT SEAT BELT ASSEMBLY RH
CAUTION: Do not disassemble the retractor.
(a) Before installing the seat belt, check the ELR.
(1) When the inclination of the retractor is 15° or less, check that the belt can be pulled from the
retractor. When the inclination of the retractor
is over 45°, check that the belt locks. If the operation is not as specified, replace the seat belt
assembly.
(b) Check the fastening function of the child restraint system.
NOTICE: The check should be performed with the outer belt installed.
(1) When the belt is pulled out fully, the belt should automatically start to retract.
(2) After the belt has fully retracted, the belt should be able to be pulled out and retracted again.
If the operation is not as specified, replace the belt assembly.
Components
Hood Shock / Support: Service and Repair Components
ENGINE HOOD / DOOR: HOOD SUPPORT: COMPONENTS
Page 8261
(a) Remove the bolt and disconnect the seat belt anchor.
HINT The rear No. 1 seat inner belt is fixed with the same bolt as the rear center seat outer belt's
anchor. Therefore, it becomes disconnected when the bolt is removed.
4. REMOVE REAR SEAT CUSHION COVER WITH PAD LH See: Body and Frame/Seats/Service
and Repair/Overhaul/Rear Seat Assembly (for
Crewmax LH Side)/Disassembly
5. REMOVE REAR SEATBACK BOARD LH See: Body and Frame/Seats/Service and
Repair/Overhaul/Rear Seat Assembly (for Crewmax LH
Side)/Disassembly
6. REMOVE REAR SEAT ARMREST ASSEMBLY See: Body and Frame/Seats/Service and
Repair/Overhaul/Rear Seat Assembly (for Crewmax
LH Side)/Disassembly
7. REMOVE REAR SEAT HEADREST ASSEMBLY LH
8. REMOVE CENTER REAR SEAT HEADREST ASSEMBLY
9. REMOVE REAR SEAT HEADREST SUPPORT See: Body and Frame/Seats/Service and
Repair/Overhaul/Rear Seat Assembly (for Crewmax
LH Side)/Disassembly
10. REMOVE REAR SEATBACK LOCK STRIKER COVER LH See: Body and
Frame/Seats/Service and Repair/Overhaul/Rear Seat Assembly
(for Crewmax LH Side)/Disassembly
11. REMOVE REAR SEAT LOCK CONTROL LEVER SUB-ASSEMBLY LH See: Body and
Frame/Seats/Service and Repair/Overhaul/Rear Seat
Assembly (for Crewmax LH Side)/Disassembly
12. REMOVE LOWER REAR SEATBACK COVER SUB-ASSEMBLY LH See: Body and
Frame/Seats/Service and Repair/Overhaul/Rear Seat
Assembly (for Crewmax LH Side)/Disassembly
13. REMOVE REAR SEATBACK COVER WITH PAD See: Body and Frame/Seats/Service and
Repair/Overhaul/Rear Seat Assembly (for
Crewmax LH Side)/Disassembly
14. REMOVE CENTER RECLINING ADJUSTER INSIDE COVER See: Body and
Frame/Seats/Service and Repair/Overhaul/Rear Seat Assembly
(for Crewmax LH Side)/Disassembly
15. REMOVE REAR SEATBACK HINGE COVER See: Body and Frame/Seats/Service and
Repair/Overhaul/Rear Seat Assembly (for Crewmax
LH Side)/Disassembly
16. REMOVE REAR SEAT SHOULDER BELT HOLE COVER
(a) Remove the screw and the cover.
Components
Tire Pressure Module: Service and Repair Components
TIRE AND WHEEL: TIRE PRESSURE WARNING ECU: COMPONENTS
Page 4597
(a) For an open circuit in the wire harness in Fig. 1, check the resistance or voltage, as described
below.
(b) Check the resistance.
(1) Disconnect connectors A and C and measure the resistance between them.
Standard resistance (Fig. 2):
HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally.
If the results match the examples above, an open circuit exists between terminal 1 of connector A
and terminal 1 of connector C.
(2) Disconnect connector B and measure the resistance between the connectors.
Standard resistance (Fig. 3):
* If the results match the examples above, an open circuit exists between terminal 1 of connector
B2 and terminal 1 of connector C.
(c) Check the voltage.
Inspection
Variable Valve Timing Actuator: Testing and Inspection Inspection
1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT OIL CONTROL VALVE: INSPECTION
1. INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) If the result is not as specified, replace the camshaft timing oil control valve assembly.
(c) Connect the battery's positive (+) lead to terminal 1 and the negative (-) lead to terminal 2, and
check the movement of the valve.
OK:
(d) If the result is not as specified, replace the camshaft timing oil control valve assembly. If the
valve cannot return properly because of foreign
matter, a small pressure leak in the advanced direction may occur and a DTC may be output.
Page 3721
NG -- REPLACE RELAY OK -- Continue to next step.
3. CHECK HARNESS AND CONNECTOR (ECM - BODY GROUND)
(a) Disconnect the ECM connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR OK -- Continue to next step.
4. INSPECT ECM (IGSW VOLTAGE)
(a) Disconnect the ECM connectors.
(b) Turn the ignition switch to ON.
(c) Measure the voltage according to the value(s) in the table below.
Page 816
Traction Control Switch: Locations From 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 6375
Page 3348
Engine Temperature Sensor: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: ENGINE COOLANT TEMPERATURE SENSOR:
INSTALLATION
1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR
(a) Install a new gasket to the sensor.
(b) Using a 19 mm ball joint lock nut wrench, install the sensor.
Torque : 20 Nm (200 kgf-cm, 14 ft-lbf)
NOTICE: Use the formula to calculate special torque values for situations where ball joint lock nut
wrench is combined with a torque wrench See: Service Precautions
(c) Connect the sensor connector.
2. ADD ENGINE COOLANT See: Engine, Cooling and Exhaust/Cooling System/Coolant/Service
and Repair
3. INSPECT FOR COOLANT LEAK See: Engine, Cooling and Exhaust/Cooling System/Testing
and Inspection
4. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Installation
5. INSTALL NO. 1 ENGINE UNDER COVER See: Engine, Cooling and Exhaust/Engine/Engine
Lubrication/Engine Oil/Service and
Repair/Replacement
Page 6629
HINT Tape the screwdriver tip before use.
7. REMOVE REAR POWER OUTLET SOCKET COVER (for Double Cab)
(a) Detach the 2 claws and remove the power outlet socket cover.
Installation
OTHER SYSTEM: CENTER POWER OUTLET SOCKET (for Floor Shift Type): INSTALLATION
1. INSTALL REAR POWER OUTLET SOCKET COVER (for Double Cab)
(a) Attach the 2 claws to install the power outlet socket cover.
2. INSTALL REAR POWER OUTLET SOCKET ASSEMBLY (for Double Cab)
(a) Attach the claw to install the power outlet socket.
3. INSTALL REAR CONSOLE END PANEL SUB-ASSEMBLY (for Double Cab) See: Body and
Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Floor Shift Type)/Installation
4. INSTALL POWER OUTLET SOCKET COVER
(a) Attach the 2 claws to install the power outlet socket cover.
Page 7634
Use a volt/ohmmeter with high impedance (10 kohms/V minimum) for troubleshooting of the
electrical circuit.
Disconnection of Male and Female Connectors
DISCONNECTION OF MALE AND FEMALE CONNECTORS
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Finding A Short Circuit
FINDING A SHORT CIRCUIT
Specifications
Water Pump: Specifications
WATER PUMP ASSEMBLY
Install a new gasket and the water pump with the 8 bolts shown in the illustration.
For bolt A - Torque...............................................................................................................................
....................................47 Nm (479 kgf-cm, 35 ft-lbf)
For bolt B - Torque...............................................................................................................................
....................................23 Nm (235 kgf-cm, 17 ft-lbf)
For bolt C - Torque...............................................................................................................................
....................................20 Nm (204 kgf-cm, 15 ft-lbf)
Page 367
NOTE
On some models, DTCs may set as a result of reprogramming. If DTCs are present, clear codes
and run the Health Check again. Troubleshoot any remaining Current, Pending, or History codes.
Permanent codes will not be cleared using Techstream. Permanent codes do not illuminate the MIL
and do not require troubleshooting. They will clear during normal driving once the Universal Trip
Drive Pattern is performed.
4. Attach the Authorized Modifications Label.
A. Using a permanent marker or ball point pen complete the Authorized Modifications Label and
attach to the vehicle. The Authorized
Modifications Label is available through the MDC P/N 00451-00001-LBL.
B. Attach the label under the hood in the location determined by the specific TSB or Campaign.
NOTE
Wait 60 - 90 seconds for ink to set before handling.
Page 5945
Page 9266
Page 2473
Crankshaft Main Bearing Seal: Service and Repair Installation
1UR-FE ENGINE MECHANICAL: REAR CRANKSHAFT OIL SEAL: INSTALLATION
1. INSTALL REAR CRANKSHAFT OIL SEAL
(a) Apply MP grease to the lip of a new oil seal.
(b) Using SST and a hammer, tap in the oil seal until its surface is flush with the rear oil seal
retainer edge.
SST : 09223-56010
NOTICE: *
Keep the lip free from foreign matter.
* Do not tap on the oil seal at an angle.
2. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY See: Service and Repair/Removal
and Replacement/Engine
Assembly/Installation
3. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY
(a) for 2WD:
Refer to the following procedures .
(b) for 4WD:
Refer to the following procedures See: Transmission and Drivetrain/Automatic
Transmission/Transaxle/Service and Repair/Removal and Replacement/Installation.
4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Page 6047
"Case2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 3508
OK -- REPAIR OR REPLACE NO. 1 JUNCTION CONNECTOR
13. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (COMBINATION METER ECU)
(a) Disconnect the J28 combination meter ECU connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE CAN MAIN WIRE CONNECTED TO COMBINATION METER ECU
(CANH, CANL)
OK -- REPLACE COMBINATION METER ASSEMBLY
14. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (MAIN BODY ECU)
(a) Disconnect the J2 main body ECU connector.
Page 7946
Tire size:
Must exceed the following dimensions
Width 185 mm (7.28 in.)
Inner diameter 360 mm (14.2 in.)
(2) Tie the lower No. 1 instrument panel airbag to the tire with several wire harnesses.
CAUTION: *
Make sure that the wire harnesses are tight. If there is slack in the wire harnesses, the lower No. 1
instrument panel airbag may become loose due to the shock when the airbag is deployed.
* Always tie down the lower No. 1 instrument panel airbag with the airbag deployment side facing
inside the tire.
NOTICE: As the tire may be damaged by the airbag deployment, use a tire that you are planning to
throw away.
(d) Connect SST connector to the lower No. 1 instrument panel airbag.
SST : 09082-00780
(e) Place tires.
(1) Place at least 2 tires under the tire which the lower No. 1 instrument panel airbag is tied to.
(2) Place at least 2 tires over the tire which the lower No. 1 instrument panel airbag is tied to. The
top tire should have a disc wheel installed.
NOTICE: *
Do not place SST connector under the tires because it could be damaged.
* As the disc wheel may be damaged by the airbag deployment, use a disc wheel that you are
planning to throw away.
* As the tires may be damaged by the airbag deployment, use tires that you are planning to throw
away.
(3) Tie the tires together with 2 wire harnesses.
Page 3171
Accelerator Pedal Position Sensor: Diagrams
Symptom Related Diagnostic Procedures
Axle Shaft Assembly: Symptom Related Diagnostic Procedures
AXLE: AXLE SYSTEM: PROBLEM SYMPTOMS TABLE
HINT Use the table below to help determine the cause of problem symptoms. If multiple suspected
areas are listed, the potential causes of the symptoms are listed in order of probability in the
"Suspected Area" column of the table. Check each symptom by checking the suspected areas in
the order they are listed. Replace parts as necessary.
Page 8208
Seat Belt: Testing and Inspection Front Seat Outer Belt Assembly (for CrewMax)
SEAT BELT: FRONT SEAT OUTER BELT ASSEMBLY (for CrewMax): INSPECTION
1. INSPECT FRONT SEAT OUTER BELT ASSEMBLY
CAUTION: Do not disassemble the retractor.
(a) Before installing the seat belt, check the ELR.
(1) When the inclination of the retractor is 15° or less, check that the belt can be pulled from the
retractor. When the inclination of the retractor
is over 45°, check that the belt locks. If the operation is not as specified, replace the seat belt
assembly.
(b) for Passenger's Seat only:
Check the fastening function of the child restraint system.
NOTICE: The check should be performed with the outer belt installed.
(1) When the belt is pulled out fully, the belt should automatically start to retract.
(2) After the belt has fully retracted, the belt should be able to be pulled out and retracted again.
If the operation is not as specified, replace the belt assembly.
Page 5966
NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do
not operate the ignition switch, any other switches, or the doors.
(a) If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the
harness and connector.
(b) Connect the cable of the Techstream to the DLC3, turn the ignition switch ON and attempt to
use the tester. If the display indicates that a
communication error has occurred, there is a problem either with the vehicle or with the tester.
HINT *
If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of
the original vehicle.
* If communication is still not possible when the tester is connected to another vehicle, the problem
may be in the tester itself. Consult the Service Department listed in the tester's instruction manual.
How To Proceed With Troubleshooting
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: HOW TO
PROCEED WITH TROUBLESHOOTING
1. OPERATION FLOW
HINT Perform troubleshooting in accordance with the procedures below. The following is an outline
of basic troubleshooting procedures. Confirm the troubleshooting procedures for the circuit you are
working on before beginning troubleshooting.
1. VEHICLE BROUGHT TO WORKSHOP
NEXT -- Continue to next step.
2. CUSTOMER PROBLEM ANALYSIS
(a) Ask the customer about the conditions and environment when the problem occurred.
NEXT -- Continue to next step.
3. INSPECT BATTERY VOLTAGE
Standard voltage:
11 to 14 V
If the voltage is below 11 V, recharge or replace the battery before proceeding.
NEXT -- Continue to next step.
Page 4068
(f) Disconnect the wire harness clamp.
(g) Remove the 4 bolts and canister.
Page 6051
Establish conditions in which voltage is present at the check point.
Example:
- [A] - Ignition SW on
- [B] - Ignition SW and SW1 on
- [C] - Ignition SW, SW1 and Relay on (SW2 off)
Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or component terminal.
This check can be done with a test light instead of a voltmeter.
Electronic Circuit Inspection Procedure
Page 3634
Power Steering Pressure Switch: Diagrams Power Steering Oil Pressure Switch
Page 8381
Removal
SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Regular Cab): REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Regular Cab)/Disassembly
3. REMOVE FRONT ARMREST BASE PANEL UPPER LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Page 565
Page 7664
Removal
AIR CONDITIONING: COMPRESSOR (for 1UR-FE): REMOVAL
1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM See: Service and Repair
2. REMOVE FENDER APRON MUDGUARD SEAL LH
Page 3663
Parts Information
Required Tools & Equipment
Repair Procedure
1. Confirm the condition matches the Introduction.
Page 7064
(e) * for 5 leaf spring
7. ADJUST CAMBER AND CASTER
HINT After the camber has been adjusted, inspect the toe-in.
(a) Loosen the toe adjusting cam bolt and camber adjusting cam nut.
(b) Turn the toe adjusting cam and camber adjusting cam in both directions, and adjust the camber
and caster to the center value.
HINT The camber and caster should be as close as possible to the center value.
Page 4977
Transmission Speed Sensor: Service and Repair Removal
A760F AUTOMATIC TRANSMISSION: SPEED SENSOR: REMOVAL
1. REMOVE SPEED SENSOR NT
(a) Disconnect the sensor connector.
(b) Remove the bolt and sensor.
(c) Remove the O-ring from the sensor.
2. REMOVE SPEED SENSOR SP2
(a) Disconnect the sensor connector.
(b) Remove the bolt and sensor.
(c) Remove the O-ring from the sensor.
Engine - Controls - Non-Linear Acceleration From A Stop
Engine Control Module: All Technical Service Bulletins Engine - Controls - Non-Linear Acceleration
From A Stop
T-SB-0273-10
September 28, 2010
Non-Linear Acceleration from a Stop
Service Category Engine/Hybrid System
Section Engine Control
Market USA
Applicability
Introduction
Some 2010 model year Tundra vehicles with the 1UR-FE (4.6 L) engine may exhibit non-linear
acceleration from a stop under certain conditions of low engine rpm with high engine load. The
Engine Control Module/ECM (SAE term: Powertrain Control Module/PCM) logic has been revised
to address this condition. Use the following repair procedure to recalibrate the ECM (PCM).
Calibration Information
Warranty Information
Applicable Warranty
^ This repair is covered under the Toyota Federal Emission Warranty. This warranty is in effect for
96 months or 80,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Locations
Steering Control Module: Locations
Instrument Panel (Floor Shift)
Instrument Panel (Column Shift)
Page 2728
Torque : 54 Nm (554 kgf-cm, 40 ft-lbf)
(b) Connect the air fuel ratio sensor connector.
(c) Connect the front No. 3 exhaust pipe to the exhaust pipe support.
(d) Install a new gasket and the front No. 3 exhaust pipe to the front No. 2 exhaust pipe with the 2
bolts and 2 new nuts.
Torque : 48 Nm (489 kgf-cm, 35 ft-lbf)
10. INSTALL HEATED OXYGEN SENSOR (for Bank 1 Sensor 2) See: Powertrain
Management/Computers and Control Systems/Oxygen
Sensor/Service and Repair/Heated Oxygen Sensor/Installation
11. INSTALL PROPELLER SHAFT HEAT INSULATOR (for 4WD) See: Transmission and
Drivetrain/Drive/Propeller Shafts, Bearings and
Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Front Propeller Shaft
Assembly/Installation
12. INSTALL CENTER EXHAUST PIPE ASSEMBLY
(a) Connect the center exhaust pipe to the 3 exhaust pipe supports.
(b) Install 2 new gaskets to the front exhaust pipes.
(c) Install the center exhaust pipe with the 4 bolts.
Torque : 48 Nm (489 kgf-cm, 35 ft-lbf)
13. INSTALL TAILPIPE ASSEMBLY
(a) Connect the tailpipe to the exhaust pipe support.
(b) Install a new gasket to the center exhaust pipe.
Page 7079
Steering Column Control Module: Service and Repair Installation
STEERING COLUMN: MULTIPLEX TILT AND TELESCOPIC ECU (for Power Tilt and Power
Telescopic Steering Column): INSTALLATION
1. INSTALL MULTIPLEX TILT AND TELESCOPIC ECU
(a) Install the ECU with the 2 screws.
Torque : 1.5 Nm (15 kgf-cm, 13 in-lbf)
(b) Connect the 2 ECU connectors.
2. INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY See: Steering/Steering Column/Service and
Repair/Removal and Replacement/Steering Column
Assembly (for Power Tilt and Power Telescopic Steering Column)/Removal
3. INSTALL LOWER NO. 1 INSTRUMENT PANEL AIR BAG ASSEMBLY See: Restraint
Systems/Air Bag Systems/Air Bag/Service and
Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Installation
4. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Floor Shift Type)/Removal
5. INSTALL HOOD LOCK CONTROL LEVER SUB-ASSEMBLY See: Body and Frame/Doors,
Hood and Trunk/Hood/Hood Latch Release
Cable/Service and Repair/Installation
6. INSTALL LOWER STEERING COLUMN COVER
(a) Attach the 2 claws to install the steering column lower cover.
7. INSTALL UPPER STEERING COLUMN COVER
Page 7869
4. INSTALL COOLING UNIT DAMPER SERVO SUB-ASSEMBLY (for Automatic Air Conditioning
System)
(a) Install the damper servo with the 3 screws, as shown in the illustration.
(b) Connect the connector.
5. INSTALL BLOWER DAMPER SERVO SUB-ASSEMBLY
(a) Install the damper servo with the 3 screws.
(b) Connect the connector.
6. INSTALL BLOWER CASE SUB-ASSEMBLY
(a) Attach the 3 claws to install the case.
(b) Install the 3 screws.
Page 9080
Trailer Towing Part 2
Engine Controls - ECM Update For Shift Performance
PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - ECM
Update For Shift Performance
T-SB-0285-10
October 12, 2010
ECM Calibration: Enhancement to Shifting Performance
Service Category Drivetrain
Section Automatic Transmission/Transaxle
Market USA
Applicability
Introduction
Some vehicles may exhibit the following shifting conditions:
^ Harsh shift on acceleration below 20 mph during the 2-1 downshift.
^ Excessive lock-up operation at freeway speeds about 50 - 60 mph, sometimes referred to as
"busy shifting".
The Engine Control Module/ECM (SAE term: Powertrain Control Module/PCM) calibration has
been revised. Use the following repair procedure to address these conditions.
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Federal Emission Warranty. This warranty is in effect for
96 months or 80,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Page 1307
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Page 1097
(b) Using a screwdriver, detach the claw and remove the windshield wiper switch.
HINT Tape the screwdriver tip before use.
NOTICE: If the claw is pressed forcefully, it will break.
16. REMOVE HEADLIGHT DIMMER SWITCH ASSEMBLY
(a) Disconnect the connector.
(b) While loosening the band clamp as shown in the illustration, detach the claw to remove the
headlight dimmer switch.
NOTICE: If the claw is pressed forcefully, it will break.
Page 6394
Page 4237
Accelerator Pedal Position Sensor: Diagrams
Page 8336
Impact Sensor: Testing and Inspection Front Airbag Sensor
SUPPLEMENTAL RESTRAINT SYSTEM: FRONT AIRBAG SENSOR: ON-VEHICLE
INSPECTION
1. CHECK FRONT AIRBAG SENSOR (VEHICLE NOT INVOLVED IN COLLISION)
(a) Perform a diagnostic system check See: Air Bag Systems/Testing and Inspection/Initial
Inspection and Diagnostic Overview/Diagnosis
System.
2. CHECK FRONT AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS
NOT DEPLOYED)
(a) Perform a diagnostic system check See: Air Bag Systems/Testing and Inspection/Initial
Inspection and Diagnostic Overview/Diagnosis
System.
(b) When the front bumper of the vehicle or its area is damaged, check if there is any damage to
the front airbag sensor. If the front airbag sensor
has defects as mentioned below, replace it with a new one:
* Cracks, dents or chips on the sensor housing.
* Cracks or other damage to the connector.
* Peeling off of the label or damage to the serial number.
CAUTION: For removal and installation procedures of the front airbag sensor, be sure to follow the
correct procedure.
3. CHECK FRONT AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS
DEPLOYED)
(a) Replace the front airbag sensor.
CAUTION: *
For removal and installation procedures of the front airbag sensor, be sure to follow the correct
procedure.
* If the airbags have deployed, replace the front airbag sensor on the side in which the collision
occurred. Replace both if necessary.
Page 6719
Establish conditions in which voltage is present at the check point.
Example:
- [A] - Ignition SW on
- [B] - Ignition SW and SW1 on
- [C] - Ignition SW, SW1 and Relay on (SW2 off)
Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or component terminal.
This check can be done with a test light instead of a voltmeter.
Electronic Circuit Inspection Procedure
Page 8043
Clockspring Assembly / Spiral Cable: Diagrams Sprial Cable, Cruise Control Switch
Page 1032
Brake Light Switch: Service and Repair Removal
LIGHTING: STOP LIGHT SWITCH: REMOVAL
1. REMOVE STOP LIGHT SWITCH ASSEMBLY
(a) Disconnect the connector.
(b) Rotate the stop light switch in the direction of the arrow and remove it.
2. REMOVE STOP LIGHT SWITCH MOUNTING ADJUSTER
(a) Detach the 2 claws and remove the adjuster.
Page 6227
Diode: Diagrams Diode (Ignition)
Page 6275
Establish conditions in which voltage is present at the check point.
Example:
- [A] - Ignition SW on
- [B] - Ignition SW and SW1 on
- [C] - Ignition SW, SW1 and Relay on (SW2 off)
Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or component terminal.
This check can be done with a test light instead of a voltmeter.
Electronic Circuit Inspection Procedure
Bleeding
Brake Bleeding: Service and Repair Bleeding
BRAKE: BRAKE FLUID: BLEEDING
NOTICE: *
Perform fluid replacement with the parking brake applied.
* Perform fluid replacement while maintaining the brake fluid level between the MIN/MAX level on
the brake fluid reservoir.
* Do not allow brake fluid to contact the vehicle's paint surfaces. If contact occurs, clean it off
immediately.
* After adding brake fluid, make sure the reservoir is sufficiently full.
* When bleeding air, select the suitable procedure listed below.
1. BLEED BRAKE LINE
(a) Bleed brake line
(1) Remove the brake master cylinder reservoir filler cap assembly.
(2) Add brake fluid into the reservoir between MAX and MIN level on the brake fluid reservoir.
Brake fluid:
SAE J1703 or FMVSS No. 116 DOT3
(3) Connect a vinyl tube to the bleeder plug of the front disc brake cylinder RH.
(4) Depress the brake pedal several times, and then loosen the bleeder plug with the pedal
depressed.*1
(5) When fluid stops coming out, tighten the bleeder plug, and then release the brake pedal.*2
(6) Repeat *1 and *2 until all the air in the brake fluid is completely bled out and the new brake fluid
comes out.
(7) Tighten the bleeder plug completely.
Torque : 11 Nm (110 kgf-cm, 8 ft-lbf)
(8) Replace the brake fluid from the front disc brake cylinder LH using the same procedure as for
RH.
(9) Connect a vinyl tube to the bleeder plug of the rear disc brake cylinder RH.
(10)Depress the brake pedal several times, and then loosen the bleeder plug with the pedal
depressed.*1
(11)When fluid stops coming out, tighten the bleeder plug, and then release the brake pedal.*2
(12)Repeat *1 and *2 until all the air in the brake fluid is completely bled out and the new brake
fluid comes out.
(13)Tighten the bleeder plug completely.
Torque : 11 Nm (110 kgf-cm, 8 ft-lbf)
(14)Replace the brake fluid from the rear disc brake cylinder LH using the same procedure as for
RH.
(b) Check and bleed brake system.
(1) If the following malfunction symptoms occur, air may have entered the brake fluid line. Perform
the following air bleed procedures.
Front Occupant Classification Sensor
Seat Occupant Sensor: Diagrams Front Occupant Classification Sensor
Page 200
Page 6485
Components
Air Flow Meter/Sensor: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: COMPONENTS
Page 2829
(q) WAVEFORM 16:
HINT The wavelength changes when the air injection control driver detects malfunctions in the air
injection system See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble
Code Tests and Associated Procedures/P Code Charts/P0412
(r) WAVEFORM 17:
Components
Positive Crankcase Ventilation Valve: Service and Repair Components
1UR-FE EMISSION CONTROL: PCV VALVE: COMPONENTS
Page 8852
(a) Temporarily install the speaker by attaching the claws of the speaker to the door panel.
(b) Install the speaker with the 3 screws.
NOTICE: Do not touch the cone part of the speaker.
HINT Install the screws in the order shown in the illustration.
(c) Connect the connector.
2. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY LH See: Body and Frame/Doors, Hood
and Trunk/Doors/Rear Door/Service and
Repair/Rear Door (for Double Cab)/Reassembly
3. INSTALL COURTESY LIGHT ASSEMBLY See: Body and Frame/Doors, Hood and
Trunk/Doors/Rear Door/Service and Repair/Rear Door
(for Double Cab)/Reassembly
4. INSTALL REAR DOOR ARMREST COVER LH
5. INSTALL REAR UPPER DOOR ARMREST BASE PANEL LH See: Body and Frame/Doors,
Hood and Trunk/Doors/Rear Door/Service and
Repair/Rear Door (for Double Cab)/Reassembly
6. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG LH See: Body and Frame/Doors, Hood
and Trunk/Doors/Rear Door/Service and
Repair/Rear Door (for Double Cab)/Reassembly
7. INSTALL REAR DOOR FRAME GARNISH LH See: Body and Frame/Doors, Hood and
Trunk/Doors/Rear Door/Service and Repair/Rear
Door (for Double Cab)/Reassembly
8. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
From 11/2009
AUDIO / VISUAL: REAR DOOR SPEAKER (for Double Cab): INSTALLATION
HINT *
Use the same procedures for the LH side and RH side.
* The procedures listed below are for the LH side.
1. INSTALL REAR NO. 1 SPEAKER ASSEMBLY
(a) Temporarily install the speaker by attaching the claws of the speaker to the door panel.
(b) Install the speaker with the 3 screws.
NOTICE: Do not touch the cone part of the speaker.
HINT Install the screws in the order shown in the illustration.
(c) Connect the connector.
2. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY LH See: Body and Frame/Doors, Hood
and Trunk/Doors/Rear Door/Service and
Repair/Rear Door (for Double Cab)/Reassembly
Page 3298
Then click Start.
I. Do NOT disturb the vehicle during flash reprogramming.
NOTE
^ ECU flash reprogramming may take anywhere from 3 - 30 minutes per calibration file.
^ Reprogramming time will vary depending on model and ECU communication protocol. Vehicles
using CAN communication protocol will reprogram much faster (2 - 7 minutes).
NOTE
^ If vehicle requires only ONE calibration update, then proceed to step N in this bulletin.
^ If vehicle requires a SECOND calibration update, then continue as follows:
^ For serial communication vehicles, go to step J.
^ For CAN communication vehicles, go to step L.
Page 5755
Page 8090
Removal
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift
Type): REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal
3. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding
/ Trim/Dashboard / Instrument
Page 5372
Four Wheel Drive Selector Switch: Service and Repair Installation
JF1A TRANSFER: 4WD CONTROL SWITCH: INSTALLATION
1. INSTALL 4WD CONTROL SWITCH
(a) Attach the 3 claws to install the switch.
2. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Panel,
Gauges and Warning Indicators/Instrument Cluster
/ Carrier/Service and Repair/Combination Meter/Installation
Page 6339
Use a volt/ohmmeter with high impedance (10 kohms/V minimum) for troubleshooting of the
electrical circuit.
Disconnection of Male and Female Connectors
DISCONNECTION OF MALE AND FEMALE CONNECTORS
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Finding A Short Circuit
FINDING A SHORT CIRCUIT
Page 3791
Camshaft Position Sensor: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT POSITION SENSOR: INSTALLATION
1. INSTALL CAMSHAFT POSITION SENSOR
(a) Install the sensor with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(b) Connect the sensor connector.
2. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Installation
Page 6021
4. REMOVE GENERATOR COIL ASSEMBLY
(a) Remove the 4 bolts.
(b) Using SST, remove the coil assembly.
SST : 09950-40011
09951-04020
09952-04010
09953-04020
09954-04010
09955-04071
09957-04010
09958-04011
(c) Remove the generator washer.
5. REMOVE GENERATOR ROTOR ASSEMBLY
6. REMOVE GENERATOR DRIVE END FRAME BEARING
(a) Remove the 4 screws and retainer plate.
Components
Ignition Switch: Service and Repair Components
1UR-FE STARTING: IGNITION SWITCH: COMPONENTS
Page 3714
M. Turn ignition OFF for a minimum of 10 seconds. Then click Next.
N. Turn ignition to the ON position. Then click Next.
0. Confirm all calibrations were updated as specified in the service bulletin. Then click Finish.
Page 7765
(b) for Floor Shift Type:
Install the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation.
4. INSTALL STEERING COLUMN ASSEMBLY
(a) Install the steering column See: Steering and Suspension/Steering/Steering Column/Service
and Repair/Removal and Replacement/Steering
Column Assembly (for Manual Tilt)/Installation.
5. INSTALL FRONT WIPER MOTOR AND BRACKET
(a) Install the front wiper motor and bracket See: Wiper and Washer Systems/Wiper Motor/Service
and Repair/Installation.
6. CONNECT HEATER WATER INLET HOSE AND HEATER WATER OUTLET HOSE
(a) Connect the 2 heater water hoses and attach the 2 clips.
7. CONNECT SUCTION PIPE SUB-ASSEMBLY AND LIQUID TUBE
(a) Remove the attached vinyl tape from the tubes.
(b) Sufficiently apply compressor oil to 2 new O-rings and the fitting surface of the suction pipe
sub-assembly and liquid tube.
Compressor oil:
ND-OIL 8 or equivalent
(c) Install the 2 O-rings on the suction pipe sub-assembly and liquid tube.
(d) Connect the suction pipe sub-assembly and liquid tube.
HINT After the connection, check that the claw of the piping clamp is engaged.
(e) Attach the plate as shown in the illustration and install the bolt.
Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)
Page 3777
Air Flow Meter/Sensor: Testing and Inspection On-Vehicle Inspection
1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: ON-VEHICLE INSPECTION
1. CHECK MASS AIR FLOW METER
(a) Check the mass air flow value.
(1) Connect the Techstream to the DLC3.
(2) Turn the ignition switch to ON.
(3) Turn the Techstream main switch ON.
(4) Enter the following menus: Powertrain / Engine / Data List / All Data / MAF.
(5) Blow air into the MAF meter, and check that the MAF value fluctuates.
(6) If the result is not as specified, check the MAF meter See: Inspection, or wiring and ECM See:
Testing and Inspection/Diagnostic
Trouble Code Tests and Associated Procedures/P Code Charts/P0102.
Page 1360
Air Bag Deactivation Switch: Diagrams Curtain Airbag Cutoff Switch
Page 2209
Tire Pressure Sensor: Service and Repair Disposal
TIRE AND WHEEL: TIRE PRESSURE WARNING VALVE AND TRANSMITTER: DISPOSAL
HINT The tire pressure warning valve is powered by a lithium battery. When disposing of the tire
pressure warning valve and transmitter, remove the battery and dispose of it correctly.
1. DISPOSE OF TIRE PRESSURE WARNING VALVE AND TRANSMITTER
(a) Use the tip of a screwdriver to pry off the back cover.
(b) The battery and base board are exposed. While taking out the battery, cut the 2 terminals that
connect the battery to the base board.
Page 5633
Traction Control Switch: Diagrams
Page 5964
(2) Disconnect connector B and measure the resistance.
Standard resistance (Fig. 7):
* If the results match the examples above, a short circuit exists between terminal 1 of connector B2
and terminal 1 of connector C.
4. CHECK AND REPLACE ECU
NOTICE: *
The connector should not be disconnected from the ECU. Perform the inspection from the backside
of the connector on the wire harness side.
* When no measuring condition is specified, perform the inspection with the engine stopped and
the ignition switch ON.
* Check that the connectors are fully seated. Check for loose, corroded or broken wires.
(a) First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be
faulty. Temporarily replace the ECU with a
normally functioning one and check if the symptoms occur. If the trouble symptoms disappear,
replace the original ECU.
(1) Measure the resistance between the ECU ground terminal and body ground.
Standard resistance:
Below 1 Ohms
(2) Disconnect the ECU connector. Check the ground terminal on the ECU side and wire harness
side for bending, corrosion or foreign matter.
Lastly, check the contact pressure of the female terminals.
Page 523
Tire Pressure Module: Diagrams
CAN Communication System
Body Control Module: Locations CAN Communication System
CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: PARTS LOCATION
Diagram Information and Instructions
Ignition Switch: Diagram Information and Instructions
Wiring Color Codes
Abbreviations Used Within Diagrams
Abbreviations Used Within Diagrams
Page 6916
Push the terminal retainer down to the temporary lock position.
Page 3337
Engine Control Module: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: ECM: REMOVAL
1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Removal
2. REMOVE AIR CLEANER ASSEMBLY See: Ignition System/Ignition Coil/Service and
Repair/Removal
3. DISCONNECT CONNECTOR HOLDER BLOCK
(a) Remove the connector holder block cover.
(b) Remove the 3 bolts and move the connector holder block so that the ECM can be removed in
the next step.
4. REMOVE ECM
(a) Disconnect the wire harness clamp.
(b) Raise the 2 levers while pushing the locks on the 2 levers shown in the illustration.
NOTICE: Make sure that the lock lever is raised 90° as shown in the illustration before
disconnecting the connectors. Failure to do this may cause the connectors to break.
(c) Disconnect the 2 connectors.
(d) Remove the 4 bolts and ECM.
5. REMOVE GASKET
(a) Peel off the rubber part of the gasket.
Page 7771
(a) Disconnect the connector.
(b) Remove the 3 screws and damper servo.
14. REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY
(a) Remove the 3 screws and plate.
(b) Detach the 3 claws and remove the heater clamp.
(c) Remove the heater radiator unit.
15. REMOVE NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY
(a) Remove the packing.
(b) Remove the 6 screws and detach the 4 claws.
Page 3241
NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do
not operate the ignition switch, any other switches, or the doors.
(a) If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the
harness and connector.
(b) Connect the cable of the Techstream to the DLC3, turn the ignition switch ON and attempt to
use the tester. If the display indicates that a
communication error has occurred, there is a problem either with the vehicle or with the tester.
HINT *
If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of
the original vehicle.
* If communication is still not possible when the tester is connected to another vehicle, the problem
may be in the tester itself. Consult the Service Department listed in the tester's instruction manual.
How To Proceed With Troubleshooting
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: HOW TO
PROCEED WITH TROUBLESHOOTING
1. OPERATION FLOW
HINT Perform troubleshooting in accordance with the procedures below. The following is an outline
of basic troubleshooting procedures. Confirm the troubleshooting procedures for the circuit you are
working on before beginning troubleshooting.
1. VEHICLE BROUGHT TO WORKSHOP
NEXT -- Continue to next step.
2. CUSTOMER PROBLEM ANALYSIS
(a) Ask the customer about the conditions and environment when the problem occurred.
NEXT -- Continue to next step.
3. INSPECT BATTERY VOLTAGE
Standard voltage:
11 to 14 V
If the voltage is below 11 V, recharge or replace the battery before proceeding.
NEXT -- Continue to next step.
Page 8568
Parking Assist Distance Sensor: Diagrams
Locations
Transmission Temperature Sensor/Switch: Locations
A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS
LOCATION
Page 7035
for CrewMax of standard deck
Page 1686
for Double Cab of Long Deck
Page 5488
Transfer Case Actuator: Locations JF1A Transfer Case
JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION
Page 7577
Page 8827
Removal
AUDIO / VISUAL: INSTRUMENT PANEL SPEAKER (for CrewMax): REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE FRONT PILLAR GARNISH LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for
CrewMax)/Removal
3. REMOVE FRONT PILLAR GARNISH RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for
CrewMax)/Removal
4. REMOVE NO. 1 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY
Page 7983
1. INSTALL FRONT PASSENGER AIRBAG ASSEMBLY
(a) Attach the 5 hooks (A).
(b) Attach the 5 hooks (B) and install the front passenger airbag on the instrument panel.
(c) Install the 2 screws.
(d) Connect the 2 connectors and install the instrument panel wire to the front passenger airbag.
NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness.
2. INSTALL SIDE NO. 2 DEFROSTER NOZZLE DUCT See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service
and Repair/Overhaul/Instrument Panel Safety Pad (for Column Shift Type)/Reassembly
3. INSTALL NO. 1 HEATER TO REGISTER DUCT WITH NO. 2 HEATER TO REGISTER DUCT
See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Overhaul/Instrument Panel Safety Pad (for
Column Shift Type)/Reassembly
4. INSTALL NO. 4 INSTRUMENT PANEL REGISTER ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Overhaul/Instrument Panel Safety Pad (for Column Shift
Type)/Reassembly
5. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY
HINT *
Refer to the procedures from "INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY"
(for Column Shift Type) See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column
Shift Type)/Installation
* Refer to the procedures from "INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY"
(for Floor Shift Type) See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
7. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
Components
SUPPLEMENTAL RESTRAINT SYSTEM: FRONT PASSENGER SIDE KNEE AIRBAG
ASSEMBLY: COMPONENTS
Engine Controls - ECM Update For Shift Performance
PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - ECM
Update For Shift Performance
T-SB-0285-10
October 12, 2010
ECM Calibration: Enhancement to Shifting Performance
Service Category Drivetrain
Section Automatic Transmission/Transaxle
Market USA
Applicability
Introduction
Some vehicles may exhibit the following shifting conditions:
^ Harsh shift on acceleration below 20 mph during the 2-1 downshift.
^ Excessive lock-up operation at freeway speeds about 50 - 60 mph, sometimes referred to as
"busy shifting".
The Engine Control Module/ECM (SAE term: Powertrain Control Module/PCM) calibration has
been revised. Use the following repair procedure to address these conditions.
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Federal Emission Warranty. This warranty is in effect for
96 months or 80,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Page 8481
Page 2346
Variable Valve Timing Actuator: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT OIL CONTROL VALVE: REMOVAL
1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Service and Repair/Removal and
Replacement/Engine Assembly/Removal
2. REMOVE AIR CLEANER HOSE ASSEMBLY See: Service and Repair/Removal and
Replacement/Engine Assembly/Removal
3. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side of Bank
1)
(a) Disconnect the oil control valve connector.
(b) Remove the bolt and oil control valve.
(c) Remove the O-ring from the oil control valve.
4. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side of Bank 1)
(a) Disconnect the oil control valve connector.
(b) Remove the bolt and oil control valve.
(c) Remove the O-ring from the oil control valve.
5. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side of Bank 2)
(a) Disconnect the oil control valve connector.
(b) Remove the bolt and oil control valve.
(c) Remove the O-ring from the oil control valve.
6. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side of Bank
2)
(a) Disconnect the oil control valve connector.
(b) Remove the bolt and oil control valve.
(c) Remove the O-ring from the oil control valve.
Page 7985
(b) Disconnect the connector.
NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness.
Installation
SUPPLEMENTAL RESTRAINT SYSTEM: FRONT PASSENGER SIDE KNEE AIRBAG
ASSEMBLY: INSTALLATION
1. INSTALL LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY
(a) Connect the connector.
NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness.
(b) Install the 3 bolts to install the instrument panel airbag.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
2. INSTALL LOWER INSTRUMENT PANEL See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
3. INSTALL NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY See: Body and
Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Column Shift Type)/Installation
4. INSTALL INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
5. INSTALL COWL SIDE TRIM BOARD RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Installation
6. INSTALL FRONT DOOR SCUFF PLATE RH (for Regular Cab) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Installation
7. INSTALL FRONT DOOR SCUFF PLATE RH (for Double Cab, CrewMax) See: Body and
Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Installation
8. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
9. CHECK SRS WARNING LIGHT
Page 9091
Page 3576
Page 6154
Push the secondary locking device or terminal retainer in to the full lock position.
CONNECT CONNECTOR
Voltage Check
VOLTAGE CHECK
Locations
Door Sensor/Switch (For Alarm): Locations
THEFT DETERRENT: THEFT DETERRENT SYSTEM: PARTS LOCATION
Components
Four Wheel Drive Selector Switch: Service and Repair Components
JF1A TRANSFER: 4WD CONTROL SWITCH: COMPONENTS
Page 6472
Push the terminal retainer down to the temporary lock position.
Page 5429
Control Module: Service and Repair Installation
JF1A TRANSFER: 4WD CONTROL ECU: INSTALLATION
1. INSTALL 4WD CONTROL ECU
(a) Install the ECU with the bolt.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
(b) Connect the 2 ECU connectors.
2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Installation
3. INSTALL INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
4. INSTALL COWL SIDE TRIM BOARD RH
(a) Install the cowl side trim board RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Installation.
HINT Use the same procedures described for the LH side.
5. INSTALL FRONT DOOR SCUFF PLATE RH (for Regular Cab)
(a) Install the front door scuff plate RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Installation.
HINT Use the same procedures described for the LH side.
6. INSTALL FRONT DOOR SCUFF PLATE RH (for Double Cab, for CrewMax)
(a) Install the front door scuff plate RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Installation.
HINT Use the same procedures described for the LH side.
Page 5756
Page 2910
Camshaft Position Sensor: Locations Ignition System
1UR-FE IGNITION: IGNITION SYSTEM: PARTS LOCATION
Page 6348
Release the locking lug from terminal and pull the terminal out from rear.
INSTALL TERMINAL TO CONNECTOR
Insert the terminal.
HINT: Make sure the terminal is positioned correctly.
Insert the terminal until the locking lug locks firmly.
Insert the terminal with terminal retainer in the temporary lock position.
Page 7656
* In the DTC check, it is very important to determine whether the problem indicated by the DTC is
either: 1) still occurring; or 2) occurred in the past but has since returned to normal. In addition, the
DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs
should be checked before and after confirmation of symptoms (i.e., whether or not problem
symptoms exist) to determine current system conditions, as shown in the flowchart below.
* Never skip the DTC check. Failing to check DTCs may, depending on the case, result in
unnecessary troubleshooting for systems operating normally or lead to repairs not related to the
problem. Follow the procedures listed in the flowchart in the correct order.
* The following flowchart shows how to proceed with troubleshooting using the DTC check.
Directions from the flowchart will indicate how to proceed either to DTC troubleshooting or to the
troubleshooting of each problem symptom.
1. DTC CHECK
NEXT -- Continue to next step.
2. MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR MEMORY
NEXT -- Continue to next step.
3. SYMPTOM CONFIRMATION
B -- Go to step 5 A -- Continue to next step.
4. SIMULATION TEST USING SYMPTOM SIMULATION METHODS
NEXT -- Continue to next step.
5. DTC CHECK
B -- TROUBLESHOOTING OF PROBLEM INDICATED BY DTC A -- Continue to next step.
6. SYMPTOM CONFIRMATION
Page 1269
Air Flow Meter/Sensor: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: REMOVAL
1. REMOVE MASS AIR FLOW METER
(a) Disconnect the MAF connector.
(b) Remove the 2 screws and MAF meter.
Page 5290
(c) Measure dimension A between the snap ring grooves.
(d) Insert the spider bearing into the spider journal portion, and then measure dimension B of the
universal joint.
NOTICE: When measuring dimension B, fix the spider and needle roller bearings in a vise and hold
them firmly together.
(e) Select snap rings to make dimensions A and B the same.
Snap ring type:
NOTICE: *
Use new snap rings.
* If possible, use snap rings of the same thickness for both edges.
(f) Insert the spider into the flange yoke, and then using SST, press in the spider bearing into the
snap ring groove.
SST : 09332-25010
HINT Press in the spider bearing on the opposite side in the same way.
NOTICE: When pressing in the spider bearing, be careful not to damage its lip.
Page 3836
A/F and 02 Sensor Identification
Page 7006
Driver Side J/B Inner Circuit
Capacity Specifications
Fluid - Transfer Case: Capacity Specifications
Transfer Oil
Capacity ...............................................................................................................................................
............................................................ 1.2 qt (1.12L)
Page 9026
4. SYMPTOM CONFIRMATION AND DTC (INCLUDING FREEZE FRAME DATA) CHECK
(a) Visually check the wire harnesses, connectors and fuses for open and short circuits.
(b) Warm up the engine to the normal operating temperature.
(c) Confirm the problem symptoms and conditions, and check for DTCs.
B -- Go to step 6 A -- Continue to next step.
5. DTC CHART
(a) Check the results obtained in the DTC check. Then find the output DTC in the DTC chart. Look
at the "Trouble Area" column for a list of
potentially malfunctioning circuits and / or parts.
NEXT -- Go to step 7
6. PROBLEM SYMPTOMS TABLE
(a) Check the results obtained in the symptom confirmation. Then find the problem symptoms in
the problem symptoms table. Look at the
"Suspected Area" column for a list of potentially malfunctioning circuits and / or parts.
NEXT -- Continue to next step.
7. CIRCUIT INSPECTION OR PARTS INSPECTION
(a) Confirm the malfunctioning circuit or part.
NEXT -- Continue to next step.
8. ADJUST, REPAIR OR REPLACE
(a) Adjust, repair or replace the malfunctioning circuit or parts.
NEXT -- Continue to next step.
9. CONFIRMATION TEST
(a) After the adjustment, repairs or replacement, confirm that the malfunction no longer exists. If the
malfunction does not reoccur, perform a
confirmation test under the same conditions and in the same environment as when the malfunction
occurred the first time.
NEXT -- END
2. CUSTOMER PROBLEM ANALYSIS
HINT *
In troubleshooting, confirm that the problem symptoms have been accurately identified.
Preconceptions should be discarded in order to make an accurate judgment. To clearly understand
what the problem symptoms are, it is extremely important to ask the customer about the problem
and the conditions at the time the malfunction occurred.
* Gather as much information as possible for reference. Past problems that seem unrelated may
also help in some cases.
* The following 5 questions are important points in the problem analysis:
Page 2673
Engine Temperature Sensor: Testing and Inspection
1UR-FE ENGINE CONTROL SYSTEM: ENGINE COOLANT TEMPERATURE SENSOR:
INSPECTION
1. INSPECT ENGINE COOLANT TEMPERATURE SENSOR
(a) Partially immerse the sensor in water and warm up the water.
(b) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(c) If the result is not as specified, replace the engine coolant temperature sensor.
NOTICE: When checking the sensor in water, keep the terminals dry. After the check, wipe the
sensor dry.
HINT If the result is as specified, do not replace the engine coolant temperature sensor.
Components
Steering Column Control Module: Service and Repair Components
STEERING COLUMN: MULTIPLEX TILT AND TELESCOPIC ECU (for Power Tilt and Power
Telescopic Steering Column): COMPONENTS
Components
Drive Belt: Service and Repair Components
1UR-FE ENGINE MECHANICAL: DRIVE BELT: COMPONENTS
Page 276
Push the secondary locking device or terminal retainer in to the full lock position.
CONNECT CONNECTOR
Voltage Check
VOLTAGE CHECK
Page 2566
Variable Valve Timing Actuator: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT OIL CONTROL VALVE: INSTALLATION
1. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side of Bank 1)
(a) Apply a light coat of engine oil to the O-ring.
(b) Install a new O-ring to the oil control valve.
(c) Install the oil control valve with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(d) Connect the oil control valve connector.
2. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side of Bank 1)
(a) Apply a light coat of engine oil to the O-ring.
(b) Install a new O-ring to the oil control valve.
(c) Install the oil control valve with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(d) Connect the oil control valve connector.
3. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side of Bank 2)
(a) Apply a light coat of engine oil to the O-ring.
(b) Install a new O-ring to the oil control valve.
(c) Install the oil control valve with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(d) Connect the oil control valve connector.
4. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side of Bank 2)
Page 6915
"Case2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Diagrams
Fuel Injector: Diagrams
Page 7984
Removal
SUPPLEMENTAL RESTRAINT SYSTEM: FRONT PASSENGER SIDE KNEE AIRBAG
ASSEMBLY: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to disable the SRS system.
2. REMOVE FRONT DOOR SCUFF PLATE RH (for Regular Cab) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Removal
3. REMOVE FRONT DOOR SCUFF PLATE RH (for Double Cab, CrewMax) See: Body and
Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Removal
4. REMOVE COWL SIDE TRIM BOARD RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Removal
5. REMOVE INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal
6. REMOVE NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY See: Body and
Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Column Shift Type)/Removal
7. REMOVE LOWER INSTRUMENT PANEL See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal
8. REMOVE LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY
(a) Remove the 3 bolts and remove the instrument panel airbag.
Page 7933
CAUTION: *
The lower No. 2 instrument panel airbag becomes extremely hot when the airbag is deployed, so
do not touch it for at least 30 minutes after deployment.
* Use gloves and safety glasses when handling a lower No. 2 instrument panel airbag with a
deployed airbag.
* Do not apply water to a lower No. 2 instrument panel airbag with a deployed airbag.
* Always wash your hands with water after completing the operation.
(1) Remove the lower No. 2 instrument panel airbag from the tire.
(2) Place the lower No. 2 instrument panel airbag in a plastic bag, tie it tightly and dispose of it in
the same way as other general parts.
Front Seat Side Airbag Assembly (except Fold Down Seat Type)
SUPPLEMENTAL RESTRAINT SYSTEM: FRONT SEAT SIDE AIRBAG ASSEMBLY (except Fold
Down Seat Type): DISPOSAL
HINT When scrapping a vehicle equipped with the SRS or disposing of the front seat side airbag,
be sure to deploy the airbag first in accordance with the procedure described below. If any
abnormality occurs with the airbag deployment, contact the SERVICE DEPT. of TOYOTA MOTOR
SALES, U.S.A., INC.
CAUTION: *
Never dispose of a front seat side airbag that has an unactivated airbag.
* The airbag produces an exploding sound when it is deployed, so perform the operation outdoors
and where it will not create a nuisance to nearby residents.
* When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool).
Perform the operation in a place away from electrical noise.
* When deploying the airbag, perform the operation at least 10 m (32.8 ft.) away from the airbag.
* The front seat side airbag becomes extremely hot when the airbag is deployed, so do not touch it
for at least 30 minutes after deployment.
* Use gloves and safety glasses when handling a front seat side airbag with a deployed airbag.
* Do not apply water to a front seat side airbag with a deployed airbag.
* Always wash your hands with water after completing the operation.
* An airbag or pretensioner may be activated by static electricity. To prevent this, be sure to touch a
metal surface with bare hands to discharge static electricity before performing this procedure.
1. DISPOSE OF FRONT SEAT SIDE AIRBAG ASSEMBLY (WHEN INSTALLED IN VEHICLE)
HINT Prepare a battery as the power source to deploy the airbag.
(a) Check the function of SST See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
(b) Read the precaution See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
(c) Disconnect the cable from the negative (-) battery terminal.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
(d) Remove the front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Manual
Seat)/Removal for manual seat, See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Power
Page 5607
Hydraulic Control Assembly - Antilock Brakes: Overhaul
Disassembly
BRAKE CONTROL: BRAKE ACTUATOR: DISASSEMBLY
1. REMOVE BRAKE ACTUATOR BRACKET ASSEMBLY
(a) Using a T30 "TORX" wrench, remove the 3 screws and actuator bracket.
Reassembly
BRAKE CONTROL: BRAKE ACTUATOR: REASSEMBLY
1. INSTALL BRAKE ACTUATOR BRACKET ASSEMBLY
(a) Using a T30 "TORX" wrench, install the actuator bracket with the 3 screws.
Torque : 9.5 Nm (97 kgf-cm, 84 in-lbf)
Page 6911
DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector.
Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
Page 5626
Traction Control Relay: Locations From 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 8100
(b) Check that the cable is disconnected from the battery negative (-) terminal.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
(c) Install the door airbag sensor with the screw.
Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)
NOTICE: *
If the door airbag sensor has been dropped, or there are any cracks, dents or other defects in the
case, bracket or connector, replace it with a new one.
* When installing the door airbag sensor, be careful that the SRS wiring does not interfere with
other parts and that it is not pinched between other parts.
(d) Check that there is no looseness in the installation parts of the door airbag sensor.
(e) Connect the connector.
2. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Reassembly
3. INSTALL COURTESY LIGHT ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood
and Trunk/Doors/Front Door/Service and
Repair/Front Door (for Double Cab)/Reassembly
4. INSTALL FRONT LOWER DOOR FRAME BRACKET GARNISH LH (for Front Side) See: Body
and Frame/Doors, Hood and
Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly
5. INSTALL FRONT UPPER ARMREST BASE PANEL LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Reassembly
6. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Reassembly
7. INSTALL REAR SIDE AIRBAG SENSOR
(a) Check that the ignition switch is OFF.
(b) Check that the cable is disconnected from the battery negative (-) terminal.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
(c) Install the side airbag sensor with the bolt.
Page 3406
* If CAN communication system DTCs are output, the trouble cannot be determined solely from the
DTCs. Perform troubleshooting according to "HOW TO PROCEED WITH TROUBLESHOOTING"
See: CAN Communication System/How to Proceed With Troubleshooting
(a) MULTIPLEX TILT AND TELESCOPIC ECU
HINT DTC communication uses the CAN communication system.
(b) MAIN BODY ECU
HINT DTC communication uses the CAN communication system.
(c) ECM
HINT The ECM is connected to the CAN communication system but CAN communication DTCs
are not output.
(d) SKID CONTROL ECU WITH ACTUATOR
HINT DTC communication uses the CAN communication system.
(e) COMBINATION METER ECU
HINT DTC communication uses the CAN communication system.
(f) AIR CONDITIONING AMPLIFIER
HINT DTC communication uses the CAN communication system.
(g) STEERING ANGLE SENSOR
HINT
Page 9243
(b) Attach the claw to install the courtesy light.
4. INSTALL REAR DOOR FRAME GARNISH LH
(a) Attach the 5 clips to install the rear door frame garnish.
5. INSTALL REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY
(a) Attach the 4 claws to install the regulator switch.
6. INSTALL REAR UPPER DOOR ARMREST BASE PANEL LH
(a) Connect the connector.
(b) Attach the 2 clips to install the rear door armrest upper base panel.
7. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG LH
(a) Attach the 4 claws to install the bezel plug.
Page 6127
Starter Relay: Testing and Inspection
1UR-FE STARTING: STARTER RELAY: ON-VEHICLE INSPECTION
1. REMOVE STARTER RELAY (ST)
(a) Remove the engine room relay box cover.
(b) Remove the starter relay from the engine room relay block.
2. INSPECT STARTER RELAY
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) If the result is not as specified, replace the relay.
3. INSTALL STARTER RELAY
Page 894
Variable Valve Timing Actuator Position Sensor: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: VVT SENSOR: REMOVAL
1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Removal
2. REMOVE AIR CLEANER HOSE ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Removal
3. REMOVE VVT SENSOR
(a) Disconnect the 4 sensor connectors.
(b) Remove the 4 bolts and 4 sensors.
Starter (for 1.6 Kw Type)
Starter Motor: Testing and Inspection Starter (for 1.6 Kw Type)
1UR-FE STARTING: STARTER (for 1.6 kW Type): INSPECTION
1. INSPECT STARTER ASSEMBLY
CAUTION: As a large electric current passes through the cable during this inspection, a think cable
must be used.
If not, the cable may became hot and cause injury.
NOTICE: Perform each of the following tests within 3 to 5 seconds.
(a) Perform a pull-in test.
(1) Remove the nut, and then disconnect the field coil lead wire from terminal C.
(2) Connect the battery to the magnet starter switch as shown in the illustration. Then check that
the clutch pinion gear moves outward.
If the clutch pinion gear does not move, replace the magnet starter switch assembly.
(b) Perform a holding test.
(1) When the battery is connected as above with the clutch pinion gear out, disconnect the negative
(-) lead from terminal C. Check that the
pinion gear remains out.
If the clutch pinion gear moves inward, replace the magnet starter switch assembly.
(c) Inspect the clutch pinion gear return.
(1) Disconnect the negative (-) lead from the starter body. Check that the clutch pinion gear returns
inward.
If the clutch pinion gear does not return inward, replace the magnet starter switch assembly.
(d) Perform an operation test without load.
Page 4422
Fuel Pump Control Unit: Locations Engine Control System - SFI System
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 6640
3. REMOVE FRONT SEAT ASSEMBLY LH (for Power Seat)
(a) Remove the front seat LH See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Power
Seat)/Removal.
4. REMOVE FRONT SEAT ASSEMBLY RH (for Power Seat)
HINT Use the same procedures described for the LH side.
5. REMOVE CENTER FRONT SEAT ASSEMBLY
(a) Remove the center front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Center
Seat)/Removal.
6. REMOVE POWER OUTLET SOCKET ASSEMBLY
(a) Disconnect the power outlet socket connector.
(b) Using a screwdriver, detach the claw and remove the power outlet socket.
HINT Tape the screwdriver tip before use.
7. REMOVE POWER OUTLET SOCKET COVER
(a) Detach the 2 claws and remove the power outlet socket cover.
8. REMOVE CENTER SEATBACK PANEL (for Double Cab) See: Body and Frame/Seats/Service
and Repair/Overhaul/Front Seat Assembly (for
Center Seat)/Disassembly
9. REMOVE REAR POWER OUTLET SOCKET ASSEMBLY (for Double Cab)
(a) Using a screwdriver, detach the claw and remove the power outlet socket.
Page 2292
(a) Apply a light coat of engine oil to the O-ring.
(b) Install a new O-ring to the oil control valve.
(c) Install the oil control valve with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(d) Connect the oil control valve connector.
5. INSTALL AIR CLEANER HOSE ASSEMBLY See: Service and Repair/Removal and
Replacement/Engine Assembly/Installation
6. INSTALL V-BANK COVER SUB-ASSEMBLY See: Service and Repair/Removal and
Replacement/Engine Assembly/Installation
Recall 10V017000: Accelerator Pedal Sticking
Accelerator Pedal: Recalls Recall 10V017000: Accelerator Pedal Sticking
VEHICLE MAKE/MODEL: MODEL YEAR(S): Toyota/Avalon 2005-2010 Toyota/Camry 2007-2010
Toyota/Corolla 2009-2010 Toyota/Corolla Matrix 2009-2010 Toyota/Highlander 2010 Toyota/ RAV4
2009-2010 Toyota/Sequoia 2008-2010 Toyota/Tundra 2007-2010 MANUFACTURER: Toyota
Motor North America, Inc.
MFR'S REPORT DATE: January 21, 2010
NHTSA CAMPAIGN ID NUMBER: 10V017000
NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Accelerator Assembly:
Pedal/Linkage
POTENTIAL NUMBER OF UNITS AFFECTED: ?
SUMMARY: Toyota is recalling certain model year 2005-2010 Avalon, model year 2007-2010
Camry, model year 2009-2010 Corolla, Corolla Matrix, RAV4, model year 2010 Highlander, model
year 2008-2010 Sequoia, and model year 2007-2010 Tundra. due to the manner in which the
friction lever interacts with the sliding surface of the accelerator pedal inside the pedal sensor
assembly, the sliding surface of the lever may become smooth during vehicle operation. In this
condition, if condensation occurs on the surface, as may occur from heater operation (without A/C)
when the pedal assembly is cold, the friction when the accelerator pedal is operated may increase,
which may result in the accelerator pedal becoming harder to depress, slower to return, or, in the
worst case, mechanically stuck in a partially depressed position.
CONSEQUENCE: The accelerator pedal may become hard to depress, slow to return to idle, or, in
the worst case, mechanically stuck in a partially depressed position, increasing the risk of a crash.
REMEDY: Toyota has not yet provided a remedy plan or an owner notification schedule. Owners
may contact Toyota at 1-800-331-4331.
NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle
Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov.
Page 6817
Page 9404
(a) Attach the clip to install the lower radiator grille bracket.
(b) Install the bolt and nut.
Torque : 7.0 Nm (71 kgf-cm, 62 in-lbf)
2. INSTALL LOWER RADIATOR GRILLE BRACKET RH
HINT Use the same procedures described for the LH side.
3. INSTALL RADIATOR GRILLE SUB-ASSEMBLY
(a) Attach the 5 clips to install the radiator grille.
(b) Install the 10 bolts.
Torque : 7.0 Nm (71 kgf-cm, 62 in-lbf)
(c) Install the 2 bolts.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
Removal
EXTERIOR: RADIATOR GRILLE: REMOVAL
1. REMOVE RADIATOR GRILLE SUB-ASSEMBLY
(a) Put protective tape around the radiator grille.
Page 5871
Parking Brake Warning Switch: Testing and Inspection
PARKING BRAKE: PARKING BRAKE SWITCH: ON-VEHICLE INSPECTION
1. REMOVE PARKING BRAKE SWITCH ASSEMBLY See: Parking Brake System/Parking Brake
Pedal/Service and
Repair/Overhaul/Disassembly
2. CHECK PARKING BRAKE SWITCH ASSEMBLY
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the parking brake switch assembly.
3. INSTALL PARKING BRAKE SWITCH ASSEMBLY See: Parking Brake System/Parking Brake
Pedal/Service and
Repair/Overhaul/Reassembly
Testing and Inspection
Oil Cooler: Testing and Inspection
1UR-FE LUBRICATION: ENGINE OIL COOLER: INSPECTION
1. INSPECT OIL COOLER ASSEMBLY
(a) Check the oil cooler for damage or clogging.
If necessary, replace the oil cooler assembly.
2. INSPECT OIL PUMP RELIEF VALVE
(a) Coat the relief valve with engine oil.
(b) Check that the relief valve falls smoothly into the valve hole by its own weight.
If the relief valve is not as specified, replace it. If necessary, replace the oil filter bracket.
Locations
Tilt Wheel Switch: Locations
STEERING COLUMN: POWER TILT AND POWER TELESCOPIC STEERING COLUMN
SYSTEM: PARTS LOCATION
Page 2095
Relay Box: Electrical Diagrams
Engine Room R/B And Engine Room J/B Inner Circuit
Removal and Replacement
Suspension Strut / Shock Absorber: Removal and Replacement
Components
SUSPENSION: FRONT SHOCK ABSORBER: COMPONENTS
Page 5328
Control Module: Service and Repair Removal
JF1A TRANSFER: 4WD CONTROL ECU: REMOVAL
1. REMOVE FRONT DOOR SCUFF PLATE RH (for Regular Cab)
(a) Remove the front door scuff plate RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Removal.
HINT Use the same procedures described for the LH side.
2. REMOVE FRONT DOOR SCUFF PLATE RH (for Double Cab, for CrewMax)
(a) Remove the front door scuff plate RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Removal.
HINT Use the same procedures described for the LH side.
3. REMOVE COWL SIDE TRIM BOARD RH
(a) Remove the cowl side trim board RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Removal.
HINT Use the same procedures described for the LH side.
4. REMOVE INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal
5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and
Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument
Panel Safety Pad (for Column Shift Type)/Removal
6. REMOVE 4WD CONTROL ECU
(a) Disconnect the 2 ECU connectors.
(b) Remove the bolt and ECU.
Page 5606
Use the formula to calculate special torque values for situations where a union nut wrench is
combined with a torque wrench See: Service Precautions
3. INSTALL BRAKE TUBE
(a) Using a union nut wrench, connect the 2 brake tubes to the brake master cylinder.
Torque : 20 Nm (199 kgf-cm, 14 ft-lbf)
NOTICE: Use the formula to calculate special torque values for situations where a union nut
wrench is combined with a torque wrench See: Service Precautions
(b) Using a union nut wrench, connect the 2 brake tubes to the VSC actuator.
Torque : 20 Nm (199 kgf-cm, 14 ft-lbf)
NOTICE: Use the formula to calculate special torque values for situations where a union nut
wrench is combined with a torque wrench See: Service Precautions
4. CONNECT VSC ACTUATOR CONNECTOR
(a) Connect the VSC actuator connector.
5. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
6. BLEED BRAKE SYSTEM See: Brake Bleeding/Service and Repair/Bleeding
Up to 11/2009
Brake Fluid Solenoid Valve Relay: Locations Up to 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 8357
Removal
SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Double Cab): REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Disassembly
3. REMOVE FRONT ARMREST BASE PANEL UPPER LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Page 7619
Cabin Temperature Sensor / Switch: Service and Repair Removal
AIR CONDITIONING: ROOM TEMPERATURE SENSOR (for Automatic Air Conditioning System):
REMOVAL
1. REMOVE FRONT DOOR SCUFF PLATE LH
(a) for Regular Cab:
Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular Cab)/Removal.
(b) for Double Cab:
Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Removal.
(c) for CrewMax:
Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for CrewMax)/Removal.
2. REMOVE COWL SIDE TRIM BOARD LH
(a) for Regular Cab:
Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular Cab)/Removal.
(b) for Double Cab:
Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Removal.
(c) for CrewMax:
Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for CrewMax)/Removal.
3. REMOVE INSTRUMENT SIDE PANEL LH
(a) for Column Shift Type:
Remove the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Column Shift Type)/Removal.
(b) for Floor Shift Type:
Remove the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Floor Shift Type)/Removal.
4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH
(a) for Column Shift Type:
Remove the instrument panel finish panel See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument
Panel Safety Pad (for Column Shift Type)/Removal.
(b) for Floor Shift Type:
Remove the instrument panel finish panel See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument
Panel Safety Pad (for Floor Shift Type)/Removal.
5. REMOVE ROOM TEMPERATURE SENSOR
Specifications
Fluid Pan: Specifications
AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY
Install a new gasket and the oil pan with the 20 bolts.
Torque..................................................................................................................................................
.....................................7.0 Nm (71 kgf-cm, 62 in-lbf)
Page 2666
Radiator: Service and Repair Installation
1UR-FE COOLING: RADIATOR: INSTALLATION
1. INSTALL RADIATOR ASSEMBLY
(a) Install a new O-ring to the drain cock plug.
(b) Install the drain cock plug.
(c) Install the outlet radiator hose into the radiator.
HINT Install the hose so that the direction of the hose clamp is as indicated in the illustration.
(d) Set the radiator bracket hooks to the radiator support holes.
(e) Install the radiator with the 4 bolts.
Torque : 18 Nm (184 kgf-cm, 13 ft-lbf)
2. INSTALL RADIATOR SIDE DEFLECTOR LH
(a) Install the deflector with the 6 clips.
(b) Connect the wire harness clamp.
3. INSTALL RADIATOR SIDE DEFLECTOR RH
(a) Install the deflector with the 6 clips.
ACC Cut Relay
Power Distribution Relay: Testing and Inspection ACC Cut Relay
1UR-FE STARTING: ACC CUT RELAY: ON-VEHICLE INSPECTION
1. REMOVE ACC CUT RELAY
(a) Remove the clip.
(b) Detach the 2 clips and remove the cowl side trim board RH.
(c) Remove the relay.
2. INSPECT ACC CUT RELAY
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) If the result is not as specified, replace the relay.
3. INSTALL ACC CUT RELAY
(a) Install the relay.
(b) Attach the 2 clips to install the cowl side trim board RH.
(c) Install the clip.
Page 768
(1) Keep the vehicle stationary on a level surface for 1 second or more.
HINT *
The zero point calibration is performed only once after the system enters test mode.
* Calibration cannot be performed again until the stored data is cleared once.
(2) Check that the buzzer sounds for 3 seconds and DTC C1336 is erased.
(3) Turn the ignition switch off.
6. PERFORM INITIALIZATION OF STEERING ANGLE SENSOR
NOTICE: Complete the adjustment of the steering wheel and wheel alignment, and then initialize
the steering angle sensor. If the order is reversed, the steering wheel and wheel alignment will
become misaligned.
(a) Check that the steering wheel is in the centered position.
(b) Disconnect the negative battery terminal for more than 2 seconds.
NOTICE: After the ignition switch is turned OFF, the navigation system requires approximately 90
seconds to record various types of memory and settings. As a result, after turning the ignition
switch OFF, wait 90 seconds or more before disconnecting the cable from the negative (-) battery
terminal.
(c) Reconnect the negative battery terminal.
Page 6941
J/B No.4 - Instrument Panel Center
Page 8258
(a) Attach the 7 clips to install the quarter trim panel.
(b) Twist the seat belt clockwise and install the seat belt anchor with the bolt.
Torque : 42 Nm (428 kgf-cm, 31 ft-lbf)
HINT For the RH side, twist the seat belt counterclockwise.
(c) Attach the 2 claws to install the cover.
3. INSTALL LUGGAGE COMPARTMENT BOX RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof
Headlining (For Regular Cab)/Installation
4. INSTALL LUGGAGE COMPARTMENT BOX LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof
Headlining (For Regular Cab)/Installation
5. INSTALL UPPER BACK PANEL GARNISH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining
(For Regular Cab)/Installation
6. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP
7. INSTALL FRONT DOOR SCUFF PLATE See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Installation
8. INSTALL FRONT SEAT ASSEMBLY
(a) for Manual Seat:
Install the front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Manual Seat)/Installation.
(b) for Power Seat:
Install the front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Power Seat)/Installation.
Page 6142
Auxiliary Power Outlet: Diagnostic Aids
Continuity and Resistance Check
CONTINUITY AND RESISTANCE CHECK
Disconnect the battery terminal or wire so there is no voltage between the check points.
Contact the two leads of an ohmmeter to each of the check points.
Page 5039
Reassembly
DIFFERENTIAL: DIFFERENTIAL CARRIER ASSEMBLY (for 1GR-FE, 1UR-FE): REASSEMBLY
1. INSTALL REAR DIFFERENTIAL DYNAMIC DAMPER (for Regular Cab Standard Deck)
(a) Install the dynamic and washer damper with the bolt.
Torque : 17 Nm (168 kgf-cm, 12 ft-lbf)
2. INSTALL REAR DIFFERENTIAL DUST DEFLECTOR
(a) Using SST, a press and steel plate, press in the dust deflector.
SST : 09523-36010
NOTICE: Be careful not to damage the dust deflector.
3. INSTALL DIFFERENTIAL CASE ASSEMBLY
(a) Install the 2 side gear thrust washers to the side gears.
(b) Install the 2 side gears with the thrust washers, 2 pinion gears, 2 pinion gear thrust washers and
pinion shaft.
HINT
Page 3325
Page 6917
Release the locking lug from terminal and pull the terminal out from rear.
INSTALL TERMINAL TO CONNECTOR
Insert the terminal.
HINT: Make sure the terminal is positioned correctly.
Insert the terminal until the locking lug locks firmly.
Insert the terminal with terminal retainer in the temporary lock position.
Page 5056
(b) Using a press, press out the drive pinion.
NOTICE: Do not drop the drive pinion.
12. REMOVE FRONT DRIVE PINION FRONT RADIAL BALL BEARING
(a) Remove the bearing (inner race) from the differential carrier.
13. REMOVE FRONT DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR
(a) Remove the 2 bolts and oil deflector.
14. REMOVE FRONT DIFFERENTIAL UNION
(a) Remove the front differential union from the differential carrier.
15. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING
(a) Using SST and a press, press out the bearing (inner race).
SST : 09950-00020
Page 5748
* Use a torque wrench with a fulcrum length of 300 mm (11.8 in.).
* This torque value is effective when union nut wrench is parallel to the torque wrench.
3. CONNECT REAR NO. 1 BRAKE TUBE
(a) Using a union nut wrench, connect the brake tube (labeled B) to the brake master cylinder.
without union nut wrench - Torque : 20 Nm (199 kgf-cm, 14 ft-lbf)
with union nut wrench - Torque : 18 Nm (186 kgf-cm, 13 ft-lbf)
* Use a torque wrench with a fulcrum length of 300 mm (11.8 in.).
* This torque value is effective when union nut wrench is parallel to the torque wrench.
4. CONNECT BRAKE FLUID LEVEL WARNING SWITCH CONNECTOR
(a) Connect the brake fluid level warning switch connector.
5. BLEED BRAKE SYSTEM See: Brake Bleeding/Service and Repair/Bleeding
Front Seat Inner Belt Assembly
Seat Belt: Testing and Inspection Front Seat Inner Belt Assembly
SEAT BELT: FRONT SEAT INNER BELT ASSEMBLY: INSPECTION
1. INSPECT FRONT SEAT INNER BELT ASSEMBLY (for Driver Side)
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
* If the result is not as specified, replace the inner belt assembly.
Page 8638
(a) Remove the 4 bolts.
(b) Detach the clip and 2 claws, and remove the bracket.
Installation
AUDIO / VISUAL: TELEVISION DISPLAY: INSTALLATION
1. INSTALL TELEVISION DISPLAY BRACKET
Page 5079
(b) Clean the contact surfaces with any residual FIPG material using gasoline or alcohol.
(c) Apply seal packing to the bearing retainer as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
HINT Install the differential tube within 10 minutes of applying seal packing.
(d) Install the differential tube onto the bearing retainer.
(e) Clean the threads of 4 new bolts and the retainer bolt holes with toluene or trichloroethylene.
(f) Apply adhesive to 2 to 3 threads of each bolt end.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
(g) Install the 4 bolts.
Torque : 65 Nm (663 kgf-cm, 48 ft-lb for less)
NOTICE: Do not add oil or drive the vehicle immediately after installing the cover, and leave it as is
for at least an hour. Also, for 12 hours or less, avoid rapid acceleration/deceleration.
45. INSTALL AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR
(a) Remove any old FIPG material and be careful not to drop oil on the contact surfaces of the
differential tube and actuator.
(b) Clean the contact surfaces with any residual FIPG material using gasoline or alcohol.
(c) Apply seal packing to the differential tube as shown in the illustration.
Page 4906
Page 9012
"Case2" Open the secondary locking device.
[B] For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray
Gray or White : Black
Locations
Fog/Driving Lamp Relay: Locations
LIGHTING: LIGHTING SYSTEM: PARTS LOCATION
Page 7584
[A] For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
"Case1" Raise the terminal retainer up to the temporary lock position.
Page 2939
Knock Sensor: Testing and Inspection
1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: INSPECTION
1. INSPECT KNOCK SENSOR
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) If the result is not as specified, replace the knock sensor.
Components
Cellular Phone Microphone: Service and Repair Components
AUDIO / VISUAL: MICROPHONE AMPLIFIER: COMPONENTS
Recall 10V017000: Accelerator Pedal Sticking
Accelerator Pedal Position Sensor: All Technical Service Bulletins Recall 10V017000: Accelerator
Pedal Sticking
VEHICLE MAKE/MODEL: MODEL YEAR(S): Toyota/Avalon 2005-2010 Toyota/Camry 2007-2010
Toyota/Corolla 2009-2010 Toyota/Corolla Matrix 2009-2010 Toyota/Highlander 2010 Toyota/ RAV4
2009-2010 Toyota/Sequoia 2008-2010 Toyota/Tundra 2007-2010 MANUFACTURER: Toyota
Motor North America, Inc.
MFR'S REPORT DATE: January 21, 2010
NHTSA CAMPAIGN ID NUMBER: 10V017000
NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Accelerator Assembly:
Pedal/Linkage
POTENTIAL NUMBER OF UNITS AFFECTED: ?
SUMMARY: Toyota is recalling certain model year 2005-2010 Avalon, model year 2007-2010
Camry, model year 2009-2010 Corolla, Corolla Matrix, RAV4, model year 2010 Highlander, model
year 2008-2010 Sequoia, and model year 2007-2010 Tundra. due to the manner in which the
friction lever interacts with the sliding surface of the accelerator pedal inside the pedal sensor
assembly, the sliding surface of the lever may become smooth during vehicle operation. In this
condition, if condensation occurs on the surface, as may occur from heater operation (without A/C)
when the pedal assembly is cold, the friction when the accelerator pedal is operated may increase,
which may result in the accelerator pedal becoming harder to depress, slower to return, or, in the
worst case, mechanically stuck in a partially depressed position.
CONSEQUENCE: The accelerator pedal may become hard to depress, slow to return to idle, or, in
the worst case, mechanically stuck in a partially depressed position, increasing the risk of a crash.
REMEDY: Toyota has not yet provided a remedy plan or an owner notification schedule. Owners
may contact Toyota at 1-800-331-4331.
NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle
Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov.
Page 2205
Tire Pressure Sensor: Service and Repair Removal
TIRE AND WHEEL: TIRE PRESSURE WARNING VALVE AND TRANSMITTER: REMOVAL
1. REMOVE TIRE
2. REMOVE TIRE PRESSURE WARNING VALVE AND TRANSMITTER
(a) Remove the valve core and cap, and release the air from the tire.
(b) After ensuring that a sufficient amount of air has been released, remove the nut and washer
that is used to secure the tire pressure warning
valve and transmitter. Then drop the tire pressure warning valve and transmitter inside the tire.
HINT Keep the removed cap, valve core, nut and washer.
(c) Disengage the bead using the shoe of a tire remover.
NOTICE: Be careful as the tire pressure warning valve and transmitter may become damaged due
to interference between the sensor and tire bead.
(d) Remove the bead on the upper side.
(e) Take out the tire pressure warning valve and transmitter from the tire, then remove the bead on
the lower side.
HINT *
The grommet is a non-reusable part.
* Check that there are no cracks or damage on the grommet. If any damage is found, replace the
washer and nut.
Page 6515
Page 6597
Release the locking lug from terminal and pull the terminal out from rear.
INSTALL TERMINAL TO CONNECTOR
Insert the terminal.
HINT: Make sure the terminal is positioned correctly.
Insert the terminal until the locking lug locks firmly.
Insert the terminal with terminal retainer in the temporary lock position.
Page 7700
(b) Disconnect the connector and remove the panel.
16. REMOVE RADIO RECEIVER ASSEMBLY WITH BRACKET (w/o USB Audio System) See:
Accessories and Optional Equipment/Radio,
Stereo, and Compact Disc/Radio/Stereo/Service and Repair/Radio Receiver (for Column Shift
Type)/Removal
17. REMOVE RADIO RECEIVER ASSEMBLY WITH BRACKET (w/ USB Audio System) See:
Accessories and Optional Equipment/Radio,
Stereo, and Compact Disc/Radio/Stereo/Service and Repair/Radio Receiver (for Column Shift
Type)/Removal
18. REMOVE NAVIGATION RECEIVER ASSEMBLY WITH BRACKET (w/ Navigation System)
See: Accessories and Optional
Equipment/Navigation System/Service and Repair/Navigation Receiver (for Column Shift
Type)/Removal
Installation
AIR CONDITIONING: AIR CONDITIONING PANEL (for Column Shift Type): INSTALLATION
1. INSTALL NAVIGATION RECEIVER ASSEMBLY WITH BRACKET (w/ Navigation System) See:
Accessories and Optional
Equipment/Navigation System/Service and Repair/Navigation Receiver (for Column Shift
Type)/Installation
2. INSTALL RADIO RECEIVER ASSEMBLY WITH BRACKET (w/o USB Audio System) See:
Accessories and Optional Equipment/Radio,
Stereo, and Compact Disc/Radio/Stereo/Service and Repair/Radio Receiver (for Column Shift
Type)/Installation
3. INSTALL RADIO RECEIVER ASSEMBLY WITH BRACKET (w/ USB Audio System) See:
Accessories and Optional Equipment/Radio,
Stereo, and Compact Disc/Radio/Stereo/Service and Repair/Radio Receiver (for Column Shift
Type)/Installation
4. INSTALL INTEGRATION CONTROL AND PANEL ASSEMBLY
(a) Connect the connector.
(b) Attach the 4 clips to install the panel.
5. INSTALL INSTRUMENT PANEL CUP HOLDER ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column
Shift Type)/Installation
6. INSTALL LOWER INSTRUMENT CLUSTER FINISH PANEL See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column
Shift Type)/Installation
7. INSTALL FRONT ASH RECEPTACLE BOX SUB-ASSEMBLY
8. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column
Shift Type)/Installation
Locations
Transmission Speed Sensor: Locations
A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS
LOCATION
Page 3790
Camshaft Position Sensor: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT POSITION SENSOR: REMOVAL
1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Removal
2. REMOVE CAMSHAFT POSITION SENSOR
(a) Disconnect the sensor connector.
(b) Remove the bolt and sensor.
Page 1856
NOTE
On some models, DTCs may set as a result of reprogramming. If DTCs are present, clear codes
and run the Health Check again. Troubleshoot any remaining Current, Pending, or History codes.
Permanent codes will not be cleared using Techstream. Permanent codes do not illuminate the MIL
and do not require troubleshooting. They will clear during normal driving once the Universal Trip
Drive Pattern is performed.
4. Attach the Authorized Modifications Label.
A. Using a permanent marker or ball point pen complete the Authorized Modifications Label and
attach to the vehicle. The Authorized
Modifications Label is available through the MDC P/N 00451-00001-LBL.
B. Attach the label under the hood in the location determined by the specific TSB or Campaign.
NOTE
Wait 60 - 90 seconds for ink to set before handling.
Page 3321
Engine Control Module: Pinout Values and Diagnostic Parameters
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: TERMINALS OF ECM
1. CHECK ECM
(a) Measure the voltage according to the value(s) in the table below.
HINT The standard voltage between each pair of ECM terminals is shown in the table below. The
appropriate conditions for checking each pair of terminals are also indicated. The result of checks
should be compared with the standard voltage for that pair of terminals, displayed in the Specified
Condition column. The illustration above can be used as a reference to identify the ECM terminal
locations.
Page 109
Brake Fluid Solenoid Valve Relay: Locations From 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 3499
Standard resistance:
NG -- CHECK FOR SHORT IN CAN BUS WIRES (ECM)
OK -- REPAIR OR REPLACE NO. 2 JUNCTION CONNECTOR
23. CHECK FOR SHORT IN CAN BUS WIRES (AIR CONDITIONING AMPLIFIER)
(a) Disconnect the J19 air conditioning amplifier connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO AIR CONDITIONING
AMPLIFIER (CANH, CANL)
OK -- REPLACE AIR CONDITIONING AMPLIFIER ASSEMBLY
24. CHECK FOR SHORT IN CAN BUS WIRES (BUS BUFFER ECU)
(a) Disconnect the J59 bus buffer ECU connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO BUS BUFFER ECU (CAN+,
CAN-)
Components
Engine Control Module: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: ECM: COMPONENTS
Page 1693
for Regular Cab of Long Deck
for Double Cab of Standard Deck
Page 1384
Overview/Diagnosis System.
(b) When the quarter panel of the vehicle or its area is damaged, check if there is any damage to
the rear airbag sensor. If there are any defects as
mentioned below, replace the side airbag sensor with a new one:
* Cracks, dents or chips on the sensor housing.
* Cracks or other damage to the connector.
* Peeling off of the label or damage to the serial number.
CAUTION: For removal and installation procedures of the side airbag sensor, be sure to follow the
correct procedure.
3. CHECK REAR AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS
DEPLOYED)
(a) Replace the side airbag sensor.
CAUTION: *
For removal and installation procedures of the side airbag sensor, be sure to follow the correct
procedure.
* If the airbags have deployed, replace the rear airbag sensor on the side in which the collision
occurred. Replace both if necessary.
Side Airbag Sensor (for Regular Cab)
SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Regular Cab):
ON-VEHICLE INSPECTION
1. CHECK SIDE AIRBAG SENSOR (VEHICLE NOT INVOLVED IN COLLISION)
(a) Perform a diagnostic system check See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
2. CHECK SIDE AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS
NOT DEPLOYED)
(a) Perform a diagnostic system check See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
(b) When the center pillar of the vehicle or its area is damaged, check if there is any damage to the
side airbag sensor. If there are any defects as
mentioned below, replace the side airbag sensor with a new one:
* Cracks, dents or chips on the sensor housing.
* Cracks or other damage to the connector.
* Peeling off of the label or damage to the serial number.
CAUTION: For removal and installation procedures of the side airbag sensor, be sure to follow the
correct procedure.
3. CHECK SIDE AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS
DEPLOYED)
(a) Replace the side airbag sensor.
CAUTION: *
For removal and installation procedures of the side airbag sensor, be sure to follow the correct
procedure.
* If the airbags have deployed, replace the side airbag sensor on the side in which the collision
occurred. Replace both if necessary.
Page 6303
Driver Side J/B Inner Circuit
Page 3227
[A] For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
"Case1" Raise the terminal retainer up to the temporary lock position.
Page 9165
1. Wrap a pry bar with a soft shop towel then gently pull the step pad in an upward motion from
front to back using the pry bar to assist.
Be careful NOT to damage the chrome/painted surface.
2. If the plastic posts break off when the step pad is removed and stay in the tube use a punch and
hammer to punch the plastic bits into the tube. Use an
air gun to blow the posts out through the end of the tube.
3. Discard the step pad.
4. Using a pair of pliers pull out the old stainless post retainers (12 pieces) and discard.
5. Install the new post retainers into the holes in the tube.
6. Line up the replacement step posts with the holes in the post retainers.
7. Using the palm of your hand push firmly down in all post locations.
Then using a rubber mallet strike the pad along its entire length to ensure it is seated properly.
Page 7998
When removing the steering pad, do not pull the airbag wire harness.
(c) Disconnect the 2 connectors and remove the steering pad.
NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness.
Installation
SUPPLEMENTAL RESTRAINT SYSTEM: STEERING PAD: INSTALLATION
1. INSTALL STEERING PAD (w/ Steering Pad Switch)
(a) Support the steering pad with one hand.
(b) Connect the 2 connectors to the steering pad.
NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness.
(c) Confirm that the circumference groove of the screw fits in the screw case, and place the
steering pad onto the steering wheel.
(d) Using a T30 "TORX" socket wrench, tighten the 2 screws.
Torque : 8.8 Nm (90 kgf-cm, 78 in-lbf)
2. INSTALL STEERING PAD (w/o Steering Pad Switch)
(a) Support the steering pad with one hand.
(b) Connect the 2 connectors to the steering pad.
NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness.
(c) Confirm that the circumference groove of the screw fits in the screw case, and place the
steering pad onto the steering wheel.
(d) Using a T30 "TORX" socket wrench, tighten the 2 screws.
Torque : 8.8 Nm (90 kgf-cm, 78 in-lbf)
3. INSTALL LOWER NO. 3 STEERING WHEEL COVER
(a) Attach the 2 claws to install the cover.
Page 4113
(3) Check for dirt or mud on the pipe and around the connector before disconnection. Clean if
necessary.
(4) Pinch the connector and disconnect the connector and pipe.
(5) If the connector and the pipe are stuck together, pinch the connector, push and pull the pipe to
disconnect the pipe and pull it out.
NOTICE: Do not use any tools.
(6) Check for dirt or mud on the seal surface of the disconnected pipe. Clean if necessary.
(7) To protect the disconnected pipe and connector from damage and contamination, cover it with a
plastic bag.
(e) Observe these precautions when connecting the fuel tube connector (for Quick Type).
(1) Check that there is no damage or contamination in the connected part of the pipe.
(2) Align the axis of the connector with the axis of the pipe. Push the pipe into the connector until
the connector makes a "click" sound. If the
connection is tight, apply a small amount of fresh spindle oil or gasoline on the tip of the pipe.
(3) After having finished the connection, try to pull apart the pipe and the connector to confirm that
they are securely connected.
Page 1881
(g) Apply a small amount of engine oil to a new drain plug O-ring, and install it to the oil filter cap.
NOTICE: Before installing the O-ring, remove any dirt or foreign matter from the installation surface
of the oil filter cap.
(h) Install the oil filter drain plug.
Torque : 13 Nm (127 kgf-cm, 9 ft-lbf)
NOTICE: Be careful that the O-ring does not get caught between any surrounding parts.
5. ADD ENGINE OIL
(a) Add fresh oil.
Standard Oil Grade (for USA):
Standard Oil Grade (for Canada):
Standard Oil Capacity:
(b) Install the oil filler cap.
6. INSPECT FOR OIL LEAK
(a) Start the engine. Make sure that there are no oil leaks from the area that was worked on.
7. CHECK ENGINE OIL LEVEL See: Engine, Cooling and Exhaust/Engine/Engine
Lubrication/Testing and Inspection
8. INSTALL NO. 1 ENGINE UNDER COVER
Page 5503
Control Module: Diagrams
Page 1874
Repair Procedure
Page 9395
10. Lower the cab back onto the No. 3 cab mount.
11. Install the new bolt through the No.3 cab mount and install the large washer and NEW nut and
torque to specifications.
Torque: 54 N*m (551 kgf*cm, 40 ft*lbf)
12. Torque the nuts to the specified torque range on the No.2 mounts.
Torque: 54 N*m (551 kgf*cm, 40 ft*lbf)
Page 8853
3. INSTALL REAR DOOR ARMREST COVER LH
4. INSTALL REAR UPPER DOOR ARMREST BASE PANEL LH See: Body and Frame/Doors,
Hood and Trunk/Doors/Rear Door/Service and
Repair/Rear Door (for Double Cab)/Reassembly
5. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG LH See: Body and Frame/Doors, Hood
and Trunk/Doors/Rear Door/Service and
Repair/Rear Door (for Double Cab)/Reassembly
6. INSTALL REAR DOOR FRAME GARNISH LH See: Body and Frame/Doors, Hood and
Trunk/Doors/Rear Door/Service and Repair/Rear
Door (for Double Cab)/Reassembly
7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Locations
Trailer Towing Relay: Locations
Engine Room R/B, J/B - Engine Compartment Left
Locations
Transmission Mode Switch: Locations
A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS
LOCATION
Page 6274
Push the secondary locking device or terminal retainer in to the full lock position.
CONNECT CONNECTOR
Voltage Check
VOLTAGE CHECK
Page 7315
(a) Using a clip remover, remove the 5 clips and apron seal.
7. REMOVE FRONT SUSPENSION UPPER ARM ASSEMBLY
(a) Remove the nut, bolt, 2 washers and suspension upper arm.
Installation
SUSPENSION: FRONT UPPER SUSPENSION ARM: INSTALLATION
HINT *
Use the same procedures for the RH side and LH side.
* The procedures listed below are for the LH side.
* A bolt without a torque specification is shown in the standard bolt chart See:
Specifications/Mechanical Specifications/Standard Bolt - Specified Torque For Standard Bolts
1. TEMPORARILY INSTALL FRONT SUSPENSION UPPER ARM ASSEMBLY LH
(a) Temporarily install the suspension upper arm with the 2 washers, bolt and nut.
HINT After stabilizing the suspension, tighten the nut.
2. INSTALL FRONT FENDER APRON SEAL REAR LH
(a) Install the apron seal with the 5 clips.
3. INSTALL FRONT FENDER APRON SEAL LH
(a) Install the apron seal with the 6 clips.
4. CONNECT STEERING KNUCKLE LH
(a) Connect the steering knuckle to the suspension upper arm.
(b) Install the nut and a new cotter pin.
Torque : 110 Nm (1122 kgf-cm, 81 ft-lbf)
Page 6442
Power Distribution Module: Service and Repair Removal
OTHER SYSTEM: VOLTAGE INVERTER (for CrewMax): REMOVAL
1. REMOVE BACK PANEL TRIM LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for
CrewMax)/Removal
2. REMOVE BACK PANEL TRIM RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for
CrewMax)/Removal
3. REMOVE REAR DOOR SCUFF PLATE LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining
(for CrewMax)/Removal
4. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH
5. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY LH See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (for CrewMax)/Removal
6. REMOVE VOLTAGE INVERTER ASSEMBLY
(a) Remove the 2 bolts.
(b) Disconnect the voltage inverter connector and removal the voltage inverter.
Page 2755
Parts Information
Required Tools & Equipment
Repair Procedure
1. Confirm the condition matches the Introduction.
Transponder Key ECU
Alarm Module: Diagrams Transponder Key ECU
Page 3368
DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector.
Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
Page 4282
J. When Cal 1 has completed the update process turn ignition OFF for a minimum of 10 seconds.
Then click Next.
K. Turn ignition to the ON position. Then click Start.
L. Do NOT disturb the vehicle during flash reprogramming.
Page 616
Parking Assist Switch: Service and Repair Installation
PARK ASSIST / MONITORING: CLEARANCE SONAR MAIN SWITCH: INSTALLATION
1. INSTALL DRIVE MONITOR SWITCH
(a) Attach the 2 claws to install the monitor switch.
2. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Panel,
Gauges and Warning Indicators/Instrument Cluster
/ Carrier/Service and Repair/Combination Meter/Installation
Page 6085
Neutral Safety Switch: Adjustments
A760F AUTOMATIC TRANSMISSION: PARK / NEUTRAL POSITION SWITCH: ADJUSTMENT
1. ADJUST PARK/NEUTRAL POSITION SWITCH ASSEMBLY
(a) Loosen the bolt of the park/neutral position switch and move the shift lever to N.
(b) Align the groove with the neutral basic line.
(c) Hold the switch in position and tighten the bolt.
Torque : 13 Nm (130 kgf-cm, 9 ft-lbf)
(d) After the adjustment, perform the on-vehicle inspection See: Testing and Inspection/Initial
Inspection and Diagnostic Overview.
Bleeding
Brake Bleeding: Service and Repair Bleeding
BRAKE: BRAKE FLUID: BLEEDING
NOTICE: *
Perform fluid replacement with the parking brake applied.
* Perform fluid replacement while maintaining the brake fluid level between the MIN/MAX level on
the brake fluid reservoir.
* Do not allow brake fluid to contact the vehicle's paint surfaces. If contact occurs, clean it off
immediately.
* After adding brake fluid, make sure the reservoir is sufficiently full.
* When bleeding air, select the suitable procedure listed below.
1. BLEED BRAKE LINE
(a) Bleed brake line
(1) Remove the brake master cylinder reservoir filler cap assembly.
(2) Add brake fluid into the reservoir between MAX and MIN level on the brake fluid reservoir.
Brake fluid:
SAE J1703 or FMVSS No. 116 DOT3
(3) Connect a vinyl tube to the bleeder plug of the front disc brake cylinder RH.
(4) Depress the brake pedal several times, and then loosen the bleeder plug with the pedal
depressed.*1
(5) When fluid stops coming out, tighten the bleeder plug, and then release the brake pedal.*2
(6) Repeat *1 and *2 until all the air in the brake fluid is completely bled out and the new brake fluid
comes out.
(7) Tighten the bleeder plug completely.
Torque : 11 Nm (110 kgf-cm, 8 ft-lbf)
(8) Replace the brake fluid from the front disc brake cylinder LH using the same procedure as for
RH.
(9) Connect a vinyl tube to the bleeder plug of the rear disc brake cylinder RH.
(10)Depress the brake pedal several times, and then loosen the bleeder plug with the pedal
depressed.*1
(11)When fluid stops coming out, tighten the bleeder plug, and then release the brake pedal.*2
(12)Repeat *1 and *2 until all the air in the brake fluid is completely bled out and the new brake
fluid comes out.
(13)Tighten the bleeder plug completely.
Torque : 11 Nm (110 kgf-cm, 8 ft-lbf)
(14)Replace the brake fluid from the rear disc brake cylinder LH using the same procedure as for
RH.
(b) Check and bleed brake system.
(1) If the following malfunction symptoms occur, air may have entered the brake fluid line. Perform
the following air bleed procedures.
Page 7293
09951-00180
09951-00320
09952-06010
SST : 09950-70010
09951-07150
(c) Using SST and a press, install the control valve upper bearing.
SST : 09950-60010
09951-00180
09951-00340
09952-06010
SST : 09950-70010
09951-07150
8. INSTALL POWER STEERING CONTROL VALVE ASSEMBLY
(a) Expand 4 new control valve rings with your fingers.
NOTICE: Be careful not to over expand the control valve rings.
(b) Coat the 4 control valve rings with power steering fluid.
(c) Install the 4 control valve rings onto the control valve, and position them with your fingers.
(d) Carefully slide the tapered end of SST over the control valve rings until they fit to the control
valve.
Page 4044
Air Injection Pump: Service and Repair Installation
1UR-FE EMISSION CONTROL: AIR PUMP: INSTALLATION
1. INSTALL AIR PUMP ASSEMBLY
(a) Connect the 6 air pump insulators to the air pump and install the air pump to the bracket.
(b) Attach the 2 wire harness clamps to the bracket.
2. CONNECT NO. 1 AIR INJECTION SYSTEM HOSE
(a) Connect the 2 No. 1 air injection system hoses to the air pump.
HINT Insert the hoses until the hose ends are aligned with the stoppers.
3. INSTALL AIR PUMP INLET
(a) Connect the air pump inlet to the No. 1 air injection system hoses to install it, and then slide the
2 clips onto the hoses.
HINT Insert the inlet until the inlet stoppers are aligned with the hose ends.
(b) Install the 2 bolts.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
4. INSTALL AIR PUMP ASSEMBLY WITH BRACKET
(a) Install the air pump to the vehicle.
Page 2749
1. Test drive the vehicle and confirm there is a harsh shift on acceleration below 20 mph and or
excessive lock-up operation at freeway speeds about 50
- 60 mph.
2. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in
Figure 1. Confirm if the ECM (PCM) calibration has
been updated. If the calibration ID listed is NOT the latest ECM (PCM) calibration - go to step 3.
3. Flash reprogram the ECM (PCM).
NOTE
^ The GR8 Battery Diagnostic Station MUST be used in Power Supply Mode to maintain battery
voltage at 13.5 volts while flash reprogramming the vehicle.
^ For details on how to use the GR8 Battery Diagnostic Station, refer to the GR8 Instruction Manual
located on the Technical Information System (TIS), Diagnostics - Battery.
Follow the procedures outlined in TSB No. T-SB-0064-10, "Techstream ECU Flash
Reprogramming Procedure", and flash the ECM (PCM) with the NEW calibration file update.
4. Start the engine and warm it up to normal operating temperature before test driving.
5. Test drive the vehicle to confirm proper vehicle operation and ECM (PCM) initial learning. Refer
to the Technical Information System (TIS) 2010
Tundra Repair Manual:
Drivetrain - Automatic Transmission/Transaxle - "A760E / A760F Automatic
Transmission/Transaxle: Automatic Transmission System: Initialization"
6. Install the Authorized Modifications Label.
A. Using a permanent marker enter the following information on the label:
^ ECM part number [Refer to the Parts Information section for the CURRENT PART NUMBER]
Page 2656
Engine Temperature Sensor: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: ENGINE COOLANT TEMPERATURE SENSOR:
REMOVAL
1. REMOVE NO. 1 ENGINE UNDER COVER See: Engine/Engine Lubrication/Engine Oil/Service
and Repair/Replacement
2. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine/Service and Repair/Removal and
Replacement/Engine Assembly/Removal
3. DRAIN ENGINE COOLANT See: Coolant/Service and Repair
4. REMOVE ENGINE COOLANT TEMPERATURE SENSOR
(a) Disconnect the sensor connector.
(b) Using a 19 mm ball joint lock nut wrench, remove the sensor.
(c) Remove the gasket from the sensor.
Diagram Information and Instructions
Relay Box: Diagram Information and Instructions
Wiring Color Codes
Abbreviations Used Within Diagrams
Abbreviations Used Within Diagrams
Page 6185
HINT Tape the screwdriver tip before use.
7. REMOVE REAR POWER OUTLET SOCKET COVER (for Double Cab)
(a) Detach the 2 claws and remove the power outlet socket cover.
Installation
OTHER SYSTEM: CENTER POWER OUTLET SOCKET (for Floor Shift Type): INSTALLATION
1. INSTALL REAR POWER OUTLET SOCKET COVER (for Double Cab)
(a) Attach the 2 claws to install the power outlet socket cover.
2. INSTALL REAR POWER OUTLET SOCKET ASSEMBLY (for Double Cab)
(a) Attach the claw to install the power outlet socket.
3. INSTALL REAR CONSOLE END PANEL SUB-ASSEMBLY (for Double Cab) See: Body and
Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Floor Shift Type)/Installation
4. INSTALL POWER OUTLET SOCKET COVER
(a) Attach the 2 claws to install the power outlet socket cover.
Page 2099
Driver Side J/B Inner Circuit
Page 8111
(b) Check that the cable is disconnected from the battery negative (-) terminal.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation
(c) Install the door airbag sensor with the screw.
Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)
NOTICE: *
If the door airbag sensor has been dropped, or there are any cracks, dents or other defects in the
case, bracket or connector, replace it with a new one.
* When installing the door airbag sensor, be careful that the SRS wiring does not interfere with
other parts and that it is not pinched between other parts.
(d) Check that there is no looseness in the installation parts of the side airbag sensor.
(e) Connect the connector.
2. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Regular Cab)/Reassembly
3. INSTALL COURTESY LIGHT ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood
and Trunk/Doors/Front Door/Service and
Repair/Front Door (for Regular Cab)/Reassembly
4. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH LH (for Front Side) See: Body
and Frame/Doors, Hood and
Trunk/Doors/Front Door/Service and Repair/Front Door (for Regular Cab)/Reassembly
5. INSTALL FRONT DOOR WINDOW REGULATOR HANDLE ASSEMBLY (for Front Side) See:
Body and Frame/Doors, Hood and
Trunk/Doors/Front Door/Service and Repair/Front Door (for Regular Cab)/Reassembly
6. INSTALL FRONT ARMREST BASE PANEL UPPER LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Regular Cab)/Reassembly
7. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Regular Cab)/Reassembly
8. INSTALL REAR SIDE AIRBAG SENSOR
(a) Check that the ignition switch is OFF.
(b) Check that the cable is disconnected from the battery negative (-) terminal.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
(c) Install the side airbag sensor with the bolt.
Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)
NOTICE: *
If the side airbag sensor has been dropped, or there are any cracks, dents or other defects in the
case, bracket or connector, replace it with a new one.
* When installing the side airbag sensor, be careful that the SRS wiring does not interfere with
other parts and that it is not pinched
Page 8858
Accessory Relay: Diagrams
Page 3564
10. CHECK COMBINATION METER ECU
(a) Disconnect the J28 ECU connector.
(b) Measure the resistance according to the value(s) in the table below.
HINT *
*1: for V bus
* *2: for MS bus
11. CHECK STEERING ANGLE SENSOR
(a) Disconnect the J6 sensor connector.
Page 3170
Accelerator Pedal Position Sensor: Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Up to 11/2009
Brake Fluid Pump Relay: Locations Up to 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 3443
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- CHECK FOR SHORT TO B+ IN CAN BUS WIRE (MAIN BODY ECU) OK -- Continue to next
step.
9. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (NO. 1 JUNCTION CONNECTOR - SKID
CONTROL ECU WITH ACTUATOR)
(a) Disconnect the A46 No. 1 junction connector connector.
(b) Measure the resistance according to the value(s) in the table below.
Page 199
3. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE
HINT The diagnostic system in the TOYOTA TUNDRA has various functions.
* The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU
memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a
previous malfunction's DTC can be checked by a technician during troubleshooting.
* Another function is the Input Signal Check, which checks if the signals from various switches are
sent to the ECU correctly.
* By using these functions, the problem areas can be narrowed down and troubleshooting is more
effective. Diagnostic functions are incorporated in the following systems in the TOYOTA TUNDRA.
Page 8534
11. INSTALL FRONT DOOR SCUFF PLATE LH
(a) for Regular Cab:
Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular Cab)/Installation.
(b) for Double Cab:
Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Installation.
(c) for CrewMax:
Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for CrewMax)/Installation.
Page 1958
Refrigerant Oil: Fluid Type Specifications
COMPRESSOR OIL
Type......................................................................................................................................................
..............................................ND-OIL 8 or equivalent
Page 3243
3. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE
HINT The diagnostic system in the TOYOTA TUNDRA has various functions.
* The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU
memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a
previous malfunction's DTC can be checked by a technician during troubleshooting.
* Another function is the Input Signal Check, which checks if the signals from various switches are
sent to the ECU correctly.
* By using these functions, the problem areas can be narrowed down and troubleshooting is more
effective. Diagnostic functions are incorporated in the following systems in the TOYOTA TUNDRA.
Heated Oxygen Sensor
Oxygen Sensor: Testing and Inspection Heated Oxygen Sensor
1UR-FE ENGINE CONTROL SYSTEM: HEATED OXYGEN SENSOR: ON-VEHICLE
INSPECTION
1. CHECK HEATED OXYGEN SENSOR
(a) Disconnect the heated oxygen sensor connector.
(b) Measure the heater resistance according to the value(s) in the table below.
Standard Resistance:
(c) If the result is not as specified, replace the heated oxygen sensor.
(d) Connect the heated oxygen sensor connector.
Page 4407
Installation Procedure
1. Insert the tip of the fuel sender unit upper cover into the hole on the fuel sender unit lower cover
(2 places).
2. Fasten the tab of the fuel sender unit upper cover to the lip on the fuel sender unit lower cover (1
place).
Locations
Manifold Pressure/Vacuum Sensor: Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Diagrams
Variable Valve Timing Actuator Position Sensor: Diagrams
Page 602
HINT The type of claw on the top and bottom of the sensor are different. Observe the claws
carefully before removing the sensor.
12. REMOVE NO. 1 ULTRASONIC SENSOR RETAINER
(a) Detach the 2 claws and remove the sensor retainer from the front bumper.
Installation
PARK ASSIST / MONITORING: ULTRASONIC SENSOR (for Front Side): INSTALLATION
1. INSTALL NO. 1 ULTRASONIC SENSOR RETAINER
(a) Align the keyhole and protrusion as shown in the illustration.
(b) Install the sensor retainer to the front bumper.
NOTICE: Do not damage the bumper with the protrusion when installing the retainer.
2. INSTALL NO. 1 ULTRASONIC SENSOR
(a) Attach the 2 claws to install the ultrasonic sensor.
Page 6531
Push the secondary locking device or terminal retainer in to the full lock position.
CONNECT CONNECTOR
Voltage Check
VOLTAGE CHECK
Page 2022
Page 8454
Alarm Module: Locations Theft Deterrent System
THEFT DETERRENT: THEFT DETERRENT SYSTEM: PARTS LOCATION
Page 3133
This TSB applies to all Sequoia and Tundra vehicles equipped with lUR-FE (4.6L) 2UZ-FE (4.7L)
and 3UR-FE/FBE (5.7L) engines produced BEFORE the Production Change Effective VINs shown.
Repair Procedure
1. Remove and replace the air cleaner lid.
2. Remove and replace the front right hand (RH) fender liner.
Page 4920
8. INSTALL COLUMN SHIFT LEVER COMPRESSION SPRING
(a) Apply MP grease to the spring as shown in the illustration.
(b) Temporarily install the spring to the column shift control shift lever retainer with the bolt.
(c) With the shift lever protrusion pushed towards the N position wall of the control shift lever
retainer, align the spring roller with the groove as
shown in the illustration. Then tighten the bolt.
Torque : 3.8 Nm (38 kgf-cm, 33 in-lbf)
9. INSTALL COLUMN SHIFT SHIFTING BELLCRANK ASSEMBLY
Page 2629
Water Pump: Service and Repair Installation
1UR-FE COOLING: WATER PUMP: INSTALLATION
1. INSTALL WATER PUMP ASSEMBLY
(a) Install a new gasket and the water pump with the 8 bolts shown in the illustration.
for bolt A - Torque : 47 Nm (479 kgf-cm, 35 ft-lbf)
for bolt B - Torque : 23 Nm (235 kgf-cm, 17 ft-lbf)
for bolt C - Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)
2. INSTALL WATER PUMP PULLEY
(a) Temporarily install the pulley with the 4 bolts.
(b) Using SST, hold the pulley and tighten the 4 bolts.
SST : 09960-10010
09962-01000
09963-01000
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
3. INSTALL WATER INLET HOUSING
(a) Install a new gasket to the water pump.
(b) Install the water inlet housing with the 3 bolts.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
4. CONNECT NO. 5 WATER BY-PASS HOSE
(a) Connect the water by-pass hose.
Recall 11V185000 - TPMS Non-Compliance
Tire Pressure Module: Recalls Recall 11V185000 - TPMS Non-Compliance
VEHICLE MAKE/MODEL: MODEL YEAR(S) Toyota/FJ Cruiser 2011
Toyota/Tundra 2009-2011
MANUFACTURER: Gulf States Toyota, Inc.
MFR'S REPORT DATE: March 16, 2011
NHTSA CAMPAIGN ID NUMBER: 11V185000
NHTSA ACTION NUMBER: N/A
COMPONENT: Tires: Pressure Monitoring and Regulating Systems
POTENTIAL NUMBER OF UNITS AFFECTED: 1,489
SUMMARY: Gulf States Toyota is recalling certain model year 2011 FJ Cruiser and model year
2009-2011 Tundra vehicles for failing to comply with the requirements of Federal Motor Vehicle
Safety Standard No. 138, "Tire Pressure Monitoring Systems." The TPMS on some vehicles may
not have been properly calibrated and as a result the low tire pressure warning lamp may not
illuminate should the inflation pressure in one or more of the vehicle's tires fall below the threshold
for when the low tire pressure warning lamp should illuminate.
CONSEQUENCE: Drivers will not receive a warning from the tire pressuring monitor that one or
more tires are underinflated increasing the risk that a vehicle will be driven with one or more
underinflated tires and increasing the risk of a tire failure that may lead to a crash.
REMEDY: Dealers will recalibrate the tire pressure monitoring system in accordance with the
regulation free of charge. The safety recall is expected to begin during April 2011. Owners may
contact Gulf State Toyota Customer Assistance Center toll free at 1-800-444-1074 Monday through
Thursday, 8:30 AM to 5:00 PM, or Friday 8:30 AM to 4:00 PM Central Standard Time.
NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle
Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov.
Page 5942
Page 9177
Installation
EXTERIOR: SIDE STEP: INSTALLATION
HINT *
Use the same procedures for the RH side and LH side.
* The procedures listed below are for the LH side.
1. INSTALL SIDE STEP ASSEMBLY
(a) Install the side step with the 8 bolts.
Torque : 19.5 Nm (199 kgf-cm, 14 ft-lbf)
Page 4924
Page 4736
1. Test drive the vehicle and confirm there is a harsh shift on acceleration below 20 mph and or
excessive lock-up operation at freeway speeds about 50
- 60 mph.
2. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in
Figure 1. Confirm if the ECM (PCM) calibration has
been updated. If the calibration ID listed is NOT the latest ECM (PCM) calibration - go to step 3.
3. Flash reprogram the ECM (PCM).
NOTE
^ The GR8 Battery Diagnostic Station MUST be used in Power Supply Mode to maintain battery
voltage at 13.5 volts while flash reprogramming the vehicle.
^ For details on how to use the GR8 Battery Diagnostic Station, refer to the GR8 Instruction Manual
located on the Technical Information System (TIS), Diagnostics - Battery.
Follow the procedures outlined in TSB No. T-SB-0064-10, "Techstream ECU Flash
Reprogramming Procedure", and flash the ECM (PCM) with the NEW calibration file update.
4. Start the engine and warm it up to normal operating temperature before test driving.
5. Test drive the vehicle to confirm proper vehicle operation and ECM (PCM) initial learning. Refer
to the Technical Information System (TIS) 2010
Tundra Repair Manual:
Drivetrain - Automatic Transmission/Transaxle - "A760E / A760F Automatic
Transmission/Transaxle: Automatic Transmission System: Initialization"
6. Install the Authorized Modifications Label.
A. Using a permanent marker enter the following information on the label:
^ ECM part number [Refer to the Parts Information section for the CURRENT PART NUMBER]
Components
Remote Switch: Service and Repair Components
AUDIO / VISUAL: STEERING PAD SWITCH: COMPONENTS
Page 9100
Page 729
Seat Heater Switch: Locations Seat Heater System
SEAT: SEAT HEATER SYSTEM: PARTS LOCATION
Page 7547
12. INSTALL NO. 1 PARKING BRAKE SHOE ASSEMBLY LH See: Brakes and Traction
Control/Parking Brake System/Service and
Repair/Reassembly
13. INSTALL PARKING BRAKE SHOE RETURN TENSION SPRING LH See: Brakes and Traction
Control/Parking Brake System/Service and
Repair/Reassembly
14. CHECK PARKING BRAKE INSTALLATION See: Brakes and Traction Control/Parking Brake
System/Service and Repair/Reassembly
15. INSTALL REAR DISC LH See: Brakes and Traction Control/Disc Brake System/Service and
Repair/Removal and Replacement/Rear
Brake/Installation
16. ADJUST PARKING BRAKE SHOE CLEARANCE See: Brakes and Traction Control/Parking
Brake System/Adjustments
17. CONNECT REAR DISC BRAKE CYLINDER ASSEMBLY LH See: Brakes and Traction
Control/Parking Brake System/Service and
Repair/Reassembly
18. INSTALL REAR WHEEL LH
for Aluminum Wheel - Torque : 131 Nm (1336 kgf-cm, 97 ft-lbf)
for Steel Wheel - Torque : 209 Nm (2131 kgf-cm, 154 ft-lbf)
19. CHECK PARKING BRAKE TRAVEL See: Brakes and Traction Control/Parking Brake
System/Adjustments
20. ADJUST PARKING BRAKE TRAVEL See: Brakes and Traction Control/Parking Brake
System/Adjustments
Page 8848
(a) Temporarily install the speaker by attaching the claws of the speaker to the door panel.
(b) Install the speaker with the 3 screws.
NOTICE: Do not touch the cone part of the speaker.
HINT Install the screws in the order shown in the illustration.
(c) Connect the connector.
3. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY LH See: Body and Frame/Doors, Hood
and Trunk/Doors/Rear Door/Service and
Repair/Rear Door (for CrewMax)/Reassembly
4. INSTALL COURTESY LIGHT ASSEMBLY See: Body and Frame/Doors, Hood and
Trunk/Doors/Rear Door/Service and Repair/Rear Door
(for CrewMax)/Reassembly
5. INSTALL REAR DOOR ARMREST COVER LH
6. INSTALL REAR UPPER DOOR ARMREST BASE PANEL LH See: Body and Frame/Doors,
Hood and Trunk/Doors/Rear Door/Service and
Repair/Rear Door (for CrewMax)/Reassembly
7. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG LH See: Body and Frame/Doors, Hood
and Trunk/Doors/Rear Door/Service and
Repair/Rear Door (for CrewMax)/Reassembly
8. INSTALL REAR DOOR FRAME GARNISH LH See: Body and Frame/Doors, Hood and
Trunk/Doors/Rear Door/Service and Repair/Rear
Door (for CrewMax)/Reassembly
9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Up to 11/2009
AUDIO / VISUAL: REAR DOOR SPEAKER (for Double Cab): COMPONENTS
Page 1912
Fluid - A/T: Fluid Type Specifications
Transmission Fluid
Type .....................................................................................................................................................
......................................... Toyota Genuine ATF WS
Notice: Using automatic transmission fluid other than "Toyota Genuine ATF WS" may cause
deterioration in shift quality, locking up of your transmission accompanied by vibration, and
ultimately damage the automatic transmission of your vehicle.
Page 808
Page 3823
Manifold Pressure/Vacuum Sensor: Diagrams
Page 5506
Control Module: Service and Repair Removal
JF1A TRANSFER: 4WD CONTROL ECU: REMOVAL
1. REMOVE FRONT DOOR SCUFF PLATE RH (for Regular Cab)
(a) Remove the front door scuff plate RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Removal.
HINT Use the same procedures described for the LH side.
2. REMOVE FRONT DOOR SCUFF PLATE RH (for Double Cab, for CrewMax)
(a) Remove the front door scuff plate RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Removal.
HINT Use the same procedures described for the LH side.
3. REMOVE COWL SIDE TRIM BOARD RH
(a) Remove the cowl side trim board RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Removal.
HINT Use the same procedures described for the LH side.
4. REMOVE INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal
5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and
Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument
Panel Safety Pad (for Column Shift Type)/Removal
6. REMOVE 4WD CONTROL ECU
(a) Disconnect the 2 ECU connectors.
(b) Remove the bolt and ECU.
Page 3424
NG -- REPAIR OR REPLACE CAN BRANCH WIRE OR CONNECTOR (CENTER AIRBAG
SENSOR)
OK -- REPLACE CENTER AIRBAG SENSOR
12. CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (4WD CONTROL ECU)
NOTICE: For vehicles without 4WD, go to "CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH
WIRE (POWER STEERING ECU)".
(a) Disconnect the A25 4WD control ECU connector.
(b) Reconnect the cable to the negative (-) battery terminal.
(c) Select "CAN Bus Check" on the Techstream.
Result
B -- CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (POWER STEERING ECU) A -Continue to next step.
13. CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (4WD CONTROL ECU BRANCH
WIRE)
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE CAN BRANCH WIRE OR CONNECTOR (4WD CONTROL ECU)
OK -- REPLACE 4WD CONTROL ECU
14. CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (POWER STEERING ECU)
NOTICE: For vehicles without a power steering ECU, go to "CHECK FOR OPEN IN ONE SIDE OF
CAN BRANCH WIRE (AIR CONDITIONING AMPLIFIER BRANCH WIRE)".
(a) Disconnect the J101 power steering ECU connector.
Diagrams
Shift Interlock Solenoid: Diagrams
Body/Frame - Choppy Ride Condition
Body / Frame Mount Bushing: Customer Interest Body/Frame - Choppy Ride Condition
T-SB-0369-10
December 23, 2010
Choppy Ride (Tundra D-Cab Short Bed)
Service Category Suspension
Section Rear Suspension
Market USA
Applicability
Introduction
Some 2007 - 2010 Tundra vehicles may exhibit a body vibration when driving under certain road
conditions. A newly designed cab mount has been developed to help improve this condition.
NOTE
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for
36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Page 5764
Page 6576
Accessory Relay: Diagrams
Page 5048
16. REMOVE REAR DRIVE PINION NUT
(a) Using SST to hold the companion flange, remove the nut.
SST : 09330-00021
09330-00030
17. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY See: Differential
Carrier Assembly/Disassembly
18. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
19. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
(a) Using SST, remove the bearing (inner race).
SST : 09556-22010
20. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER
(a) Install a new spacer onto the drive pinion.
Page 4720
Four Wheel Drive Selector Switch: Service and Repair Installation
JF1A TRANSFER: 4WD CONTROL SWITCH: INSTALLATION
1. INSTALL 4WD CONTROL SWITCH
(a) Attach the 3 claws to install the switch.
2. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Panel,
Gauges and Warning Indicators/Instrument Cluster
/ Carrier/Service and Repair/Combination Meter/Installation
Page 382
(a) Remove the AM2 fuse, IG2 MAIN fuse, EFI NO. 1 fuse and IGN fuse from the engine room
relay block.
(b) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
NG -- CHECK FOR SHORT IN ALL HARNESSES AND CONNECTORS CONNECTED TO FUSE
AND REPLACE FUSE OK -- Continue to next step.
2. INSPECT RELAY (IG2, EFI)
(a) Remove the integration relay from the engine room relay block.
(b) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
Page 6525
[A] For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
"Case1" Raise the terminal retainer up to the temporary lock position.
Page 4673
Control Module: Diagrams
Page 6523
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION: Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC
terminals are touched, the IC may be destroyed by static electricity.)
When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact with the terminals of leads from the IC, etc. of the
replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown on the left.
DISCONNECT CONNECTOR
Specifications
Alignment: Specifications
SERVICE SPECIFICATIONS: SUSPENSION: SERVICE DATA
Stanard Vehicle Height
for Regular Cab of Standard Deck
for Regular Cab of Long Deck
for Double Cab of Standard Deck
Page 7450
No further tightening is required once the nut is tightened with the specified torque.
2. INSTALL WHEEL
for Aluminum Wheel - Torque : 131 Nm (1336 kgf-cm, 97 ft-lbf)
for Steel Wheel - Torque : 209 Nm (2131 kgf-cm, 154 ft-lbf)
3. INSPECT TIRE
(a) Inspect the tire See: Testing and Inspection/Component Tests and General Diagnostics.
4. REGISTRATION OF TRANSMITTER ID
(a) Register the transmitter ID See: Tire Monitoring System/Testing and Inspection/Programming
and Relearning/Registration.
5. PERFORM INITIALIZATION
(a) Perform initialization See: Tire Monitoring System/Testing and Inspection/Programming and
Relearning/Initialization.
NOTICE: Be sure to inflate all tires to the proper inflation pressure before initialization.
6. CHECK TIRE PRESSURE AFTER REPAIRS
(a) After repairs, confirm that the actual tire pressures are displayed in the DATA LIST See: Tire
Monitoring System/Testing and
Inspection/Scan Tool Testing and Procedures/Data List / Active Test.
Audio and Visual System
Remote Switch: Locations Audio and Visual System
AUDIO / VISUAL: AUDIO AND VISUAL SYSTEM: PARTS LOCATION
Page 3898
Refer to the Technical Information System (TIS) applicable model and model year Repair Manual:
2. Verify the vehicle has the proper coolant and oil levels.
3. Clear all DTCs and confirm the condition has been corrected.
Page 1818
When using Techstream Lite, select Generic J2534 Interface. Then click Next.
E. Confirm the following:
^ PC is connected to VIM.
^ VIM is connected to DLC3 connector.
^ Ignition is ON and engine is OFF or "READY" OFF (hybrid vehicles).
Page 5634
Traction Control Switch: Testing and Inspection
BRAKE CONTROL: VSC OFF SWITCH: INSPECTION
1. INSPECT VSC OFF SWITCH
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the VSC OFF switch.
Page 1889
Hose/Line HVAC: Service and Repair From 11/2009
AIR CONDITIONING: REFRIGERANT LINE: COMPONENTS
Page 6993
Engine Room R/B, J/B - Engine Compartment Left
Page 7762
11. REMOVE AIR CONDITIONING UNIT
(a) Remove the nut and air conditioning unit.
Installation
AIR CONDITIONING: AIR CONDITIONING UNIT: INSTALLATION
1. INSTALL AIR CONDITIONING UNIT ASSEMBLY
(a) Install the air conditioning unit with the nut.
Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)
Page 4258
Parts Information
Calibration Information
Required Tools & Equipment
Repair Procedure
Page 5972
(2) CONNECTORS
Slightly shake the connector vertically and horizontally.
(3) WIRE HARNESS
Slightly shake the wire harness vertically and horizontally.
HINT The connector joint and fulcrum of the vibration are the major areas that should be checked
thoroughly.
(b) HEAT METHOD:
When a malfunction seems to occur when the area in question is heated.
(1) Heat the component that is the possible cause of the malfunction with a hair dryer or similar
device. Check if the malfunction occurs.
NOTICE: *
Do not heat to more than 60°C (140°F). Exceeding this temperature may damage components.
* Do not apply heat directly to the parts in the ECU.
(c) WATER SPRINKLING METHOD:
When a malfunction seems to occur on a rainy day or in high-humidity.
(1) Sprinkle water onto the vehicle and check if the malfunction occurs.
NOTICE: *
Never sprinkle water directly into the engine compartment. Indirectly change the temperature and
humidity by spraying water onto the front of the radiator.
* Never apply water directly onto the electronic components.
HINT If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU
or connections. Look for evidence of corrosion or short circuits. Proceed with caution during water
tests.
(d) HIGH ELECTRICAL LOAD METHOD:
When a malfunction seems to occur when the electrical load is excessive.
(1) Turn on the heater blower, headlights, rear window defogger and all other electrical loads.
Check if the malfunction reoccurs.
5. DIAGNOSTIC TROUBLE CODE CHART
Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate
section's Diagnostic Trouble Code Chart. Use the chart to determine the trouble area and the
proper inspection procedure. A description of each of the chart's columns is below.
Page 6483
4. SYMPTOM CONFIRMATION AND DTC (INCLUDING FREEZE FRAME DATA) CHECK
(a) Visually check the wire harnesses, connectors and fuses for open and short circuits.
(b) Warm up the engine to the normal operating temperature.
(c) Confirm the problem symptoms and conditions, and check for DTCs.
B -- Go to step 6 A -- Continue to next step.
5. DTC CHART
(a) Check the results obtained in the DTC check. Then find the output DTC in the DTC chart. Look
at the "Trouble Area" column for a list of
potentially malfunctioning circuits and / or parts.
NEXT -- Go to step 7
6. PROBLEM SYMPTOMS TABLE
(a) Check the results obtained in the symptom confirmation. Then find the problem symptoms in
the problem symptoms table. Look at the
"Suspected Area" column for a list of potentially malfunctioning circuits and / or parts.
NEXT -- Continue to next step.
7. CIRCUIT INSPECTION OR PARTS INSPECTION
(a) Confirm the malfunctioning circuit or part.
NEXT -- Continue to next step.
8. ADJUST, REPAIR OR REPLACE
(a) Adjust, repair or replace the malfunctioning circuit or parts.
NEXT -- Continue to next step.
9. CONFIRMATION TEST
(a) After the adjustment, repairs or replacement, confirm that the malfunction no longer exists. If the
malfunction does not reoccur, perform a
confirmation test under the same conditions and in the same environment as when the malfunction
occurred the first time.
NEXT -- END
2. CUSTOMER PROBLEM ANALYSIS
HINT *
In troubleshooting, confirm that the problem symptoms have been accurately identified.
Preconceptions should be discarded in order to make an accurate judgment. To clearly understand
what the problem symptoms are, it is extremely important to ask the customer about the problem
and the conditions at the time the malfunction occurred.
* Gather as much information as possible for reference. Past problems that seem unrelated may
also help in some cases.
* The following 5 questions are important points in the problem analysis:
Page 5858
Brake Fluid Pressure Sensor/Switch: Locations From 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 8371
Door/Service and Repair/Front Door (for Double Cab)/Disassembly
4. REMOVE FRONT LOWER DOOR FRAME BRACKET GARNISH LH (for Front Side) See: Body
and Frame/Doors, Hood and
Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly
5. REMOVE COURTESY LIGHT ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood
and Trunk/Doors/Front Door/Service and
Repair/Front Door (for Double Cab)/Disassembly
6. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Disassembly
7. REMOVE FRONT SIDE AIRBAG SENSOR
(a) Disconnect the connector.
(b) Remove the screw and side airbag sensor.
8. REMOVE REAR SEAT ASSEMBLY (for Rear Side)
(a) Remove the rear seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Rear Seat Assembly (for Double
Cab)/Removal.
9. REMOVE REAR DOOR SCUFF PLATE LH (for Rear Side) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and Repair/Roof
Headlining (For Double Cab)/Removal
10. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH (for Rear Side)
11. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY LH (for Rear Side) See: Body and
Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal
12. REMOVE REAR SIDE AIRBAG SENSOR
(a) Remove the bolt and side airbag sensor.
(b) Disconnect the connector.
Installation
SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for CrewMax):
INSTALLATION
1. INSTALL FRONT SIDE AIRBAG SENSOR
(a) Check that the ignition switch is OFF.
Page 7061
Standard steering axis inclination (unloaded vehicle):
for Regular Cab of Long Deck
Standard steering axis inclination (unloaded vehicle):
for Double Cab of Standard Deck
Page 2920
Crankshaft Position Sensor: Locations Ignition System
1UR-FE IGNITION: IGNITION SYSTEM: PARTS LOCATION
Page 3425
(b) Reconnect the cable to the negative (-) battery terminal.
(c) Select "CAN Bus Check" on the Techstream.
Result
NG -- CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (AIR CONDITIONING
AMPLIFIER BRANCH WIRE) OK -- Continue to next step.
15. CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (POWER STEERING ECU
BRANCH WIRE)
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE CAN BRANCH WIRE OR CONNECTOR (POWER STEERING
ECU)
OK -- REPLACE POWER STEERING ECU See: Relays and Modules/Relays and Modules Steering and Suspension/Relays and Modules - Steering/Steering Control Module/Service and
Repair/Removal
16. CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (AIR CONDITIONING
AMPLIFIER BRANCH WIRE)
(a) Disconnect the J19 air conditioning amplifier connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
Audio System - USB/iPod(R) Not Recognized
Auxiliary Input / Output Jack: Customer Interest Audio System - USB/iPod(R) Not Recognized
T-SB-0013-11
February 15, 2011
USB/Pod Not Recognized
Service Category Audio/Visual/Telematics
Section Audio/Video
Market USA
Applicability
Introduction
Some 2010 - 2011 Toyota vehicles may exhibit intermittent operation of USB/iPod(TM) devices
while in use. A newly designed Multi-Media Interface ECU has been developed to correct this
condition.
This bulletin applies to the models shown.
This bulletin does not apply to the following models: iPod(TM) mini iPod(TM) shuffle iPod(TM)
photo iPhone(TM) and 4th generation and earlier models. These versions of the iPod(TM) are NOT
compatible with this system.
* iPhone(TM) has limited compatibility with this system. Some functions may not operate properly.
Production Change Information
Page 6199
Removal
OTHER SYSTEM: CENTER POWER OUTLET SOCKET (for Floor Shift Type): REMOVAL
1. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding
/ Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
2. REMOVE CONSOLE BOX BEZEL
Page 4211
Page 9158
1. Wrap a pry bar with a soft shop towel then gently pull the step pad in an upward motion from
front to back using the pry bar to assist.
Be careful NOT to damage the chrome/painted surface.
2. If the plastic posts break off when the step pad is removed and stay in the tube use a punch and
hammer to punch the plastic bits into the tube. Use an
air gun to blow the posts out through the end of the tube.
3. Discard the step pad.
4. Using a pair of pliers pull out the old stainless post retainers (12 pieces) and discard.
5. Install the new post retainers into the holes in the tube.
6. Line up the replacement step posts with the holes in the post retainers.
7. Using the palm of your hand push firmly down in all post locations.
Then using a rubber mallet strike the pad along its entire length to ensure it is seated properly.
Fuel Sender Gauge Assembly
Fuel Gauge Sender: Service and Repair Fuel Sender Gauge Assembly
Components
1UR-FE FUEL: FUEL SENDER GAUGE ASSEMBLY: COMPONENTS
Removal
1UR-FE FUEL: FUEL SENDER GAUGE ASSEMBLY: REMOVAL
1. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY
Page 8438
HINT A bolt without a torque specification is shown in the standard bolt chart See:
Specifications/Mechanical Specifications/Standard Bolt - Specified Torque For Standard Bolts
1. INSTALL FENDER ANTENNA ASSEMBLY
(a) Install the antenna with the bolt.
(b) Attach the 5 clamps and install the bolt.
(c) Connect the connector.
2. INSTALL FENDER APRON MUDGUARD SEAL RH See: Body and Frame/Fender/Front
Fender/Front Fender Liner/Service and
Repair/Installation
3. INSTALL ANTENNA ORNAMENT
Page 5276
(1) Temporarily install the center support bearing to the crossmember with the 2 mounting bolts.
(b) w/ Bearing Washer:
(1) Temporarily install the center support bearing to the crossmember with the 2 bearing washers
and 2 mounting bolts.
(c) Align the matchmarks on the flange yoke and transfer flange.
(d) Install the propeller shaft to the transfer side with the 4 nuts.
Torque : 70 Nm (714 kgf-cm, 52 ft-lbf)
(e) Align the matchmarks on the flange yoke and differential flange.
(f) Install the propeller shaft to the differential side with the 4 bolts and 4 nuts.
Torque : 70 Nm (714 kgf-cm, 52 ft-lbf)
Page 8074
Impact Sensor: Service and Repair Front Airbag Sensor
Components
SUPPLEMENTAL RESTRAINT SYSTEM: FRONT AIRBAG SENSOR: COMPONENTS
Removal
SUPPLEMENTAL RESTRAINT SYSTEM: FRONT AIRBAG SENSOR: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
Page 8260
Removal
SEAT BELT: REAR CENTER SEAT OUTER BELT ASSEMBLY (for CrewMax): REMOVAL
1. DISCONNECT REAR SEAT INNER BELT ASSEMBLY See: Rear Seat Inner Belt Assembly (for
CrewMax)/Removal
2. REMOVE REAR SEAT ASSEMBLY LH See: Body and Frame/Seats/Service and
Repair/Removal and Replacement/Rear Seat Assembly (for
Crewmax LH Side)/Removal
3. DISCONNECT CENTER REAR SEAT OUTER BELT ASSEMBLY
Page 3402
CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: HOW TO PROCEED WITH
TROUBLESHOOTING
HINT *
DTCs for the CAN communication system are as follows: U0073, U0100, U0114, U0123, U0124,
U0126, U0129, U0199, U0208, U1002, U1115, B1499, and B2621
* Refer to the troubleshooting procedures of each system if DTCs regarding the CAN
communication system are not output.
* Before measuring the resistance, leave the vehicle for at least 1 minute and do not operate the
ignition switch, any switches or doors. If doors need to be opened in order to check connectors,
open the doors and leave them open.
HINT *
Operating the ignition switch, any switches or any doors triggers related ECU and sensor
communication with the CAN, which causes resistance variation.
* *: Use the Techstream.
1. VEHICLE BROUGHT TO WORKSHOP
NEXT -- Continue to next step.
2. INSPECT BATTERY VOLTAGE
Standard voltage:
11 to 14 V
If the voltage is below 11 V, recharge or replace the battery before proceeding.
NEXT -- Continue to next step.
3. CHECK AND CLEAR DTC*
(a) Using the Techstream, perform the ALL DTC check.
NOTICE: *
If a CAN communication malfunction code that informs that an ECU or sensor has a power
malfunction or interior malfunction is causing a communication stop, the problem may not be in the
communication line. There is a high possibility that the ECU or sensor has a signal transmission
failure. Therefore, first troubleshoot any DTCs related to the ECU or sensor.
* When CAN communication related connectors are disconnected with the ignition switch ON or
ACC, the ECU related to the connector and ECUs of related systems will store a CAN
communication DTC. NEXT -- Continue to next step.
4. CHECK INSTALLED SYSTEMS (ECU AND SENSOR) THAT USE CAN COMMUNICATION
(a) Based on the vehicle equipment and specifications, confirm the systems that use CAN
communication See: CAN Communication
System/Diagnosis System.
NEXT -- Continue to next step.
5. CHECK DLC3 BRANCH WIRE AND V BUS CIRCUIT MAIN WIRE (CANH - CANL)
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
Page 2060
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION: Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC
terminals are touched, the IC may be destroyed by static electricity.)
When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact with the terminals of leads from the IC, etc. of the
replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown on the left.
DISCONNECT CONNECTOR
Page 3843
Oxygen Sensor: Testing and Inspection Air Fuel Ratio Sensor
1UR-FE ENGINE CONTROL SYSTEM: AIR FUEL RATIO SENSOR: ON-VEHICLE INSPECTION
1. INSPECT AIR FUEL RATIO SENSOR
(a) Disconnect the 2 sensor connectors.
(b) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(c) If the result is not as specified, replace the air fuel ratio sensor.
(d) Connect the 2 sensor connectors.
Page 7773
AIR CONDITIONING: AIR CONDITIONING UNIT: REASSEMBLY
1. INSTALL COOLER EXPANSION VALVE
(a) Sufficiently apply compressor oil to 4 new O-rings and the fitting surface of the hose joint.
Compressor oil:
ND-OIL 8 or equivalent
(b) Install the 2 O-rings to the cooler evaporator.
(c) Install the 2 O-rings to the tube and accessory.
(d) Install the cooler expansion valve and tube and accessory to the evaporator.
(e) Using a 4 mm hexagon wrench, install the 2 bolts.
Torque : 3.5 Nm (36 kgf-cm, 31 in-lbf)
2. INSTALL NO. 1 COOLER THERMISTOR
NOTICE: If reusing the evaporator, do not insert the sensor into a location where the sensor was
previously inserted.
(a) Insert the sensor to a location that is 1 fin to the right or left of its previous location.
Standard:
3. INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY
Page 6478
(a) For an open circuit in the wire harness in Fig. 1, check the resistance or voltage, as described
below.
(b) Check the resistance.
(1) Disconnect connectors A and C and measure the resistance between them.
Standard resistance (Fig. 2):
HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally.
If the results match the examples above, an open circuit exists between terminal 1 of connector A
and terminal 1 of connector C.
(2) Disconnect connector B and measure the resistance between the connectors.
Standard resistance (Fig. 3):
* If the results match the examples above, an open circuit exists between terminal 1 of connector
B2 and terminal 1 of connector C.
(c) Check the voltage.
Page 3849
with SST - Torque : 40 Nm (408 kgf-cm, 30 ft-lbf)
HINT *
Use a torque wrench with a fulcrum length of 30 cm (11.8 in.). When using a torque wrench with a
fulcrum length that is not 30 cm (11.8 in.), calculate the torque specification for the torque wrench
and SST based on the "without SST" torque specification See: Service Precautions
* Make sure SST and the wrench are connected in a straight line.
4. INSTALL PROPELLER SHAFT HEAT INSULATOR (for 4WD) See: Transmission and
Drivetrain/Drive/Propeller Shafts, Bearings and
Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Front Propeller Shaft
Assembly/Installation
5. INSTALL FRONT EXHAUST PIPE ASSEMBLY
(a) Install a new gasket and the front exhaust pipe to the exhaust manifold RH with 3 new nuts.
Torque : 54 Nm (554 kgf-cm, 40 ft-lbf)
(b) Connect the air fuel ratio sensor connector.
(c) Connect the heated oxygen sensor connector and 2 clamps.
6. INSTALL CENTER EXHAUST PIPE ASSEMBLY See: Engine, Cooling and Exhaust/Exhaust
System/Exhaust Pipe/Service and
Repair/Exhaust Pipe (for Regular Cab Standard Deck)/Installation
7. INSTALL TAILPIPE ASSEMBLY See: Engine, Cooling and Exhaust/Exhaust System/Exhaust
Pipe/Service and Repair/Exhaust Pipe (for
Regular Cab Standard Deck)/Installation
8. INSPECT FOR EXHAUST GAS LEAK See: Engine, Cooling and Exhaust/Exhaust
System/Exhaust Manifold/Service and Repair/Installation
Page 1678
for Regular Cab of Long Deck
for Double Cab of Standard Deck
Page 7922
(b) With the front seat side airbag installed on the vehicle, perform a visual check. If there are any
defects as mentioned below, replace the front
seat with a new one:
Cuts, minute cracks or marked discoloration on the front seatback around the front seat side
airbag.
2. CHECK FRONT SEAT SIDE AIRBAG ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND
AIRBAG HAS NOT DEPLOYED)
(a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnosis System.
(b) With the front seat side airbag removed from the vehicle, perform a visual check. If there are
any defects as mentioned below, replace the front
seat side airbag with a new one:
* Cuts, minute cracks or marked discoloration on the front seat side airbag.
* Cracks or other damage to the wire harness or connector.
CAUTION: For removal and installation procedures of the front seat side airbag, be sure to follow
the correct procedure.
Front Passenger Side Knee Airbag Assembly
SUPPLEMENTAL RESTRAINT SYSTEM: FRONT PASSENGER SIDE KNEE AIRBAG
ASSEMBLY: ON-VEHICLE INSPECTION
1. CHECK LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY (VEHICLE NOT
INVOLVED IN COLLISION)
(a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnosis System.
(b) With the lower No. 2 instrument panel airbag installed on the vehicle, perform a visual check. If
there are any defects as mentioned below,
replace the lower No. 2 instrument panel airbag with a new one:
Cuts, minute cracks or marked discoloration on the lower No. 2 instrument panel airbag.
2. CHECK LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY (VEHICLE INVOLVED IN
COLLISION AND AIRBAG HAS NOT
DEPLOYED)
(a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnosis System.
Page 202
If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness
or connector in that circuit in the past. Check the wire harness and connectors.
B -- SYSTEM NORMAL
A -- TROUBLESHOOTING OF EACH PROBLEM SYMPTOM
The problem is still occurring in a place other than the diagnostic circuit (the DTC displayed first is
either for a past problem or a secondary problem).
4. SYMPTOM SIMULATION
HINT The most difficult case in troubleshooting is when no problem symptoms occur. In such a
case, a thorough problem analysis must be carried out. A simulation of the same or similar
conditions and environment in which the problem occurred in the customer's vehicle should be
carried out. No matter how much skill or experience a technician has, troubleshooting without
confirming the problem symptoms will lead to important repairs being overlooked and mistakes or
delays.
For example:
With a problem that only occurs when the engine is cold or as a result of vibration caused by the
road during driving, the problem can never be determined if the symptoms are being checked on a
stationary vehicle or on a vehicle with a warmed-up engine. Vibration, heat or water penetration
(moisture) is difficult to reproduce. The symptom simulation tests below are effective substitutes for
the conditions and can be applied on a stationary vehicle.
Important points in the symptom simulation test:
In the symptom simulation test, the problem symptoms as well as the problem area or parts must
be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then,
connect the tester and carry out the symptom simulation test, judging whether the circuit being
tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the
problem symptoms table for each system to narrow down the possible causes.
To reproduce DTCs, it is necessary to satisfy the respective DTC detection conditions.
(a) VIBRATION METHOD:
When a malfunction seems to occur as a result of vibration.
(1) PART AND SENSOR
Apply slight vibration with a finger to the part of the sensor suspected to be the cause of the
problem, and check whether or not the malfunction occurs.
NOTICE: Applying strong vibration to relays may open them.
Page 6688
Page 7931
Cross-sectional area of stripped wire harness section:
1.25 mm2 or more (0.00192 in.2 or more)
CAUTION: If the wire harness is too thin or an alternative object is used to tie down the lower No. 2
instrument panel airbag, it may be snapped by the shock when the airbag is deployed. Always use
a wire harness for vehicle use with a cross-sectional area of at least 1.25 mm2 (0.00192 in.2).
HINT To calculate the cross-sectional area of the stripped wire harness section: Cross-sectional
area = 3.14 x (Diameter)2 / 4
(1) Position the lower No. 2 instrument panel airbag inside a tire with the airbag deployment side
facing inside.
Tire size:
Must exceed the following dimensions
Width 185 mm (7.28 in.)
Inner diameter 360 mm (14.2 in.)
(2) Tie the lower No. 2 instrument panel airbag to the tire with several wire harnesses.
CAUTION: *
Make sure that the wire harnesses are tight. If there is slack in the wire harnesses, the lower No. 2
instrument panel airbag may become loose due to the shock when the airbag is deployed.
* Always tie down the lower No. 2 instrument panel airbag with the airbag deployment side facing
inside the tire.
NOTICE: As the tire may be damaged by the airbag deployment, use a tire that you are planning to
throw away.
(d) Connect SST connector to the lower No. 2 instrument panel airbag.
SST : 09082-00780
(e) Place tires.
Page 8785
(b) If the result is not as specified, replace the speaker assembly.
Page 3691
Then click Next.
F. Verify correct current calibration and new calibration information. Then click Next.
NOTE
^ The total number of calibration IDs in the calibration file corresponds to the number of
reprogrammable processors in the ECU.
^ Each calibration file may contain up to three separate calibrations.
Page 1086
Headlamp Alignment Switch: Service and Repair Installation
LIGHTING: HEADLIGHT LEVELING SWITCH: INSTALLATION
1. INSTALL HEADLIGHT LEVELING SWITCH
(a) Attach the 2 claws to install the switch.
2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Installation
3. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
4. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Installation
5. INSTALL FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Installation
6. INSTALL FRONT DOOR SCUFF PLATE LH (for Double Cab, CrewMax) See: Body and
Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular Cab)/Installation
Page 7318
(a) Remove the nut and bolt, and disconnect the shock absorber from the lower side.
4. DISCONNECT FRONT LOWER BALL JOINT ATTACHMENT LH
(a) Remove the 2 bolts and disconnect the attachment from the steering knuckle.
5. REMOVE FRONT NO. 1 SUSPENSION ARM SUB-ASSEMBLY LOWER LH
(a) Place matchmarks on the No. 2 camber adjusting cam and No. 2 toe adjusting plate.
(b) Remove the nut, washer, No. 2 camber adjusting cam, camber adjusting cam assembly, bolt,
toe adjusting cam, No. 2 toe adjusting plate and
front No. 1 suspension arm lower LH.
6. REMOVE FRONT LOWER BALL JOINT ATTACHMENT LH
(a) Remove the cotter pin and nut.
(b) Using SST, remove the lower ball joint attachment.
Removal and Replacement
Starter Motor: Removal and Replacement
Components
1UR-FE STARTING: STARTER (for 1.6 kW Type): COMPONENTS
Removal
1UR-FE STARTING: STARTER (for 1.6 kW Type): REMOVAL
1. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH
Testing and Inspection
Stabilizer Link: Testing and Inspection
SUSPENSION: FRONT STABILIZER BAR: INSPECTION
1. INSPECT FRONT STABILIZER LINK ASSEMBLY LH
(a) Temporarily install the nut, and flip the ball joint stud back and forth 5 times as shown in the
illustration.
(b) Use a torque wrench to turn the nut continuously at a rate of 2 to 3 seconds per turn. Take the
torque reading on the fifth turn.
Standard turning torque - Torque : 0.5 to 3.4 Nm (5.1 to 36 kgf-cm, 4.4 to 30 in-lbf)
* If the value is not within the specified range, replace the front suspension toe control link with a
new one.
(c) Check the dust boot for cracks or grease leakage.
Page 2357
Step 2:
Mark the front of the bearing cap bolts with paint.
Tighten the bearing cap bolts another 90° in the order shown in step 1.
Check that the painted marks are now at a 90° angle to the front.
Install and uniformly tighten the 10 main bearing cross cap bolts and 10 new seal washers in
several steps, in the sequence shown in the illustration.
Torque..................................................................................................................................................
.....................................45 Nm (459 kgf-cm, 33 ft-lbf)
MAIN BEARING SIZE CODES
Refer to the table below for the appropriate bearing number. There are 6 sizes of standard
bearings. For the No. 1 and No. 5 position bearings, use bearings marked 4, 5, 6, 7, 8 and 9. For
other bearings, use bearings marked 3, 4, 5, 6, 7 and 8.
A = Cylinder block number mark
B = Crankshaft number mark
Page 8462
(a) Disconnect the connectors.
(b) Remove the 2 nuts and junction block.
(c) Remove the nut and ECU.
Page 2765
NOTE
Only Toyota Certified Technicians and above may access calibration files.
2. Connect the GR8 Battery Diagnostic Station.
A. Connect the GR8 Battery Diagnostic Station to the vehicle and turn it ON.
B. Select Power Supply Mode by following the screen flow below.
NOTICE
^ ECU damage may occur if the correct battery charger and mode setting are NOT used.
Page 1482
Release the locking lug from terminal and pull the terminal out from rear.
INSTALL TERMINAL TO CONNECTOR
Insert the terminal.
HINT: Make sure the terminal is positioned correctly.
Insert the terminal until the locking lug locks firmly.
Insert the terminal with terminal retainer in the temporary lock position.
Page 7930
(2) Install the lower No. 2 instrument panel airbag See: Removal and Replacement/Front
Passenger Side Knee Airbag Assembly/Installation.
NOTICE: Take care not to damage SST wire harness.
(3) Move SST at least 10 m (32.8 ft.) away from the vehicle front side window.
(4) Maintaining enough clearance for SST wire harness in the front side window, close all doors
and windows of the vehicle.
NOTICE: Take care not to damage SST wire harness.
(5) Connect the red clip of SST to the positive (+) battery terminal and the black clip of SST to the
negative (-) battery terminal.
(f) Deploy the airbag.
(1) Check that no one is inside the vehicle or within a 10 m (32.8 ft.) radius of the vehicle.
(2) Press SST activation switch to deploy the airbag.
CAUTION: *
When deploying the airbag, make sure that no one is near the vehicle.
* The lower No. 2 instrument panel airbag becomes extremely hot when the airbag is deployed, so
do not touch it for at least 30 minutes after deployment.
* Use gloves and safety glasses when handling a lower No. 2 instrument panel airbag with a
deployed airbag.
* Do not apply water to a lower No. 2 instrument panel airbag with a deployed airbag.
* Always wash your hands with water after completing the operation.
HINT The airbag is deployed as the LED of SST activation switch comes on.
2. DISPOSE OF LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY (WHEN NOT
INSTALLED IN VEHICLE)
NOTICE: Be sure to follow the procedure detailed below when deploying the airbag.
HINT Prepare a battery as the power source to deploy the airbag.
(a) Check the function of SST See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
(b) Remove the lower No. 2 instrument panel airbag See: Removal and Replacement/Front
Passenger Side Knee Airbag Assembly/Removal.
CAUTION: *
When removing the lower No. 2 instrument panel airbag, wait at least 90 seconds after the ignition
switch is turned off and the cable is disconnected from the negative (-) battery terminal before
starting work.
* When storing the lower No. 2 instrument panel airbag, keep the airbag deployment side facing
upward.
(c) Using a service-purpose wire harness for the vehicle, tie down the lower No. 2 instrument panel
airbag to a tire.
Locations
Ignition Switch: Locations
1UR-FE STARTING: STARTING SYSTEM: PARTS LOCATION
Page 2489
Front Crankshaft Seal: Service and Repair Removal
1UR-FE ENGINE MECHANICAL: FRONT CRANKSHAFT OIL SEAL: REMOVAL
1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Service and Repair/Removal and
Replacement/Engine Assembly/Removal
2. REMOVE NO. 1 ENGINE UNDER COVER See: Engine Lubrication/Engine Oil/Service and
Repair/Replacement
3. DRAIN ENGINE COOLANT See: Cooling System/Coolant/Service and Repair
4. REMOVE INLET RADIATOR HOSE See: Cooling System/Radiator Cooling Fan/Service and
Repair/Removal
5. REMOVE FAN AND GENERATOR V BELT See: Drive Belts, Mounts, Brackets and
Accessories/Drive Belt/Service and Repair/Removal
6. REMOVE FAN SHROUD See: Cooling System/Radiator Cooling Fan/Service and
Repair/Removal
7. DISCONNECT FRONT STABILIZER BAR
(a) Remove the 4 bolts, 2 stabilizer brackets and 2 stabilizer bushes. Then disconnect the stabilizer
bar.
8. DISCONNECT COOLER COMPRESSOR ASSEMBLY See: Engine Lubrication/Oil
Pump/Service and Repair/Removal and
Replacement/Removal
9. REMOVE OIL PRESSURE SENDER GAUGE ASSEMBLY See: Engine Lubrication/Oil Pressure
Sender/Service and Repair/Removal
10. REMOVE WATER BY-PASS PIPE (w/ Oil Cooler) See: Water Pump/Service and
Repair/Removal
11. REMOVE NO. 1 OIL COOLER BRACKET (w/ Oil Cooler) See: Engine Lubrication/Oil
Cooler/Service and Repair/Removal and
Replacement/Removal
12. REMOVE OIL FILTER BRACKET SUB-ASSEMBLY See: Engine Lubrication/Oil Cooler/Service
and Repair/Removal and
Replacement/Removal
13. REMOVE CRANKSHAFT PULLEY See: Engine Lubrication/Oil Pump/Service and
Repair/Removal and Replacement/Removal
14. REMOVE CRANKSHAFT TIMING GEAR KEY
(a) Remove the crankshaft timing gear key from the crankshaft.
15. REMOVE FRONT CRANKSHAFT OIL SEAL
(a) Using a screwdriver, pry out the oil seal.
Page 9324
This TSB applies to all Sequoia and Tundra vehicles equipped with lUR-FE (4.6L) 2UZ-FE (4.7L)
and 3UR-FE/FBE (5.7L) engines produced BEFORE the Production Change Effective VINs shown.
Repair Procedure
1. Remove and replace the air cleaner lid.
2. Remove and replace the front right hand (RH) fender liner.
Page 1669
Wiper Switch: Service and Repair Removal
WIPER AND WASHER: WIPER SWITCH: REMOVAL
1. REMOVE LOWER STEERING COLUMN COVER
(a) for Manual Tilt and Telescopic:
(1) Operate the tilt and telescopic lever to fully extend and lower the steering column.
(b) for Power Tilt and Telescopic:
(1) Turn the ignition switch ON. Operate the tilt and telescopic switch to fully extend and lower the
steering column.
(c) While turning the steering wheel to the right and left, remove the 2 screws and lower steering
column cover.
(d) Detach the 2 claws to remove the lower steering column cover.
NOTICE: Do not damage the tilt and telescopic switch.
2. REMOVE UPPER STEERING COLUMN COVER
(a) Detach the 4 clips.
(b) Detach the claw to remove the upper steering column cover.
3. REMOVE WINDSHIELD WIPER SWITCH ASSEMBLY
(a) Disconnect the 2 connectors.
Page 6490
Relay Box: Connector Views
Engine Room R/B, J/B - Engine Compartment Left
Page 3560
HINT *
*1: w/ 4WD
* *2: w/ Bus Buffer ECU
(c) NO. 3 JUNCTION CONNECTOR
HINT *
*1: for MS bus
* *2: w/ Seat Memory
3. TERMINALS OF CONNECTORS FOR JUNCTION CONNECTOR (No. 1 JUNCTION
CONNECTOR)
Page 9112
"Case1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (/\ Mark) and pull the terminal retainer
up to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Airbag Cut-OFF Switch
Air Bag Deactivation Switch: Testing and Inspection Airbag Cut-OFF Switch
SUPPLEMENTAL RESTRAINT SYSTEM: AIRBAG CUT-OFF SWITCH: INSPECTION
1. INSPECT AIRBAG CUT-OFF SWITCH
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
Page 5899
Traction Control Switch: Service and Repair Installation
BRAKE CONTROL: VSC OFF SWITCH: INSTALLATION
1. INSTALL VSC OFF SWITCH
(a) Attach the 2 claws to install the VSC OFF switch into the lower instrument panel finish panel
LH.
(b) Connect the VSC OFF switch connector.
2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Installation
3. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Installation
4. INSTALL FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Installation
5. INSTALL FRONT DOOR SCUFF PLATE LH (for Double Cab, CrewMax) See: Body and
Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Installation
Page 7076
Page 1764
(4) Connect the engine wire harness clamp.
3. INSTALL AIR CLEANER ASSEMBLY
(a) Install the air cleaner with the 2 bolts.
Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)
(b) Tighten the hose clamp.
Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf)
(c) Connect the ventilation hose and vacuum hose.
(d) Connect the MAF meter connector and clamp.
4. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Installation
Page 2876
(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(2) If the result is not as specified, replace the integration relay.
3. INSTALL INTEGRATION RELAY
(a) Connect the 3 connectors.
(b) Install the integration relay to the engine room relay block.
(c) Install the engine room relay block cover.
Page 6410
Page 8781
Speaker: Testing and Inspection Floor Speaker (for Double Cab)
AUDIO / VISUAL: FLOOR SPEAKER (for Double Cab): INSPECTION
1. INSPECT BOX SPEAKER ASSEMBLY
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the speaker assembly.
Page 4895
Standard Resistance:
(c) If the result is not as specified, replace the transmission floor shift assembly.
Related Testing (Shift Lever Diagnostics)
For information regarding additional/related testing for this system, please refer to Transmission
Control System testing. See: Transmission Control Systems/Testing and Inspection
Page 6656
Installation
OTHER SYSTEM: POWER OUTLET SOCKET (for CrewMax Floor Shift Type): INSTALLATION
1. INSTALL REAR POWER POINT SOCKET (for AC Power Supply)
(a) Attach the 2 claws to install the power outlet socket.
2. INSTALL REAR POWER OUTLET SOCKET COVER (for Standard)
(a) Attach the 2 claws to install the power outlet socket cover.
3. INSTALL REAR POWER OUTLET SOCKET (for Standard)
(a) Attach the claw to install the power outlet socket.
4. INSTALL CONSOLE BOX BEZEL
Diagram Information and Instructions
Information Bus: Diagram Information and Instructions
Wiring Color Codes
Abbreviations Used Within Diagrams
Abbreviations Used Within Diagrams
Page 1039
Cargo Lamp Switch: Testing and Inspection
LIGHTING: CARGO LIGHT SWITCH: INSPECTION
1. INSPECT CARGO LIGHT SWITCH
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the switch.
(c) Inspect the switch illumination.
(1) Connect the battery's positive (+) lead to terminal 1 (ILL+) and the negative (-) lead to terminal 4
(ILL-).
(2) Check that the door courtesy light comes on.
OK:
Light comes on.
(3) If the result is not as specified, replace the light switch.
Page 583
Integrated Accessory Switch Assembly: Diagrams
Page 204
6. PROBLEM SYMPTOMS TABLE
When a "Normal" code is output during a DTC check but the problem is still occurring, use the
Problem Symptoms Table. The suspected areas (circuits or parts) for each problem symptom are
in the table. The suspected areas are listed in order of probability. A description of each of the
chart's columns is below.
HINT In some cases, the problem is not detected by the diagnostic system even though a problem
symptom is present. It is possible that the problem is occurring outside the detection range of the
diagnostic system, or that the problem is occurring in a completely different system.
7. CIRCUIT INSPECTION
A description of the main areas of each circuit inspection is below.
Page 1866
* Never reuse the O-ring.
* When placing a new O-ring on the injector, do not damage it.
* Coat a new O-ring with spindle oil or gasoline before installing it. Do not use engine oil, gear oil or
brake oil.
(c) Install the injector to the delivery pipe and intake manifold as shown in the illustration.
NOTICE: Before installing the injector, apply spindle oil or gasoline on the place where the delivery
pipe contacts the O-ring of the injector.
(d) Observe these precautions when disconnecting the fuel tube connector (for Quick Type).
(1) for Fuel Hose Connector Cover Type:
Detach the lock claw by lifting up the cover, as shown in the illustration.
(2) for Fuel Pipe Clamp Type:
Remove the fuel pipe clamp from the fuel tube connector.
Page 6222
Auxiliary Power Outlet Switch: Service and Repair Installation
OTHER SYSTEM: INVERTER MAIN SWITCH (for CrewMax): INSTALLATION
1. INSTALL INVERTER MAIN SWITCH
(a) Attach the 2 claws to install the main switch.
2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Floor Shift Type)/Installation
3. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation
4. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Installation
5. INSTALL FRONT DOOR SCUFF PLATE LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining
(For Double Cab)/Installation
Locations
Variable Induction Control Solenoid: Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Engine - Oil Filter Cap Assembly Precaution
Oil Filter: Technical Service Bulletins Engine - Oil Filter Cap Assembly Precaution
T-SB-01 04-09
April 10, 2009
Oil Filter Cap Assembly Precautions
Service Category Engine/Hybrid System
Section Lubrication
Market USA
Applicability
TSB SUPERSESSION NOTICE
The information contained in this TSB supersedes TSB No. T-SB-0332-08.
^ Applicability has been updated to include 2009 - 2010 model year Highlander, 2010 model year
Camry, Corolla, Matrix, Sequoia, Tundra, and 2009 model year Venza vehicles.
^ The SST table has been updated with an illustration.
^ The Notice in the Repair Procedure has been updated with a Figure and torque specification
ranges to clarify SST usage.
TSB No. T-SB-0332-08 is Obsolete and any printed versions should be discarded. Be sure to
review the entire content of this service bulletin before proceeding.
Introduction
To prevent damage to the oil filter cap assembly this procedure must be closely followed during oil
filter replacement to avoid immediate and future oil filter serviceability concerns.
The following engines are equipped with a plastic oil filter cap assembly:
^ 1UR-FE (Tundra Sequoia)
^ 3UR-FE (Tundra Sequoia Land Cruiser)
^ 2ZR-FE (Corolla Matrix)
Page 3463
ERROR: stackunderflow
OFFENDING COMMAND: ~
STACK:
Page 5949
Remove the blown fuse and disconnect all loads of the fuse.
Connect a test light in place of the fuse.
Establish conditions in which the test light comes on.
Example:
- [A] - Ignition SW on
- [B] - Ignition SW and SW1 on
- [C] - Ignition SW, SW1 and Relay on (Connect the Relay) and SW2 off (or Disconnect SW2)
Disconnect and reconnect the connectors while watching the test light.
Door Control Receiver (for CrewMax)
Keyless Entry Module: Service and Repair Door Control Receiver (for CrewMax)
Components
DOOR LOCK: DOOR CONTROL RECEIVER (for CrewMax): COMPONENTS
Removal
DOOR LOCK: DOOR CONTROL RECEIVER (for CrewMax): REMOVAL
1. REMOVE BACK PANEL TRIM RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for
CrewMax)/Removal
Page 267
Remove the blown fuse and disconnect all loads of the fuse.
Connect a test light in place of the fuse.
Establish conditions in which the test light comes on.
Example:
- [A] - Ignition SW on
- [B] - Ignition SW and SW1 on
- [C] - Ignition SW, SW1 and Relay on (Connect the Relay) and SW2 off (or Disconnect SW2)
Disconnect and reconnect the connectors while watching the test light.
Page 1410
(b) Loosen the nut, move the stay off the battery, and remove the battery.
3. REMOVE FRONT AIRBAG SENSOR
(a) Remove the nut and front airbag sensor from the body.
(b) Disconnect the connector.
Installation
SUPPLEMENTAL RESTRAINT SYSTEM: FRONT AIRBAG SENSOR: INSTALLATION
1. INSTALL FRONT AIRBAG SENSOR
(a) Check that the ignition switch is OFF.
(b) Check that the cable is disconnected from the battery negative (-) terminal.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
(c) Connect the connector.
(d) Install the front airbag sensor with the nut.
Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)
NOTICE: *
If the front airbag sensor has been dropped, or there are any cracks, dents or other defects in the
case, bracket or connector, replace it with a new one.
* When installing the front airbag sensor, be careful that the SRS wiring does not interfere with
other parts and that it is not pinched between other parts.
(e) Check that there is no looseness in the installation parts of the front airbag sensor.
2. INSTALL BATTERY
Page 6728
3. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE
HINT The diagnostic system in the TOYOTA TUNDRA has various functions.
* The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU
memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a
previous malfunction's DTC can be checked by a technician during troubleshooting.
* Another function is the Input Signal Check, which checks if the signals from various switches are
sent to the ECU correctly.
* By using these functions, the problem areas can be narrowed down and troubleshooting is more
effective. Diagnostic functions are incorporated in the following systems in the TOYOTA TUNDRA.
Page 5489
Page 6273
Release the locking lug from terminal and pull the terminal out from rear.
INSTALL TERMINAL TO CONNECTOR
Insert the terminal.
HINT: Make sure the terminal is positioned correctly.
Insert the terminal until the locking lug locks firmly.
Insert the terminal with terminal retainer in the temporary lock position.
Page 3683
^ Engine Control Module (ECM)
^ Transmission Control Module (TCM)
^ Or any other Toyota specific control unit
Warranty Information
Parts Information
Required Tools & Equipment
NOTE
Additional SSTs may be ordered by calling 1-800-933-8335.
Process Overview
Techstream ECU flash reprogramming is a 4-step process:
1. Verify the vehicle's applicability for recalibration and locate desired calibration file by performing
the Techstream Health Check function.
NOTE
Techstream will automatically search TIS for the appropriate service bulletin using the current
Calibration ID from the vehicle. Calibration file links can be found embedded in the corresponding
service bulletin.
2. Connect the GR8 Battery Diagnostic Station using "Power Supply Mode" only.
The GR8 Battery Diagnostic Station includes a Power Supply Mode to help maintain battery
voltage at 13.5 volts during ECU reprogramming.
ECU damage may occur if the correct battery charger mode setting is NOT used.
3. Locate appropriate calibration ID and reprogram the vehicle ECU with Techstream.
Techstream uses the Calibration Update Wizard (CUW) application to open calibration files and
facilitate the ECU flash reprogramming process.
Page 6149
"Case2" Open the secondary locking device.
[B] For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray
Gray or White : Black
Page 7505
Tire Pressure Warning Reset Switch: Testing and Inspection
TIRE AND WHEEL: TIRE PRESSURE WARNING RESET SWITCH: INSPECTION
1. CHECK TIRE PRESSURE WARNING RESET SWITCH
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the switch.
Specifications
Water Pump: Specifications
WATER PUMP ASSEMBLY
Install a new gasket and the water pump with the 8 bolts shown in the illustration.
For bolt A - Torque...............................................................................................................................
....................................47 Nm (479 kgf-cm, 35 ft-lbf)
For bolt B - Torque...............................................................................................................................
....................................23 Nm (235 kgf-cm, 17 ft-lbf)
For bolt C - Torque...............................................................................................................................
....................................20 Nm (204 kgf-cm, 15 ft-lbf)
Page 6458
Page 4045
(1) Insert the bracket tab into the slot and insert the stud bolt into the bracket hole as shown in
illustration A. Then slide the bracket.
(2) Insert the bracket tab into the slot shown in illustration B.
(3) Install the 2 bolts and 2 nuts.
for bolt - Torque : 18 Nm (184 kgf-cm, 13 ft-lbf)
for nut - Torque : 12 Nm (122 kgf-cm, 9 ft-lbf)
(b) Connect the 2 air pump connectors and attach the 3 wire harness claws.
5. INSTALL NO. 3 AIR INJECTION SYSTEM HOSE
(a) Connect the No. 3 air injection system hose so that its paint mark aligns with the air pump's rib
as shown in the illustration below labeled A.
(b) Connect the clamp to the No. 3 air injection system hose shown in the illustration below labeled
B. Then insert the clamp's clip into the body
hole.
HINT Align the paint mark of the No. 3 air injection system hose with the edge of the clamp.
(c) Connect the No. 3 air injection system hose to the air tube shown in the illustration below
labeled C.
HINT *
Make sure the paint mark of the No. 3 air injection system hose is facing upward.
* Make sure the direction of the hose clamp is as shown in the illustration.
(d) Connect the clamp to the No. 3 air injection system hose and wire harness shown in the
illustration below labeled D. Then insert the clamp's
clip into the body hole.
HINT Align the paint mark of the No. 3 air injection system hose and paint mark of the wire harness
with the edge of the clamp.
6. INSTALL NO. 2 AIR INJECTION SYSTEM HOSE
(a) Connect the No. 2 air injection system hose so that its paint mark aligns with the air pump's rib
as shown in the illustration below labeled E.
(b) Connect the No. 2 air injection system hose to the air tube shown in the illustration below
labeled F.
HINT *
Make sure the paint mark of the No. 2 air injection system hose is facing upward.
* Make sure the direction of the hose clamp is as shown in the illustration.
(c) Connect the white colored clamp to the No. 2 air injection system hose and wire harness shown
in the illustration below labeled G.
HINT
Page 3100
Ignition Switch: Service and Repair Removal
1UR-FE STARTING: IGNITION SWITCH: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE STEERING COLUMN ASSEMBLY
(a) for Manual Tilt:
Remove the steering column See: Steering and Suspension/Steering/Steering Column/Service and
Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Removal.
(b) for Manual Tilt and Manual Telescopic Steering Column:
Remove the steering column See: Steering and Suspension/Steering/Steering Column/Service and
Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt and Manual
Telescopic Steering Column)/Removal.
(c) for Power Tilt and Power Telescopic Steering Column:
Remove the steering column See: Steering and Suspension/Steering/Steering Column/Service and
Repair/Removal and Replacement/Steering Column Assembly (for Power Tilt and Power
Telescopic Steering Column)/Removal.
3. REMOVE UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Manual
Tilt) See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering Column Assembly
(for Manual Tilt)/Disassembly
4. REMOVE UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Manual Tilt
and Manual Telescopic Steering Column)
See: Steering and Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering
Column Assembly (for Manual Tilt and Manual Telescopic Steering Column)/Disassembly
5. REMOVE UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Power Tilt
and Power Telescopic Steering Column)
See: Steering and Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering
Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Disassembly
6. REMOVE IGNITION SWITCH ASSEMBLY
(a) Detach the 2 claws and remove the ignition switch from the steering lock.
Page 886
Oil Pressure Sender: Service and Repair Removal
1UR-FE LUBRICATION: OIL PRESSURE SWITCH: REMOVAL
1. REMOVE NO. 1 ENGINE UNDER COVER See: Engine, Cooling and Exhaust/Engine/Engine
Lubrication/Engine Oil/Service and
Repair/Replacement
2. REMOVE OIL PRESSURE SENDER GAUGE ASSEMBLY
(a) Disconnect the sender gauge connector.
(b) Remove the oil pressure sender gauge.
Locations
Gear Sensor/Switch: Locations
JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION
Page 4788
When using Techstream Lite, select Generic J2534 Interface. Then click Next.
E. Confirm the following:
^ PC is connected to VIM.
^ VIM is connected to DLC3 connector.
^ Ignition is ON and engine is OFF or "READY" OFF (hybrid vehicles).
Page 7321
(a) Tighten the nut.
Torque : 195 Nm (1988 kgf-cm, 144 ft-lbf)
8. INSTALL FRONT WHEEL
for Aluminum Wheel - Torque : 131 Nm (1336 kgf-cm, 97 ft-lbf)
for Steel Wheel - Torque : 209 Nm (2131 kgf-cm, 154 ft-lbf)
9. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
(a) Inspect and adjust the front wheel alignment See: Alignment/Service and Repair.
Page 9082
Trailer Towing Part 4
Component Tests and General Diagnostics
Steering Angle Sensor: Component Tests and General Diagnostics
BRAKE CONTROL: STEERING ANGLE SENSOR: INSPECTION
1. CHECK STEERING ANGLE SENSOR
(a) Check the steering angle sensor.
Under any of the following conditions, replace the sensor with a new one:
* The surface of the sensor is cracked, dented, or chipped.
* The connector is scratched, cracked, or damaged.
* The sensor has been dropped.
Engine - Snow Ingestion Into Air Cleaner Box
Air Cleaner Housing: All Technical Service Bulletins Engine - Snow Ingestion Into Air Cleaner Box
T-SB-0396-09
December 8, 2009
Snow Entry Into Air Cleaner Box
Service Category Engine/Hybrid System
Section Intake/Exhaust
Market USA
Applicability
Introduction
Some Sequoia and Tundra vehicles operated in areas with significant snow volume may
experience snow accumulation in the air cleaner box which can cause the lid to fracture. The air
cleaner lid and fender liner have been revised to reduce accumulation.
Parts Information
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for
36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Production Change Information
Page 2396
Engine Oil: Service and Repair Replacement
1UR-FE LUBRICATION: OIL AND OIL FILTER: REPLACEMENT
CAUTION: *
Prolonged and repeated contact with engine oil will result in the removal of natural oils from the
skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially
harmful contaminants which may cause skin cancer.
* Precautions should be taken when replacing engine oil to minimize the risk of your skin making
contact with used engine oil. Protective clothing and gloves that cannot be penetrated by oil should
be worn. The skin should be washed with soap and water, or use waterless hand cleaner, to
remove any used engine oil thoroughly. Do not use gasoline, thinners, or solvents.
* In order to protect the environment, used oil and used oil filters must be disposed of at designated
disposal sites.
1. DRAIN ENGINE OIL
(a) Remove the oil filler cap.
(b) Remove the oil pan drain plug and gasket, and drain the engine oil into a container.
(c) Install a new gasket and the oil pan drain plug.
Torque : 40 Nm (408 kgf-cm, 30 ft-lbf)
2. REMOVE NO. 1 ENGINE UNDER COVER
(a) Remove the 3 screws and 5 bolts.
(b) Unhook the engine under cover from the vehicle body as shown in the illustration.
3. REMOVE OIL FILTER ELEMENT
(a) Connect a hose with an inside diameter of 15 mm (0.591 in.) to the pipe.
Page 8800
Removal
AUDIO / VISUAL: FRONT DOOR SPEAKER (for CrewMax): REMOVAL
HINT *
Use the same procedures for the LH side and RH side.
* The procedures listed below are for the LH side.
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE FRONT LOWER DOOR FRAME BRACKET GARNISH LH See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for CrewMax)/Disassembly
3. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH See: Body and Frame/Doors,
Hood and Trunk/Doors/Front Door/Service and
Repair/Front Door (for CrewMax)/Disassembly
Audio and Visual System
Remote Switch: Locations Audio and Visual System
AUDIO / VISUAL: AUDIO AND VISUAL SYSTEM: PARTS LOCATION
Page 7545
Wheel Fastener: Service and Repair Rear Axle Hub Bolt
Components
AXLE: REAR AXLE HUB BOLT: COMPONENTS
Replacement
AXLE: REAR AXLE HUB BOLT: REPLACEMENT
HINT *
Use the same procedures for the LH side and RH side.
Page 2009
Push the terminal retainer down to the temporary lock position.
Page 4713
Four Wheel Drive Selector Switch: Diagrams
Page 4748
^ Engine Control Module (ECM)
^ Transmission Control Module (TCM)
^ Or any other Toyota specific control unit
Warranty Information
Parts Information
Required Tools & Equipment
NOTE
Additional SSTs may be ordered by calling 1-800-933-8335.
Process Overview
Techstream ECU flash reprogramming is a 4-step process:
1. Verify the vehicle's applicability for recalibration and locate desired calibration file by performing
the Techstream Health Check function.
NOTE
Techstream will automatically search TIS for the appropriate service bulletin using the current
Calibration ID from the vehicle. Calibration file links can be found embedded in the corresponding
service bulletin.
2. Connect the GR8 Battery Diagnostic Station using "Power Supply Mode" only.
The GR8 Battery Diagnostic Station includes a Power Supply Mode to help maintain battery
voltage at 13.5 volts during ECU reprogramming.
ECU damage may occur if the correct battery charger mode setting is NOT used.
3. Locate appropriate calibration ID and reprogram the vehicle ECU with Techstream.
Techstream uses the Calibration Update Wizard (CUW) application to open calibration files and
facilitate the ECU flash reprogramming process.
Page 5092
5. Replace the affected oil baffle.
A. Using a double nut configuration remove 2 axle housing stud bolts to allow the oil baffle to be
removed. See Figures 3 and 4 and attached video
below for reference.
B. Use a 10 mm 1.25 thread chaser or cleaner to carefully clean the axle housing threads.
NOTICE
After cleaning the axle housing threads be sure to thoroughly clean out the axle housing of any
debris to prevent damage to the differential assembly.
C. Replace the oil baffle and fully seat the new baffle against the upper and lower tabs. See Figure
5 for reference.
D. Using a double nut configuration install the new axle housing stud bolts until they are fully
seated.
Torque: 36 N*m (373 kgf*cm, 27 ft*lbf)
6. Install the rear differential and axle shafts.
Take special care not to damage the oil baffle or axle seals when installing the axle shaft assembly.
Refer to TIS applicable model year Tundra Repair Manual:
7. Test drive the vehicle and confirm proper operation.
Page 6395
Page 5441
Four Wheel Drive Selector Switch: Diagrams
Page 3318
Standard Voltage:
NG -- CHECK HARNESS AND CONNECTOR (RELAY BLOCK - ECM, IGNITION SWITCH,
BATTERY AND BODY GROUND)
OK -- REPLACE ECM See: Service and Repair/Removal
5. CHECK HARNESS AND CONNECTOR (RELAY BLOCK - ECM, IGNITION SWITCH, BATTERY
AND BODY GROUND)
(a) Disconnect the ECM connector.
(b) Disconnect the ignition switch connector.
(c) Disconnect the cable from the battery positive (+) terminal.
(d) Remove the AM2 fuse and integration relay.
Recall 10V017000: Accelerator Pedal Sticking
Accelerator Pedal Position Sensor: Recalls Recall 10V017000: Accelerator Pedal Sticking
VEHICLE MAKE/MODEL: MODEL YEAR(S): Toyota/Avalon 2005-2010 Toyota/Camry 2007-2010
Toyota/Corolla 2009-2010 Toyota/Corolla Matrix 2009-2010 Toyota/Highlander 2010 Toyota/ RAV4
2009-2010 Toyota/Sequoia 2008-2010 Toyota/Tundra 2007-2010 MANUFACTURER: Toyota
Motor North America, Inc.
MFR'S REPORT DATE: January 21, 2010
NHTSA CAMPAIGN ID NUMBER: 10V017000
NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Accelerator Assembly:
Pedal/Linkage
POTENTIAL NUMBER OF UNITS AFFECTED: ?
SUMMARY: Toyota is recalling certain model year 2005-2010 Avalon, model year 2007-2010
Camry, model year 2009-2010 Corolla, Corolla Matrix, RAV4, model year 2010 Highlander, model
year 2008-2010 Sequoia, and model year 2007-2010 Tundra. due to the manner in which the
friction lever interacts with the sliding surface of the accelerator pedal inside the pedal sensor
assembly, the sliding surface of the lever may become smooth during vehicle operation. In this
condition, if condensation occurs on the surface, as may occur from heater operation (without A/C)
when the pedal assembly is cold, the friction when the accelerator pedal is operated may increase,
which may result in the accelerator pedal becoming harder to depress, slower to return, or, in the
worst case, mechanically stuck in a partially depressed position.
CONSEQUENCE: The accelerator pedal may become hard to depress, slow to return to idle, or, in
the worst case, mechanically stuck in a partially depressed position, increasing the risk of a crash.
REMEDY: Toyota has not yet provided a remedy plan or an owner notification schedule. Owners
may contact Toyota at 1-800-331-4331.
NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle
Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov.
Page 8787
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the speaker assembly.
2. INSPECT FRONT NO. 1 SPEAKER ASSEMBLY (for 12 Speakers)
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the speaker assembly.
3. INSPECT FRONT NO. 3 SPEAKER ASSEMBLY (for 12 Speakers)
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the speaker assembly.
Front Door Speaker (for Double Cab)
AUDIO / VISUAL: FRONT DOOR SPEAKER (for Double Cab): INSPECTION
Page 2739
Page 6443
Power Distribution Module: Service and Repair Installation
OTHER SYSTEM: VOLTAGE INVERTER (for CrewMax): INSTALLATION
1. INSTALL VOLTAGE INVERTER ASSEMBLY
(a) Connect the voltage inverter connector.
(b) Install the voltage inverter with the 2 bolts.
Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
2. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY LH See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (for CrewMax)/Installation
3. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH
4. INSTALL REAR DOOR SCUFF PLATE LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for
CrewMax)/Installation
5. INSTALL BACK PANEL TRIM LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for
CrewMax)/Installation
6. INSTALL BACK PANEL TRIM RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for
CrewMax)/Installation
Page 4308
^ Power Supply Mode is used to maintain battery voltage at 13.5 volts while flash reprogramming
the vehicle.
^ For details on how to use the GR8 Battery Diagnostic Station, refer to the located on TIS,
Diagnostics - Tools & Equipment - Battery Diagnostics.
3. Click the appropriate calibration ID and reprogram the vehicle's ECU with Techstream.
A. After reviewing the procedures outlined in the selected TSB, click the appropriate calibration ID
link by matching the vehicle's current
calibration ID to the Previous Calibration ID in the Calibration Identification Chart.
NOTE
^ Calibration files are embedded as live links in the service bulletin.
^ Some vehicles require special preparation - please review the selected TSB carefully.
B. Click Open to load calibration file information.
Techstream pulls calibration files as needed to ensure the latest calibration file is used. Do NOT
save calibrations locally on the hard drive or other media.
NOTICE
Errors during the flash reprogramming process can permanently damage the vehicle ECU.
Minimize the risk by following the steps below.
^ Battery voltage MUST NOT FALL BELOW 11.4 volts during reprogramming. Confirm battery
voltage is higher than 11.4 volts, but be sure voltage DOES NOT RISE ABOVE 16.0 volts during
reprogramming.
^ Turn OFF all vehicle accessories (e.g. audio system, A/C, interior lights, DRL, etc.). Do NOT add
to or significantly change the vehicle's electrical
Page 4280
^ Figure 17 shows an example of the update procedure for a two-processor ECU.
G. Turn ignition OFF. Then click Next.
H. Confirm the following:
^ Ignition is ON and engine is OFF or "READY" OFF (hybrid vehicles).
^ Hood is open.
^ All accessories are OFF.
^ Battery voltage is above 11.4 volts.
NOTICE
Verify the vehicle is connected to a battery charger before continuing - If battery voltage falls below
11.4 volts, ECU damage may occur.
Air Conditioning System (for Automatic Air Conditioning
System)
Compressor Speed Sensor: Locations Air Conditioning System (for Automatic Air Conditioning
System)
AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Automatic Air Conditioning System):
PARTS LOCATION
Locations
Power Distribution Relay: Locations
Instrument Panel (Floor Shift)
Instrument Panel (Column Shift)
Page 6315
AJ1-AJ8
Page 4606
If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness
or connector in that circuit in the past. Check the wire harness and connectors.
B -- SYSTEM NORMAL
A -- TROUBLESHOOTING OF EACH PROBLEM SYMPTOM
The problem is still occurring in a place other than the diagnostic circuit (the DTC displayed first is
either for a past problem or a secondary problem).
4. SYMPTOM SIMULATION
HINT The most difficult case in troubleshooting is when no problem symptoms occur. In such a
case, a thorough problem analysis must be carried out. A simulation of the same or similar
conditions and environment in which the problem occurred in the customer's vehicle should be
carried out. No matter how much skill or experience a technician has, troubleshooting without
confirming the problem symptoms will lead to important repairs being overlooked and mistakes or
delays.
For example:
With a problem that only occurs when the engine is cold or as a result of vibration caused by the
road during driving, the problem can never be determined if the symptoms are being checked on a
stationary vehicle or on a vehicle with a warmed-up engine. Vibration, heat or water penetration
(moisture) is difficult to reproduce. The symptom simulation tests below are effective substitutes for
the conditions and can be applied on a stationary vehicle.
Important points in the symptom simulation test:
In the symptom simulation test, the problem symptoms as well as the problem area or parts must
be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then,
connect the tester and carry out the symptom simulation test, judging whether the circuit being
tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the
problem symptoms table for each system to narrow down the possible causes.
To reproduce DTCs, it is necessary to satisfy the respective DTC detection conditions.
(a) VIBRATION METHOD:
When a malfunction seems to occur as a result of vibration.
(1) PART AND SENSOR
Apply slight vibration with a finger to the part of the sensor suspected to be the cause of the
problem, and check whether or not the malfunction occurs.
NOTICE: Applying strong vibration to relays may open them.
Page 7564
Ambient Temperature Sensor / Switch HVAC: Service and Repair Removal
AIR CONDITIONING: AMBIENT TEMPERATURE SENSOR: REMOVAL
1. REMOVE AMBIENT TEMPERATURE SENSOR
(a) Disconnect the connector.
(b) Using a screwdriver, detach the clamp and remove the ambient temperature sensor.
HINT Tape the screwdriver tip before use.
Page 5804
Vacuum Brake Booster: Service and Repair Installation
BRAKE: BRAKE BOOSTER: INSTALLATION
1. INSTALL BRAKE VACUUM CHECK VALVE ASSEMBLY
2. INSTALL BRAKE BOOSTER ASSEMBLY
(a) Install the clevis.
(b) Install a new brake booster gasket to the brake booster.
(c) Install the brake booster with the 4 nuts.
Torque : 15 Nm (155 kgf-cm, 11 ft-lbf)
3. INSTALL PUSH ROD PIN See: Brake Pedal Assy/Service and Repair/Installation
4. INSTALL LOWER NO. 1 INSTRUMENT PANEL AIR BAG ASSEMBLY See: Restraint
Systems/Air Bag Systems/Air Bag/Service and
Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Installation
5. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Installation
6. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Installation
7. INSTALL FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Installation
8. INSTALL FRONT DOOR SCUFF PLATE LH (for Double Cab, CrewMax) See: Body and
Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Installation
9. CONNECT BRAKE BOOSTER CONNECTOR
(a) Connect the 2 brake booster connectors to the brake booster.
10. CONNECT VACUUM HOSE ASSEMBLY
(a) Connect the vacuum hose onto the check valve.
NOTICE: Do not use lubricant when installing a vacuum hose on the brake booster and check
valve sides.
11. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY
(a) Install the brake master cylinder See: Hydraulic System/Brake Master Cylinder/Service and
Repair/Removal and Replacement/Installation.
12. CHECK AND ADJUST BRAKE PEDAL
(a) Check and adjust brake pedal See: Brake Pedal Assy/Adjustments.
13. CHECK BRAKE BOOSTER See: Testing and Inspection
14. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
15. BLEED BRAKE SYSTEM See: Brake Bleeding/Service and Repair/Bleeding
Page 3439
B -- REPLACE ECM
A -- REPLACE ECM See: Engine Control Module/Service and Repair/Removal
Short to B+ in CAN Bus Line
CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: Short to B+ in CAN Bus Line - Short
to B+ in CAN Bus Line
DESCRIPTION
There may be a short circuit between the CAN bus line and +B when there is resistance between
terminals 6 (CANH) and 16 (BAT) or terminals 14 (CANL) and 16 (BAT) of the DLC3.
HINT *
*1: w/ Bus Buffer ECU
* *2: w/ 4WD
* *3: w/ Power Steering ECU
WIRING DIAGRAM
Page 7372
(a) Using SST, compress the coil spring.
SST : 09727-30021
09727-00010
09727-00021
09727-00031
NOTICE: *
Do not compress the coil spring more than necessary.
* Do not use an impact wrench. It will damage SST.
(b) Install the coil spring to the shock absorber.
HINT Fit the lower end of the coil spring into the recess of the spring seat of the shock absorber.
2. INSTALL FRONT SUSPENSION SUPPORT SUB-ASSEMBLY LH
(a) Install the 2 cushions, 2 retainers and suspension support to the piston rod.
(b) Temporarily install a new suspension support to front shock absorber nut.
(c) Position the suspension support as shown in the illustration.
(d) Remove SST.
NOTICE: Do not use an impact wrench. It will damage the shock absorber rod.
Page 5244
2. Inspect the front driveshaft (propeller shaft assembly) for a loose parts label that may be
contacting other components (see Figure 1).
Is the label on the front driveshaft (propeller shaft assembly) loose and contacting other
components?
^ YES - Go to step 3.
^ NO - This TSB does NOT apply. Continue diagnosis to isolate the cause of this condition.
3. Completely remove the front driveshaft parts label.
4. Test drive and confirm there is no abnormal noise present when in 4WD.
Page 6296
J/B No.3 - Instrument Panel Right
Page 2458
Intake Manifold: Service and Repair Removal
1UR-FE INTAKE: INTAKE MANIFOLD: REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE See: Powertrain Management/Fuel Delivery and Air
Induction/Fuel Injector/Service and
Repair/Removal
2. REMOVE EGR VALVE ASSEMBLY
(a) Remove the EGR valve See: Powertrain Management/Emission Control Systems/Exhaust Gas
Recirculation/EGR Valve/Service and
Repair/Removal.
3. REMOVE FRONT WIPER MOTOR AND LINK ASSEMBLY
(a) Remove the front wiper motor and link See: Wiper and Washer Systems/Wiper Motor/Service
and Repair/Removal.
4. REMOVE COWL TOP OUTER PANEL SUB-ASSEMBLY
(a) Disconnect the washer hose and 2 wire harness clamps.
(b) Remove the 7 bolts and outer panel.
5. REMOVE VENTILATION HOSE ASSEMBLY
(a) Disconnect the ventilation hose from the ventilation pipe of the cylinder head cover LH and RH.
(b) Remove the bolt and ventilation hose.
6. REMOVE AIR TUBE SUB-ASSEMBLY LH See: Cooling System/Thermostat/Service and
Repair/Removal
7. REMOVE INTAKE MANIFOLD
(a) Disconnect the No. 4 water by-pass hose.
(b) Disconnect the throttle body connector.
(c) Disconnect the No. 1 ventilation hose.
(d) Disconnect the purge VSV connector.
Page 7280
Remove the engine assembly See: Engine, Cooling and Exhaust/Engine/Service and
Repair/Removal and Replacement/Engine Assembly/Removal.
(b) for 3UR-FBE:
Remove the engine assembly See: Engine, Cooling and Exhaust/Engine/Service and
Repair/Removal and Replacement/Engine Assembly/Removal.
(c) for 1UR-FE:
Remove the engine assembly See: Engine, Cooling and Exhaust/Engine/Service and
Repair/Removal and Replacement/Engine Assembly/Removal.
(d) for 3UR-FE:
Remove the engine assembly See: Engine, Cooling and Exhaust/Engine/Service and
Repair/Removal and Replacement/Engine Assembly/Removal.
4. DISCONNECT NO. 2 STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY
(a) Put matchmarks on the No. 2 steering intermediate shaft and the power steering gear.
(b) Remove the bolt and disconnect the No. 2 steering intermediate shaft from the power steering
gear.
5. DISCONNECT TIE ROD END SUB-ASSEMBLY LH
(a) Remove the cotter pin and nut.
(b) Using SST, disconnect the tie rod end LH from the steering knuckle.
SST : 09610-20012
NOTICE: *
Hang SST with a string, etc. to prevent it from falling.
* Do not damage the front disc brake dust cover.
* Do not damage the ball joint dust cover.
* Do not damage the steering knuckle.
6. DISCONNECT TIE ROD END SUB-ASSEMBLY RH
HINT
Up to 11/2009
Brake Fluid Solenoid Valve Relay: Locations Up to 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 4478
Throttle Body: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: THROTTLE BODY: REMOVAL
1. REMOVE NO. 1 ENGINE UNDER COVER See: Engine, Cooling and Exhaust/Engine/Engine
Lubrication/Engine Oil/Service and
Repair/Replacement
2. DRAIN ENGINE COOLANT See: Engine, Cooling and Exhaust/Cooling System/Coolant/Service
and Repair
3. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Removal
4. REMOVE AIR CLEANER HOSE ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Removal
5. REMOVE THROTTLE BODY ASSEMBLY
(a) Disconnect the 2 water by-pass hoses.
(b) Disconnect the throttle position sensor and control motor connector.
(c) Remove the 4 bolts, throttle body and gasket.
(d) Remove the No. 12 water by-pass hose from the throttle body.
(e) Remove the No. 4 water by-pass hose from the throttle body.
Page 8067
* Peeling off of the label or damage to the serial number.
CAUTION: For removal and installation procedures of the front airbag sensor, be sure to follow the
correct procedure.
3. CHECK FRONT AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS
DEPLOYED)
(a) Replace the front airbag sensor.
CAUTION: *
For removal and installation procedures of the front airbag sensor, be sure to follow the correct
procedure.
* If the airbags have deployed, replace the front airbag sensor on the side in which the collision
occurred. Replace both if necessary.
Side Airbag Sensor (for CrewMax)
SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for CrewMax): ON-VEHICLE
INSPECTION
1. CHECK REAR AIRBAG SENSOR (VEHICLE NOT INVOLVED IN COLLISION)
(a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnosis System.
2. CHECK REAR AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS
NOT DEPLOYED)
(a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnosis System.
(b) When the quarter panel of the vehicle or its area is damaged, check if there is any damage to
the rear airbag sensor. If there are any defects as
mentioned below, replace the side airbag sensor with a new one:
* Cracks, dents or chips on the sensor housing.
* Cracks or other damage to the connector.
* Peeling off of the label or damage to the serial number.
CAUTION: For removal and installation procedures of the side airbag sensor, be sure to follow the
correct procedure.
3. CHECK REAR AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS
DEPLOYED)
(a) Replace the side airbag sensor.
CAUTION: *
For removal and installation procedures of the side airbag sensor, be sure to follow the correct
procedure.
* If the airbags have deployed, replace the rear airbag sensor on the side in which the collision
occurred. Replace both if necessary.
Side Airbag Sensor (for Double Cab)
SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Double Cab):
ON-VEHICLE INSPECTION
1. CHECK REAR AIRBAG SENSOR (VEHICLE NOT INVOLVED IN COLLISION)
(a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnosis System.
2. CHECK REAR AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS
NOT DEPLOYED)
(a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnosis System.
(b) When the quarter panel of the vehicle or its area is damaged, check if there is any damage to
the rear airbag sensor. If there are any defects as
mentioned below, replace the side airbag sensor with a new one:
* Cracks, dents or chips on the sensor housing.
* Cracks or other damage to the connector.
* Peeling off of the label or damage to the serial number.
Page 5926
Yaw Rate Sensor: Locations From 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 2472
Crankshaft Main Bearing Seal: Service and Repair Removal
1UR-FE ENGINE MECHANICAL: REAR CRANKSHAFT OIL SEAL: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY
(a) for 2WD:
Refer to the following procedures .
(b) for 4WD:
Refer to the following procedures See: Transmission and Drivetrain/Automatic
Transmission/Transaxle/Service and Repair/Removal and Replacement/Removal.
3. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY See: Service and Repair/Removal
and Replacement/Engine
Assembly/Removal
4. REMOVE REAR CRANKSHAFT OIL SEAL
(a) Using a knife, cut off the lip of the oil seal.
(b) Using a screwdriver, pry out the oil seal.
NOTICE: Do not damage the surface of the oil seal press fit hole and crankshaft.
HINT Tape the screwdriver tip before use.
Service and Repair
Keyless Entry Transmitter Battery: Service and Repair
DOOR LOCK: TRANSMITTER BATTERY: REPLACEMENT
1. REPLACE TRANSMITTER BATTERY
NOTICE: Be careful when handling each component as they are precision electronic components.
(a) Insert a precision screwdriver into the gap, and turn the screwdriver to detach the cover.
HINT Tape the screwdriver tip before use.
NOTICE: Do not forcibly pry up the cover.
(b) Remove the battery (lithium battery: CR2032).
NOTICE: *
Do not push the terminals with your finger.
* Do not forcibly pry up the battery. The terminals may be damaged.
* Do not touch the battery with wet hands. Water may cause rust.
* Do not touch or move any components inside the transmitter, it may interfere with the proper
operation.
(c) Install a battery (lithium battery: CR2032) with the positive (+) side facing upward, as shown in
the illustration.
NOTICE: *
Do not bend the transmitter battery electrode during insertion.
* Keep the transmitter cover interior free of dust and oil.
(d) Attach the cover securely.
Page 2054
Page 1379
Impact Sensor: Testing and Inspection Center Airbag Sensor Assembly (for Floor Shift Type)
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift
Type): ON-VEHICLE INSPECTION
1. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION)
(a) Perform a diagnostic system check See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
2. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND
AIRBAG HAS NOT DEPLOYED)
(a) Perform a diagnostic system check See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
3. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND
AIRBAG IS DEPLOYED)
(a) Replace the center airbag sensor.
CAUTION: For removal and installation procedures of the center airbag sensor, be sure to follow
the correct procedure.
HINT The center airbag sensor should be replaced after any of the airbags has deployed, as it has
been subjected to the impact.
Page 9167
Auxiliary Step / Running Board: By Symptom
Technical Service Bulletin # SB0164-10 Date: 100628
Body - Tube Step Step Pad Lifting/Cracking
T-SB-0164-10
June 28, 2010
Tube Step - Step Pad Lifting/Cracked
Service Category Vehicle Exterior
Section Exterior Panels/Trim
Market USA
Applicability
Introduction
Some 2007 - 2010 model year Tundra vehicles equipped with PPO/DIO tube steps may exhibit a
condition where the step pad has lifted or cracked. To improve the serviceability of the tube step
the step pad is now available as a separate service part. Follow the procedure in this bulletin to
replace the step pad. Removal of the tube step is not required to perform step pad replacement.
Parts Information
Warranty Information
APPLICABLE WARRANTY
^ Toyota accessories installed as original equipment are covered under the Toyota Comprehensive
Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the
vehicle's in-service date.
^ Toyota accessories installed after the new vehicle purchase are warranted for 12 months,
regardless of mileage, from the date of installation on the vehicle, or the remainder of the
applicable New Vehicle Limited Warranty, whichever provides the greater coverage.
^ Toyota accessories purchased over-the-counter are covered for 12 months from the date of
purchase.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Repair Procedure
Page 4836
Fluid - A/T: Fluid Type Specifications
Transmission Fluid
Type .....................................................................................................................................................
......................................... Toyota Genuine ATF WS
Notice: Using automatic transmission fluid other than "Toyota Genuine ATF WS" may cause
deterioration in shift quality, locking up of your transmission accompanied by vibration, and
ultimately damage the automatic transmission of your vehicle.
Page 9343
(2) w/ Front Fender Mudguard:
Install the front fender mudguard See: Spoilers, Flaps, and Air Dams/Mud Flap/Service and
Repair/Installation.
(3) w/ Side Step:
Install the side step See: Auxiliary Step / Running Board/Service and Repair/Removal and
Replacement/Installation.
(b) for Resin Type Bumper:
Install the fender apron mudguard seal.
(1) Install the fender apron mudguard with the 2 clips and 15 new clips labeled A.
(2) Install the pin hold clip so that its groove is vertical.
(3) w/ Front Fender Mudguard:
Install the front fender mudguard See: Spoilers, Flaps, and Air Dams/Mud Flap/Service and
Repair/Installation.
(4) w/ Side Step:
Install the side step See: Auxiliary Step / Running Board/Service and Repair/Removal and
Replacement/Installation.
Page 9179
Auxiliary Step / Running Board: Overhaul
Disassembly
EXTERIOR: SIDE STEP: DISASSEMBLY
1. REMOVE STEP PLATE COVER LH
(a) for Double Cab:
Remove the step plate cover.
(1) Detach the 19 clips and remove the step plate cover.
(b) for CrewMax:
Remove the step plate cover.
(1) Detach the 23 clips and remove the step plate cover.
2. REMOVE STEP COVER PROTECTOR LH
3. REMOVE STEP ARM SPACER LH
4. REMOVE SIDE STEP BRACKET LH
(a) Remove the 2 bolts and side step bracket.
Page 7655
Page 3956
This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown.
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60
months or 60,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Op Code EG9029 or EG9024: For California specification vehicles sold, registered, and operated
in California, Connecticut, Maine, Massachusetts, New Jersey, Oregon, Pennsylvania, Rhode
Island, Vermont, and Washington, this repair is covered under the California Emission Warranty.
This warranty is in effect for 84 months or 70,000 miles, whichever occurs first, from the vehicle's
in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Page 5365
Four Wheel Drive Selector Switch: Diagrams
Page 7719
Remove the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Floor Shift Type)/Removal.
6. REMOVE LOWER INSTRUMENT PANEL
(a) for Column Shift Type:
Remove the lower instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Column Shift Type)/Removal.
(b) for Floor Shift Type:
Remove the lower instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Floor Shift Type)/Removal.
7. REMOVE LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY
(a) for Column Shift Type:
Remove the No. 2 instrument panel airbag assembly See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument
Panel Safety Pad (for Column Shift Type)/Removal.
(b) for Floor Shift Type:
Remove the No. 2 instrument panel airbag assembly See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument
Panel Safety Pad (for Floor Shift Type)/Removal.
8. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH
(a) for Column Shift Type:
Remove the instrument panel finish panel See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument
Panel Safety Pad (for Column Shift Type)/Removal.
(b) for Floor Shift Type:
Remove the instrument panel finish panel See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument
Panel Safety Pad (for Floor Shift Type)/Removal.
9. REMOVE NO. 2 AIR DUCT SUB-ASSEMBLY
(a) Remove the screw and duct.
10. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY
Page 9036
Trailer Towing Part 3
Page 4054
Canister Purge Control Valve: Service and Repair Installation
1UR-FE EMISSION CONTROL: PURGE VALVE: INSTALLATION
1. INSTALL PURGE VSV
(a) Install the purge VSV with the bolt.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
(b) Connect the connector.
2. CONNECT PURGE LINE HOSE
(a) Connect the 2 hoses.
HINT Turn the claw of the clip to the upper side.
3. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Installation
Page 5550
Four Wheel Drive Selector Switch: Service and Repair Installation
JF1A TRANSFER: 4WD CONTROL SWITCH: INSTALLATION
1. INSTALL 4WD CONTROL SWITCH
(a) Attach the 3 claws to install the switch.
2. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Panel,
Gauges and Warning Indicators/Instrument Cluster
/ Carrier/Service and Repair/Combination Meter/Installation
Page 2158
Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf)
NOTICE: *
No further tightening is required once the nut is tightened with the specified torque.
* Check that there is no foreign matter on the washer and nut.
* Check that there is no oil, water or lubricant around the rim hole, tire pressure warning valve,
washer and nut. Failing to do so may result in improper installation.
(d) Set the wheel disc to a mounting machine and install the lower tire bead. Position the main
body of the tire pressure warning valve and
transmitter in the shaded area as shown in the illustration.
NOTICE: *
If the tire pressure warning valve and transmitter is positioned outside this area, the tire bead will
interfere with the tire pressure warning valve and transmitter, and may cause damage to it.
* If the use of lubricant is required when installing the bead, do not apply the lubricant directly to the
tire pressure warning valve and transmitter.
(e) Install the upper bead.
NOTICE: Make sure that the tire bead and tool do not interfere with the main body of the tire
pressure warning valve and transmitter and that the tire pressure warning valve and transmitter is
not clamped by the bead.
(f) Inflate the tire. Retighten the nut to the specified torque and then check for air leaks with soapy
water.
Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf)
NOTICE:
Page 1728
Fuel Pressure: Testing and Inspection
1UR-FE FUEL: FUEL SYSTEM: ON-VEHICLE INSPECTION
1. CHECK FUEL PUMP OPERATION AND FOR FUEL LEAK
(a) Connect the Techstream to the DLC3.
(b) Turn the ignition switch to ON.
NOTICE: Do not start the engine.
(c) Turn the Techstream main switch ON.
(d) Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump /
Speed.
(e) Check the fuel pump operation.
(1) Check for pressure in the fuel inlet tube from the fuel line. Check that the sound of fuel flowing
in the fuel tank can be heard.
If there is no sound, check the integration relay, fuel pump, ECM and wiring connector.
(f) Check for fuel leak.
(1) Check that there are no fuel leaks after performing maintenance anywhere on the system.
If there are fuel leaks, repair or replace parts as necessary.
2. CHECK FUEL PRESSURE
(a) Check that the battery voltage is 11 to 14 V.
(b) Perform the "DISCHARGE FUEL SYSTEM PRESSURE" procedures See: Powertrain
Management/Fuel Delivery and Air
Induction/Service Precautions.
(c) Disconnect the cable from the negative (-) battery terminal.
(d) Remove the fuel pipe clamp from the fuel tube connector.
(e) Pinch and pull the fuel tube (fuel tube connector) to disconnect it.
CAUTION: *
Always read the precautions See: Powertrain Management/Fuel Delivery and Air Induction/Service
Precautions before disconnecting the fuel tube connector (quick type).
* The fuel tube may spray fuel as a result of pressure that remains in it. Do not allow fuel to be
sprayed in the engine compartment.
Page 6356
General Information
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: GENERAL
INFORMATION
* A large number of ECU controlled systems are used in the TOYOTA TUNDRA. In general, ECU
controlled systems are considered to be very intricate, requiring a high level of technical knowledge
to troubleshoot. However, most problem checking procedures only involve inspecting the ECU
controlled system's circuits one by one. An adequate understanding of the system and a basic
knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and
necessary repairs.
1. TROUBLESHOOTING PROCEDURES
* The troubleshooting procedures consist of diagnosis procedures for when a DTC is stored and
diagnosis procedures for when no DTC is stored. The basic idea is explained in the following table.
* Vehicle systems are complex and use many ECUs that are difficult to inspect independently.
Therefore, a process of elimination is used, where components that can be inspected individually
are inspected, and if no problems are found in these components, the related ECU is identified as
the problem and replaced.
* It is extremely important to ask the customer about the environment and the conditions present
when the problem occurred (Customer Problem Analysis). This makes it possible to simulate the
conditions and confirm the symptom. If the symptom cannot be confirmed or the DTC does not
recur, the malfunctioning part may not be identified using the troubleshooting procedure, and the
ECU for the related system may be replaced even though it is not defective. If this happens, the
original problem will not be solved.
* In order to prevent endless expansion of troubleshooting procedures, the troubleshooting
procedures are written with the assumption that multiple malfunctions do not occur simultaneously
for a single problem symptom.
* To identify the malfunctioning part, troubleshooting procedures narrow down the target by
separating components, ECUs and wire harnesses during the inspection. If the wire harness is
identified as the cause of the problem, it is necessary to inspect not only the connections to
components and ECUs but also all of the wire harness connectors between the component and the
ECU.
DIAGNOSTIC TESTER
2. DESCRIPTION
System data and the Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector
3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the Techstream* to
check for a malfunction and perform repairs.
HINT *: Techstream is the name for the diagnostic tester in North America.
3. DATA LINK CONNECTOR 3 (DLC3)
(a) The vehicle's ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of
the DLC3 complies with SAE J1962 and
matches the ISO 15765-4 format.
Page 4651
Actuator: Service and Repair Removal
DIFFERENTIAL: AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR (for 4WD):
REMOVAL
1. REMOVE NO. 1 ENGINE UNDER COVER See: Engine, Cooling and Exhaust/Engine/Drive
Belts, Mounts, Brackets and Accessories/Drive
Belt/Service and Repair/Removal
2. REMOVE AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR
(a) Disconnect the actuator hose.
(b) Disconnect the actuator connector.
(c) Remove the 4 bolts and actuator.
Air Conditioning System (for Automatic Air Conditioning
System)
Ambient Temperature Sensor / Switch HVAC: Locations Air Conditioning System (for Automatic Air
Conditioning System)
AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Automatic Air Conditioning System):
PARTS LOCATION
Page 7677
Compressor Clutch Relay: Testing and Inspection
AIR CONDITIONING: MAGNETIC CLUTCH RELAY: ON-VEHICLE INSPECTION
1. INSPECT MAGNETIC CLUTCH RELAY (MG CLT)
(a) Remove the magnetic clutch relay from the engine room relay block.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
* If the result is not as specified, replace the relay.
(c) Install the magnetic clutch relay.
Page 4592
Release the locking lug from terminal and pull the terminal out from rear.
INSTALL TERMINAL TO CONNECTOR
Insert the terminal.
HINT: Make sure the terminal is positioned correctly.
Insert the terminal until the locking lug locks firmly.
Insert the terminal with terminal retainer in the temporary lock position.
Page 2071
when inserting and after full engagement.
NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal.
(d) REPAIR METHOD OF CONNECTOR TERMINAL
(1) If there is any foreign matter on the terminal, clean the contact point using an air gun or cloth.
Never rub the contact point using sandpaper
as the plating may come off.
(2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is
gold-plated (gold color), use a gold-plated female
terminal; if it is silver-plated (silver color), use a silver-plated female terminal.
(3) Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock
into the housing, the housing may have to be
replaced.
(e) HANDLING OF WIRE HARNESS
(1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be
restored in the same way.
(2) Never twist, pull or slacken the wire harness more than necessary.
(3) The wire harness should never come into contact with a high temperature part, or rotating,
moving, vibrating or sharp-edged parts. Avoid
contact with panel edges, screw tips and other sharp items.
(4) When installing parts, never pinch the wire harness.
(5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with
vinyl tape.
2. CHECK FOR OPEN CIRCUIT
Page 1702
Standard toe-in (unloaded vehicle):
for Double Cab of Long Deck
Standard toe-in (unloaded vehicle):
for CrewMax of standard deck
Page 9276
Hood Shock / Support: Service and Repair Installation
ENGINE HOOD / DOOR: HOOD SUPPORT: INSTALLATION
NOTICE: *
As much as possible avoid touching the stroke portions of the rod to prevent foreign matter from
attaching to it. Be sure to hold the cylinders while servicing.
* Do not wear cotton gloves or other similar materials when handling the rod. Fibers may attach to
the rod and result in gas leaks.
* Do not apply any load to the cylinders in the horizontal direction in order to prevent the rod from
being deformed.
HINT *
Use the same procedures for the RH side and LH side.
* The procedures listed below are for the LH side.
1. INSTALL NO. 1 HOOD SUPPORT BOLT
(a) Install the hood support bolt.
Torque : 22 Nm (224 kgf-cm, 16 ft-lbf)
CAUTION: Install the hood support bolt while supporting the hood by hand.
2. INSTALL HOOD SUPPORT ASSEMBLY LH
(a) Install the hood support assembly.
CAUTION: Install the hood support while supporting the hood by hand.
NOTICE: Check that the hood support is engaged in the ball joint and it cannot be pulled out.
Page 3242
4. SYMPTOM CONFIRMATION AND DTC (INCLUDING FREEZE FRAME DATA) CHECK
(a) Visually check the wire harnesses, connectors and fuses for open and short circuits.
(b) Warm up the engine to the normal operating temperature.
(c) Confirm the problem symptoms and conditions, and check for DTCs.
B -- Go to step 6 A -- Continue to next step.
5. DTC CHART
(a) Check the results obtained in the DTC check. Then find the output DTC in the DTC chart. Look
at the "Trouble Area" column for a list of
potentially malfunctioning circuits and / or parts.
NEXT -- Go to step 7
6. PROBLEM SYMPTOMS TABLE
(a) Check the results obtained in the symptom confirmation. Then find the problem symptoms in
the problem symptoms table. Look at the
"Suspected Area" column for a list of potentially malfunctioning circuits and / or parts.
NEXT -- Continue to next step.
7. CIRCUIT INSPECTION OR PARTS INSPECTION
(a) Confirm the malfunctioning circuit or part.
NEXT -- Continue to next step.
8. ADJUST, REPAIR OR REPLACE
(a) Adjust, repair or replace the malfunctioning circuit or parts.
NEXT -- Continue to next step.
9. CONFIRMATION TEST
(a) After the adjustment, repairs or replacement, confirm that the malfunction no longer exists. If the
malfunction does not reoccur, perform a
confirmation test under the same conditions and in the same environment as when the malfunction
occurred the first time.
NEXT -- END
2. CUSTOMER PROBLEM ANALYSIS
HINT *
In troubleshooting, confirm that the problem symptoms have been accurately identified.
Preconceptions should be discarded in order to make an accurate judgment. To clearly understand
what the problem symptoms are, it is extremely important to ask the customer about the problem
and the conditions at the time the malfunction occurred.
* Gather as much information as possible for reference. Past problems that seem unrelated may
also help in some cases.
* The following 5 questions are important points in the problem analysis:
Page 2086
Engine Room R/B, J/B - Engine Compartment Left
Page 5729
without union nut wrench - Torque : 15 Nm (155 kgf-cm, 11 ft-lbf)
with union nut wrench - Torque : 14 Nm (145 kgf-cm, 10 ft-lbf)
HINT *
Use a torque wrench with a fulcrum length of 300 mm (11.8 in.).
* This torque value is effective when union nut wrench is parallel to the torque wrench.
NOTICE: *
Do not bend or damage the brake tube.
* Do not allow any foreign matter such as dirt and dust to enter the brake tube from the connecting
point.
2. BLEED BRAKE LINE See: Brake Bleeding/Service and Repair/Bleeding
3. INSTALL REAR WHEEL See: Steering and Suspension/Suspension/Suspension Strut / Shock
Absorber/Service and Repair/Removal and
Replacement/Rear Shock Absorber/Installation
Page 2727
(b) Install the 2 No. 1 monolithic converter protectors with the 4 bolts and 4 nuts.
Torque : 11 Nm (107 kgf-cm, 8 ft-lbf)
HINT Install the monolithic converter protector within the angle range specified in the illustration.
5. INSTALL AIR FUEL RATIO SENSOR (for Bank 1 Sensor 1)
(a) Install the sensor to the front No. 2 exhaust pipe by hand.
(b) Using SST, tighten the sensor.
SST : 09224-00010
without SST - Torque : 44 Nm (449 kgf-cm, 32 ft-lbf)
with SST - Torque : 40 Nm (408 kgf-cm, 30 ft-lbf)
HINT *
Use a torque wrench with a fulcrum length of 30 cm (11.8 in.). If using a torque wrench with a
length that is not 30 cm (11.8 in.), calculate the torque specification for the torque wrench and SST
based on the "without SST" torque specification See: Service Precautions
* Make sure SST and the wrench are connected in a straight line.
6. INSTALL AIR FUEL RATIO SENSOR (for Bank 2 Sensor 1) See: Powertrain
Management/Computers and Control Systems/Oxygen
Sensor/Service and Repair/Air Fuel Ratio Sensor/Installation
7. INSTALL FRONT EXHAUST PIPE ASSEMBLY
(a) Install a new gasket and the front exhaust pipe to the exhaust manifold RH with 3 new nuts.
Torque : 54 Nm (554 kgf-cm, 40 ft-lbf)
(b) Connect the air fuel ratio sensor connector.
8. INSTALL HEATED OXYGEN SENSOR (for Bank 2 Sensor 2) See: Powertrain
Management/Computers and Control Systems/Oxygen
Sensor/Service and Repair/Heated Oxygen Sensor/Installation
9. INSTALL FRONT NO. 2 EXHAUST PIPE ASSEMBLY
(a) Install a new gasket and the front No. 2 exhaust pipe to the exhaust manifold LH with 3 new
nuts.
Page 366
M. Turn ignition OFF for a minimum of 10 seconds. Then click Next.
N. Turn ignition to the ON position. Then click Next.
0. Confirm all calibrations were updated as specified in the service bulletin. Then click Finish.
Locations
Washer Fluid Level Switch: Locations
WIPER AND WASHER: WIPER AND WASHER SYSTEM: PARTS LOCATION
Page 6828
Page 8430
Antenna, Navigation: Service and Repair Installation
NAVIGATION: NAVIGATION ANTENNA: INSTALLATION
1. INSTALL NAVIGATION ANTENNA ASSEMBLY
(a) Install the antenna with the 2 screws.
(b) Attach the clamp.
2. INSTALL DEFROSTER NOZZLE ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Overhaul/Instrument Panel Safety Pad (for Column Shift Type)/Reassembly
3. INSTALL NO. 1 SIDE DEFROSTER NOZZLE DUCT See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service
and Repair/Overhaul/Instrument Panel Safety Pad (for Column Shift Type)/Reassembly
4. INSTALL NO. 2 SIDE DEFROSTER NOZZLE DUCT See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service
and Repair/Overhaul/Instrument Panel Safety Pad (for Column Shift Type)/Reassembly
5. INSTALL NO. 1 HEATER TO REGISTER DUCT WITH NO. 2 HEATER TO REGISTER DUCT
See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Overhaul/Instrument Panel Safety Pad (for
Column Shift Type)/Reassembly
6. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY
(a) for Column Shift Type:
Install the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column
Shift Type)/Installation.
(b) for Floor Shift Type:
Install the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation.
7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Components
Oil Filter: Service and Repair Components
1UR-FE LUBRICATION: OIL AND OIL FILTER: COMPONENTS
Page 4908
Removal
A760F AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY (for Floor Shift Type):
REMOVAL
1. REMOVE FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Removal
2. REMOVE FRONT DOOR SCUFF PLATE LH (for Double Cab, CrewMax) See: Body and
Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Removal
3. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Removal
4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
Page 1065
(b) Disconnect the connector and remove the courtesy switch.
Installation
LIGHTING: REAR DOOR COURTESY SWITCH: INSTALLATION
HINT *
Use the same procedures for the RH and LH side.
* The procedures listed below are for the LH side.
* A bolt without a torque specification is shown in the standard bolt chart See:
Specifications/Mechanical Specifications/Standard Bolt - Specified Torque For Standard Bolts
1. INSTALL REAR DOOR COURTESY SWITCH
(a) Connect the connector.
(b) Install the courtesy switch with the bolt.
Page 2858
Fuel Pump Control Unit: Service and Repair Removal
1UR-FE FUEL: FUEL PUMP ECU: REMOVAL
1. REMOVE FUEL PUMP ECU
(a) Disconnect the 2 fuel pump ECU connectors.
(b) Remove the 2 bolts and fuel pump ECU.
NOTICE: Make sure the fuel pump ECU is not subjected to physical shocks such as being
dropped, etc.
Up to 11/2009
Electronic Brake Control Module: Locations Up to 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Components
Control Module: Service and Repair Components
JF1A TRANSFER: 4WD CONTROL ECU: COMPONENTS
Page 2007
"Case1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (/\ Mark) and pull the terminal retainer
up to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Page 8214
(a) Check the ELR.
(1) When the inclination of the retractor is 15° or less, check that the belt can be pulled from the
retractor. When the inclination of the retractor
is over 45°, check that the belt locks.
If the operation is not as specified, replace the seat belt assembly.
(b) Check the fastening function of the child restraint system.
NOTICE: The check should be performed with the outer belt installed.
(1) When the belt is pulled out fully, the belt should automatically start to retract.
(2) After the belt has fully retracted, the belt should be able to be pulled out and retracted again.
If the operation is not as specified, replace the belt assembly.
Page 622
Remote Switch: Testing and Inspection
AUDIO / VISUAL: STEERING PAD SWITCH: INSPECTION
1. INSPECT STEERING PAD SWITCH ASSEMBLY
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the steering pad switch assembly.
Occupant Classification System
Air Bag Control Module: Locations Occupant Classification System
SUPPLEMENTAL RESTRAINT SYSTEM: OCCUPANT CLASSIFICATION SYSTEM: PARTS
LOCATION
Page 841
Wheel Speed Sensor: Service and Repair Rear Speed Sensor
Components
BRAKE CONTROL: REAR SPEED SENSOR: COMPONENTS
Removal
BRAKE CONTROL: REAR SPEED SENSOR: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
Page 8233
(a) Remove the front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Manual
Seat)/Removal.
3. REMOVE FRONT SEAT ASSEMBLY (for Power Seat)
(a) Remove the front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Power
Seat)/Removal.
4. REMOVE FRONT SEAT INNER CUSHION SHIELD (for Manual Seat) See: Body and
Frame/Seats/Service and Repair/Overhaul/Front Seat
Assembly (for Manual Seat)/Disassembly
5. REMOVE FRONT SEAT INNER BELT ASSEMBLY
(a) Driver Side:
Disconnect the 2 connectors and detach the 4 clamps.
(b) Passenger Side:
Disconnect the connector and detach the clamp.
(c) Remove the nut and front seat inner belt.
Installation
SEAT BELT: FRONT SEAT INNER BELT ASSEMBLY: INSTALLATION
1. INSTALL FRONT SEAT INNER BELT ASSEMBLY
(a) Install the front seat inner belt with the nut.
Torque : 42 Nm (428 kgf-cm, 31 ft-lbf)
NOTICE: Do not allow the anchor part of the front seat inner belt to overlap the protruding part of
the front seat adjuster.
(b) Driver Side:
(1) Connect the 2 connectors and attach the 4 clamps.
(c) Passenger Side:
Page 4479
Throttle Body: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: THROTTLE BODY: INSTALLATION
1. INSTALL THROTTLE BODY ASSEMBLY
(a) Install the No. 4 water by-pass hose to the throttle body.
HINT When installing the hose, make sure the paint mark and clip are as shown in the illustration.
(b) Install the No. 12 water by-pass hose to the throttle body.
HINT When installing the hose, make sure the paint mark and clip are as shown in the illustration.
(c) Install a new gasket to the intake air surge tank.
HINT Align the protrusion of the gasket with the groove of the intake air surge tank.
(d) Install the throttle body with the 4 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(e) Connect the throttle position sensor and control motor connector.
Page 3089
3. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE
HINT The diagnostic system in the TOYOTA TUNDRA has various functions.
* The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU
memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a
previous malfunction's DTC can be checked by a technician during troubleshooting.
* Another function is the Input Signal Check, which checks if the signals from various switches are
sent to the ECU correctly.
* By using these functions, the problem areas can be narrowed down and troubleshooting is more
effective. Diagnostic functions are incorporated in the following systems in the TOYOTA TUNDRA.
Page 1466
Symbols Used Within Diagrams
Symbols Used Within Diagrams
Air Conditioning System (for Automatic Air Conditioning
System)
Compressor Speed Sensor: Locations Air Conditioning System (for Automatic Air Conditioning
System)
AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Automatic Air Conditioning System):
PARTS LOCATION
Page 477
Seat Occupant Classification Module - Air Bag: Testing and Inspection
SUPPLEMENTAL RESTRAINT SYSTEM: OCCUPANT CLASSIFICATION ECU: ON-VEHICLE
INSPECTION
1. CHECK OCCUPANT CLASSIFICATION ECU (VEHICLE NOT INVOLVED IN COLLISION)
(a) Perform a diagnostic system check See: Restraint Systems/Testing and Inspection/Initial
Inspection and Diagnostic Overview/Diagnosis
System.
2. CHECK OCCUPANT CLASSIFICATION ECU (VEHICLE INVOLVED IN COLLISION AND
AIRBAG HAS NOT DEPLOYED)
(a) Perform a diagnostic system check See: Restraint Systems/Testing and Inspection/Initial
Inspection and Diagnostic Overview/Diagnosis
System.
3. CHECK OCCUPANT CLASSIFICATION ECU (VEHICLE INVOLVED IN COLLISION AND
AIRBAG IS DEPLOYED)
(a) Replace the ECU.
CAUTION: *
For removal and installation procedures of the occupant classification ECU, be sure to follow the
correct procedure.
* If the airbags have deployed, replace the occupant classification ECU on the side in which the
collision occurred. Replace both if necessary.
Page 1047
Dome Lamp Switch: Diagrams
Page 6059
4. SYMPTOM CONFIRMATION AND DTC (INCLUDING FREEZE FRAME DATA) CHECK
(a) Visually check the wire harnesses, connectors and fuses for open and short circuits.
(b) Warm up the engine to the normal operating temperature.
(c) Confirm the problem symptoms and conditions, and check for DTCs.
B -- Go to step 6 A -- Continue to next step.
5. DTC CHART
(a) Check the results obtained in the DTC check. Then find the output DTC in the DTC chart. Look
at the "Trouble Area" column for a list of
potentially malfunctioning circuits and / or parts.
NEXT -- Go to step 7
6. PROBLEM SYMPTOMS TABLE
(a) Check the results obtained in the symptom confirmation. Then find the problem symptoms in
the problem symptoms table. Look at the
"Suspected Area" column for a list of potentially malfunctioning circuits and / or parts.
NEXT -- Continue to next step.
7. CIRCUIT INSPECTION OR PARTS INSPECTION
(a) Confirm the malfunctioning circuit or part.
NEXT -- Continue to next step.
8. ADJUST, REPAIR OR REPLACE
(a) Adjust, repair or replace the malfunctioning circuit or parts.
NEXT -- Continue to next step.
9. CONFIRMATION TEST
(a) After the adjustment, repairs or replacement, confirm that the malfunction no longer exists. If the
malfunction does not reoccur, perform a
confirmation test under the same conditions and in the same environment as when the malfunction
occurred the first time.
NEXT -- END
2. CUSTOMER PROBLEM ANALYSIS
HINT *
In troubleshooting, confirm that the problem symptoms have been accurately identified.
Preconceptions should be discarded in order to make an accurate judgment. To clearly understand
what the problem symptoms are, it is extremely important to ask the customer about the problem
and the conditions at the time the malfunction occurred.
* Gather as much information as possible for reference. Past problems that seem unrelated may
also help in some cases.
* The following 5 questions are important points in the problem analysis:
Page 7650
(2) Disconnect connector B and measure the resistance.
Standard resistance (Fig. 7):
* If the results match the examples above, a short circuit exists between terminal 1 of connector B2
and terminal 1 of connector C.
4. CHECK AND REPLACE ECU
NOTICE: *
The connector should not be disconnected from the ECU. Perform the inspection from the backside
of the connector on the wire harness side.
* When no measuring condition is specified, perform the inspection with the engine stopped and
the ignition switch ON.
* Check that the connectors are fully seated. Check for loose, corroded or broken wires.
(a) First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be
faulty. Temporarily replace the ECU with a
normally functioning one and check if the symptoms occur. If the trouble symptoms disappear,
replace the original ECU.
(1) Measure the resistance between the ECU ground terminal and body ground.
Standard resistance:
Below 1 Ohms
(2) Disconnect the ECU connector. Check the ground terminal on the ECU side and wire harness
side for bending, corrosion or foreign matter.
Lastly, check the contact pressure of the female terminals.
Page 2929
Engine Temperature Sensor: Testing and Inspection
1UR-FE ENGINE CONTROL SYSTEM: ENGINE COOLANT TEMPERATURE SENSOR:
INSPECTION
1. INSPECT ENGINE COOLANT TEMPERATURE SENSOR
(a) Partially immerse the sensor in water and warm up the water.
(b) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(c) If the result is not as specified, replace the engine coolant temperature sensor.
NOTICE: When checking the sensor in water, keep the terminals dry. After the check, wipe the
sensor dry.
HINT If the result is as specified, do not replace the engine coolant temperature sensor.
Page 3769
Accelerator Pedal Position Sensor: Diagrams
Components
Camshaft Position Sensor: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT POSITION SENSOR: COMPONENTS
Page 6242
Fuse: Application and ID
Fuse Layout and Amperage Ratings
Fuse Block Location - Engine Compartment
Fuse Location - Engine Compartment
Page 9295
Components
Control Module: Service and Repair Components
JF1A TRANSFER: 4WD CONTROL ECU: COMPONENTS
Page 9041
Connectors Part 4
Locations: The locations of components, connectors, ground points, and splices referred to within
these diagrams can be found at Vehicle Locations. See: Locations
Page 1916
Standard condition:
Indicator light [D] remains illuminated for 2 seconds and then turns off.
(f) When using the Techstream:
Return the shift lever to P and terminate the Active Test on the Techstream.
(g) When not using the Techstream:
Return the shift lever to P and disconnect SST from the DLC3.
(h) Allow the engine to idle until the fluid temperature reaches 53 to 59°C (127 to 138°F).
HINT The indicator [D] will come on again when the fluid temperature reaches 53°C (127°F) and
will blink if it is higher than 59°C (138°F).
(i) Remove the overflow plug and gasket with the engine idling.
(j) Wait until the overflow slows to a trickle.
NOTICE: If the fluid does not overflow, perform the following:
(1) Remove the refill plug and gasket.
(2) Refill the transmission through the refill hole until fluid begins to trickle out of the overflow tube.
(3) Wait until the overflow slows to a trickle.
(4) Install a new gasket and the refill plug.
Torque : 39 Nm (400 kgf-cm, 29 ft-lbf)
(k) Install a new gasket and the overflow plug.
Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)
6. COMPLETE
(a) Turn the ignition switch off.
Emissions - MIL ON/Multiple Air Injection DTC's Set
Air Diverter Valve: All Technical Service Bulletins Emissions - MIL ON/Multiple Air Injection DTC's
Set
T-SB-0350-09
Rev1
October 1, 2009
Air Injection Pump With Water Intrusion: MIL "ON" DTC P04181P0419 and/or P244 #
Service Category Engine/Hybrid System
Section Engine Control
Market USA
Applicability
TSB REVISION NOTICE
May 21, 2010 Rev1:
^ DTCs P0418 and P0419 have been added to the TSB.
^ The Applicable Warranty has been updated in the Warranty Information section. Any previous
printed versions of this service bulletin should be discarded.
Introduction
Some 2010 model year Tundra vehicles built in the Texas plant may exhibit a MIL "ON" condition
with Diagnostic Trouble Code (DTC) P0418, P0419, P2440, P2441, P2442, P2443, P2446, and/or
P2447. This concern may be caused by water intrusion into the air injection pump assembly. Use
the following procedure to address this condition.
Parts Information
Production Change Information
Page 6447
Power Distribution Relay: Diagrams
Page 4184
Page 4958
(a) Coat 2 new O-rings with ATF and install them to the grooves of the transmission oil cooler.
(b) Install the transmission oil cooler to the transmission oil cooler spacer with the 3 bolts.
Torque : 14 Nm (143 kgf-cm, 10 ft-lbf)
(c) Install the 2 No. 1 transmission oil cooler hoses to the transmission oil cooler spacer.
NOTICE: Make sure the pinching portion of each clip is facing the direction shown in the
illustration.
(d) Connect the 2 No. 1 transmission oil cooler hoses to the transmission.
NOTICE: Make sure the pinching portion of each clip is facing the direction shown in the
illustration.
(e) Temporarily install the transmission oil cooler together with the transmission oil cooler spacer
with bolt C. Temporarily install bolt A and bolt
B. Tighten the bolts in alphabetical order.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
7. CONNECT WATER BY-PASS PIPE ASSEMBLY
(a) Connect the 2 water by-pass hoses to the transmission oil cooler and connect the water
by-pass pipe with the bolt.
Torque : 18 Nm (184 kgf-cm, 13 ft-lbf)
NOTICE: Make sure the paint marks and pinching portion of each clip are facing the directions
shown in the illustration.
8. INSTALL FRONT EXHAUST PIPE ASSEMBLY
(a) for Regular Cab Standard Deck:
Install the front exhaust pipe See: Engine, Cooling and Exhaust/Exhaust System/Exhaust
Pipe/Service and Repair/Exhaust Pipe (for Regular Cab Standard Deck)/Installation.
(b) except Regular Cab Standard Deck:
Page 1626
Page 3224
Remove the blown fuse and disconnect all loads of the fuse.
Connect a test light in place of the fuse.
Establish conditions in which the test light comes on.
Example:
- [A] - Ignition SW on
- [B] - Ignition SW and SW1 on
- [C] - Ignition SW, SW1 and Relay on (Connect the Relay) and SW2 off (or Disconnect SW2)
Disconnect and reconnect the connectors while watching the test light.
Page 6547
Relay Box: Connector Views
Engine Room R/B, J/B - Engine Compartment Left
Page 6872
Power Distribution Relay: Testing and Inspection ACC Relay
1UR-FE STARTING: ACC RELAY: ON-VEHICLE INSPECTION
1. INSPECT MAIN BODY ECU (ACC RELAY)
(a) Measure the resistance of the ACC relay circuit.
(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(2) If the result is not as specified, replace the main body ECU.
Page 7410
(h) It is extremely dangerous to perform any work on a vehicle raised on a jack alone, even for
work that can be finished quickly. Safety stands
must be used to support the vehicle.
Page 6949
Driver Side J/B Inner Circuit
Page 8246
(a) Align the vehicle's claws with the seat belt retractor positioning holes.
(b) Install the seat belt with the 2 bolts.
HINT First install bolt A, and then install bolt B.
for bolt A - Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
for bolt B - Torque : 42 Nm (428 kgf-cm, 31 ft-lbf)
(c) Connect the pretensioner connector as shown in the illustration.
(d) Install the shoulder anchor to the shoulder belt anchor adjuster with the nut.
Torque : 42 Nm (428 kgf-cm, 31 ft-lbf)
2. INSTALL CENTER PILLAR GARNISH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Installation
3. INSTALL LOWER CENTER PILLAR GARNISH
Page 6806
If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness
or connector in that circuit in the past. Check the wire harness and connectors.
B -- SYSTEM NORMAL
A -- TROUBLESHOOTING OF EACH PROBLEM SYMPTOM
The problem is still occurring in a place other than the diagnostic circuit (the DTC displayed first is
either for a past problem or a secondary problem).
4. SYMPTOM SIMULATION
HINT The most difficult case in troubleshooting is when no problem symptoms occur. In such a
case, a thorough problem analysis must be carried out. A simulation of the same or similar
conditions and environment in which the problem occurred in the customer's vehicle should be
carried out. No matter how much skill or experience a technician has, troubleshooting without
confirming the problem symptoms will lead to important repairs being overlooked and mistakes or
delays.
For example:
With a problem that only occurs when the engine is cold or as a result of vibration caused by the
road during driving, the problem can never be determined if the symptoms are being checked on a
stationary vehicle or on a vehicle with a warmed-up engine. Vibration, heat or water penetration
(moisture) is difficult to reproduce. The symptom simulation tests below are effective substitutes for
the conditions and can be applied on a stationary vehicle.
Important points in the symptom simulation test:
In the symptom simulation test, the problem symptoms as well as the problem area or parts must
be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then,
connect the tester and carry out the symptom simulation test, judging whether the circuit being
tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the
problem symptoms table for each system to narrow down the possible causes.
To reproduce DTCs, it is necessary to satisfy the respective DTC detection conditions.
(a) VIBRATION METHOD:
When a malfunction seems to occur as a result of vibration.
(1) PART AND SENSOR
Apply slight vibration with a finger to the part of the sensor suspected to be the cause of the
problem, and check whether or not the malfunction occurs.
NOTICE: Applying strong vibration to relays may open them.
Page 6162
NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do
not operate the ignition switch, any other switches, or the doors.
(a) If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the
harness and connector.
(b) Connect the cable of the Techstream to the DLC3, turn the ignition switch ON and attempt to
use the tester. If the display indicates that a
communication error has occurred, there is a problem either with the vehicle or with the tester.
HINT *
If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of
the original vehicle.
* If communication is still not possible when the tester is connected to another vehicle, the problem
may be in the tester itself. Consult the Service Department listed in the tester's instruction manual.
How To Proceed With Troubleshooting
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: HOW TO
PROCEED WITH TROUBLESHOOTING
1. OPERATION FLOW
HINT Perform troubleshooting in accordance with the procedures below. The following is an outline
of basic troubleshooting procedures. Confirm the troubleshooting procedures for the circuit you are
working on before beginning troubleshooting.
1. VEHICLE BROUGHT TO WORKSHOP
NEXT -- Continue to next step.
2. CUSTOMER PROBLEM ANALYSIS
(a) Ask the customer about the conditions and environment when the problem occurred.
NEXT -- Continue to next step.
3. INSPECT BATTERY VOLTAGE
Standard voltage:
11 to 14 V
If the voltage is below 11 V, recharge or replace the battery before proceeding.
NEXT -- Continue to next step.
Page 2010
Release the locking lug from terminal and pull the terminal out from rear.
INSTALL TERMINAL TO CONNECTOR
Insert the terminal.
HINT: Make sure the terminal is positioned correctly.
Insert the terminal until the locking lug locks firmly.
Insert the terminal with terminal retainer in the temporary lock position.
Page 5301
(c) Align the matchmarks on the joint yoke and intermediate shaft.
(d) Install the washer.
(e) Clamp the yoke in a vise, and press the bearing into position by installing a new lock nut.
Torque : 128 Nm (1305 kgf-cm, 94 ft-lbf)
(f) Loosen the lock nut.
(g) Tighten the lock nut again.
Torque : 128 Nm (1305 kgf-cm, 94 ft-lbf)
(h) Using a chisel and hammer, stake the lock nut.
3. INSTALL REAR PROPELLER SHAFT UNIVERSAL JOINT SPIDER BEARING (for 3 Joint Type)
(a) Apply MP grease to a new spider and 4 new bearings.
NOTICE: Be careful not to apply too much grease.
(b) Measure dimension A between the snap ring grooves.
(c) Install the 4 spider bearings to the spider journal portions, and then measure dimension B of the
universal joint.
Page 2938
Page 763
Acceleration/Deceleration Sensor: Locations From 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 6318
JQ1-LJ1
Locations
Collision Avoidance Module: Locations
PARK ASSIST / MONITORING: INTUITIVE PARKING ASSIST SYSTEM: PARTS LOCATION
Page 8114
Removal
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Column
Shift Type): REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service
and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Removal
3. REMOVE CENTER AIRBAG SENSOR ASSEMBLY
Page 7622
Cab)/Installation.
(b) for Double Cab:
Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Installation.
(c) for CrewMax:
Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for CrewMax)/Installation.
Page 5062
30. INSPECT DIFFERENTIAL CLUTCH SLEEVE AND DIFFERENTIAL SIDE GEAR INTER
SHAFT
(a) Check for wear and damage to the clutch hub and side gear inter shaft.
(b) Check that the clutch sleeve slides smoothly on the side gear inter shaft.
31. INSPECT DIFFERENTIAL CLUTCH SLEEVE AND CLUTCH SLEEVE FORK CLEARANCE
(a) Using a feeler gauge, measure the clearance between the sleeve fork and clutch sleeve.
Maximum clearance:
0.35 mm (0.0138 in.)
(b) If the clearance exceeds the maximum, replace the fork or clutch sleeve.
Reassembly
DIFFERENTIAL: FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD): REASSEMBLY
1. INSTALL STRAIGHT PIN
(a) Using a plastic-faced hammer, tap in the straight pins until their protrusion amounts are at the
specified values shown in the illustration below.
Page 6519
Relay Box: Diagnostic Aids
Continuity and Resistance Check
CONTINUITY AND RESISTANCE CHECK
Disconnect the battery terminal or wire so there is no voltage between the check points.
Contact the two leads of an ohmmeter to each of the check points.
Page 4914
(c) Insert a thin-bladed screwdriver, release the locking lug of terminal 4 (SFTD-), 5 (SFTD+) and
11 (E), and pull the terminals out from the rear.
(d) Detach the 2 claws and remove the control shaft tube clamp from the column shift control shift
lever retainer.
6. REMOVE SHIFT LOCK SOLENOID
(a) Detach the 2 claws and remove the shift lock solenoid bracket.
(b) Remove the screw, collar, 2 bushes and shift lock solenoid with No. 1 shift lock plate
sub-assembly from the column shift control shift lever
retainer.
(c) Insert a thin-bladed screwdriver, release the locking lug of terminal 1 (SLS+) and 8 (E), and pull
the terminals out from the rear.
Page 2466
(a) Install the front wiper motor and link See: Wiper and Washer Systems/Wiper Motor/Service and
Repair/Installation.
15. INSTALL EGR VALVE ASSEMBLY
(a) Install the EGR valve See: Powertrain Management/Emission Control Systems/Exhaust Gas
Recirculation/EGR Valve/Service and
Repair/Installation.
16. CHECK FOR FUEL LEAK See: Powertrain Management/Fuel Delivery and Air Induction/Fuel
Injector/Service and Repair/Installation
Page 1024
Ambient Light Sensor: Service and Repair Installation
LIGHTING: AUTOMATIC LIGHT CONTROL SENSOR: INSTALLATION
1. INSTALL AUTOMATIC LIGHT CONTROL SENSOR
(a) Attach the 2 claws to install the sensor.
(b) Connect the connector.
2. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY
(a) for Column Shift Type:
Install the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column
Shift Type)/Installation.
(b) for Floor Shift Type:
Install the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation.
Page 162
Page 3554
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE 4WD CONTROL ECU BRANCH WIRE OR CONNECTOR (CANH,
CANL) OK -- Continue to next step.
3. CHECK HARNESS AND CONNECTOR (4WD CONTROL ECU - BATTERY AND BODY
GROUND)
(a) Reconnect the cable to the negative (-) battery terminal before measuring the resistances of the
main wire and the branch wire.
(b) Disconnect the A26 4WD control ECU connector.
(c) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(d) Measure the voltage according to the value(s) in the table below.
Standard voltage:
NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- REPLACE 4WD CONTROL ECU
Page 579
Hood Sensor/Switch (For Alarm): Diagrams
Page 4953
Transmission Cooler: Service and Repair Removal
A760F AUTOMATIC TRANSMISSION: OIL COOLER: REMOVAL
1. DRAIN ENGINE COOLANT See: Engine, Cooling and Exhaust/Cooling System/Coolant/Service
and Repair
2. REMOVE FRONT EXHAUST PIPE ASSEMBLY
(a) for Regular Cab Standard Deck:
Remove the front exhaust pipe See: Engine, Cooling and Exhaust/Exhaust System/Exhaust
Pipe/Service and Repair/Exhaust Pipe (for Regular Cab Standard Deck)/Removal.
(b) except Regular Cab Standard Deck:
Remove the front exhaust pipe See: Engine, Cooling and Exhaust/Exhaust System/Exhaust
Pipe/Service and Repair/Exhaust Pipe (Except Regular Cab Standard Deck)/Removal.
3. DISCONNECT WATER BY-PASS PIPE ASSEMBLY
(a) Remove the bolt and disconnect the 2 water by-pass hoses from the transmission oil cooler to
disconnect the water by-pass pipe.
HINT Use a container to catch any coolant which flows out of the water by-pass hoses.
4. REMOVE TRANSMISSION OIL COOLER ASSEMBLY (w/o Trailer Towing System)
(a) Disconnect the 2 No. 1 transmission oil cooler hoses from the transmission.
(b) Remove the 3 bolts and transmission oil cooler with transmission oil cooler spacer.
(c) Remove the 2 No. 1 transmission oil cooler hoses from the transmission oil cooler spacer.
(d) Remove the 3 bolts and transmission oil cooler from the transmission oil cooler spacer.
(e) Remove the 2 O-rings from the grooves of the transmission oil cooler.
5. REMOVE TRANSMISSION OIL COOLER ASSEMBLY (w/ Trailer Towing System)
Components
Manifold Pressure/Vacuum Sensor: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: MANIFOLD ABSOLUTE PRESSURE SENSOR:
COMPONENTS
Door Control Receiver (for CrewMax)
Keyless Entry Module: Service and Repair Door Control Receiver (for CrewMax)
Components
DOOR LOCK: DOOR CONTROL RECEIVER (for CrewMax): COMPONENTS
Removal
DOOR LOCK: DOOR CONTROL RECEIVER (for CrewMax): REMOVAL
1. REMOVE BACK PANEL TRIM RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for
CrewMax)/Removal
ACC Cut Relay
Power Distribution Relay: Testing and Inspection ACC Cut Relay
1UR-FE STARTING: ACC CUT RELAY: ON-VEHICLE INSPECTION
1. REMOVE ACC CUT RELAY
(a) Remove the clip.
(b) Detach the 2 clips and remove the cowl side trim board RH.
(c) Remove the relay.
2. INSPECT ACC CUT RELAY
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) If the result is not as specified, replace the relay.
3. INSTALL ACC CUT RELAY
(a) Install the relay.
(b) Attach the 2 clips to install the cowl side trim board RH.
(c) Install the clip.
Page 9365
8. With the cab still raised install the new No.3 cab mounts
9. Install the two bolts on top that were previously removed from the No.3 cab mount and torque to
specification.
Torque: 61 N*m (622 kgf*cm, 45 ft*lbf)
10. Lower the cab back onto the No.3 cab mount.
11. Install the new bolt through the No.3 cab mount and install the NEW larger washer and NEW
nut and torque to specifications.
Torque: 54 N*m (551 kgf*cm, 40 ft*lbf)
Page 8469
Alarm System Transmitter: Service and Repair Removal
ENGINE IMMOBILISER: TRANSPONDER KEY ECU: REMOVAL
1. REMOVE AIR CONDITIONING UNIT
(a) Remove the air conditioning unit See: Heating and Air Conditioning/Housing Assembly
HVAC/Service and Repair/Removal and
Replacement/Removal.
2. REMOVE TRANSPONDER KEY BRACKET (w/ Bracket)
(a) Remove the 2 screws and transponder key bracket.
3. REMOVE TRANSPONDER KEY ECU
(a) Disconnect the lower part of the ECU, and then upper part in that order to remove the ECU.
Page 8344
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
4. REMOVE UPPER CONSOLE REAR PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
5. REMOVE REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
6. REMOVE CONSOLE BOX CARPET
7. REMOVE REAR CONSOLE BOX ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal
8. REMOVE FRONT CONSOLE BOX See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal
and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal
9. REMOVE CENTER AIRBAG SENSOR ASSEMBLY
(a) Disconnect the holder (with connectors).
(b) Remove the 3 bolts and airbag sensor.
Installation
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift
Type): INSTALLATION
1. INSTALL CENTER AIRBAG SENSOR ASSEMBLY
(a) Check that the ignition switch is OFF.
(b) Check that the cable is disconnected from the battery negative (-) terminal.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
(c) Install the airbag sensor with the 3 bolts.
Torque : 18 Nm (184 kgf-cm, 13 ft-lbf)
NOTICE: *
If the center airbag sensor has been dropped, or there are any cracks, dents or other defects in the
case, bracket or connector, replace it with a new one.
* When installing the center airbag sensor, be careful that the SRS wiring does not interfere with
other parts and that it is not pinched between other parts.
(d) Check that there is no looseness in the installation parts of the center airbag sensor.
Page 2830
ERROR: stackunderflow
OFFENDING COMMAND: ~
STACK:
Page 1647
ERROR: stackunderflow
OFFENDING COMMAND: ~
STACK:
Page 8813
Page 5266
4. INSPECT NO. 1 CENTER SUPPORT BEARING ASSEMBLY (for 3 Joint Type)
(a) Check that the bearing turns freely.
* If the bearing is damaged, worn, or does not turn freely, replace it.
Page 4677
Control Module: Service and Repair Installation
JF1A TRANSFER: 4WD CONTROL ECU: INSTALLATION
1. INSTALL 4WD CONTROL ECU
(a) Install the ECU with the bolt.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
(b) Connect the 2 ECU connectors.
2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Installation
3. INSTALL INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
4. INSTALL COWL SIDE TRIM BOARD RH
(a) Install the cowl side trim board RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Installation.
HINT Use the same procedures described for the LH side.
5. INSTALL FRONT DOOR SCUFF PLATE RH (for Regular Cab)
(a) Install the front door scuff plate RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Installation.
HINT Use the same procedures described for the LH side.
6. INSTALL FRONT DOOR SCUFF PLATE RH (for Double Cab, for CrewMax)
(a) Install the front door scuff plate RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Installation.
HINT Use the same procedures described for the LH side.
Page 7032
*: for 5 leaf spring
Standard Caster Inclination
for Regular Cab of Standard Deck
Components
Alarm Module: Service and Repair Components
THEFT DETERRENT: THEFT WARNING ECU: COMPONENTS
Page 3877
Variable Valve Timing Actuator Position Sensor: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: VVT SENSOR: REMOVAL
1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Removal
2. REMOVE AIR CLEANER HOSE ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Removal
3. REMOVE VVT SENSOR
(a) Disconnect the 4 sensor connectors.
(b) Remove the 4 bolts and 4 sensors.
Page 474
Page 9133
Trailer Connector: Electrical Diagrams
Trailer Towing Part 1
Page 2062
[A] For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
"Case1" Raise the terminal retainer up to the temporary lock position.
Page 3326
Page 6183
Auxiliary Power Outlet: Service and Repair Center Power Outlet Socket (for Floor Shift Type)
Components
OTHER SYSTEM: CENTER POWER OUTLET SOCKET (for Floor Shift Type): COMPONENTS
Removal
OTHER SYSTEM: CENTER POWER OUTLET SOCKET (for Floor Shift Type): REMOVAL
1. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding
/ Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
Page 7125
Power Steering Pressure Switch: Testing and Inspection
1UR-FE ENGINE CONTROL SYSTEM: POWER STEERING OIL PRESSURE SWITCH:
ON-VEHICLE INSPECTION
1. INSPECT POWER STEERING OIL PRESSURE SWITCH
(a) Check the oil pressure switch.
(1) Connect the Techstream to the DLC3.
(2) Turn the ignition switch to ON.
(3) Turn the Techstream main switch on.
(4) Enter the following menus: Powertrain / Engine and ECT / Data List / All Data / Power Steering
pressure.
(5) Start the engine.
(6) Operate the steering wheel while idling, and read the value on the Techstream.
Standard:
(7) If not as specified, check for DTCs See: Powertrain Management/Computers and Control
Systems/Testing and Inspection/Reading and
Clearing Diagnostic Trouble Codes/DTC Check / Clear. If the power steering system inspection
results are normal and a DTC is not output, replace the power steering oil pressure switch.
Inspect the power steering system See: Steering/Testing and Inspection/Component Tests and
General Diagnostics/Power Steering System/On-Vehicle Inspection. If the power steering system
inspection results are normal and a DTC is not output, replace the power steering oil pressure
switch.
Components
Power Distribution Module: Service and Repair Components
OTHER SYSTEM: VOLTAGE INVERTER (for CrewMax): COMPONENTS
Page 8791
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the speaker assembly.
3. INSPECT FRONT NO. 4 SPEAKER ASSEMBLY (for 10 Speakers)
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the speaker assembly.
Instrument Panel Speaker (for Regular Cab)
AUDIO / VISUAL: INSTRUMENT PANEL SPEAKER (for Regular Cab): INSPECTION
1. INSPECT FRONT NO. 2 SPEAKER ASSEMBLY
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
Page 4347
(4) Install the O-ring to the fuel injector.
(5) Install SST and the tube to the fuel injector.
SST : 09268-31012
09268-41500
90467-13001
95336-08070
09268-41300
09268-41600
(6) Put the injector into a graduated cylinder.
CAUTION: Install a strong rubber tube onto the injector to prevent gasoline from splashing.
(7) Operate the fuel pump (turn the ignition switch to ON).
(8) Connect SST (wire) to the injector and the battery for 15 seconds, and measure the injection
volume with the graduated cylinder. Test each
injector 2 or 3 times.
SST : 09842-30090
Standard injection volume:
83 to 99 cm3 (5.0 to 6.0 cu in.) per 15 seconds
Difference between each injector:
16 cm3 (1.0 cu in.) or less
(9) If the injection volume is not as specified, replace the injector assembly.
Page 5145
5. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL
(a) Using SST, remove the oil seal.
SST : 09308-10010
6. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
7. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
(a) Using SST, remove the front bearing (inner race).
SST : 09556-22010
(b) Using SST, remove the bearing (outer race).
SST : 09308-00010
8. REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER
9. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER
(a) Install a new bearing spacer.
10. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
(a) Using SST and a hammer, tap in the bearing (outer race).
SST : 09316-60011
09316-00011
09316-00021
Page 7770
(1) Detach the claw and remove the main plate.
(2) Remove the 2 screws and damper servo.
10. REMOVE DAMPER SERVO SUB-ASSEMBLY
(a) Disconnect the connector.
(b) Remove the 3 screws and damper servo.
11. REMOVE BLOWER CASE SUB-ASSEMBLY
(a) Remove the 3 screws.
(b) Detach the 2 claws and remove the case.
12. REMOVE BLOWER DAMPER SERVO SUB-ASSEMBLY
(a) Disconnect the connector.
(b) Remove the 3 screws and damper servo.
13. REMOVE COOLING UNIT DAMPER SERVO SUB-ASSEMBLY (for Automatic Air Conditioning
System)
Page 8954
Replacement/Rear Bumper (for Resin Type Bumper)/Installation
7. INSTALL REAR BUMPER PLATE RH (for Steel Type Bumper) See: Body and
Frame/Bumper/Rear Bumper/Service and Repair/Removal and
Replacement/Rear Bumper (for Steel Type Bumper)/Installation
8. INSTALL REAR BUMPER PLATE LH (for Steel Type Bumper) See: Body and
Frame/Bumper/Rear Bumper/Service and Repair/Removal and
Replacement/Rear Bumper (for Steel Type Bumper)/Installation
9. INSTALL REAR BUMPER PAD SUB-ASSEMBLY (for Steel Type Bumper) See: Body and
Frame/Bumper/Rear Bumper/Service and
Repair/Removal and Replacement/Rear Bumper (for Steel Type Bumper)/Installation
10. INSTALL LICENSE PLATE LIGHT ASSEMBLY RH (for Steel Type Bumper) See: Body and
Frame/Bumper/Rear Bumper/Service and
Repair/Removal and Replacement/Rear Bumper (for Resin Type Bumper)/Installation
11. INSTALL LICENSE PLATE LIGHT ASSEMBLY RH (for Resin Type Bumper) See: Body and
Frame/Bumper/Rear Bumper/Service and
Repair/Removal and Replacement/Rear Bumper (for Resin Type Bumper)/Installation
12. INSTALL LICENSE PLATE LIGHT ASSEMBLY LH (for Steel Type Bumper) See: Body and
Frame/Bumper/Rear Bumper/Service and
Repair/Removal and Replacement/Rear Bumper (for Steel Type Bumper)/Installation
13. INSTALL LICENSE PLATE LIGHT ASSEMBLY LH (for Resin Type Bumper) See: Body and
Frame/Bumper/Rear Bumper/Service and
Repair/Removal and Replacement/Rear Bumper (for Resin Type Bumper)/Installation
14. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Components
Camshaft Position Sensor: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT POSITION SENSOR: COMPONENTS
Page 1381
Impact Sensor: Testing and Inspection Side Airbag Sensor (for CrewMax)
SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for CrewMax): ON-VEHICLE
INSPECTION
1. CHECK REAR AIRBAG SENSOR (VEHICLE NOT INVOLVED IN COLLISION)
(a) Perform a diagnostic system check See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
2. CHECK REAR AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS
NOT DEPLOYED)
(a) Perform a diagnostic system check See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
(b) When the quarter panel of the vehicle or its area is damaged, check if there is any damage to
the rear airbag sensor. If there are any defects as
mentioned below, replace the side airbag sensor with a new one:
* Cracks, dents or chips on the sensor housing.
* Cracks or other damage to the connector.
* Peeling off of the label or damage to the serial number.
CAUTION: For removal and installation procedures of the side airbag sensor, be sure to follow the
correct procedure.
3. CHECK REAR AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS
DEPLOYED)
(a) Replace the side airbag sensor.
CAUTION: *
For removal and installation procedures of the side airbag sensor, be sure to follow the correct
procedure.
* If the airbags have deployed, replace the rear airbag sensor on the side in which the collision
occurred. Replace both if necessary.
Page 3090
Locations
Manifold Pressure/Vacuum Sensor: Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 5907
Page 8027
Air Bag Deactivation Switch: Diagrams Curtain Airbag Cutoff Switch
Components
Tire Pressure Module: Service and Repair Components
TIRE AND WHEEL: TIRE PRESSURE WARNING ECU: COMPONENTS
Page 6157
when inserting and after full engagement.
NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal.
(d) REPAIR METHOD OF CONNECTOR TERMINAL
(1) If there is any foreign matter on the terminal, clean the contact point using an air gun or cloth.
Never rub the contact point using sandpaper
as the plating may come off.
(2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is
gold-plated (gold color), use a gold-plated female
terminal; if it is silver-plated (silver color), use a silver-plated female terminal.
(3) Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock
into the housing, the housing may have to be
replaced.
(e) HANDLING OF WIRE HARNESS
(1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be
restored in the same way.
(2) Never twist, pull or slacken the wire harness more than necessary.
(3) The wire harness should never come into contact with a high temperature part, or rotating,
moving, vibrating or sharp-edged parts. Avoid
contact with panel edges, screw tips and other sharp items.
(4) When installing parts, never pinch the wire harness.
(5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with
vinyl tape.
2. CHECK FOR OPEN CIRCUIT
Page 4871
Transmission Speed Sensor: Testing and Inspection
A760F AUTOMATIC TRANSMISSION: SPEED SENSOR: INSPECTION
1. INSPECT SPEED SENSOR NT
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) If the result is not as specified, replace the sensor.
2. INSPECT SPEED SENSOR SP2
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) If the result is not as specified, replace the sensor.
Page 8078
Page 3477
NOTICE: *1: MIL turns on only during VSC or ABS failure status.
Reading and Clearing Diagnostic Trouble Codes
MULTIPLEX COMMUNICATION: LIN COMMUNICATION SYSTEM: DTC CHECK / CLEAR
HINT Refer to the Techstream operator's manual for further details.
1. CHECK DTC
(a) Connect the Techstream to the DLC3.
(b) Turn the ignition switch ON.
(c) Turn the Techstream on.
(d) Enter the following menus: Body Electrical / Main Body / Trouble Codes.
(e) Read the DTCs.
Page 6778
Page 5270
Page 2677
Engine Temperature Sensor: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: ENGINE COOLANT TEMPERATURE SENSOR:
INSTALLATION
1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR
(a) Install a new gasket to the sensor.
(b) Using a 19 mm ball joint lock nut wrench, install the sensor.
Torque : 20 Nm (200 kgf-cm, 14 ft-lbf)
NOTICE: Use the formula to calculate special torque values for situations where ball joint lock nut
wrench is combined with a torque wrench See: Service Precautions
(c) Connect the sensor connector.
2. ADD ENGINE COOLANT See: Coolant/Service and Repair
3. INSPECT FOR COOLANT LEAK See: Testing and Inspection
4. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine/Service and Repair/Removal and
Replacement/Engine Assembly/Installation
5. INSTALL NO. 1 ENGINE UNDER COVER See: Engine/Engine Lubrication/Engine Oil/Service
and Repair/Replacement
Components
Crankshaft Position Sensor: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: CRANKSHAFT POSITION SENSOR: COMPONENTS
Bleeding
Brake Bleeding: Service and Repair Bleeding
BRAKE: BRAKE FLUID: BLEEDING
NOTICE: *
Perform fluid replacement with the parking brake applied.
* Perform fluid replacement while maintaining the brake fluid level between the MIN/MAX level on
the brake fluid reservoir.
* Do not allow brake fluid to contact the vehicle's paint surfaces. If contact occurs, clean it off
immediately.
* After adding brake fluid, make sure the reservoir is sufficiently full.
* When bleeding air, select the suitable procedure listed below.
1. BLEED BRAKE LINE
(a) Bleed brake line
(1) Remove the brake master cylinder reservoir filler cap assembly.
(2) Add brake fluid into the reservoir between MAX and MIN level on the brake fluid reservoir.
Brake fluid:
SAE J1703 or FMVSS No. 116 DOT3
(3) Connect a vinyl tube to the bleeder plug of the front disc brake cylinder RH.
(4) Depress the brake pedal several times, and then loosen the bleeder plug with the pedal
depressed.*1
(5) When fluid stops coming out, tighten the bleeder plug, and then release the brake pedal.*2
(6) Repeat *1 and *2 until all the air in the brake fluid is completely bled out and the new brake fluid
comes out.
(7) Tighten the bleeder plug completely.
Torque : 11 Nm (110 kgf-cm, 8 ft-lbf)
(8) Replace the brake fluid from the front disc brake cylinder LH using the same procedure as for
RH.
(9) Connect a vinyl tube to the bleeder plug of the rear disc brake cylinder RH.
(10)Depress the brake pedal several times, and then loosen the bleeder plug with the pedal
depressed.*1
(11)When fluid stops coming out, tighten the bleeder plug, and then release the brake pedal.*2
(12)Repeat *1 and *2 until all the air in the brake fluid is completely bled out and the new brake
fluid comes out.
(13)Tighten the bleeder plug completely.
Torque : 11 Nm (110 kgf-cm, 8 ft-lbf)
(14)Replace the brake fluid from the rear disc brake cylinder LH using the same procedure as for
RH.
(b) Check and bleed brake system.
(1) If the following malfunction symptoms occur, air may have entered the brake fluid line. Perform
the following air bleed procedures.
Locations
Tire Pressure Warning Reset Switch: Locations
TIRE AND WHEEL: TIRE PRESSURE WARNING SYSTEM: PARTS LOCATION
Page 5928
Yaw Rate Sensor: Testing and Inspection
BRAKE CONTROL: YAW RATE AND DECELERATION SENSOR: INSPECTION
1. CHECK YAW RATE SENSOR
(a) Check the yaw rate sensor.
Under any of the following conditions, replace the sensor with a new one:
* The surface of the sensor is cracked, dented, or chipped.
* The connector is scratched, cracked, or damaged.
* The sensor has been dropped.
Page 4489
Variable Induction Control Solenoid: Diagrams
Page 3353
Information Bus: Locations CAN Communication System
CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: PARTS LOCATION
Page 3055
Crankshaft Position Sensor: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: CRANKSHAFT POSITION SENSOR: REMOVAL
1. REMOVE CRANKSHAFT POSITION SENSOR PROTECTOR
(a) Remove the 2 bolts and sensor protector.
2. REMOVE CRANKSHAFT POSITION SENSOR
(a) Disconnect the sensor connector.
(b) Remove the bolt and sensor.
Page 6614
Auxiliary Power Outlet: Connector Views
Power Outlet Socket
Components
Oil Pressure Sender: Service and Repair Components
1UR-FE LUBRICATION: OIL PRESSURE SWITCH: COMPONENTS
Page 2483
* Gently place the cylinder head in order not to damage the gasket with the bottom part of the
head.
* Ensure that no oil is on the mounting surface of the cylinder head.
HINT The cylinder head bolts are tightened in 3 progressive steps.
(b) Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.
(c) Step 1:
Page 699
Page 8323
Air Bag Deactivation Switch: Service and Repair Curtain Shield Airbag Cutoff Switch
Components
SUPPLEMENTAL RESTRAINT SYSTEM: CURTAIN SHIELD AIRBAG CUTOFF SWITCH:
COMPONENTS
Removal
SUPPLEMENTAL RESTRAINT SYSTEM: CURTAIN SHIELD AIRBAG CUTOFF SWITCH:
REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Removal
3. REMOVE FRONT DOOR SCUFF PLATE LH (for Double Cab, CrewMax) See: Body and
Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Removal
4. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Removal
5. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal
6. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Removal
7. REMOVE CURTAIN SHIELD AIRBAG CUTOFF SWITCH
(a) Disconnect the connector.
Page 6632
2. REMOVE FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Removal
3. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Removal
4. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal
5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Removal
6. REMOVE CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service
and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Removal
7. REMOVE FRONT ASH RECEPTACLE BOX SUB-ASSEMBLY
8. REMOVE LOWER INSTRUMENT CLUSTER FINISH PANEL See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column
Shift Type)/Removal
9. REMOVE POWER OUTLET SOCKET ASSEMBLY
(a) Using a screwdriver, detach the claw and remove the power outlet socket.
HINT Tape the screwdriver tip before use.
10. REMOVE POWER OUTLET SOCKET COVER
(a) Detach the 2 claws and remove the power outlet socket cover.
Installation
OTHER SYSTEM: POWER OUTLET SOCKET (for Column Shift Type): INSTALLATION
1. INSTALL POWER OUTLET SOCKET COVER
Locations
Sunroof / Moonroof Module: Locations
SLIDING ROOF: SLIDING ROOF SYSTEM: PARTS LOCATION
Page 3232
Release the locking lug from terminal and pull the terminal out from rear.
INSTALL TERMINAL TO CONNECTOR
Insert the terminal.
HINT: Make sure the terminal is positioned correctly.
Insert the terminal until the locking lug locks firmly.
Insert the terminal with terminal retainer in the temporary lock position.
Page 5757
Parking Brake Cable: Service and Repair Removal
PARKING BRAKE: PARKING BRAKE CABLE: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to disable the SRS system.
2. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal
3. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Removal
4. REMOVE LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY See: Restraint
Systems/Air Bag Systems/Air Bag/Service and
Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Removal
5. RELEASE PARKING BRAKE PEDAL
6. DISCONNECT NO. 1 PARKING BRAKE CABLE ASSEMBLY See: Parking Brake Pedal/Service
and Repair/Removal and
Replacement/Removal
7. REMOVE FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY (for 1GR-FE)
(a) for Regular Cab Standard Deck:
Remove the front No. 3 exhaust pipe See: Engine, Cooling and Exhaust/Exhaust System/Exhaust
Pipe/Service and Repair/Exhaust Pipe (for Regular Cab Standard Deck)/Removal.
8. REMOVE FRONT NO. 2 EXHAUST PIPE ASSEMBLY (for 1GR-FE)
(a) for Regular Cab Standard Deck:
Remove the front No. 2 exhaust pipe See: Engine, Cooling and Exhaust/Exhaust System/Exhaust
Pipe/Service and Repair/Exhaust Pipe (for Regular Cab Standard Deck)/Removal.
(b) except Regular Cab Standard Deck:
Remove the front No. 2 exhaust pipe See: Engine, Cooling and Exhaust/Exhaust System/Exhaust
Pipe/Service and Repair/Exhaust Pipe (Except Regular Cab Standard Deck)/Removal.
9. REMOVE FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY (for 1UR-FE)
(a) for Regular Cab Standard Deck:
Remove the front No. 3 exhaust pipe See: Engine, Cooling and Exhaust/Exhaust System/Exhaust
Pipe/Service and Repair/Exhaust Pipe (for Regular Cab Standard Deck)/Removal.
10. REMOVE FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY (for 3UR-FE)
(a) for Regular Cab Standard Deck:
Remove the front No. 3 exhaust pipe See: Engine, Cooling and Exhaust/Exhaust System/Exhaust
Pipe/Service and Repair/Exhaust Pipe (for Regular Cab Standard Deck)/Removal.
11. REMOVE FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY (for 3UR-FBE)
(a) for Regular Cab Standard Deck:
Remove the front No. 3 exhaust pipe See: Engine, Cooling and Exhaust/Exhaust System/Exhaust
Pipe/Service and Repair/Exhaust Pipe (for Regular Cab Standard Deck)/Removal.
12. REMOVE FRONT NO. 2 EXHAUST PIPE ASSEMBLY (for 1UR-FE)
Locations
Entertainment System Control Module: Locations
Instrument Panel (Floor Shift)
Instrument Panel (Column Shift)
Page 2006
"Case2" Open the secondary locking device.
[B] For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray
Gray or White : Black
Page 1387
Removal
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift
Type): REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal
3. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding
/ Trim/Dashboard / Instrument
Page 2924
Crankshaft Position Sensor: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: CRANKSHAFT POSITION SENSOR: REMOVAL
1. REMOVE CRANKSHAFT POSITION SENSOR PROTECTOR
(a) Remove the 2 bolts and sensor protector.
2. REMOVE CRANKSHAFT POSITION SENSOR
(a) Disconnect the sensor connector.
(b) Remove the bolt and sensor.
Page 3106
Page 6831
Page 587
Integrated Accessory Switch Assembly: Service and Repair Removal
METER: DRIVE MONITOR SWITCH: REMOVAL
1. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Panel,
Gauges and Warning Indicators/Instrument Cluster
/ Carrier/Service and Repair/Combination Meter/Removal
2. REMOVE DRIVE MONITOR SWITCH
(a) Detach the 2 claws and remove the monitor switch.
Page 186
"Case2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 2480
(b) Install the 16 valve stem caps to the cylinder head.
6. INSTALL VALVE LASH ADJUSTER ASSEMBLY
(a) Inspect the valve lash adjuster See: Testing and Inspection/Engine Unit.
(b) Install the 16 lash adjusters to the cylinder head.
NOTICE: Install the lash adjuster at the same place it was removed from.
7. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
(a) Apply engine oil to the lash adjuster tips and valve stem cap ends.
(b) Install the 16 valve rocker arms as shown in the illustration.
8. INSTALL CAMSHAFTS (for Bank 1)
(a) Install the camshafts See: Camshaft, Lifters and Push Rods/Camshaft/Service and
Repair/Camshaft (for Bank 1)/Installation.
9. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH
(a) Install the exhaust manifold LH See: Exhaust System/Exhaust Manifold/Service and
Repair/Installation.
Page 8023
Locations
Horn Relay: Locations
HORN: HORN SYSTEM: PARTS LOCATION
Page 8649
Entertainment System Control Module: Diagrams
Page 3467
(b) Wait 1 minute and then check the display of the connected ECUs and sensors.
NOTICE: ECUs and sensors that are not present will not be displayed. Be careful not to mistake
them for communication stop malfunctions.
HINT *
If the display of an ECU is intermittent during the check, one side of an ECU or sensor branch wire
is open. (The signal of the ECU is treated as noise, which affects the response and display of the
Techstream.)
* The main body ECU checks for proper ECU communication for ECUs that are connected to the
CAN MS bus circuit, and the results are displayed on the Techstream. If communication stops
between an ECU and the main body ECU for 10 seconds or more, the ECU disappears from the
Techstream display.
* For communication stop mode of ECUs connected to the CAN MS bus circuit, refer to the DTC
flowchart of the respective communication stop. B -- GO TO DTC U1002 FLOWCHART See:
Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/U Code
Charts/U1002
C -- GO TO MAIN BODY ECU COMMUNICATION STOP MODE FLOWCHART See: Component
Tests and General Diagnostics/Main Body ECU Communication Stop Mode
D -- GO TO PROBLEM SYMPTOMS TABLE See: Symptom Related Diagnostic Procedures/CAN
Communication System/Problem Symptoms Table
E -- GO TO OPEN IN ONE SIDE OF CAN BRANCH WIRE FLOWCHART
See: Symptom Related Diagnostic Procedures/CAN Communication System
A -- Continue to next step.
9. CHECK COMMUNICATION MALFUNCTION DTC (PAST DTC CHECK)*
(a) Select "CAN Bus Check" from the "System Select".
(b) Write down all of the DTCs stored in each ECU.
HINT *
If there are communication malfunction DTCs stored but the Techstream's "CAN Bus Check Communication Bus Check" screen displays all of the ECUs and sensors connected to the CAN
system, the communication malfunction DTCs may be past malfunctions that are no longer
present.
* For V bus main wire malfunctions, related ECUs are also detected. Therefore, determine the
malfunctioning area based on all of the DTCs that are output.
* For MS bus malfunctions, DTCs are output based on the detection of communication stop
malfunctions and network malfunctions of ECUs that are connected by the main body ECU.
B -- GO TO DTC U1002 FLOWCHART See: Testing and Inspection/Diagnostic Trouble Code
Tests and Associated Procedures/U Code Charts/U1002
Disassembly
Parking Brake Warning Switch: Service and Repair Disassembly
PARKING BRAKE: PARKING BRAKE PEDAL: DISASSEMBLY
1. REMOVE PARKING BRAKE SWITCH ASSEMBLY
(a) Remove the screw and switch.
Page 4354
Fuel Injector: Service and Repair Installation
1UR-FE FUEL: FUEL INJECTOR: INSTALLATION
1. INSTALL FUEL INJECTOR ASSEMBLY
(a) Attach the 3 clamps to install the No. 6 wire harness to the delivery pipe RH.
(b) Attach the 3 clamps to install the No. 7 wire harness to the delivery pipe LH.
(c) Apply gasoline or spindle oil to a new O-ring and install it to the injector.
NOTICE: Make sure that there is no damage or foreign material in the groove of the injector when
installing the O-ring.
(d) Connect the injector connector.
(e) Install the injector to the delivery pipe as shown in the illustration.
Page 4875
Transmission Speed Sensor: Service and Repair Installation
A760F AUTOMATIC TRANSMISSION: SPEED SENSOR: INSTALLATION
1. INSTALL SPEED SENSOR SP2
(a) Coat a new O-ring with ATF and install it to the sensor.
(b) Install the sensor with the bolt.
Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)
(c) Connect the sensor connector.
2. INSTALL SPEED SENSOR NT
(a) Coat a new O-ring with ATF and install it to the sensor.
(b) Install the sensor with the bolt.
Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)
(c) Connect the sensor connector.
Page 9031
(2) CONNECTORS
Slightly shake the connector vertically and horizontally.
(3) WIRE HARNESS
Slightly shake the wire harness vertically and horizontally.
HINT The connector joint and fulcrum of the vibration are the major areas that should be checked
thoroughly.
(b) HEAT METHOD:
When a malfunction seems to occur when the area in question is heated.
(1) Heat the component that is the possible cause of the malfunction with a hair dryer or similar
device. Check if the malfunction occurs.
NOTICE: *
Do not heat to more than 60°C (140°F). Exceeding this temperature may damage components.
* Do not apply heat directly to the parts in the ECU.
(c) WATER SPRINKLING METHOD:
When a malfunction seems to occur on a rainy day or in high-humidity.
(1) Sprinkle water onto the vehicle and check if the malfunction occurs.
NOTICE: *
Never sprinkle water directly into the engine compartment. Indirectly change the temperature and
humidity by spraying water onto the front of the radiator.
* Never apply water directly onto the electronic components.
HINT If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU
or connections. Look for evidence of corrosion or short circuits. Proceed with caution during water
tests.
(d) HIGH ELECTRICAL LOAD METHOD:
When a malfunction seems to occur when the electrical load is excessive.
(1) Turn on the heater blower, headlights, rear window defogger and all other electrical loads.
Check if the malfunction reoccurs.
5. DIAGNOSTIC TROUBLE CODE CHART
Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate
section's Diagnostic Trouble Code Chart. Use the chart to determine the trouble area and the
proper inspection procedure. A description of each of the chart's columns is below.
Page 2358
(Cylinder block journal diameter - crankshaft journal diameter - 5) X 1000 = A + B
Standard Bearing Chart:
No. 1 and No. 5 Journals:
Other Journals:
EXAMPLE:
No. 1 and No. 5 journals
Cylinder block "7" + Crankshaft "6" = Total number 13 (Use upper bearing "6" and lower bearing
"7")
Other journals
Cylinder block "7" + Crankshaft "6" = Total number 13 (Use upper bearing "5" and lower bearing
"6")
Standard Bearing Chart:
Standard Cylinder Block Crankshaft Journal Bore Diameter (A)
Standard Crankshaft Journal Diameter (B):
Page 2661
If the fins are blocked, wash them with water or a steam cleaner.
NOTICE: *
If the distance between the steam cleaner and core is too close, the fins may be damaged.
* Keep the following injection distance.
Standard injection distance:
* If the fins are bent, straighten them with a screwdriver or pliers.
* Never apply water directly onto the electric components.
(b) Dry the fins with compressed air.
Page 9299
Page 475
Seat Occupant Classification Module - Air Bag: Locations Seat Belt Warning System
SEAT BELT: SEAT BELT WARNING SYSTEM: PARTS LOCATION
Page 3715
NOTE
On some models, DTCs may set as a result of reprogramming. If DTCs are present, clear codes
and run the Health Check again. Troubleshoot any remaining Current, Pending, or History codes.
Permanent codes will not be cleared using Techstream. Permanent codes do not illuminate the MIL
and do not require troubleshooting. They will clear during normal driving once the Universal Trip
Drive Pattern is performed.
4. Attach the Authorized Modifications Label.
A. Using a permanent marker or ball point pen complete the Authorized Modifications Label and
attach to the vehicle. The Authorized
Modifications Label is available through the MDC P/N 00451-00001-LBL.
B. Attach the label under the hood in the location determined by the specific TSB or Campaign.
NOTE
Wait 60 - 90 seconds for ink to set before handling.
Page 4304
4. Attach the Authorized Vehicle Modification Label.
Modifications to ECU calibrations MUST be recorded and properly displayed on the vehicle using
the Authorized Modification Label.
Techstream Preparation
Selecting the TIS Techstream VIM or the Mongoose MFC VIM.
Techstream software requires a VIM selection before you can use the Mongoose MFC VIM.
If using TIS Techstream no changes are needed.
Perform the following:
1. Select Setup from the Techstream Main Menu screen.
2. Select VIM Select from the Setup drop down menu.
3. Select the correct Interface Setup from the drop down list.
^ If using Techstream Lite select Mongoose MFC.
NOTE
Page 6826
Instrumental Panel Wire
Air Conditioning System (for Automatic Air Conditioning
System)
Ambient Temperature Sensor / Switch HVAC: Locations Air Conditioning System (for Automatic Air
Conditioning System)
AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Automatic Air Conditioning System):
PARTS LOCATION
Page 3046
Camshaft Position Sensor: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT POSITION SENSOR: INSTALLATION
1. INSTALL CAMSHAFT POSITION SENSOR
(a) Install the sensor with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(b) Connect the sensor connector.
2. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Installation
Locations
Four Wheel Drive Selector Switch: Locations
JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION
Locations
Transmission Temperature Sensor/Switch: Locations
A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS
LOCATION
Page 5887
Steering Angle Sensor: Service and Repair Removal
BRAKE CONTROL: STEERING ANGLE SENSOR: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to disable the SRS system.
2. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
3. REMOVE LOWER NO. 3 STEERING WHEEL COVER See: Restraint Systems/Air Bag
Systems/Air Bag/Service and Repair/Removal and
Replacement/Steering Pad/Removal
4. REMOVE LOWER NO. 2 STEERING WHEEL COVER See: Restraint Systems/Air Bag
Systems/Air Bag/Service and Repair/Removal and
Replacement/Steering Pad/Removal
5. REMOVE STEERING PAD See: Restraint Systems/Air Bag Systems/Air Bag/Service and
Repair/Removal and Replacement/Steering
Pad/Removal
6. REMOVE STEERING WHEEL ASSEMBLY See: Steering and Suspension/Steering/Steering
Column/Service and Repair/Removal and
Replacement/Steering Column Assembly (for Manual Tilt)/Removal
7. REMOVE LOWER STEERING COLUMN COVER See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Removal and
Replacement/Steering Column Assembly (for Manual Tilt)/Removal
8. REMOVE UPPER STEERING COLUMN COVER See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Removal and
Replacement/Steering Column Assembly (for Manual Tilt)/Removal
9. REMOVE SPIRAL CABLE SUB-ASSEMBLY See: Restraint Systems/Air Bag
Systems/Clockspring Assembly / Spiral Cable/Service and
Repair/Removal
10. REMOVE STEERING ANGLE SENSOR See: Restraint Systems/Air Bag Systems/Clockspring
Assembly / Spiral Cable/Service and
Repair/Removal
Page 6599
Establish conditions in which voltage is present at the check point.
Example:
- [A] - Ignition SW on
- [B] - Ignition SW and SW1 on
- [C] - Ignition SW, SW1 and Relay on (SW2 off)
Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or component terminal.
This check can be done with a test light instead of a voltmeter.
Electronic Circuit Inspection Procedure
Page 262
Page 8792
(b) If the result is not as specified, replace the speaker assembly.
Rear Door Speaker (for CrewMax)
AUDIO / VISUAL: REAR DOOR SPEAKER (for CrewMax): INSPECTION
1. INSPECT REAR NO. 1 SPEAKER ASSEMBLY (for Standard)
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the speaker assembly.
2. INSPECT REAR NO. 1 SPEAKER ASSEMBLY (for 12 Speakers)
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the speaker assembly.
3. INSPECT REAR NO. 2 SPEAKER ASSEMBLY (for 12 Speakers)
Page 8703
Seat Memory Switch: Service and Repair Installation
SEAT: SEAT MEMORY SWITCH (w/ Seat Position Memory System): INSTALLATION
1. INSTALL SEAT MEMORY SWITCH
(a) Install the seat memory with the 2 screws.
2. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH See: Body and Frame/Doors,
Hood and Trunk/Doors/Front Door/Service and
Repair/Front Door (for Double Cab)/Reassembly
3. INSTALL FRONT DOOR ARMREST COVER LH
4. INSTALL COURTESY LIGHT ASSEMBLY See: Body and Frame/Doors, Hood and
Trunk/Doors/Front Door/Service and Repair/Front Door
(for Double Cab)/Reassembly
5. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH LH See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Reassembly
6. INSTALL FRONT ARMREST UPPER BASE PANEL LH See: Body and Frame/Doors, Hood and
Trunk/Doors/Front Door/Service and
Repair/Front Door (for Double Cab)/Reassembly
7. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH See: Body and Frame/Doors,
Hood and Trunk/Doors/Front Door/Service and
Repair/Front Door (for Double Cab)/Reassembly
Page 3206
Crankshaft Position Sensor: Diagrams
Locations
Headlamp Relay: Locations
LIGHTING: LIGHTING SYSTEM: PARTS LOCATION
Page 6749
Driver Side J/B Inner Circuit
Page 6171
Power Outlet Socket (115V)
Page 1923
Fluid - Differential: Service and Repair
DIFFERENTIAL: DIFFERENTIAL OIL: REPLACEMENT
1. DRAIN DIFFERENTIAL OIL
(a) Stop the vehicle on a level place.
(b) for Front Differential:
(1) Using a 10 mm hexagon wrench, remove the filler plug and gasket.
(2) Using a 10 mm hexagon wrench, remove the drain plug and gasket, and drain the oil.
(3) Using a 10 mm hexagon wrench, install a new gasket and the drain plug.
Torque : 39 Nm (398 kgf-cm, 29 ft-lbf)
(c) for Rear Differential:
(1) Remove the filler plug and gasket.
(2) Remove the drain plug and gasket, and drain the oil.
(3) Install a new gasket and the drain plug.
Torque : 49 Nm (500 kgf-cm, 36 ft-lbf)
2. ADD DIFFERENTIAL OIL
(a) Add differential oil so that the oil level is between 0 to 5 mm (0 to 0.197 in.) from the bottom lip
of the differential filler plug hole.
NOTICE: *
Too much or too little oil will lead to differential problems.
* After changing the oil, drive the vehicle and then check the oil level again.
Oil type:
Front differential capacity:
Rear differential capacity:
Page 7769
(a) Disconnect the 2 connectors.
(b) Remove the 4 screws and damper servo.
(c) Remove the servo motor.
(1) Detach the claw and remove the main plate.
(2) Remove the 2 screws and damper servo.
(d) Remove the servo motor.
Radio Antenna
Antenna, Radio: Service and Repair Radio Antenna
Components
AUDIO / VISUAL: RADIO ANTENNA: COMPONENTS
Page 8532
(a) Detach the 4 clips.
(b) Disconnect the connector and remove the panel.
11. REMOVE GLASS BREAKAGE SENSOR MICROPHONE
(a) Detach the 2 claws and remove the sensor.
Installation
THEFT DETERRENT: GLASS BREAKAGE SENSOR (for Column Shift Type): INSTALLATION
1. INSTALL GLASS BREAKAGE SENSOR MICROPHONE
(a) Attach the 2 claws to install the sensor.
2. INSTALL INTEGRATION CONTROL AND PANEL ASSEMBLY
Page 5583
Brake Fluid Solenoid Valve Relay: Locations From 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 147
Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular Cab)/Installation.
(b) for Double Cab:
Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Installation.
(c) for CrewMax:
Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for CrewMax)/Installation.
10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
11. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Reading and Clearing Diagnostic Trouble
Codes/Check Mode Procedure.
Locations
Tire Pressure Monitor Receiver / Transponder: Locations
TIRE AND WHEEL: TIRE PRESSURE WARNING SYSTEM: PARTS LOCATION
Skid Control Sensor Wire
Wheel Speed Sensor: Diagrams Skid Control Sensor Wire
Page 6543
* In the DTC check, it is very important to determine whether the problem indicated by the DTC is
either: 1) still occurring; or 2) occurred in the past but has since returned to normal. In addition, the
DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs
should be checked before and after confirmation of symptoms (i.e., whether or not problem
symptoms exist) to determine current system conditions, as shown in the flowchart below.
* Never skip the DTC check. Failing to check DTCs may, depending on the case, result in
unnecessary troubleshooting for systems operating normally or lead to repairs not related to the
problem. Follow the procedures listed in the flowchart in the correct order.
* The following flowchart shows how to proceed with troubleshooting using the DTC check.
Directions from the flowchart will indicate how to proceed either to DTC troubleshooting or to the
troubleshooting of each problem symptom.
1. DTC CHECK
NEXT -- Continue to next step.
2. MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR MEMORY
NEXT -- Continue to next step.
3. SYMPTOM CONFIRMATION
B -- Go to step 5 A -- Continue to next step.
4. SIMULATION TEST USING SYMPTOM SIMULATION METHODS
NEXT -- Continue to next step.
5. DTC CHECK
B -- TROUBLESHOOTING OF PROBLEM INDICATED BY DTC A -- Continue to next step.
6. SYMPTOM CONFIRMATION
Page 7352
(a) Temporarily install the spring seat and 2 U bolts with the 4 washers and 4 nuts.
NOTICE: *
Tighten the nuts in the order shown in the illustration.
* Install the U bolts so that the lengths of the 4 ends under the spring seat are the same.
6. CONNECT NO. 3 PARKING BRAKE CABLE ASSEMBLY
(a) Connect the parking brake cable to the vehicle with the 3 bolts.
for Bolt A - Torque : 19 Nm (194 kgf-cm, 14 ft-lbf)
for Bolt B - Torque : 14 Nm (138 kgf-cm, 10 ft-lbf)
7. STABILIZE SUSPENSION See: Suspension Strut / Shock Absorber/Service and
Repair/Removal and Replacement/Rear Shock
Absorber/Installation
8. TIGHTEN REAR SPRING ASSEMBLY LH
(a) Tighten the 3 nuts.
Torque : 105 Nm (1071 kgf-cm, 77 ft-lbf)
9. TIGHTEN REAR SPRING U BOLT
(a) Tighten the 4 nuts.
Torque : 100 Nm (1020 kgf-cm, 74 ft-lbf)
10. INSTALL REAR WHEEL
for Aluminum Wheel - Torque : 131 Nm (1336 kgf-cm, 97 ft-lbf)
for Steel Wheel - Torque : 209 Nm (2131 kgf-cm, 154 ft-lbf)
11. INSTALL SPARE TIRE
12. REMOVE SAFETY STANDS
Page 302
Junction Connector (CAN No.2) - Lower Finish Panel
Page 1873
^ 1AR-FE (Highlander Venza)
^ 2AR-FE (RAV4 Camry)
Warranty Information
Required Tools & Equipment
Page 1499
Ignition Switch: Connector Views
Page 2972
without SST - Torque : 44 Nm (449 kgf-cm, 32 ft-lbf)
with SST - Torque : 40 Nm (408 kgf-cm, 30 ft-lbf)
HINT *
Use a torque wrench with a fulcrum length of 30 cm (11.8 in.). When using a torque wrench with a
fulcrum length that is not 30 cm (11.8 in.), calculate the torque specification for the torque wrench
and SST based on the "without SST" torque specification See: Service Precautions
* Make sure SST and the wrench are connected in a straight line.
(c) for 2WD:
Connect the air fuel ratio sensor connector.
2. INSTALL FRONT NO. 2 EXHAUST PIPE ASSEMBLY (for 4WD)
(a) Connect the front No. 2 exhaust pipe to the exhaust pipe support.
(b) Install a new gasket and the front No. 2 exhaust pipe to the exhaust manifold LH with 3 new
nuts.
Torque : 54 Nm (554 kgf-cm, 40 ft-lbf)
(c) Connect the air fuel ratio sensor connector.
(d) Connect the heated oxygen sensor connector.
3. INSTALL AIR FUEL RATIO SENSOR (for Bank 2 Sensor 1)
(a) Install the sensor to the exhaust pipe by hand.
(b) Using SST, tighten the sensor.
SST : 09224-00010
without SST - Torque : 44 Nm (449 kgf-cm, 32 ft-lbf)
Page 8665
DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector.
Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
Page 937
(a) Disconnect the connector.
(b) Remove the 3 screws and damper servo.
14. REMOVE COOLING UNIT DAMPER SERVO SUB-ASSEMBLY (for Automatic Air Conditioning
System)
(a) Disconnect the connector.
(b) Remove the 3 screws and damper servo.
15. REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY
(a) Remove the 3 screws and plate.
(b) Detach the 3 claws and remove the heater clamp.
(c) Remove the heater radiator unit.
16. REMOVE NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY
Page 6460
Page 8640
(a) Attach the 4 clips to install the light.
NOTICE: Do not damage the design surface of the television display when you install the light.
5. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Page 1729
(f) Install SST (pressure gauge) as shown in the illustration.
SST : 09268-31012
90467-13001
95336-08070
09268-41500
09268-41120
SST : 09268-45014
09268-41200
09268-41220
(g) Wipe off any gasoline.
(h) Reconnect the cable to the negative (-) battery terminal.
(i) Operate the fuel pump.
(1) Connect the Techstream to the DLC3.
(2) Turn the ignition switch to ON.
NOTICE: Do not start the engine.
(3) Turn the Techstream main switch ON.
(4) Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump /
Speed.
(j) Measure the fuel pressure.
Standard fuel pressure:
281 to 287 kPa (2.87 to 2.93 kgf/cm2, 41 to 42 psi)
(k) If the pressure is higher than the specification, replace the fuel pressure regulator.
If the pressure is lower than the specification, check the fuel hoses and connections, fuel pump,
fuel filter and fuel pressure regulator assembly.
(l) Start the engine.
Page 8035
(b) Detach the 2 claws and remove the switch.
Installation
SUPPLEMENTAL RESTRAINT SYSTEM: CURTAIN SHIELD AIRBAG CUTOFF SWITCH:
INSTALLATION
1. INSTALL CURTAIN SHIELD AIRBAG CUTOFF SWITCH
(a) Attach the 2 claws to install the switch.
(b) Connect the connector.
2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Installation
3. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
4. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Installation
5. INSTALL FRONT DOOR SCUFF PLATE LH (for Double Cab, CrewMax) See: Body and
Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Installation
6. INSTALL FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Installation
7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
8. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
Page 394
(c) WAVEFORM 2:
HINT The wavelength varies in accordance with the engine operating conditions.
(d) WAVEFORM 3:
HINT In the Data List, item O2S B1 S2 and O2S B2 S2 shows the ECM input values from the
heated oxygen sensor.
(e) WAVEFORM 4:
Page 461
(a) Disconnect the holder (with connectors).
(b) Remove the 3 bolts and airbag sensor.
Installation
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Column
Shift Type): INSTALLATION
1. INSTALL CENTER AIRBAG SENSOR ASSEMBLY
(a) Check that the ignition switch is OFF.
(b) Check that the cable is disconnected from the battery negative (-) terminal.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
(c) Install the airbag sensor with the 3 bolts.
Torque : 18 Nm (184 kgf-cm, 13 ft-lbf)
NOTICE: *
If the center airbag sensor has been dropped, or there are any cracks, dents or other defects in the
case, bracket or connector, replace it with a new one.
* When installing the center airbag sensor, be careful that the SRS wiring does not interfere with
other parts and that it is not pinched between other parts.
(d) Check that there is no looseness in the installation parts of the center airbag sensor.
(e) Connect the holder (with connectors).
(f) Check that the waterproof sheet is properly set.
2. INSTALL CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service
and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
NOTICE: Some systems need to be initialized after the cable is reconnected See: Testing and
Inspection/Programming and Relearning
4. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
Page 6495
Driver Side J/B - Cowl Side Left
Locations
Transmission Speed Sensor: Locations
A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS
LOCATION
Page 1677
*: for 5 leaf spring
Standard Toe-in
for Regular Cab of Standard Deck
Page 4112
* Never reuse the O-ring.
* When placing a new O-ring on the injector, do not damage it.
* Coat a new O-ring with spindle oil or gasoline before installing it. Do not use engine oil, gear oil or
brake oil.
(c) Install the injector to the delivery pipe and intake manifold as shown in the illustration.
NOTICE: Before installing the injector, apply spindle oil or gasoline on the place where the delivery
pipe contacts the O-ring of the injector.
(d) Observe these precautions when disconnecting the fuel tube connector (for Quick Type).
(1) for Fuel Hose Connector Cover Type:
Detach the lock claw by lifting up the cover, as shown in the illustration.
(2) for Fuel Pipe Clamp Type:
Remove the fuel pipe clamp from the fuel tube connector.
Page 6619
Connectors Part 1
Connectors Part 2
Page 5954
"Case1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (/\ Mark) and pull the terminal retainer
up to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Air Conditioning System (for Automatic Air Conditioning
System)
Air Door Actuator / Motor: Locations Air Conditioning System (for Automatic Air Conditioning
System)
AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Automatic Air Conditioning System):
PARTS LOCATION
Page 6046
"Case1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (/\ Mark) and pull the terminal retainer
up to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Page 3276
1. Test drive the vehicle and confirm there is a harsh shift on acceleration below 20 mph and or
excessive lock-up operation at freeway speeds about 50
- 60 mph.
2. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in
Figure 1. Confirm if the ECM (PCM) calibration has
been updated. If the calibration ID listed is NOT the latest ECM (PCM) calibration - go to step 3.
3. Flash reprogram the ECM (PCM).
NOTE
^ The GR8 Battery Diagnostic Station MUST be used in Power Supply Mode to maintain battery
voltage at 13.5 volts while flash reprogramming the vehicle.
^ For details on how to use the GR8 Battery Diagnostic Station, refer to the GR8 Instruction Manual
located on the Technical Information System (TIS), Diagnostics - Battery.
Follow the procedures outlined in TSB No. T-SB-0064-10, "Techstream ECU Flash
Reprogramming Procedure", and flash the ECM (PCM) with the NEW calibration file update.
4. Start the engine and warm it up to normal operating temperature before test driving.
5. Test drive the vehicle to confirm proper vehicle operation and ECM (PCM) initial learning. Refer
to the Technical Information System (TIS) 2010
Tundra Repair Manual:
Drivetrain - Automatic Transmission/Transaxle - "A760E / A760F Automatic
Transmission/Transaxle: Automatic Transmission System: Initialization"
6. Install the Authorized Modifications Label.
A. Using a permanent marker enter the following information on the label:
^ ECM part number [Refer to the Parts Information section for the CURRENT PART NUMBER]
Page 676
(b) Attach the 2 clips and 5 claws to install the armrest base panel.
Page 3495
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE CAN MAIN WIRE CONNECTED TO COMBINATION METER ECU
(CANH, CANL)
OK -- REPLACE COMBINATION METER ASSEMBLY
14. CHECK FOR SHORT IN CAN BUS WIRES (MAIN BODY ECU)
(a) Disconnect the J2 main body ECU connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO MAIN BODY ECU (CANH,
CANL)
OK -- REPLACE MAIN BODY ECU
15. CHECK FOR SHORT IN CAN BUS WIRES (SKID CONTROL ECU WITH ACTUATOR)
(a) Disconnect the A17 skid control ECU with actuator connector.
Page 5292
(c) Using a brass bar and hammer, slightly tap in the 4 spider bearings.
(d) Using needle-nose pliers, remove the 4 snap rings from the grooves.
(e) Using a screwdriver, remove the 4 slingers of the spider bearing.
(f) Clamp the propeller shaft in a vise between aluminum plates.
(g) Using SST, press in spider bearing B until spider bearing A can be clamped in a vise.
SST : 09950-60010
09951-00290
SST : 09950-40011
09951-04010
09952-04010
09953-04030
09954-04010
09957-04010
09958-04011
Back Power Window Switch
Power Window Switch: Testing and Inspection Back Power Window Switch
WINDSHIELD / WINDOWGLASS: BACK POWER WINDOW SWITCH: INSPECTION
1. INSPECT POWER WINDOW REGULATOR SWITCH ASSEMBLY
(a) Check the resistance.
(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(2) If the result is not as specified, replace the power window regulator switch assembly.
(b) Check that the LED illuminates.
(1) Apply battery voltage to the power window regulator switch and check that the LED illuminates.
OK:
(2) If the result is not as specified, replace the power window regulator switch assembly.
2. INSPECT POWER WINDOW REGULATOR SWITCH ASSEMBLY (for Power Slide Type)
(a) Check the resistance.
(1) Measure the resistance according to the value(s) in the table below.
Page 2855
Fuel Pump Control Unit: Diagrams
Locations
Impact Sensor: Locations
SUPPLEMENTAL RESTRAINT SYSTEM: AIRBAG SYSTEM: PARTS LOCATION
Glass Breakage Sensor (for Floor Shift Type)
Ultrasonic Sensor: Service and Repair Glass Breakage Sensor (for Floor Shift Type)
Components
THEFT DETERRENT: GLASS BREAKAGE SENSOR (for Floor Shift Type): COMPONENTS
Removal
THEFT DETERRENT: GLASS BREAKAGE SENSOR (for Floor Shift Type): REMOVAL
1. REMOVE FRONT DOOR SCUFF PLATE LH
Power Steering Oil Pressure Sensor
Power Steering Pressure Switch: Diagrams Power Steering Oil Pressure Sensor
Page 2571
Page 2139
Tire Pressure Module: Service and Repair Installation
TIRE AND WHEEL: TIRE PRESSURE WARNING ECU: INSTALLATION
1. INSTALL TIRE PRESSURE WARNING ECU
(a) Install the ECU with the 2 nuts.
Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
(b) Connect the ECU connector.
2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Installation
3. INSTALL INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
4. INSTALL COWL SIDE TRIM BOARD RH
(a) Install the cowl side trim board RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Installation.
HINT Use the same procedures described for the LH side.
5. INSTALL FRONT DOOR SCUFF PLATE RH (for Double Cab, for CrewMax)
(a) Install the front door scuff plate RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Installation.
HINT Use the same procedures described for the LH side.
6. INSTALL FRONT DOOR SCUFF PLATE RH (for Regular Cab)
(a) Install the front door scuff plate RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Installation.
HINT Use the same procedures described for the LH side.
7. REGISTRATION OF TRANSMITTER ID
(a) Register the transmitter ID See: Tire Monitoring System/Testing and Inspection/Programming
and Relearning/Registration.
8. PERFORM INITIALIZATION
(a) Perform initialization See: Tire Monitoring System/Testing and Inspection/Programming and
Relearning/Initialization.
NOTICE: Be sure to inflate all tires to the proper inflation pressure before initialization.
9. CHECK TIRE PRESSURE AFTER REPAIRS
Locations
Fuse Block: Locations
Engine Compartment
Page 3688
^ Power Supply Mode is used to maintain battery voltage at 13.5 volts while flash reprogramming
the vehicle.
^ For details on how to use the GR8 Battery Diagnostic Station, refer to the located on TIS,
Diagnostics - Tools & Equipment - Battery Diagnostics.
3. Click the appropriate calibration ID and reprogram the vehicle's ECU with Techstream.
A. After reviewing the procedures outlined in the selected TSB, click the appropriate calibration ID
link by matching the vehicle's current
calibration ID to the Previous Calibration ID in the Calibration Identification Chart.
NOTE
^ Calibration files are embedded as live links in the service bulletin.
^ Some vehicles require special preparation - please review the selected TSB carefully.
B. Click Open to load calibration file information.
Techstream pulls calibration files as needed to ensure the latest calibration file is used. Do NOT
save calibrations locally on the hard drive or other media.
NOTICE
Errors during the flash reprogramming process can permanently damage the vehicle ECU.
Minimize the risk by following the steps below.
^ Battery voltage MUST NOT FALL BELOW 11.4 volts during reprogramming. Confirm battery
voltage is higher than 11.4 volts, but be sure voltage DOES NOT RISE ABOVE 16.0 volts during
reprogramming.
^ Turn OFF all vehicle accessories (e.g. audio system, A/C, interior lights, DRL, etc.). Do NOT add
to or significantly change the vehicle's electrical
Page 7055
Standard camber inclination (unloaded vehicle):
for CrewMax of standard deck
Page 1043
Cargo Lamp Switch: Service and Repair Installation
LIGHTING: CARGO LIGHT SWITCH: INSTALLATION
1. INSTALL CARGO LIGHT SWITCH
(a) Attach the 2 claws to install the light switch.
2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH
3. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
4. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Installation
5. INSTALL FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Installation
6. INSTALL FRONT DOOR SCUFF PLATE LH (for Double cab, CrewMax) See: Body and
Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Installation
Page 2242
2. Install ChaSSiSEAR(TM) on the vehicle and attempt to isolate the source of the noise. Is the
noise loudest near the rear wheel bearing assembly?
^ YES - Go to step 3.
^ NO - This TSB does NOT apply. Continue diagnosis to isolate the source of the noise.
3. Replace the rear wheel bearing caliper bracket and related parts.
Refer to the Technical Information System (TIS) applicable model year Repair Manual:
4. Test drive the vehicle and confirm the noise is eliminated.
5. Re-check rear differential oil level and confirm NO leaks are present.
Page 6257
Symbols Used Within Diagrams
Symbols Used Within Diagrams
Page 2846
(2) If the result is not as specified, replace the integration relay.
3. INSTALL INTEGRATION RELAY See: Relays and Modules - Ignition System/Ignition
Relay/Testing and Inspection
Page 1475
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION: Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC
terminals are touched, the IC may be destroyed by static electricity.)
When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact with the terminals of leads from the IC, etc. of the
replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown on the left.
DISCONNECT CONNECTOR
Page 7046
Standard toe-in (unloaded vehicle):
for Double Cab of Long Deck
Standard toe-in (unloaded vehicle):
for CrewMax of standard deck
Page 1033
Brake Light Switch: Service and Repair Installation
LIGHTING: STOP LIGHT SWITCH: INSTALLATION
1. INSTALL STOP LIGHT SWITCH MOUNTING ADJUSTER
(a) Attach the 2 claws to install the adjuster.
2. INSTALL STOP LIGHT SWITCH ASSEMBLY
(a) Insert the stop light switch so that it contacts the pedal cushion.
NOTICE: insert the stop light switch with a force of less than 98 N*m (1000 kgf*cm 72.3 ft.*lbf).
(b) Rotate the stop light switch clockwise 90° to install it to the adjuster.
Standard:
A: 1.5 to 2.5 mm (0.0591 to 0.0984 in.)
NOTICE: *
When the stop light switch is rotated clockwise, make sure the stop light switch moves outward less
than 1 pitch (pitch: distance between 2 screw threads).
* Rotate the stop light switch with a torque of 1.5 N*m (15 kgf*cm.13 in.*lbf).
* Do not allow silicon grease to contact the stop light switch.
(c) Connect the connector.
Page 4883
Shift Interlock Control Module: Diagrams
Page 8138
Page 6305
Driver Side J/B Inner Circuit
Page 7657
If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness
or connector in that circuit in the past. Check the wire harness and connectors.
B -- SYSTEM NORMAL
A -- TROUBLESHOOTING OF EACH PROBLEM SYMPTOM
The problem is still occurring in a place other than the diagnostic circuit (the DTC displayed first is
either for a past problem or a secondary problem).
4. SYMPTOM SIMULATION
HINT The most difficult case in troubleshooting is when no problem symptoms occur. In such a
case, a thorough problem analysis must be carried out. A simulation of the same or similar
conditions and environment in which the problem occurred in the customer's vehicle should be
carried out. No matter how much skill or experience a technician has, troubleshooting without
confirming the problem symptoms will lead to important repairs being overlooked and mistakes or
delays.
For example:
With a problem that only occurs when the engine is cold or as a result of vibration caused by the
road during driving, the problem can never be determined if the symptoms are being checked on a
stationary vehicle or on a vehicle with a warmed-up engine. Vibration, heat or water penetration
(moisture) is difficult to reproduce. The symptom simulation tests below are effective substitutes for
the conditions and can be applied on a stationary vehicle.
Important points in the symptom simulation test:
In the symptom simulation test, the problem symptoms as well as the problem area or parts must
be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then,
connect the tester and carry out the symptom simulation test, judging whether the circuit being
tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the
problem symptoms table for each system to narrow down the possible causes.
To reproduce DTCs, it is necessary to satisfy the respective DTC detection conditions.
(a) VIBRATION METHOD:
When a malfunction seems to occur as a result of vibration.
(1) PART AND SENSOR
Apply slight vibration with a finger to the part of the sensor suspected to be the cause of the
problem, and check whether or not the malfunction occurs.
NOTICE: Applying strong vibration to relays may open them.
Page 718
Seat)/Installation.
Remote Starting System - Cold Weather Starting Tips
Keyless Starting System: Technical Service Bulletins Remote Starting System - Cold Weather
Starting Tips
T-SB-0100-09
Rev1
March 31, 2009
Remote Engine Starter (RES) Cold Temperature Operation Diagnostic Tips
Service Category Engine/Hybrid System
Section Starting
Market USA
Applicability
March 9, 2010 Rev1:
TSB REVISION NOTICE
Applicability has been updated to include applicable 2010 - 2011 model year vehicles. Any
previous printed versions of this service bulletin should be discarded.
Introduction
Some vehicles operated in extremely cold temperatures may exhibit a condition where the Remote
Engine Starter (RES) does not function.
Before RES diagnosis confirm with the customer the ambient temperature when the malfunction
was experienced.
The RES system was designed to operate at temperatures above -22 F (-30 C). Non-operation of
the RES system below this threshold should be considered a normal condition.
Warranty Information
Diagnostic Procedure
Page 6461
Page 384
Standard Voltage:
NG -- CHECK HARNESS AND CONNECTOR (RELAY BLOCK - ECM, IGNITION SWITCH,
BATTERY AND BODY GROUND)
OK -- REPLACE ECM See: Service and Repair/Removal
5. CHECK HARNESS AND CONNECTOR (RELAY BLOCK - ECM, IGNITION SWITCH, BATTERY
AND BODY GROUND)
(a) Disconnect the ECM connector.
(b) Disconnect the ignition switch connector.
(c) Disconnect the cable from the battery positive (+) terminal.
(d) Remove the AM2 fuse and integration relay.
Page 7807
Compressor Clutch Relay: Locations Air Conditioning System (for Manual Air Conditioning System)
AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Manual Air Conditioning System):
PARTS LOCATION
Page 8399
Page 4556
Camshaft Position Sensor: Diagrams
Page 9075
* In the DTC check, it is very important to determine whether the problem indicated by the DTC is
either: 1) still occurring; or 2) occurred in the past but has since returned to normal. In addition, the
DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs
should be checked before and after confirmation of symptoms (i.e., whether or not problem
symptoms exist) to determine current system conditions, as shown in the flowchart below.
* Never skip the DTC check. Failing to check DTCs may, depending on the case, result in
unnecessary troubleshooting for systems operating normally or lead to repairs not related to the
problem. Follow the procedures listed in the flowchart in the correct order.
* The following flowchart shows how to proceed with troubleshooting using the DTC check.
Directions from the flowchart will indicate how to proceed either to DTC troubleshooting or to the
troubleshooting of each problem symptom.
1. DTC CHECK
NEXT -- Continue to next step.
2. MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR MEMORY
NEXT -- Continue to next step.
3. SYMPTOM CONFIRMATION
B -- Go to step 5 A -- Continue to next step.
4. SIMULATION TEST USING SYMPTOM SIMULATION METHODS
NEXT -- Continue to next step.
5. DTC CHECK
B -- TROUBLESHOOTING OF PROBLEM INDICATED BY DTC A -- Continue to next step.
6. SYMPTOM CONFIRMATION
Page 4336
* Never reuse the O-ring.
* When placing a new O-ring on the injector, do not damage it.
* Coat a new O-ring with spindle oil or gasoline before installing it. Do not use engine oil, gear oil or
brake oil.
(c) Install the injector to the delivery pipe and intake manifold as shown in the illustration.
NOTICE: Before installing the injector, apply spindle oil or gasoline on the place where the delivery
pipe contacts the O-ring of the injector.
(d) Observe these precautions when disconnecting the fuel tube connector (for Quick Type).
(1) for Fuel Hose Connector Cover Type:
Detach the lock claw by lifting up the cover, as shown in the illustration.
(2) for Fuel Pipe Clamp Type:
Remove the fuel pipe clamp from the fuel tube connector.
Page 3344
Engine Temperature Sensor: Testing and Inspection
1UR-FE ENGINE CONTROL SYSTEM: ENGINE COOLANT TEMPERATURE SENSOR:
INSPECTION
1. INSPECT ENGINE COOLANT TEMPERATURE SENSOR
(a) Partially immerse the sensor in water and warm up the water.
(b) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(c) If the result is not as specified, replace the engine coolant temperature sensor.
NOTICE: When checking the sensor in water, keep the terminals dry. After the check, wipe the
sensor dry.
HINT If the result is as specified, do not replace the engine coolant temperature sensor.
Page 9372
3. Loosen and remove the No.3 cab mount nut on the bottom of each cab mount.
4. Loosen and remove the two bolts on top of each of the cab mounts and save them for reuse.
Page 832
Wheel Speed Sensor: Diagrams Front Speed Sensor
Page 7914
Air Bag: Diagrams Front Side Airbag Squib Circuit
A760F Automatic Transmission System
Control Module: Locations A760F Automatic Transmission System
A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS
LOCATION
Page 1917
(b) When using the Techstream:
Disconnect the Techstream from the DLC3.
(c) w/ Trailer Towing System (with transmission oil thermostat):
(1) Push in the shaft with a screwdriver and remove the pin.
NOTICE: Make sure the shaft of the thermostat is protruding from the hole in the cap.
(d) Inspect for automatic transmission fluid leaks.
Page 6249
Page 8287
(a) Attach the 6 clips to install the quarter trim panel lower.
(b) Install the seat belt anchor with the bolt.
Torque : 42 Nm (428 kgf-cm, 31 ft-lbf)
(c) Attach the 2 claws to install the cover.
4. INSTALL REAR DOOR SCUFF PLATE See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Installation
5. INSTALL REAR SEAT ASSEMBLY
(a) Install the rear seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Rear Seat Assembly (for Double
Cab)/Installation.
Page 3324
Page 3489
HINT *
*1: w/ Power Steering ECU
* *2: w/ 4WD
* *3: w/ Bus Buffer ECU
Short in CAN Bus Lines
CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: Short in CAN Bus Lines - Short in
CAN Bus Lines
DESCRIPTION
There may be a short circuit between the CAN bus lines when the resistance between terminals 6
(CANH) and 14 (CANL) of the DLC3 is below 54 Ohms.
HINT *
*1: w/ Bus Buffer ECU
* *2: w/ 4WD
* *3: w/ Power Steering ECU
WIRING DIAGRAM
Page 4583
Use a volt/ohmmeter with high impedance (10 kohms/V minimum) for troubleshooting of the
electrical circuit.
Disconnection of Male and Female Connectors
DISCONNECTION OF MALE AND FEMALE CONNECTORS
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Finding A Short Circuit
FINDING A SHORT CIRCUIT
Page 8006
Air Bag Control Module: Locations Seat Belt Warning System
SEAT BELT: SEAT BELT WARNING SYSTEM: PARTS LOCATION
Page 6342
DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector.
Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
Page 6493
Driver Side J/B - Cowl Side Left
Page 2801
When using Techstream Lite, select Generic J2534 Interface. Then click Next.
E. Confirm the following:
^ PC is connected to VIM.
^ VIM is connected to DLC3 connector.
^ Ignition is ON and engine is OFF or "READY" OFF (hybrid vehicles).
Page 4580
Page 8267
(a) Remove the 2 bolts and bracket.
Installation
SEAT BELT: REAR CENTER SEAT OUTER BELT ASSEMBLY (for Double Cab): INSTALLATION
1. INSTALL SEAT BELT BRACKET
(a) Install the bracket with the 2 bolts.
Torque : 42 Nm (428 kgf-cm, 31 ft-lbf)
2. INSTALL CENTER REAR SEAT OUTER BELT ASSEMBLY
(a) Align the vehicle's claws with the seat belt retractor positioning holes.
(b) Install the retractor with the 2 bolts.
HINT First install bolt A, and then install bolt B.
for bolt A - Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
for bolt B - Torque : 42 Nm (428 kgf-cm, 31 ft-lbf)
(c) Install the seat belt with the 2 bolts.
Page 2225
^ Subtract the expected lowest temperature (14°F) from the workshop temperature (68°F) = 54°F.
^ Using the Tire Pressure Chart (Figure 1), find the intersection of the warm tire line at the point
corresponding to 54°F and read off the value on the tire pressure change axis. In this case it would
be about 6.7 psi.
^ The tires should be filled to:
31.9 + 6.7 psi = 38.6 psi
Example 3: Temperature Compensation - "Hot" Tires
^ The vehicle has been driven to the shop on the highway for at least 60 minutes (vehicle has "hot"
tires) and tire pressures are set to 31.9 psi.
^ Workshop temperature is 68°F, and the expected lowest ambient temperature in the area is
expected to be 14°F.
^ Subtract the expected lowest temperature (14°F) from the workshop temperature (68°F) = 54°F.
^ Using the tire pressure chart (Figure 1), find the intersection of the hot tire line at the point
corresponding to 54°F, and read off the value on the tire pressure change axis. In this case it would
be about 9.0 psi.
^ The tires should be filled to:
31.9 + 9.0 psi = 40.9 psi
Page 2089
Driver Side J/B - Cowl Side Left
Page 6967
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION: Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC
terminals are touched, the IC may be destroyed by static electricity.)
When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact with the terminals of leads from the IC, etc. of the
replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown on the left.
DISCONNECT CONNECTOR
Locations
Turn Signal Switch: Locations
LIGHTING: LIGHTING SYSTEM: PARTS LOCATION
Page 5780
Parking Brake Pedal: Overhaul
Disassembly
PARKING BRAKE: PARKING BRAKE PEDAL: DISASSEMBLY
1. REMOVE PARKING BRAKE SWITCH ASSEMBLY
(a) Remove the screw and switch.
Reassembly
PARKING BRAKE: PARKING BRAKE PEDAL: REASSEMBLY
1. INSTALL PARKING BRAKE SWITCH ASSEMBLY
(a) Install the switch with the screw.
Torque : 0.9 Nm (9 kgf-cm, 8 in-lbf)
Page 2188
Tire Pressure Module: Service and Repair Removal
TIRE AND WHEEL: TIRE PRESSURE WARNING ECU: REMOVAL
NOTICE: *
It is necessary to perform initialization See: Testing and Inspection/Programming and
Relearning/Initialization after registration See: Testing and Inspection/Programming and
Relearning/Registration of the transmitter IDs into the tire pressure warning ECU after the ECU has
been replaced.
* When replacing the tire pressure warning ECU, read the transmitter IDs stored in the old ECU
using the intelligent tester or Techstream and write them down before removal.
1. REMOVE FRONT DOOR SCUFF PLATE RH (for Regular Cab)
(a) Remove the front door scuff plate RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Removal.
HINT Use the same procedures described for the LH side.
2. REMOVE FRONT DOOR SCUFF PLATE RH (for Double Cab, for CrewMax)
(a) Remove the front door scuff plate RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Removal.
HINT Use the same procedures described for the LH side.
3. REMOVE COWL SIDE TRIM BOARD RH
(a) Remove the cowl side trim board RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Removal.
HINT Use the same procedures described for the LH side.
4. REMOVE INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal
5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and
Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument
Panel Safety Pad (for Column Shift Type)/Removal
6. REMOVE TIRE PRESSURE WARNING ECU
(a) Disconnect the ECU connector.
(b) Remove the 2 nuts and ECU.
Page 625
Remote Switch: Service and Repair Removal
AUDIO / VISUAL: STEERING PAD SWITCH: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE LOWER NO. 2 STEERING WHEEL COVER See: Restraint Systems/Air Bag
Systems/Air Bag/Service and Repair/Removal and
Replacement/Steering Pad/Removal
3. REMOVE LOWER NO. 3 STEERING WHEEL COVER See: Restraint Systems/Air Bag
Systems/Air Bag/Service and Repair/Removal and
Replacement/Steering Pad/Removal
4. REMOVE STEERING PAD See: Restraint Systems/Air Bag Systems/Air Bag/Service and
Repair/Removal and Replacement/Steering
Pad/Removal
5. REMOVE STEERING PAD SWITCH ASSEMBLY
(a) Disconnect the connector.
(b) Remove the 2 screws.
(c) Detach the 4 pins and remove the steering pad switch.
Page 8745
2. Install ChaSSiSEAR(TM) on the vehicle and attempt to isolate the source of the noise. Is the
noise loudest near the rear wheel bearing assembly?
^ YES - Go to step 3.
^ NO - This TSB does NOT apply. Continue diagnosis to isolate the source of the noise.
3. Replace the rear wheel bearing caliper bracket and related parts.
Refer to the Technical Information System (TIS) applicable model year Repair Manual:
4. Test drive the vehicle and confirm the noise is eliminated.
5. Re-check rear differential oil level and confirm NO leaks are present.
Page 6626
(a) Attach the claw to install the power outlet socket.
(b) Connect the power outlet socket connector.
6. INSTALL CENTER FRONT SEAT ASSEMBLY
(a) Install the center front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Center
Seat)/Installation.
7. INSTALL FRONT SEAT ASSEMBLY LH (for Power Seat)
(a) Install the front seat LH See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Power
Seat)/Installation.
8. INSTALL FRONT SEAT ASSEMBLY RH (for Power Seat)
HINT Use the same procedures described for the LH side.
9. INSTALL FRONT SEAT ASSEMBLY LH (for Manual Seat)
(a) Install the front seat LH See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Manual
Seat)/Installation.
10. INSTALL FRONT SEAT ASSEMBLY RH (for Manual Seat)
HINT Use the same procedures described for the LH side.
Page 6986
Page 6732
(2) CONNECTORS
Slightly shake the connector vertically and horizontally.
(3) WIRE HARNESS
Slightly shake the wire harness vertically and horizontally.
HINT The connector joint and fulcrum of the vibration are the major areas that should be checked
thoroughly.
(b) HEAT METHOD:
When a malfunction seems to occur when the area in question is heated.
(1) Heat the component that is the possible cause of the malfunction with a hair dryer or similar
device. Check if the malfunction occurs.
NOTICE: *
Do not heat to more than 60°C (140°F). Exceeding this temperature may damage components.
* Do not apply heat directly to the parts in the ECU.
(c) WATER SPRINKLING METHOD:
When a malfunction seems to occur on a rainy day or in high-humidity.
(1) Sprinkle water onto the vehicle and check if the malfunction occurs.
NOTICE: *
Never sprinkle water directly into the engine compartment. Indirectly change the temperature and
humidity by spraying water onto the front of the radiator.
* Never apply water directly onto the electronic components.
HINT If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU
or connections. Look for evidence of corrosion or short circuits. Proceed with caution during water
tests.
(d) HIGH ELECTRICAL LOAD METHOD:
When a malfunction seems to occur when the electrical load is excessive.
(1) Turn on the heater blower, headlights, rear window defogger and all other electrical loads.
Check if the malfunction reoccurs.
5. DIAGNOSTIC TROUBLE CODE CHART
Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate
section's Diagnostic Trouble Code Chart. Use the chart to determine the trouble area and the
proper inspection procedure. A description of each of the chart's columns is below.
Locations
Power Distribution Relay: Locations
Instrument Panel (Floor Shift)
Instrument Panel (Column Shift)
Page 6944
Junction Connector (CAN No.2) - Lower Finish Panel
Page 2451
Intake Manifold: Description and Operation
1UR-FE INTAKE: INTAKE SYSTEM: SYSTEM DIAGRAM
Page 6120
(c) Remove the starter pinion drive lever.
(d) Remove the starter center bearing clutch from the starter yoke.
3. REMOVE STARTER BRUSH HOLDER ASSEMBLY
(a) Remove the 2 screws and end frame.
NOTICE: While holding down the lead wire, remove the starter commutator end frame.
(b) Disconnect the 4 brushes from the starter brush holder.
(1) Using a screwdriver, hold back the brush holder.
(2) Disconnect the brush from the brush holder.
(c) Remove the brush holder.
4. REMOVE STARTER YOKE ASSEMBLY
(a) Remove the starter yoke from the starter armature.
5. REMOVE STARTER ARMATURE PLATE
(a) Remove the starter armature plate from the starter center bearing clutch.
Page 9391
shake is a normal and unavoidable condition in certain situations with this type of vehicle. Please
use the chart below to show customers the comparison to competitors. Also, show the vehicle
driver that reducing speed by as little as 5 mph has a considerable positive effect in reducing body
vibration.
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for
36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Parts Information
Repair Procedure
1. Test drive the vehicle and confirm the condition.
Repeat remaining steps for both No.3 cab mounts.
2. Loosen the No.2 cab mount nuts (at front of cab) down to the last thread on the long bolt. This is
necessary to allow the cab to be raised to remove
the No.3 mount.
Page 8077
Impact Sensor: Service and Repair Side Airbag Sensor (for CrewMax)
Components
SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for CrewMax):
COMPONENTS
Page 8920
Page 8269
Removal
SEAT BELT: REAR SEAT INNER BELT ASSEMBLY (for CrewMax): REMOVAL
1. REMOVE REAR SEAT ASSEMBLY RH See: Body and Frame/Seats/Service and
Repair/Removal and Replacement/Rear Seat Assembly (for
Crewmax RH Side)/Removal
2. REMOVE REAR NO. 1 SEAT INNER BELT ASSEMBLY RH
Air Conditioning System (for Automatic Air Conditioning
System)
Compressor Clutch Relay: Locations Air Conditioning System (for Automatic Air Conditioning
System)
AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Automatic Air Conditioning System):
PARTS LOCATION
Page 2336
This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown.
Page 9064
Establish conditions in which voltage is present at the check point.
Example:
- [A] - Ignition SW on
- [B] - Ignition SW and SW1 on
- [C] - Ignition SW, SW1 and Relay on (SW2 off)
Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or component terminal.
This check can be done with a test light instead of a voltmeter.
Electronic Circuit Inspection Procedure
Page 1478
"Case2" Open the secondary locking device.
[B] For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray
Gray or White : Black
Page 1229
Throttle Position Sensor: Diagrams
Page 3621
with SST - Torque : 40 Nm (408 kgf-cm, 30 ft-lbf)
HINT *
Use a torque wrench with a fulcrum length of 30 cm (11.8 in.). When using a torque wrench with a
fulcrum length that is not 30 cm (11.8 in.), calculate the torque specification for the torque wrench
and SST based on the "without SST" torque specification See: Service Precautions
* Make sure SST and the wrench are connected in a straight line.
4. INSTALL PROPELLER SHAFT HEAT INSULATOR (for 4WD) See: Transmission and
Drivetrain/Drive/Propeller Shafts, Bearings and
Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Front Propeller Shaft
Assembly/Installation
5. INSTALL FRONT EXHAUST PIPE ASSEMBLY
(a) Install a new gasket and the front exhaust pipe to the exhaust manifold RH with 3 new nuts.
Torque : 54 Nm (554 kgf-cm, 40 ft-lbf)
(b) Connect the air fuel ratio sensor connector.
(c) Connect the heated oxygen sensor connector and 2 clamps.
6. INSTALL CENTER EXHAUST PIPE ASSEMBLY See: Engine, Cooling and Exhaust/Exhaust
System/Exhaust Pipe/Service and
Repair/Exhaust Pipe (for Regular Cab Standard Deck)/Installation
7. INSTALL TAILPIPE ASSEMBLY See: Engine, Cooling and Exhaust/Exhaust System/Exhaust
Pipe/Service and Repair/Exhaust Pipe (for
Regular Cab Standard Deck)/Installation
8. INSPECT FOR EXHAUST GAS LEAK See: Engine, Cooling and Exhaust/Exhaust
System/Exhaust Manifold/Service and Repair/Installation
Page 3415
Information Bus: Reading and Clearing Diagnostic Trouble Codes
MULTIPLEX COMMUNICATION: LIN COMMUNICATION SYSTEM: DTC CHECK / CLEAR
HINT Refer to the Techstream operator's manual for further details.
1. CHECK DTC
(a) Connect the Techstream to the DLC3.
(b) Turn the ignition switch ON.
(c) Turn the Techstream on.
(d) Enter the following menus: Body Electrical / Main Body / Trouble Codes.
(e) Read the DTCs.
2. CLEAR DTC
(a) Connect the Techstream to the DLC3.
(b) Turn the ignition switch ON.
(c) Turn the Techstream on.
(d) Enter the following menus: Body Electrical / Main Body / Trouble Codes.
(e) Clear the DTCs.
Page 8658
Page 962
Solar Sensor: Service and Repair Removal
AIR CONDITIONING: SOLAR SENSOR (for Automatic Air Conditioning System): REMOVAL
1. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY
(a) for Column Shift Type:
Remove the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Column Shift Type)/Removal.
(b) for Floor Shift Type:
Remove the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Floor Shift Type)/Removal.
2. REMOVE AUTOMATIC LIGHT CONTROL SENSOR (SOLAR SENSOR)
(a) Detach the 2 claws.
(b) Disconnect the connector and remove the sensor.
Page 91
(h) If the result is not as specified, the seat heater control may have a malfunction.
Engine - Controls - Non-Linear Acceleration From A Stop
Engine Control Module: Customer Interest Engine - Controls - Non-Linear Acceleration From A
Stop
T-SB-0273-10
September 28, 2010
Non-Linear Acceleration from a Stop
Service Category Engine/Hybrid System
Section Engine Control
Market USA
Applicability
Introduction
Some 2010 model year Tundra vehicles with the 1UR-FE (4.6 L) engine may exhibit non-linear
acceleration from a stop under certain conditions of low engine rpm with high engine load. The
Engine Control Module/ECM (SAE term: Powertrain Control Module/PCM) logic has been revised
to address this condition. Use the following repair procedure to recalibrate the ECM (PCM).
Calibration Information
Warranty Information
Applicable Warranty
^ This repair is covered under the Toyota Federal Emission Warranty. This warranty is in effect for
96 months or 80,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Page 8010
Air Bag Control Module: Testing and Inspection Center Airbag Sensor Assembly (for Floor Shift
Type)
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift
Type): ON-VEHICLE INSPECTION
1. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION)
(a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnosis System.
2. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND
AIRBAG HAS NOT DEPLOYED)
(a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnosis System.
3. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND
AIRBAG IS DEPLOYED)
(a) Replace the center airbag sensor.
CAUTION: For removal and installation procedures of the center airbag sensor, be sure to follow
the correct procedure.
HINT The center airbag sensor should be replaced after any of the airbags has deployed, as it has
been subjected to the impact.
Recall 09V388000: Floor Mat/Accelerator Interference
Accelerator Pedal: Recalls Recall 09V388000: Floor Mat/Accelerator Interference
VEHICLE MAKE/MODEL: MODEL YEAR(S): Lexus/ES350 2007-2010 Lexus/IS 2006-2010
Toyota/Avalon 2005-2010 Toyota/Camry 2007-2010 Toyota/Prius 2004-2009 Toyota/Tacoma
2005-2010 Toyota/Tundra 2007-2010 MANUFACTURER: Toyota Motor Corporation
MFR'S REPORT DATE: October 05, 2009
NHTSA CAMPAIGN ID NUMBER: 09V388000
NHTSA Action Number: N/A COMPONENT: Vehicle Speed Control: Accelerator Pedal
POTENTIAL NUMBER OF UNITS AFFECTED: 3800000
SUMMARY: Toyota is recalling certain model year 2004-2010 passenger vehicles. The accelerator
pedal can get stuck in the wide open position due to its being trapped by an unsecured or
incompatible driver's floor mat.
CONSEQUENCE: A stuck open accelerator pedal may result in very high vehicle speeds and
make it difficult to stop the vehicle, which could cause a crash, serious injury or death.
REMEDY: Toyota will notify owners of affected vehicles to remove any driver's floor mat and not
replace it with any other floor mat pending the development of model-specific remedies. Toyota will
mail a second notification to owners of affected vehicles notifying them of the free remedies when
they are available. The first notice is expected to be mailed during October 2009 and Toyota will
advise NHTSA of the estimated date when the remedies will be available. Owners may contact
Toyota at 1-800-331-4331, Lexus at 1-800-255-3987.
NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle
Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov.
Page 4015
Air Injection Control Valve: Service and Repair Air Switching Valve (for Bank 2)
Components
1UR-FE EMISSION CONTROL: AIR SWITCHING VALVE (for Bank 2): COMPONENTS
Removal
Components
Power Mirror Switch: Service and Repair Components
MIRROR: OUTER MIRROR SWITCH: COMPONENTS
Page 7047
(b) * for 5 leaf spring
* If the toe-in is not as specified, adjust it at the rack ends.
4. ADJUST TOE-IN
(a) Release the rack boot set clips.
(b) Loosen the tie rod end lock nuts.
(c) Turn the right and left rack ends by an equal amount to adjust the toe-in to the center value.
(d) Check that the length of the right and left rack ends are approximately the same.
Page 3976
Required Tools & Equipment
Repair Procedure
1. Using TIS Techstream check if DTC P0418, P0419, P2440, P2441, P2442, P2443, P2446
and/or P2447 are present.
2. Using Techstream perform the manual Air Injection Test (options 1 and 2) to verify if the signal
from the air injection control driver is reaching the
air pumps.
^ The pumps should be heard turning on at this point and there should be battery voltage on pin 2
of the pumps during this test.
^ If there is NO voltage refer to the Repair Manual for air injection control driver diagnosis.
Refer to the Technical Information System (TIS) 2010 model year Tundra Repair Manual:
3. If during the test voltage is present at the pump and the pump is NOT running or the Air
Pressure (gauge) value did NOT increase from 0 to 1 psi on
TIS Techstream with the pump running remove the air pump assemblies for inspection.
Refer to TIS 2010 model year Tundra Repair Manual:
4. With the pumps removed from the vehicle verify if there is liquid or evidence that liquid entered
the pumps.
^ YES - If there is liquid evidence go to step 5.
^ NO - If there is NO evidence of liquid go to step 7.
5. If liquid is present replace the affected pump assembly.
Refer to TIS 2010 model year Tundra Repair Manual:
Page 3359
Locations
Relay Box: Locations
Engine Compartment
Page 2309
HINT The crankshaft timing gear and camshaft exhaust gear will be installed with the No. 1 and
No. 2 chains connected to the gears.
(d) Install the crankshaft timing sprocket to the crankshaft.
(e) Align and attach the knock pin of the No. 3 camshaft with the pin hole of the camshaft timing
gear.
(f) Using the hexagonal portion of the No. 4 camshaft, align and attach the knock pin of the No. 4
camshaft with the pin hole of the camshaft
timing exhaust gear.
NOTICE: Because the gears' timing mark positions may shift due to looseness of the No. 1 chain,
use the hexagonal portion of the camshaft to hold the No. 3 camshaft in place until the No. 1 chain
tensioner is installed.
(g) Remove the pin from the No. 2 chain tensioner.
5. INSTALL NO. 1 CHAIN TENSIONER SLIPPER LH
HINT If you cannot install the chain tensioner slipper due to the tension of the chain, use the
hexagonal portion of the camshaft to loosen the chain and install the chain tensioner.
6. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY LH
(a) Move the stopper plate upward to release the lock, and push the plunger deep into the
tensioner.
(b) Move the stopper plate downward to set the lock, and insert a hexagon wrench into the hole of
the stopper plate.
(c) Install a new gasket and the chain tensioner with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
7. INSTALL NO. 1 CHAIN VIBRATION DAMPER LH
(a) Install the vibration damper with the 2 bolts.
Page 6685
Driver Side J/B - Cowl Side Left
Page 8752
2. Install ChaSSiSEAR(TM) on the vehicle and attempt to isolate the source of the noise. Is the
noise loudest near the rear wheel bearing assembly?
^ YES - Go to step 3.
^ NO - This TSB does NOT apply. Continue diagnosis to isolate the source of the noise.
3. Replace the rear wheel bearing caliper bracket and related parts.
Refer to the Technical Information System (TIS) applicable model year Repair Manual:
4. Test drive the vehicle and confirm the noise is eliminated.
5. Re-check rear differential oil level and confirm NO leaks are present.
Page 6328
Multiple Junction Connector: Locations Wire and Wire In Seat [Bench Seat]
JT1
JT1
Page 194
(1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be
checked by conducting a voltage check.
With each connector still connected, measure the voltage between the body ground and these
terminals (in this order): 1) terminal 1 of connector A; 2) terminal 1 of connector B; and 3) terminal
1 of connector C.
Standard voltage (Fig. 4):
* If the results match the examples above, an open circuit exists in the wire harness between
terminal 1 of connector B and terminal 1 of connector C.
3. CHECK FOR SHORT CIRCUIT
(a) If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance
check with the body ground (below).
(b) Check the resistance with the body ground.
(1) Disconnect connectors A and C and measure the resistance.
Standard resistance (Fig. 6):
HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally.
If your results match the examples above, a short circuit exists between terminal 1 of connector A
and terminal 1 of connector C.
Locations
Temperature Sensor/Switch: Locations
JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION
Page 8380
Page 6923
(1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be
checked by conducting a voltage check.
With each connector still connected, measure the voltage between the body ground and these
terminals (in this order): 1) terminal 1 of connector A; 2) terminal 1 of connector B; and 3) terminal
1 of connector C.
Standard voltage (Fig. 4):
* If the results match the examples above, an open circuit exists in the wire harness between
terminal 1 of connector B and terminal 1 of connector C.
3. CHECK FOR SHORT CIRCUIT
(a) If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance
check with the body ground (below).
(b) Check the resistance with the body ground.
(1) Disconnect connectors A and C and measure the resistance.
Standard resistance (Fig. 6):
HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally.
If your results match the examples above, a short circuit exists between terminal 1 of connector A
and terminal 1 of connector C.
Page 2767
load while reprogramming.
^ Confirm the hood is open and ensure under hood temperature does NOT exceed 158°F (70°C).
^ Confirm cable connections between the vehicle and Techstream are secure.
^ Do NOT disconnect or turn off Techstream or vehicle ignition during reprogramming.
^ Set parking brake.
^ Complete ALL flash calibration updates provided for each ECU.
^ If the battery's state of charge or capacity are in question, test with SST. No. 00002-8150-KIT
"Digital Battery Analyze," and follow TSB No. PG001-06, "Battery Maintenance for In-Stock
Vehicles & Pre-Delivery" or the appropriate "Maintenance for HV & Auxiliary Batteries" service
bulletin.
^ The GR8 Battery Diagnostic Station MUST be used in Power Supply Mode to maintain battery
voltage at 13.5 volts while flash reprogramming the vehicle. For details on how to use the GR8
Battery Diagnostic Station, refer to the GR8 Instruction Manual located on TIS, Diagnostics - Tools
& Equipment - Battery Diagnostics.
3C. Click Next to start the calibration update process.
D. When using TIS Techstream select Techstream VIM as the desired programming device. Then
click Next.
Component Tests and General Diagnostics
Engine Control Module: Component Tests and General Diagnostics
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: ECM Power Source Circuit - ECM Power
Source Circuit
DESCRIPTION
When the ignition switch is turned to ON, the battery voltage is applied to the IGSW terminal of the
ECM. The output signal from the MREL terminal of the ECM causes a current to flow to the coil,
closing the contacts of the integration relay (EFI relay) and supplying power to terminals +B and
+B2 of the ECM.
WIRING DIAGRAM
INSPECTION PROCEDURE
PROCEDURE
1. INSPECT FUSES (AM2, IG2 MAIN, EFI NO. 1, IGN)
Page 7351
2. INSTALL TUBE
(a) Install the tube to the bush.
3. TEMPORARILY INSTALL REAR SPRING ASSEMBLY LH
(a) Temporarily install the spring with the No. 2 spring shackle plate, shackle outer plate, 2 washers
and 2 nuts to the rear side.
(b) Temporarily install the spring with the bolt, washer and nut to the front side.
4. INSTALL REAR SPRING BUMPER SUB-ASSEMBLY
(a) Install the spring bumper.
NOTICE: Align the leaf spring center bolt and nut with the installation hole of the rear axle housing
and spring bumper so that they are not loose.
5. TEMPORARILY INSTALL REAR SPRING U BOLT
Drivetrain - Front Driveshaft Ticking Noise In 4WD
Drive/Propeller Shaft: Customer Interest Drivetrain - Front Driveshaft Ticking Noise In 4WD
T-SB-0045-10
January 27, 2010
Front Propeller Shaft Parts Label Delaminating - Ticking Noise
Service Category Drivetrain
Section Drive Shaft/Propeller Shaft
Market USA
Applicability
Introduction
Some 2008 - 2010 model year 4WD Sequoia and 2007 - 2010 model year 4WD Tundra vehicles
may have a ticking noise present only when in 4WD. Production changes have been made to
correct this condition. Follow the procedure in this bulletin to address this condition.
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60
months or 60,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Repair Procedure
1. Confirm there is a ticking noise only present in 4WD.
Page 2384
Assenmacher Specialty Tools 1-800-525-2943
Page 7939
(b) Read the precaution See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
(c) Disconnect the cable from the negative (-) battery terminal.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
(d) Remove the roof headlining (for Double Cab) See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining
(For Double Cab)/Removal.
(e) Remove the roof headlining (for Regular Cab) See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof
Headlining (For Regular Cab)/Removal.
(f) Install SST.
(1) Disconnect the connector from the curtain shield airbag.
NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness.
(2) After connecting SST each other, connect them to the curtain shield airbag.
SST : 09082-00700
SST : 09082-00802
09082-10801
09082-40800
NOTICE: To avoid damaging SST connector and wire harness, do not lock the secondary lock of
the twin lock.
(3) Move SST at least 10 m (32.8 ft.) away from the vehicle rear side window.
(4) Maintaining enough clearance for SST wire harness in the rear side window, close all doors and
windows of the vehicle.
Page 2462
Intake Manifold: Service and Repair Installation
1UR-FE INTAKE: INTAKE MANIFOLD: INSTALLATION
1. INSTALL THROTTLE BODY ASSEMBLY
(a) Align the protrusion of a new gasket with the groove of the intake manifold, and install the
gasket.
(b) Install the throttle body with the 4 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
2. INSTALL MANIFOLD ABSOLUTE PRESSURE SENSOR See: Powertrain
Management/Computers and Control Systems/Manifold
Pressure/Vacuum Sensor/Service and Repair/Installation
3. INSTALL UNION TO CONNECTOR TUBE HOSE ASSEMBLY
(a) Install the union to connector tube hose to the intake manifold.
(b) Install the 2 bolts and attach the hose clamp.
Torque : 8.2 Nm (84 kgf-cm, 73 in-lbf)
(c) Install the 2 wire harness brackets with the 2 bolts.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
4. INSTALL PURGE VSV
(a) Connect the purge line hose to the intake manifold.
(b) Install the purge VSV to the intake manifold with the bolt.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
5. INSTALL VACUUM SWITCHING VALVE ASSEMBLY (for ACIS)
(a) Install the vacuum switching valve to the intake manifold with the bolt.
Page 8199
(a) Remove the rear seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Rear Seat Assembly (for Double
Cab)/Removal.
2. REMOVE CHILD RESTRAINT SEAT TETHER ANCHOR BRACKET
(a) Remove the 3 bolts and 3 anchor brackets.
Installation
SEAT BELT: CHILD RESTRAINT SEAT ANCHOR BRACKET (for Double Cab): INSTALLATION
1. INSTALL CHILD RESTRAINT SEAT TETHER ANCHOR BRACKET
(a) Align the holes with the positioning pins and install the 3 anchor brackets with the 3 bolts.
Torque : 42 Nm (428 kgf-cm, 31 ft-lbf)
2. INSTALL REAR SEAT ASSEMBLY
(a) Install the rear seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Rear Seat Assembly (for Double
Cab)/Installation.
Page 2284
Page 9268
(a) Using a screwdriver, detach the cable from the clamps shown in the illustration.
HINT Tape the screwdriver tip before use.
(b) Pull the cable from the engine room and remove it.
Page 3705
C. Choose desired ECU group(s) in the Health Check dialog box.
D. Click Next.
E. Click Continue to view Health Check results.
F. Available calibration updates are indicated by a link in the Cal. Update? column. Click the link to
access the appropriate service bulletin on TIS.
NOTE
^ Note any DTCs stored in Systems that will be flash reprogrammed.
^ Clicking the link will automatically launch TIS and perform a calibration search.
G. Log in to TIS. (If already logged in skip this step.)
H. To review the TSB and access the calibration file click the service bulletin link in the Document
Title column of the Calibration Search Result
portlet.
Page 1316
Push the terminal retainer down to the temporary lock position.
Page 4427
Fuel Pump Control Unit: Service and Repair Installation
1UR-FE FUEL: FUEL PUMP ECU: INSTALLATION
1. INSTALL FUEL PUMP ECU
(a) Install the fuel pump ECU with the 2 bolts.
Torque : 20 Nm (199 kgf-cm, 14 ft-lbf)
NOTICE: Do not use the fuel pump ECU if it has been subjected to physical shocks such as being
dropped, etc.
(b) Connect the 2 fuel pump ECU connectors.
Page 3111
Knock Sensor: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: INSTALLATION
1. INSTALL KNOCK SENSOR
(a) Install the 4 sensors with the 4 bolts so that the sensors are angled as shown in the illustration.
Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)
NOTICE: The acceptable installation angle of the sensor is between 10° upward and downward
from the horizontal position.
(b) Connect the 4 sensor connectors.
2. INSTALL SEPARATOR CASE
(a) Install the separator case with the 4 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
3. INSTALL INTAKE MANIFOLD
(a) Install the intake manifold See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service
and Repair/Installation.
Page 2802
Then click Next.
F. Verify correct current calibration and new calibration information. Then click Next.
NOTE
^ The total number of calibration IDs in the calibration file corresponds to the number of
reprogrammable processors in the ECU.
^ Each calibration file may contain up to three separate calibrations.
Page 1565
Tire Pressure Warning Reset Switch: Service and Repair Installation
TIRE AND WHEEL: TIRE PRESSURE WARNING RESET SWITCH: INSTALLATION
1. INSTALL TIRE PRESSURE WARNING RESET SWITCH
(a) Attach the 2 claws to install the reset switch.
(b) Connect the switch connector.
2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Installation
3. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
4. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Installation
5. INSTALL FRONT DOOR SCUFF PLATE LH (for Double Cab, for CrewMax) See: Body and
Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation
6. INSTALL FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Installation
Page 1177
Page 8301
Page 3183
Air Flow Meter/Sensor: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: INSTALLATION
1. INSTALL MASS AIR FLOW METER
(a) Install the MAF meter with the 2 screws.
Torque : 1.7 Nm (17 kgf-cm, 15 in-lbf)
(b) Connect the MAF connector.
Transmission Control Switch
Transmission Mode Switch: Diagrams Transmission Control Switch
Page 674
Power Door Lock Switch: Service and Repair Door Control Switch (for Front RH)
Components
DOOR LOCK: DOOR CONTROL SWITCH (for Front RH): COMPONENTS
Removal
DOOR LOCK: DOOR CONTROL SWITCH (for Front RH): REMOVAL
1. REMOVE FRONT ARMREST UPPER BASE PANEL RH
Up to 11/2009
Yaw Rate Sensor: Locations Up to 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 6141
Page 3736
HINT The wavelength becomes shorter as the engine rpm increases.
(n) WAVEFORM 13:
HINT The waveform varies depending on the CAN communication signal.
(o) WAVEFORM 14:
HINT The waveform varies depending on the CAN communication signal.
(p) WAVEFORM 15:
HINT The wavelength becomes shorter as the engine rpm increases.
Differential Carrier Oil Seal
Seals and Gaskets: Service and Repair Differential Carrier Oil Seal
Components
DIFFERENTIAL: DIFFERENTIAL CARRIER OIL SEAL (for 1GR-FE, 1UR-FE): COMPONENTS
Replacement
DIFFERENTIAL: DIFFERENTIAL CARRIER OIL SEAL (for 1GR-FE, 1UR-FE): REPLACEMENT
1. DRAIN DIFFERENTIAL OIL See: Fluid - Differential/Service and Repair
Page 8279
3. REMOVE BACK PANEL TRIM LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for
CrewMax)/Removal
4. REMOVE REAR DOOR SCUFF PLATE See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Removal
5. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP
(a) Partially remove the front door opening trim weatherstrip so that the lower quarter trim panel
and front quarter trim panel can be removed.
6. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY
(a) Detach the 2 claws and remove the cover.
(b) Remove the bolt and seat belt anchor.
(c) for LH Side:
Detach the 4 clips and remove the lower quarter trim panel.
Components
Integrated Accessory Switch Assembly: Service and Repair Components
METER: DRIVE MONITOR SWITCH: COMPONENTS
Page 6302
Engine Room R/B And Engine Room J/B Inner Circuit
Locations
Accessory Relay: Locations
Instrument Panel (Floor Shift)
Instrument Panel (Column Shift)
Page 7767
Housing Assembly HVAC: Overhaul
Disassembly
AIR CONDITIONING: AIR CONDITIONING UNIT: DISASSEMBLY
1. REMOVE LOWER DEFROSTER NOZZLE ASSEMBLY
(a) Detach the 4 claws and remove the nozzle.
2. REMOVE NO. 3 AIR DUCT SUB-ASSEMBLY
(a) Detach the 4 claws and remove the duct.
3. REMOVE AIR FILTER COVER PLATE
(a) Detach the 2 clips and remove the plate.
4. REMOVE CLEAN AIR FILTER
Page 5882
Steering Angle Sensor: Programming and Relearning
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: CALIBRATION
PERFORM INITIALIZATION OF STEERING ANGLE SENSOR
NOTICE: Complete the adjustment of the steering wheel and wheel alignment, and then initialize
the steering angle sensor. If the order is reversed, the steering wheel and wheel alignment will
become misaligned.
(a) Check that the steering wheel is in the centered position.
(b) Disconnect the negative battery terminal for more than 2 seconds.
NOTICE: After the ignition switch is turned OFF, the navigation system requires approximately 90
seconds to record various types of memory and settings. As a result, after turning the ignition
switch OFF, wait 90 seconds or more before disconnecting the cable from the negative (-) battery
terminal.
(c) Reconnect the negative battery terminal.
Drivetrian - Rear End Howling/Growling Noises
Wheel Bearing: All Technical Service Bulletins Drivetrian - Rear End Howling/Growling Noises
T-SB-0151-10
June11, 2010
Rear Axle Bearing Abnormal Noise
Service Category Drivetrain
Section Axle/Differential
Market USA
Applicability
Introduction
Some 2007 - 2010 model year Tundra vehicles may exhibit a howling or growling noise from the
rear of the vehicle that increases with vehicle speed. Changes have been made to the rear axle
bearing to correct this condition. Follow the procedure in the bulletin to address customer concerns.
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60
months or 60,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Parts Information
Page 1655
(b) Attach the 2 clips and 5 claws to install the rear upper door armrest base panel.
Components
Tire Pressure Monitor Receiver / Transponder: Service and Repair Components
TIRE AND WHEEL: TIRE PRESSURE WARNING RECEIVER: COMPONENTS
Page 5188
Air Conditioning System (for Automatic Air Conditioning
System)
Evaporator Temperature Sensor / Switch: Locations Air Conditioning System (for Automatic Air
Conditioning System)
AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Automatic Air Conditioning System):
PARTS LOCATION
Page 7288
(h) Using a screwdriver, remove the 4 control valve rings.
NOTICE: Be careful not to damage the grooves for the control valve rings.
11. REMOVE POWER STEERING CONTROL VALVE UPPER OIL SEAL
(a) Using SST and a press, remove the control valve upper bearing and control valve upper oil seal
from the control valve housing.
SST : 09950-60010
09951-00250
SST : 09950-70010
09951-07150
12. REMOVE CYLINDER END STOPPER
(a) Using a screwdriver and hammer, turn the cylinder end stopper clockwise until the wire end can
be seen through the service hole.
(b) Using a screwdriver and hammer, turn the cylinder end stopper counterclockwise, and remove
the wire and cylinder end stopper.
13. REMOVE POWER STEERING RACK
14. REMOVE POWER STEERING RACK BUSH
(a) Remove the rack bush from the power steering rack.
(b) Using a screwdriver, remove the O-ring from the rack bush.
(c) Using SST, remove the rack bush oil seal.
SST : 09527-21011
SST : 09612-24014
Page 6381
Components
Canister Purge Control Valve: Service and Repair Components
1UR-FE EMISSION CONTROL: PURGE VALVE: COMPONENTS
Page 1718
Standard steering axis inclination (unloaded vehicle):
for Double Cab of Long Deck
Page 3230
"Case2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
A/C Amplifier, A/C Blower Assembly
Control Module HVAC: Diagrams A/C Amplifier, A/C Blower Assembly
Page 2461
14. REMOVE UNION TO CONNECTOR TUBE HOSE ASSEMBLY
(a) Remove the 2 bolts and detach the hose clamp.
(b) Remove the union to connector tube hose from the intake manifold.
(c) Remove the 2 bolts and 2 wire harness brackets.
15. REMOVE MANIFOLD ABSOLUTE PRESSURE SENSOR See: Powertrain
Management/Computers and Control Systems/Manifold
Pressure/Vacuum Sensor/Service and Repair/Removal
16. REMOVE THROTTLE BODY ASSEMBLY
(a) Remove the 4 bolts, throttle body and gasket.
Page 3247
(2) CONNECTORS
Slightly shake the connector vertically and horizontally.
(3) WIRE HARNESS
Slightly shake the wire harness vertically and horizontally.
HINT The connector joint and fulcrum of the vibration are the major areas that should be checked
thoroughly.
(b) HEAT METHOD:
When a malfunction seems to occur when the area in question is heated.
(1) Heat the component that is the possible cause of the malfunction with a hair dryer or similar
device. Check if the malfunction occurs.
NOTICE: *
Do not heat to more than 60°C (140°F). Exceeding this temperature may damage components.
* Do not apply heat directly to the parts in the ECU.
(c) WATER SPRINKLING METHOD:
When a malfunction seems to occur on a rainy day or in high-humidity.
(1) Sprinkle water onto the vehicle and check if the malfunction occurs.
NOTICE: *
Never sprinkle water directly into the engine compartment. Indirectly change the temperature and
humidity by spraying water onto the front of the radiator.
* Never apply water directly onto the electronic components.
HINT If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU
or connections. Look for evidence of corrosion or short circuits. Proceed with caution during water
tests.
(d) HIGH ELECTRICAL LOAD METHOD:
When a malfunction seems to occur when the electrical load is excessive.
(1) Turn on the heater blower, headlights, rear window defogger and all other electrical loads.
Check if the malfunction reoccurs.
5. DIAGNOSTIC TROUBLE CODE CHART
Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate
section's Diagnostic Trouble Code Chart. Use the chart to determine the trouble area and the
proper inspection procedure. A description of each of the chart's columns is below.
Components
Hazard Warning Switch: Service and Repair Components
LIGHTING: HAZARD WARNING SWITCH: COMPONENTS
Page 1426
Door/Service and Repair/Front Door (for Regular Cab)/Disassembly
4. REMOVE FRONT DOOR WINDOW REGULATOR HANDLE ASSEMBLY (for Front Side) See:
Body and Frame/Doors, Hood and
Trunk/Doors/Front Door/Service and Repair/Front Door (for Regular Cab)/Disassembly
5. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH (for Front Side) See: Body
and Frame/Doors, Hood and
Trunk/Doors/Front Door/Service and Repair/Front Door (for Regular Cab)/Disassembly
6. REMOVE COURTESY LIGHT ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood
and Trunk/Doors/Front Door/Service and
Repair/Front Door (for Regular Cab)/Disassembly
7. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Regular Cab)/Disassembly
8. REMOVE FRONT SIDE AIRBAG SENSOR
(a) Disconnect the connector.
(b) Remove the screw and side airbag sensor.
9. REMOVE FRONT DOOR SCUFF PLATE LH (for Rear Side) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Removal
10. REMOVE REAR SIDE AIRBAG SENSOR
(a) Remove the bolt and side airbag sensor from the body.
(b) Disconnect the connector.
Installation
SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Regular Cab):
INSTALLATION
1. INSTALL FRONT SIDE AIRBAG SENSOR
(a) Check that the ignition switch is OFF.
Page 6595
"Case2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 4276
^ Power Supply Mode is used to maintain battery voltage at 13.5 volts while flash reprogramming
the vehicle.
^ For details on how to use the GR8 Battery Diagnostic Station, refer to the located on TIS,
Diagnostics - Tools & Equipment - Battery Diagnostics.
3. Click the appropriate calibration ID and reprogram the vehicle's ECU with Techstream.
A. After reviewing the procedures outlined in the selected TSB, click the appropriate calibration ID
link by matching the vehicle's current
calibration ID to the Previous Calibration ID in the Calibration Identification Chart.
NOTE
^ Calibration files are embedded as live links in the service bulletin.
^ Some vehicles require special preparation - please review the selected TSB carefully.
B. Click Open to load calibration file information.
Techstream pulls calibration files as needed to ensure the latest calibration file is used. Do NOT
save calibrations locally on the hard drive or other media.
NOTICE
Errors during the flash reprogramming process can permanently damage the vehicle ECU.
Minimize the risk by following the steps below.
^ Battery voltage MUST NOT FALL BELOW 11.4 volts during reprogramming. Confirm battery
voltage is higher than 11.4 volts, but be sure voltage DOES NOT RISE ABOVE 16.0 volts during
reprogramming.
^ Turn OFF all vehicle accessories (e.g. audio system, A/C, interior lights, DRL, etc.). Do NOT add
to or significantly change the vehicle's electrical
Page 5064
(b) Using snap ring pliers, install a new snap ring.
4. INSTALL DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL
(a) Using SST and a plastic-faced hammer, tap in a new oil seal.
SST : 09608-32010
Standard oil seal depth:
4.8 to 5.8 mm (0.189 to 0.228 in.)
(b) Coat the lip of the oil seal with MP grease.
5. INSTALL DIFFERENTIAL CLUTCH HUB
(a) Install the clutch hub onto the side gear inter shaft.
(b) Using snap ring pliers, install a new snap ring.
NOTICE: Be sure to install the differential clutch hub in the correct direction.
6. INSTALL FRONT DIFFERENTIAL SIDE GEAR NEEDLE ROLLER BEARING
(a) Using SST and a press, press in 2 new bearings.
Page 8073
(e) Connect the holder (with connectors).
(f) Check that the waterproof sheet is properly set.
2. INSTALL FRONT CONSOLE BOX See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal
and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation
3. INSTALL REAR CONSOLE BOX ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation
4. INSTALL CONSOLE BOX CARPET
5. INSTALL REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
6. INSTALL UPPER CONSOLE REAR PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
7. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding
/ Trim/Dashboard / Instrument Panel/Service
and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
8. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation
9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
10. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
Components
Engine Oil: Service and Repair Components
1UR-FE LUBRICATION: OIL AND OIL FILTER: COMPONENTS
Page 5043
HINT First fit a washer with the same thickness as the removed washer, and then check the tooth
contact pattern. Replace the washer with one of a different thickness if necessary.
(b) Using SST and a press, press in the rear bearing (inner race).
SST : 09506-35010
10. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD
(a) Install the drive pinion, front bearing (inner race) and oil slinger.
HINT Assemble the spacer and oil seal after adjusting the gear contact pattern.
(b) Using SST, install the companion flange.
SST : 09950-30012
09951-03010
09953-03010
09954-03010
09956-03050
SST : 09955-03050
(c) Using SST to hold the companion flange.
Page 6491
Engine Room R/B, J/B - Engine Compartment Left
Components
Ignition Switch: Service and Repair Components
1UR-FE STARTING: IGNITION SWITCH: COMPONENTS
Specifications
Fuel Pressure: Specifications
FUEL PRESSURE
Page 8982
(a) Connect the connector.
(b) Attach the 4 clips to install the panel.
3. INSTALL CENTER LOWER INSTRUMENT PANEL FINISH PANEL See: Body and
Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
4. INSTALL REAR UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
5. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding
/ Trim/Dashboard / Instrument Panel/Service
and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
6. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation
7. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
8. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Floor Shift Type)/Installation
9. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation
10. INSTALL COWL SIDE TRIM BOARD LH
(a) for Regular Cab:
Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular Cab)/Installation.
(b) for Double Cab:
Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Installation.
(c) for CrewMax:
Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for CrewMax)/Installation.
Locations
Data Link Connector: Locations
CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: PARTS LOCATION
Page 3329
HINT The wavelength becomes shorter as the engine rpm increases.
(f) WAVEFORM 5:
HINT *
The wavelength becomes shorter as the engine rpm increases.
* The waveforms and amplitudes displayed differ slightly depending on the vehicle.
(g) WAVEFORM 6:
HINT The wavelength becomes shorter as engine rpm increases.
(h) WAVEFORM 7:
Page 6200
(a) Disconnect the connector.
(b) Using a screwdriver, detach the 5 claws and remove the console box bezel.
HINT Tape the screwdriver tip before use.
3. REMOVE POWER OUTLET SOCKET ASSEMBLY
(a) Using a screwdriver, detach the claw and remove the power outlet socket.
HINT Tape the screwdriver tip before use.
4. REMOVE POWER OUTLET SOCKET COVER
(a) Detach the 2 claws and remove the power outlet socket cover.
5. REMOVE REAR CONSOLE END PANEL SUB-ASSEMBLY (for Double Cab) See: Body and
Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Floor Shift Type)/Removal
6. REMOVE REAR POWER OUTLET SOCKET ASSEMBLY (for Double Cab)
(a) Using a screwdriver, detach the claw and remove the power outlet socket.
HINT Tape the screwdriver tip before use.
Page 5544
Four Wheel Drive Selector Switch: Testing and Inspection
JF1A TRANSFER: 4WD CONTROL SWITCH: ON-VEHICLE INSPECTION
1. INSPECT 4WD CONTROL SWITCH
(a) Check the harness and connector (ECU - battery and body ground).
(1) Measure the voltage and resistance according to the value(s) in the table below.
Standard voltage:
(2) If there is a malfunction, inspect the harness or connector. If the harness is malfunctioning,
repair or replace harness or connector. If the
harness or connector is normal, replace the 4WD control ECU See: Relays and Modules Transmission and Drivetrain/Relays and Modules - Transfer Case/Control Module/Service and
Repair/Removal.
Standard resistance:
(3) If there is a malfunction, repair or replace the harness or connector.
(b) Check the harness and connector (switch - ECU).
(1) Disconnect the A25 ECU connector.
(2) Disconnect the L1 switch connector.
(3) Measure the resistance according to the value(s) in the table below.
Page 7978
Torque : 11 Nm (110 kgf-cm, 8 ft-lbf)
NOTICE: Do not twist the curtain shield airbag when installing it.
(b) Connect the connector.
NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness.
2. INSTALL CURTAIN SHIELD AIRBAG ASSEMBLY (for Double Cab)
(a) Install the curtain shield airbag with the 8 bolts.
Torque : 11 Nm (110 kgf-cm, 8 ft-lbf)
NOTICE: Do not twist the curtain shield airbag when installing it.
(b) Connect the connector.
NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness.
3. INSTALL ROOF HEADLINING ASSEMBLY
(a) Refer to the procedures from "INSTALL ROOF HEADLINING ASSEMBLY" (for Double cab)
See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation.
(b) Refer to the procedures from "INSTALL ROOF HEADLINING ASSEMBLY" (for regular cab)
See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation.
4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
5. CHECK SRS WARNING LIGHT
Page 2070
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: ELECTRONIC
CIRCUIT INSPECTION PROCEDURE
1. BASIC INSPECTION
(a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS
(1) Unless otherwise stated, all resistance measurements should be made at an ambient
temperature of 20°C (68°F). Resistance measurements
may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been
running. Measurements should be made after the engine has cooled down.
(b) HANDLING CONNECTORS
(1) When disconnecting a connector, first squeeze the mating halves tightly together to release the
lock, and then press the lock claw and
separate the connector.
(2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly
and separate it.
(3) Before connecting a connector, check that there are no deformed, damaged, loose or missing
terminals.
(4) When connecting a connector, press firmly until it locks with a "click" sound.
(5) If checking a connector with a TOYOTA electrical tester, check the connector from the backside
(harness side) using a mini test lead.
NOTICE: *
As a waterproof connector cannot be checked from the backside, check it by connecting a
sub-harness.
* Do not damage the terminals by moving the inserted tester needle.
(c) CHECKING CONNECTORS
(1) Checking when a connector is connected: Squeeze the connectors together to confirm that they
are fully connected and locked.
(2) Checking when a connector is disconnected: Check by pulling the wire harness lightly from the
backside of the connector. Look for
unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for
corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or
deformed terminals.
(3) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a
female terminal, and check for ample tension
Page 1209
Removal
1UR-FE ENGINE CONTROL SYSTEM: AIR FUEL RATIO SENSOR: REMOVAL
CAUTION: *
Wear protective gloves when removing the exhaust pipe.
* The exhaust pipe is extremely hot immediately after the engine has stopped.
* Confirm that the exhaust pipe has cooled down before removing it.
1. REMOVE TAILPIPE ASSEMBLY See: Engine, Cooling and Exhaust/Exhaust System/Exhaust
Pipe/Service and Repair/Exhaust Pipe (for
Regular Cab Standard Deck)/Removal
2. REMOVE CENTER EXHAUST PIPE ASSEMBLY See: Engine, Cooling and Exhaust/Exhaust
System/Exhaust Pipe/Service and
Repair/Exhaust Pipe (for Regular Cab Standard Deck)/Removal
3. REMOVE FRONT EXHAUST PIPE ASSEMBLY
(a) Disconnect the heated oxygen sensor connector and 2 clamps.
(b) Disconnect the air fuel ratio sensor connector.
(c) Remove the 3 nuts, front exhaust pipe and gasket from the exhaust manifold RH.
4. REMOVE AIR FUEL RATIO SENSOR (for Bank 2 Sensor 1)
(a) Using SST, remove the sensor.
SST : 09224-00010
Page 6849
Rear Door Wire
Rear Sonar Wire
Page 9229
(f) Attach the clip.
2. INSTALL FRONT DOOR ARMREST COVER LH
3. INSTALL COURTESY LIGHT ASSEMBLY (w/ Power Window)
(a) Attach the claw to install the courtesy light.
(b) Connect the connector.
4. INSTALL FRONT LOWER DOOR FRAME BRACKET GARNISH LH
(a) Attach the 3 clips to install the front lower door frame bracket garnish.
5. INSTALL FRONT DOOR WINDOW REGULATOR HANDLE ASSEMBLY (w/o Power Window)
(a) Install the plate and regulator handle with the snap ring.
HINT With the door window fully closed, install the plate and the regulator handle with the snap ring
as shown in the illustration.
6. INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY (w/ Power Window)
(a) Install the power window regulator master switch with the 3 screws.
7. INSTALL FRONT UPPER ARMREST BASE PANEL LH (w/ Power Window)
Page 3563
(b) Measure the resistance according to the value(s) in the table below.
8. CHECK AIR CONDITIONING AMPLIFIER
(a) Disconnect the J19 ECU connector.
(b) Measure the resistance according to the value(s) in the table below.
9. CHECK CENTER AIRBAG SENSOR
(a) Disconnect the J46 ECU connector.
(b) Measure the resistance according to the value(s) in the table below.
Page 9240
HINT Tape the screwdriver tip before use.
2. REMOVE REAR UPPER DOOR ARMREST BASE PANEL LH
(a) Using a screwdriver, detach the 2 clips and rear upper door armrest base panel. Then
disconnect the connector.
HINT Tape the screwdriver tip before use.
3. REMOVE REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY
(a) Detach the 4 claws and remove the power window regulator switch.
4. REMOVE REAR DOOR FRAME GARNISH LH
(a) Detach the 5 clips and remove the rear door frame garnish.
5. REMOVE COURTESY LIGHT ASSEMBLY
(a) Detach the claw and remove the courtesy light from the door trim board.
Page 1531
Power Steering Pressure Switch: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: POWER STEERING OIL PRESSURE SWITCH:
INSTALLATION
1. INSTALL POWER STEERING OIL PRESSURE SWITCH
(a) Install a new O-ring to the power steering oil pressure switch.
(b) Apply a light coat of engine oil to the O-ring of the power steering oil pressure switch.
NOTICE: *
When reusing the power steering oil pressure switch, inspect the O-ring.
* If the O-ring has scratches or cuts, replace the power steering oil pressure switch.
(c) Using SST, install the power steering oil pressure switch.
SST : 09922-10010
without SST - Torque : 21 Nm (210 kgf-cm, 15 ft-lbf)
with SST - Torque : 15 Nm (148 kgf-cm, 11 ft-lbf)
HINT *
Use a torque wrench with a fulcrum length of 30 cm (11.8 in.). When using a torque wrench with a
fulcrum length that is not 30 cm (11.8 in.), calculate the torque specification for the torque wrench
and SST based on the "without SST" torque specification See: Service Precautions
* Make sure SST and the torque wrench are connected in a straight line.
(d) Connect the oil pressure switch connector.
2. INSTALL FAN AND GENERATOR V BELT
(a) Install the fan and generator V belt See: Engine, Cooling and Exhaust/Engine/Drive Belts,
Mounts, Brackets and Accessories/Drive
Belt/Service and Repair/Installation.
3. ADD POWER STEERING FLUID
4. BLEED POWER STEERING FLUID See: Steering and Suspension/Steering/Testing and
Inspection/Component Tests and General
Diagnostics/Power Steering System/On-Vehicle Inspection
5. INSPECT FOR POWER STEERING FLUID LEAK
6. CHECK FLUID LEVEL See: Steering and Suspension/Steering/Testing and
Inspection/Component Tests and General Diagnostics/Power
Steering System/On-Vehicle Inspection
7. INSTALL FRONT FENDER APRON SEAL RH See: Engine, Cooling and Exhaust/Exhaust
System/Exhaust Manifold/Service and
Repair/Installation
8. INSTALL FRONT WHEEL See: Steering and Suspension/Suspension/Suspension Strut / Shock
Absorber/Service and Repair/Removal and
Replacement/Front Shock Absorber/Installation
Diagram Information and Instructions
Ignition Switch: Diagram Information and Instructions
Wiring Color Codes
Abbreviations Used Within Diagrams
Abbreviations Used Within Diagrams
Locations
Parking Assist Distance Sensor: Locations
PARK ASSIST / MONITORING: INTUITIVE PARKING ASSIST SYSTEM: PARTS LOCATION
Page 2315
(a) Apply a light coat of engine oil to the camshaft journals, camshaft housings and bearing caps.
(b) Install the No. 1 and No. 2 camshafts to the camshaft housing.
(c) Confirm the marks and numbers on the camshaft bearing caps and place them in their proper
positions and directions.
(d) Temporarily install the 10 bolts in the order shown in the illustration.
2. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH
(a) Make sure that the valve rocker arms are installed as shown in the illustration.
(b) Apply seal packing in a continuous line as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Standard seal diameter:
3.5 to 4.0 mm (0.138 to 0.157 in.)
Page 3225
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION: Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC
terminals are touched, the IC may be destroyed by static electricity.)
When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact with the terminals of leads from the IC, etc. of the
replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown on the left.
DISCONNECT CONNECTOR
Page 2957
Applicable Vehicles
Page 1388
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
4. REMOVE UPPER CONSOLE REAR PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
5. REMOVE REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
6. REMOVE CONSOLE BOX CARPET
7. REMOVE REAR CONSOLE BOX ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal
8. REMOVE FRONT CONSOLE BOX See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal
and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal
9. REMOVE CENTER AIRBAG SENSOR ASSEMBLY
(a) Disconnect the holder (with connectors).
(b) Remove the 3 bolts and airbag sensor.
Installation
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift
Type): INSTALLATION
1. INSTALL CENTER AIRBAG SENSOR ASSEMBLY
(a) Check that the ignition switch is OFF.
(b) Check that the cable is disconnected from the battery negative (-) terminal.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
(c) Install the airbag sensor with the 3 bolts.
Torque : 18 Nm (184 kgf-cm, 13 ft-lbf)
NOTICE: *
If the center airbag sensor has been dropped, or there are any cracks, dents or other defects in the
case, bracket or connector, replace it with a new one.
* When installing the center airbag sensor, be careful that the SRS wiring does not interfere with
other parts and that it is not pinched between other parts.
(d) Check that there is no looseness in the installation parts of the center airbag sensor.
Page 6852
Page 7666
(b) Remove the 2 bolts and 2 nuts.
(c) Remove the 2 stud bolts and cooler compressor.
Installation
AIR CONDITIONING: COMPRESSOR (for 1UR-FE): INSTALLATION
1. ADJUST COMPRESSOR OIL
(a) When replacing the compressor and magnetic clutch with a new one, gradually discharge the
refrigerant gas from the service valve, and drain
the following amount of oil from the new compressor and magnetic clutch before installation.
Standard:
(Oil capacity inside the new compressor and magnetic clutch: 120 + 15 cc (4.1 + 0.51 fl.oz.)) (Remaining oil amount in the removed compressor and magnetic clutch) = (Oil amount to be
removed from the new compressor when replacing)
NOTICE: *
When checking the compressor oil level, follow the A/C system's precautions.
* If a new compressor and magnetic clutch is installed without removing some oil remaining in the
pipes of the vehicle, the oil amount will be too large. This prevents heat exchange in the refrigerant
cycle and causes refrigerant failure.
* If the volume of oil remaining in the removed compressor and magnetic clutch is too small, check
for oil leakage.
* Be sure to use ND-OIL 8 or equivalent for compressor oil.
2. INSTALL COOLER COMPRESSOR ASSEMBLY
(a) Install the cooler compressor and 2 stud bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(b) Install the 2 bolts and 2 nuts.
Torque : 24.5 Nm (250 kgf-cm, 18 ft-lbf)
HINT Tighten the bolts and nuts in the order shown in the illustration to install the cooler
compressor.
(c) Connect the connector.
3. CONNECT SUCTION HOSE
(a) Remove the attached vinyl tape from the cooler refrigerant suction hose.
(b) Sufficiently apply compressor oil to a new O-ring and the fitting surface of the cooler
compressor.
Compressor oil:
Page 2207
Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf)
NOTICE: *
No further tightening is required once the nut is tightened with the specified torque.
* Check that there is no foreign matter on the washer and nut.
* Check that there is no oil, water or lubricant around the rim hole, tire pressure warning valve,
washer and nut. Failing to do so may result in improper installation.
(d) Set the wheel disc to a mounting machine and install the lower tire bead. Position the main
body of the tire pressure warning valve and
transmitter in the shaded area as shown in the illustration.
NOTICE: *
If the tire pressure warning valve and transmitter is positioned outside this area, the tire bead will
interfere with the tire pressure warning valve and transmitter, and may cause damage to it.
* If the use of lubricant is required when installing the bead, do not apply the lubricant directly to the
tire pressure warning valve and transmitter.
(e) Install the upper bead.
NOTICE: Make sure that the tire bead and tool do not interfere with the main body of the tire
pressure warning valve and transmitter and that the tire pressure warning valve and transmitter is
not clamped by the bead.
(f) Inflate the tire. Retighten the nut to the specified torque and then check for air leaks with soapy
water.
Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf)
NOTICE:
Page 8836
(a) Using a screwdriver, detach the 4 clips and claw.
HINT Tape the screwdriver tip before use.
(b) Remove the speaker panel.
5. REMOVE NO. 2 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY
(a) Using a screwdriver, detach the 4 clips and claw.
HINT Tape the screwdriver tip before use.
(b) Remove the speaker panel.
6. REMOVE FRONT NO. 2 SPEAKER ASSEMBLY LH
(a) Remove the 2 bolts.
(b) Remove the speaker and disconnect the connector.
Page 855
Yaw Rate Sensor: Service and Repair Removal
BRAKE CONTROL: YAW RATE AND DECELERATION SENSOR: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to disable the SRS system.
2. REMOVE CENTER FRONT SEAT ASSEMBLY (for Center Seat) See: Body and
Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Center Seat)/Removal
3. REMOVE CONSOLE BOX ASSEMBLY (for Separate Seat Type)
(a) Remove the console box See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and
Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal.
4. REMOVE YAW RATE SENSOR
(a) Remove the 2 nuts (labeled A) and sensor.
(b) Disconnect the sensor connector (labeled B), and then detach the clamp (labeled C) from the
sensor bracket.
Page 9178
Page 1081
Headlamp Alignment Switch: Diagrams
Page 4146
Page 7171
(c) Using SST, disconnect the upper ball joint from the steering knuckle.
SST : 09628-62011
(d) Remove the steering knuckle.
7. REMOVE KNUCKLE GREASE RETAINER CAP LH (for 2WD)
(a) Using a screwdriver and hammer, tap out the retainer cap.
8. REMOVE STEERING KNUCKLE OIL SEAL LH (for 4WD)
(a) Using a screwdriver and hammer, tap out the oil seal.
Testing and Inspection
Parking Assist Switch: Testing and Inspection
PARK ASSIST / MONITORING: CLEARANCE SONAR MAIN SWITCH: INSPECTION
1. INSPECT DRIVE MONITOR SWITCH
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) If the result is not as specified, replace the monitor switch.
(c) Inspect the switch illumination.
(1) Connect the positive (+) lead of the battery to terminal 1 (ILL+) and the negative (-) lead to
terminal 6 (ILL-).
(2) Check that the LED comes on.
OK:
LED comes on.
(3) If the result is not as specified, replace the monitor switch.
Page 6248
Page 7740
4. INSTALL COOLING UNIT DAMPER SERVO SUB-ASSEMBLY (for Automatic Air Conditioning
System)
(a) Install the damper servo with the 3 screws, as shown in the illustration.
(b) Connect the connector.
5. INSTALL BLOWER DAMPER SERVO SUB-ASSEMBLY
(a) Install the damper servo with the 3 screws.
(b) Connect the connector.
6. INSTALL BLOWER CASE SUB-ASSEMBLY
(a) Attach the 3 claws to install the case.
(b) Install the 3 screws.
Page 6108
(i) If the undercut depth is less than the minimum, correct it with a hacksaw blade.
3. INSPECT BRUSH
(a) Using a vernier caliper, measure the brush length.
Standard length:
15.0 mm (0.591 in.)
Minimum length:
9.0 mm (0.354 in.)
(b) If the brush length is less than the minimum, replace the starter yoke assembly and starter
brush holder assembly.
4. INSPECT STARTER BRUSH HOLDER ASSEMBLY
(a) Inspect the insulation.
(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(2) If the result is not as specified, replace the starter brush holder assembly.
Components
Steering Control Module: Service and Repair Components
POWER STEERING: POWER STEERING ECU (for 1UR-FE): COMPONENTS
Page 2425
(a) Hook the engine under cover to the vehicle body as shown in the illustration.
(b) Install the 3 screws and 5 bolts.
for bolt - Torque : 29 Nm (296 kgf-cm, 21 ft-lbf)
for screw - Torque : 3.0 Nm (31 kgf-cm, 27 in-lbf)
Diagrams
Liftgate Window Motor: Diagrams
Page 4507
Camshaft Position Sensor: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT POSITION SENSOR: INSTALLATION
1. INSTALL CAMSHAFT POSITION SENSOR
(a) Install the sensor with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(b) Connect the sensor connector.
2. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Installation
Page 8338
Impact Sensor: Testing and Inspection
Center Airbag Sensor Assembly (for Column Shift Type)
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Column
Shift Type): ON-VEHICLE INSPECTION
1. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION)
(a) Perform a diagnostic system check See: Air Bag Systems/Testing and Inspection/Initial
Inspection and Diagnostic Overview/Diagnosis
System.
2. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND
AIRBAG HAS NOT DEPLOYED)
(a) Perform a diagnostic system check See: Air Bag Systems/Testing and Inspection/Initial
Inspection and Diagnostic Overview/Diagnosis
System.
3. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND
AIRBAG IS DEPLOYED)
(a) Replace the center airbag sensor.
CAUTION: For removal and installation procedures of the center airbag sensor, be sure to follow
the correct procedure.
HINT The center airbag sensor should be replaced after any of the airbags has deployed, as it has
been subjected to the impact.
Center Airbag Sensor Assembly (for Floor Shift Type)
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift
Type): ON-VEHICLE INSPECTION
1. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION)
(a) Perform a diagnostic system check See: Air Bag Systems/Testing and Inspection/Initial
Inspection and Diagnostic Overview/Diagnosis
System.
2. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND
AIRBAG HAS NOT DEPLOYED)
(a) Perform a diagnostic system check See: Air Bag Systems/Testing and Inspection/Initial
Inspection and Diagnostic Overview/Diagnosis
System.
3. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND
AIRBAG IS DEPLOYED)
(a) Replace the center airbag sensor.
CAUTION: For removal and installation procedures of the center airbag sensor, be sure to follow
the correct procedure.
HINT The center airbag sensor should be replaced after any of the airbags has deployed, as it has
been subjected to the impact.
Front Airbag Sensor
SUPPLEMENTAL RESTRAINT SYSTEM: FRONT AIRBAG SENSOR: ON-VEHICLE
INSPECTION
1. CHECK FRONT AIRBAG SENSOR (VEHICLE NOT INVOLVED IN COLLISION)
(a) Perform a diagnostic system check See: Air Bag Systems/Testing and Inspection/Initial
Inspection and Diagnostic Overview/Diagnosis
System.
2. CHECK FRONT AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS
NOT DEPLOYED)
(a) Perform a diagnostic system check See: Air Bag Systems/Testing and Inspection/Initial
Inspection and Diagnostic Overview/Diagnosis
System.
Page 6404
Recall - Accelerator Pedal Modification
Technical Service Bulletin # SC-A0A Date: 110219
Page 5914
2. INSTALL FRONT SPEED SENSOR LH
(a) Install the speed sensor (labeled D) with the hexagon socket head cap bolt (labeled E).
Torque : 11 Nm (107 kgf-cm, 8 ft-lbf)
NOTICE: *
Make sure there are no pieces of iron or other foreign matter attached to the sensor tip part.
* While inserting the speed sensor into the knuckle hole, do not strike or damage the sensor tip
part.
* After installing the speed sensor, make sure there is no clearance or foreign matter between the
sensor stay part and the knuckle.
* Make sure there is no foreign matter attached to the magnetic rotor.
3. INSTALL FRONT SKID CONTROL SENSOR WIRE LH
(a) Connect the connector (labeled A).
(b) Install the 3 harness clamps (labeled B) with the 3 bolts (labeled C).
Torque : 13 Nm (127 kgf-cm, 9 ft-lbf)
NOTICE: *
When installing the clamps, do not twist the wire harness.
* For clamps with rotation stoppers, make sure the rotation stopper touches the installation
position.
(c) Install the harness clamp with the bolt (labeled D).
Page 2565
Variable Valve Timing Actuator: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT OIL CONTROL VALVE: REMOVAL
1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Service and Repair/Removal and
Replacement/Engine Assembly/Removal
2. REMOVE AIR CLEANER HOSE ASSEMBLY See: Service and Repair/Removal and
Replacement/Engine Assembly/Removal
3. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side of Bank
1)
(a) Disconnect the oil control valve connector.
(b) Remove the bolt and oil control valve.
(c) Remove the O-ring from the oil control valve.
4. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side of Bank 1)
(a) Disconnect the oil control valve connector.
(b) Remove the bolt and oil control valve.
(c) Remove the O-ring from the oil control valve.
5. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side of Bank 2)
(a) Disconnect the oil control valve connector.
(b) Remove the bolt and oil control valve.
(c) Remove the O-ring from the oil control valve.
6. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side of Bank
2)
(a) Disconnect the oil control valve connector.
(b) Remove the bolt and oil control valve.
(c) Remove the O-ring from the oil control valve.
Page 7087
Steering Control Module: Service and Repair Removal
POWER STEERING: POWER STEERING ECU (for 1UR-FE): REMOVAL
1. REMOVE FRONT DOOR SCUFF PLATE LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining
(For Double Cab)/Removal
2. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Removal
3. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal
4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Removal
5. REMOVE LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY See: Restraint
Systems/Air Bag Systems/Air Bag/Service and
Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Removal
6. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column
Shift Type)/Removal
7. REMOVE POWER STEERING ECU ASSEMBLY
(a) Disconnect the power steering ECU connector.
(b) Remove the nut and power steering ECU.
Page 1664
Wiper Switch: Diagrams
Specifications
Engine Oil Pressure: Specifications
ENGINE OIL PRESSURE
Page 5864
Braking Sensor/Switch: Diagrams
Page 5325
Control Module: Diagrams
Engine Control System - SFI System
Camshaft Position Sensor: Locations Engine Control System - SFI System
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 5738
HINT *
*1: FR RH
* *2: FR LH
* *3: RR RH
* *4: RR LH
* *5: FR Master Cylinder
* *6: RR Master Cylinder
(b) Using a union nut wrench, disconnect the 2 brake tubes from the VSC actuator.
(c) Using a union nut wrench, remove the 2 brake tubes from the brake master cylinder.
4. DISCONNECT BRAKE TUBE
(a) Using a union nut wrench, disconnect the 4 brake tubes from the VSC actuator.
(b) Remove the clamp from the VSC actuator bracket.
5. REMOVE VSC ACTUATOR WITH ACTUATOR BRACKET ASSEMBLY
(a) Remove the 3 nuts and VSC actuator with actuator bracket.
Installation
Page 7044
(b) : for 5 leaf spring
Measuring points:
A Ground clearance of the front drive shaft center
B Ground clearance of the front adjusting cam bolt center
C Ground clearance of the rear axle shaft center
D Ground clearance of the leaf spring front side bushing center
(c) If the vehicle height is not as specified, adjust the height by pressing down on the vehicle
several times to stabilize the suspension.
3. INSPECT TOE-IN
Airbag System
Seat Occupant Sensor: Locations Airbag System
SUPPLEMENTAL RESTRAINT SYSTEM: AIRBAG SYSTEM: PARTS LOCATION
Page 306
Driver Side J/B Inner Circuit
Page 1798
Parts Information
Calibration Information
Required Tools & Equipment
Repair Procedure
Page 5442
Four Wheel Drive Selector Switch: Testing and Inspection
JF1A TRANSFER: 4WD CONTROL SWITCH: ON-VEHICLE INSPECTION
1. INSPECT 4WD CONTROL SWITCH
(a) Check the harness and connector (ECU - battery and body ground).
(1) Measure the voltage and resistance according to the value(s) in the table below.
Standard voltage:
(2) If there is a malfunction, inspect the harness or connector. If the harness is malfunctioning,
repair or replace harness or connector. If the
harness or connector is normal, replace the 4WD control ECU See: Control Module/Service and
Repair/Removal.
Standard resistance:
(3) If there is a malfunction, repair or replace the harness or connector.
(b) Check the harness and connector (switch - ECU).
(1) Disconnect the A25 ECU connector.
(2) Disconnect the L1 switch connector.
(3) Measure the resistance according to the value(s) in the table below.
Standard resistance:
Page 3502
INSPECTION PROCEDURE
HINT Operating the ignition switch, any switches or any doors triggers related ECU and sensor
communication with the CAN, which causes resistance variation.
PROCEDURE
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
(a) Disconnect the cable from the negative (-) battery terminal before measuring the resistances of
the main wire and the branch wire.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
NEXT -- Continue to next step.
2. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (DLC3 BRANCH WIRE)
(a) Disconnect the J86 No. 1 junction connector connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO DLC3 (CANH, CANL) OK -Continue to next step.
3. CONNECT CONNECTOR
Page 4537
Knock Sensor: Diagrams
Page 7743
(a) Install the motor with the 3 screws.
11. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY
(a) Install the amplifier with the 2 screws.
12. INSTALL NO. 2 AIR DUCT SUB-ASSEMBLY
(a) install the duct with the screw.
13. INSTALL CLEAN AIR FILTER
(a) Install the filter as shown in the illustration.
14. INSTALL AIR FILTER COVER PLATE
(a) Attach the 2 clips to install the plate.
Page 5004
Wiring Harness: Service and Repair Removal
A760F AUTOMATIC TRANSMISSION: TRANSMISSION WIRE: REMOVAL
1. DRAIN AUTOMATIC TRANSMISSION FLUID
(a) Remove the drain plug and gasket, and drain the ATF.
(b) Install a new gasket and the drain plug.
Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)
2. REMOVE AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY
(a) Remove the 20 bolts, oil pan and gasket from the transmission.
NOTICE: Some fluid will remain in the oil pan. Remove all the pan bolts, and carefully remove the
oil pan assembly.
(b) Examine the particles in the pan.
(1) Remove the 4 magnets and use them to collect steel particles. Carefully inspect the foreign
matter and particles in the pan and on the
magnets to anticipate the type of wear you will find in the transmission.
Steel (magnetic): bearing, gear and clutch plate wear
Brass (non-magnetic): bush wear
3. REMOVE VALVE BODY OIL STRAINER ASSEMBLY
(a) Remove the 4 bolts and oil strainer.
NOTICE: Be careful as some fluid may leak out of the oil strainer.
(b) Remove the O-ring from the oil strainer.
4. DISCONNECT TRANSMISSION WIRE
Page 6717
Release the locking lug from terminal and pull the terminal out from rear.
INSTALL TERMINAL TO CONNECTOR
Insert the terminal.
HINT: Make sure the terminal is positioned correctly.
Insert the terminal until the locking lug locks firmly.
Insert the terminal with terminal retainer in the temporary lock position.
Adjustments
Parking Assist Control Module: Adjustments
PARK ASSIST / MONITORING: CLEARANCE WARNING ECU: ADJUSTMENT
1. ADJUST BUZZER VOLUME
(a) Turn the knob on the clearance warning ECU to adjust the volume.
Page 4901
Page 3391
Information Bus: Connector Views
Page 2016
(1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be
checked by conducting a voltage check.
With each connector still connected, measure the voltage between the body ground and these
terminals (in this order): 1) terminal 1 of connector A; 2) terminal 1 of connector B; and 3) terminal
1 of connector C.
Standard voltage (Fig. 4):
* If the results match the examples above, an open circuit exists in the wire harness between
terminal 1 of connector B and terminal 1 of connector C.
3. CHECK FOR SHORT CIRCUIT
(a) If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance
check with the body ground (below).
(b) Check the resistance with the body ground.
(1) Disconnect connectors A and C and measure the resistance.
Standard resistance (Fig. 6):
HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally.
If your results match the examples above, a short circuit exists between terminal 1 of connector A
and terminal 1 of connector C.
Page 9049
Page 6514
Symbols Used Within Diagrams
Symbols Used Within Diagrams
Page 1511
Neutral Safety Switch: Component Tests and General Diagnostics
A760F AUTOMATIC TRANSMISSION: PARK / NEUTRAL POSITION SWITCH: INSPECTION
1. INSPECT PARK/NEUTRAL POSITION SWITCH ASSEMBLY
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) If the result is not as specified, replace the switch assembly.
Page 4221
Accelerator Pedal: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: ACCELERATOR PEDAL: REMOVAL
1. REMOVE ACCELERATOR PEDAL ROD ASSEMBLY
(a) Disconnect the accelerator pedal position sensor connector.
(b) Remove the 2 nuts and accelerator pedal rod.
Page 5980
Ignition Switch: Service and Repair Installation
1UR-FE STARTING: IGNITION SWITCH: INSTALLATION
1. INSTALL IGNITION SWITCH ASSEMBLY
(a) Attach the 2 claws to install the ignition switch to the steering lock.
2. INSTALL UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Manual Tilt)
See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering Column Assembly
(for Manual Tilt)/Reassembly
3. INSTALL UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Manual Tilt
and Manual Telescopic Steering Column)
See: Steering and Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering
Column Assembly (for Manual Tilt and Manual Telescopic Steering Column)/Reassembly
4. INSTALL UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Power Tilt
and Power Telescopic Steering Column)
See: Steering and Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering
Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Reassembly
5. INSTALL STEERING COLUMN ASSEMBLY
(a) for Manual Tilt:
Install the steering column See: Steering and Suspension/Steering/Steering Column/Service and
Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Installation.
(b) for Manual Tilt and Manual Telescopic Steering Column:
Install the steering column See: Steering and Suspension/Steering/Steering Column/Service and
Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt and Manual
Telescopic Steering Column)/Installation.
(c) for Power Tilt and Power Telescopic Steering Column:
Install the steering column See: Steering and Suspension/Steering/Steering Column/Service and
Repair/Removal and Replacement/Steering Column Assembly (for Power Tilt and Power
Telescopic Steering Column)/Installation.
6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Page 7977
Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal
* Refer to the procedures up to "REMOVE ROOF HEADLINING ASSEMBLY" (for Regular Cab)
See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Removal
3. REMOVE CURTAIN SHIELD AIRBAG ASSEMBLY (for Regular Cab)
(a) Disconnect the connector.
NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness.
(b) Remove the 6 bolts and curtain shield airbag.
4. REMOVE CURTAIN SHIELD AIRBAG ASSEMBLY (for Double Cab)
(a) Disconnect the connector.
NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness.
(b) Remove the 8 bolts and curtain shield airbag.
Installation
SUPPLEMENTAL RESTRAINT SYSTEM: CURTAIN SHIELD AIRBAG ASSEMBLY:
INSTALLATION
1. INSTALL CURTAIN SHIELD AIRBAG ASSEMBLY (for Regular Cab)
(a) Install the curtain shield airbag with the 6 bolts.
Page 7963
(b) Remove the curtain shield airbag See: Removal and Replacement/Curtain Shield Airbag
Assembly (for CrewMax)/Removal.
(c) Cut off the deployment section of the curtain shield airbag.
(d) Using a service-purpose wire harness for the vehicle, tie down the curtain shield airbag to the
tire.
Wire harness:
Stripped wire harness section
1.25 mm2 or more (0.00193 in.2 or more)
CAUTION: If the wire harness is too thin or an alternative object is used to tie down the curtain
shield airbag, it may be snapped by the shock when the airbag is deployed. Always use a wire
harness for vehicle use with an area of at least 1.25 mm2 (0.00193 in.2).
HINT To calculate the area of the stripped wire harness section:
Area = 3.14 x (Diameter)2 divided by 4
(1) Position the curtain shield airbag inside the tire as shown in the illustration.
Tire size:
Must exceed the following dimensions
Page 7367
Removal
SUSPENSION: REAR SHOCK ABSORBER: REMOVAL
HINT *
Use the same procedures for the RH side and LH side.
* The procedures listed below are for the LH side.
1. SUPPORT BODY WITH SAFETY STANDS
(a) Jack up and support the body on safety stands.
(b) Lower the axle housing until the leaf spring tension is free, and keep it at this position.
2. REMOVE REAR WHEEL
Page 1281
Camshaft Position Sensor: Diagrams
Page 1417
Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)
NOTICE: *
If the side airbag sensor has been dropped, or there are any cracks, dents or other defects in the
case, bracket or connector, replace it with a new one.
* When installing the side airbag sensor, be careful that the SRS wiring does not interfere with
other parts and that it is not pinched between other parts.
(d) Check that there is no looseness in the installation parts of the side airbag sensor.
(e) Connect the connector.
8. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY LH (for Rear Side) See: Body and
Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation
9. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH (for Rear Side)
10. INSTALL REAR DOOR SCUFF PLATE LH (for Rear Side) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and Repair/Roof
Headlining (For Double Cab)/Installation
11. INSTALL REAR SEAT ASSEMBLY (for Rear Side)
(a) Install the rear seat assembly See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Rear Seat Assembly (for Double
Cab)/Installation.
12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
13. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
Components
SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Double Cab):
COMPONENTS
Recall 09V388000: Floor Mat/Accelerator Interference
Accelerator Pedal: All Technical Service Bulletins Recall 09V388000: Floor Mat/Accelerator
Interference
VEHICLE MAKE/MODEL: MODEL YEAR(S): Lexus/ES350 2007-2010 Lexus/IS 2006-2010
Toyota/Avalon 2005-2010 Toyota/Camry 2007-2010 Toyota/Prius 2004-2009 Toyota/Tacoma
2005-2010 Toyota/Tundra 2007-2010 MANUFACTURER: Toyota Motor Corporation
MFR'S REPORT DATE: October 05, 2009
NHTSA CAMPAIGN ID NUMBER: 09V388000
NHTSA Action Number: N/A COMPONENT: Vehicle Speed Control: Accelerator Pedal
POTENTIAL NUMBER OF UNITS AFFECTED: 3800000
SUMMARY: Toyota is recalling certain model year 2004-2010 passenger vehicles. The accelerator
pedal can get stuck in the wide open position due to its being trapped by an unsecured or
incompatible driver's floor mat.
CONSEQUENCE: A stuck open accelerator pedal may result in very high vehicle speeds and
make it difficult to stop the vehicle, which could cause a crash, serious injury or death.
REMEDY: Toyota will notify owners of affected vehicles to remove any driver's floor mat and not
replace it with any other floor mat pending the development of model-specific remedies. Toyota will
mail a second notification to owners of affected vehicles notifying them of the free remedies when
they are available. The first notice is expected to be mailed during October 2009 and Toyota will
advise NHTSA of the estimated date when the remedies will be available. Owners may contact
Toyota at 1-800-331-4331, Lexus at 1-800-255-3987.
NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle
Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov.
Page 3018
Accelerator Pedal Position Sensor: Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 4794
NOTE
On some models, DTCs may set as a result of reprogramming. If DTCs are present, clear codes
and run the Health Check again. Troubleshoot any remaining Current, Pending, or History codes.
Permanent codes will not be cleared using Techstream. Permanent codes do not illuminate the MIL
and do not require troubleshooting. They will clear during normal driving once the Universal Trip
Drive Pattern is performed.
4. Attach the Authorized Modifications Label.
A. Using a permanent marker or ball point pen complete the Authorized Modifications Label and
attach to the vehicle. The Authorized
Modifications Label is available through the MDC P/N 00451-00001-LBL.
B. Attach the label under the hood in the location determined by the specific TSB or Campaign.
NOTE
Wait 60 - 90 seconds for ink to set before handling.
Page 7034
for Double Cab of Long Deck
Page 3432
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- CHECK FOR SHORT IN CAN BUS WIRES (POWER STEERING ECU) OK -- Continue to
next step.
12. CHECK FOR SHORT IN CAN BUS WIRES (NO. 1 JUNCTION CONNECTOR - CENTER
AIRBAG SENSOR)
(a) Disconnect the J83 No. 1 junction connector connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- CHECK FOR SHORT IN CAN BUS WIRES (CENTER AIRBAG SENSOR)
OK -- REPAIR OR REPLACE NO. 1 JUNCTION CONNECTOR
13. CHECK FOR SHORT IN CAN BUS WIRES (COMBINATION METER ECU)
(a) Disconnect the J28 combination meter ECU connector.
Page 3447
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO MAIN BODY ECU (CANH,
CANL)
OK -- REPLACE MAIN BODY ECU
15. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (SKID CONTROL ECU WITH ACTUATOR)
(a) Disconnect the A17 skid control ECU with actuator connector.
Page 8981
(a) Detach the 4 clips.
(b) Disconnect the connector and remove the panel.
11. REMOVE GLASS BREAKAGE SENSOR MICROPHONE
(a) Detach the 2 claws and remove the sensor.
Installation
THEFT DETERRENT: GLASS BREAKAGE SENSOR (for Floor Shift Type): INSTALLATION
1. INSTALL GLASS BREAKAGE SENSOR MICROPHONE
(a) Attach the 2 claws to install the sensor.
2. INSTALL INTEGRATION CONTROL AND PANEL ASSEMBLY
Page 3083
(a) For an open circuit in the wire harness in Fig. 1, check the resistance or voltage, as described
below.
(b) Check the resistance.
(1) Disconnect connectors A and C and measure the resistance between them.
Standard resistance (Fig. 2):
HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally.
If the results match the examples above, an open circuit exists between terminal 1 of connector A
and terminal 1 of connector C.
(2) Disconnect connector B and measure the resistance between the connectors.
Standard resistance (Fig. 3):
* If the results match the examples above, an open circuit exists between terminal 1 of connector
B2 and terminal 1 of connector C.
(c) Check the voltage.
Page 4994
Valve Body: Overhaul
Disassembly
A760F AUTOMATIC TRANSMISSION: VALVE BODY ASSEMBLY: DISASSEMBLY
1. REMOVE SHIFT SOLENOID VALVE SL2
(a) Remove the bolt, lock plate and 2 straight pins.
(b) Remove the shift solenoid valve.
2. REMOVE SHIFT SOLENOID VALVE SLU
3. REMOVE SHIFT SOLENOID VALVE SLT
(a) Remove the bolt, lock plate and 2 straight pins.
(b) Remove the shift solenoid valve.
4. REMOVE SHIFT SOLENOID VALVE SL1
5. REMOVE SHIFT SOLENOID VALVE SR
(a) Remove the bolt and shift solenoid valve.
Page 3738
Engine Control Module: Programming and Relearning
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: REGISTRATION
NOTICE: The Vehicle Identification Number (VIN) must be input into the replacement ECM.
HINT The VIN is in the form of a 17-digit alphanumeric vehicle identification number. The
Techstream is required to register the VIN.
1. DESCRIPTION
NOTICE: The Vehicle Identification Number (VIN) must be input into the replacement ECM.
HINT This registration section consists of two parts: Read VIN and Write VIN.
(a) Read VIN: Explains the VIN reading process in a flowchart. This process allows the VIN stored
in the ECM to be read in order to confirm that
the two VINs, the one provided with the vehicle and the one stored in the vehicle's ECM, are the
same.
(b) Write VIN: Explains the VIN writing process in a flowchart. This process allows the VIN to be
input into the ECM. If the ECM is changed, or
the ECM VIN and vehicle VIN do not match, the VIN can be registered or overwritten in the ECM
by following this procedure.
2. READ VIN
(a) Confirm the vehicle VIN.
(b) Connect the Techstream to the DLC3.
(c) Turn the ignition switch to ON.
(d) Turn the Techstream on.
(e) Enter the following menus: Powertrain / Engine and ECT / Utility / VIN / VIN Read.
3. WRITE VIN
(a) Confirm the vehicle VIN.
(b) Connect the Techstream to the DLC3.
(c) Turn the ignition switch to ON.
(d) Turn the Techstream on.
(e) Enter the following menus: Powertrain / Engine and ECT / Utility / VIN / VIN Write.
Page 4527
Ignition Coil: Service and Repair Installation
1UR-FE IGNITION: IGNITION COIL AND SPARK PLUG: INSTALLATION
1. INSTALL SPARK PLUG
(a) Using a 16 mm plug wrench, install the 8 spark plugs.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
2. INSTALL IGNITION COIL ASSEMBLY
(a) for Bank 1:
(1) Install the 4 ignition coils with the 4 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(2) Connect the 4 ignition coil connectors.
(3) Connect the 3 wire harness clamps.
(b) for Bank 2:
(1) Install the 4 ignition coils with the 4 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(2) Connect the 4 ignition coil connectors and 2 wire harness clamps.
(3) Connect the water by-pass pipe with the 2 bolts.
Torque : 18 Nm (184 kgf-cm, 13 ft-lbf)
Remote Starting System - Cold Weather Starting Tips
Keyless Starting System: Technical Service Bulletins Remote Starting System - Cold Weather
Starting Tips
T-SB-0100-09
Rev1
March 31, 2009
Remote Engine Starter (RES) Cold Temperature Operation Diagnostic Tips
Service Category Engine/Hybrid System
Section Starting
Market USA
Applicability
March 9, 2010 Rev1:
TSB REVISION NOTICE
Applicability has been updated to include applicable 2010 - 2011 model year vehicles. Any
previous printed versions of this service bulletin should be discarded.
Introduction
Some vehicles operated in extremely cold temperatures may exhibit a condition where the Remote
Engine Starter (RES) does not function.
Before RES diagnosis confirm with the customer the ambient temperature when the malfunction
was experienced.
The RES system was designed to operate at temperatures above -22 F (-30 C). Non-operation of
the RES system below this threshold should be considered a normal condition.
Warranty Information
Diagnostic Procedure
On-Vehicle Inspection
Throttle Body: Testing and Inspection On-Vehicle Inspection
1UR-FE ENGINE CONTROL SYSTEM: THROTTLE BODY: ON-VEHICLE INSPECTION
1. CHECK THROTTLE BODY ASSEMBLY
(a) Check the throttle control motor operating sounds.
(1) Turn the ignition switch to ON.
(2) When depressing the accelerator pedal, check the operating sound of the running motor. Make
sure that no friction noises emit from the
motor.
If friction noise exists, replace the throttle body.
(b) Check the throttle position sensor.
(1) Connect the Techstream to the DLC3.
(2) Turn the ignition switch to ON.
(3) Turn the Techstream main switch ON.
(4) Enter the following menus: Powertrain / Engine and ECT / Data List / All Data / Throttle Sensor
Position.
(5) Depress the accelerator pedal. When the throttle valve is fully opened, check that the value of
"Throttle Sensor Position" is within the
specification.
Standard throttle valve opening percentage:
60% or more
HINT When checking the standard throttle valve opening percentage, the shift lever should be in
the N position.
(6) If the percentage is less than 60%, replace the throttle body assembly.
Page 4167
Page 3752
Oxygen Sensor Relay: Testing and Inspection
1UR-FE ENGINE CONTROL SYSTEM: A/F SENSOR HEATER RELAY: ON-VEHICLE
INSPECTION
1. REMOVE INTEGRATION RELAY See: Ignition System/Ignition Relay/Testing and Inspection
2. INSPECT INTEGRATION RELAY (A/F)
NOTICE: *
Some relays are built into the integration relay. The integration relay cannot be disassembled. If
there is a malfunction in the circuit of the integration relay, replace the integration relay.
* The internal circuit of the integration relay is as shown in the illustration below. Inspect the
integration relay using the following procedures.
(a) Measure the resistance of the A/F fuse.
(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(2) If the result is not as specified, replace the A/F fuse.
(b) Measure the resistance of the A/F sensor heater relay.
(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
Page 7449
Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf)
NOTICE: *
No further tightening is required once the nut is tightened with the specified torque.
* Check that there is no foreign matter on the washer and nut.
* Check that there is no oil, water or lubricant around the rim hole, tire pressure warning valve,
washer and nut. Failing to do so may result in improper installation.
(d) Set the wheel disc to a mounting machine and install the lower tire bead. Position the main
body of the tire pressure warning valve and
transmitter in the shaded area as shown in the illustration.
NOTICE: *
If the tire pressure warning valve and transmitter is positioned outside this area, the tire bead will
interfere with the tire pressure warning valve and transmitter, and may cause damage to it.
* If the use of lubricant is required when installing the bead, do not apply the lubricant directly to the
tire pressure warning valve and transmitter.
(e) Install the upper bead.
NOTICE: Make sure that the tire bead and tool do not interfere with the main body of the tire
pressure warning valve and transmitter and that the tire pressure warning valve and transmitter is
not clamped by the bead.
(f) Inflate the tire. Retighten the nut to the specified torque and then check for air leaks with soapy
water.
Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf)
NOTICE:
Page 9105
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Page 1258
Accelerator Pedal Position Sensor: Diagrams
Diagram Information and Instructions
Fuse Block: Diagram Information and Instructions
Wiring Color Codes
Abbreviations Used Within Diagrams
Abbreviations Used Within Diagrams
Page 6960
Page 6813
Page 2083
6. PROBLEM SYMPTOMS TABLE
When a "Normal" code is output during a DTC check but the problem is still occurring, use the
Problem Symptoms Table. The suspected areas (circuits or parts) for each problem symptom are
in the table. The suspected areas are listed in order of probability. A description of each of the
chart's columns is below.
HINT In some cases, the problem is not detected by the diagnostic system even though a problem
symptom is present. It is possible that the problem is occurring outside the detection range of the
diagnostic system, or that the problem is occurring in a completely different system.
7. CIRCUIT INSPECTION
A description of the main areas of each circuit inspection is below.
Page 4106
Fuel Pressure: Testing and Inspection
1UR-FE FUEL: FUEL SYSTEM: ON-VEHICLE INSPECTION
1. CHECK FUEL PUMP OPERATION AND FOR FUEL LEAK
(a) Connect the Techstream to the DLC3.
(b) Turn the ignition switch to ON.
NOTICE: Do not start the engine.
(c) Turn the Techstream main switch ON.
(d) Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump /
Speed.
(e) Check the fuel pump operation.
(1) Check for pressure in the fuel inlet tube from the fuel line. Check that the sound of fuel flowing
in the fuel tank can be heard.
If there is no sound, check the integration relay, fuel pump, ECM and wiring connector.
(f) Check for fuel leak.
(1) Check that there are no fuel leaks after performing maintenance anywhere on the system.
If there are fuel leaks, repair or replace parts as necessary.
2. CHECK FUEL PRESSURE
(a) Check that the battery voltage is 11 to 14 V.
(b) Perform the "DISCHARGE FUEL SYSTEM PRESSURE" procedures See: Service Precautions.
(c) Disconnect the cable from the negative (-) battery terminal.
(d) Remove the fuel pipe clamp from the fuel tube connector.
(e) Pinch and pull the fuel tube (fuel tube connector) to disconnect it.
CAUTION: *
Always read the precautions See: Service Precautions before disconnecting the fuel tube
connector (quick type).
* The fuel tube may spray fuel as a result of pressure that remains in it. Do not allow fuel to be
sprayed in the engine compartment.
(f) Install SST (pressure gauge) as shown in the illustration.
Up to 11/2009
Wheel Speed Sensor: Locations Up to 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 4769
^ Calibration ID(s) [Refer to the Calibration Identification Chart for the NEW CALIBRATION ID]
^ Dealer Code
^ Repair Date
^ Change Authority [This TSB number]
B. Affix the Authorized Modifications Label to the vehicle at the location shown in Figure 1. The
Authorized Modifications Label is available
through the MDC P/N 00451-00001-LBL.
Page 4316
NOTE
On some models, DTCs may set as a result of reprogramming. If DTCs are present, clear codes
and run the Health Check again. Troubleshoot any remaining Current, Pending, or History codes.
Permanent codes will not be cleared using Techstream. Permanent codes do not illuminate the MIL
and do not require troubleshooting. They will clear during normal driving once the Universal Trip
Drive Pattern is performed.
4. Attach the Authorized Modifications Label.
A. Using a permanent marker or ball point pen complete the Authorized Modifications Label and
attach to the vehicle. The Authorized
Modifications Label is available through the MDC P/N 00451-00001-LBL.
B. Attach the label under the hood in the location determined by the specific TSB or Campaign.
NOTE
Wait 60 - 90 seconds for ink to set before handling.
Page 981
Door Switch: Diagrams Rear Door Courtesy Switch
Page 400
Engine Control Module: Programming and Relearning
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: REGISTRATION
NOTICE: The Vehicle Identification Number (VIN) must be input into the replacement ECM.
HINT The VIN is in the form of a 17-digit alphanumeric vehicle identification number. The
Techstream is required to register the VIN.
1. DESCRIPTION
NOTICE: The Vehicle Identification Number (VIN) must be input into the replacement ECM.
HINT This registration section consists of two parts: Read VIN and Write VIN.
(a) Read VIN: Explains the VIN reading process in a flowchart. This process allows the VIN stored
in the ECM to be read in order to confirm that
the two VINs, the one provided with the vehicle and the one stored in the vehicle's ECM, are the
same.
(b) Write VIN: Explains the VIN writing process in a flowchart. This process allows the VIN to be
input into the ECM. If the ECM is changed, or
the ECM VIN and vehicle VIN do not match, the VIN can be registered or overwritten in the ECM
by following this procedure.
2. READ VIN
(a) Confirm the vehicle VIN.
(b) Connect the Techstream to the DLC3.
(c) Turn the ignition switch to ON.
(d) Turn the Techstream on.
(e) Enter the following menus: Powertrain / Engine and ECT / Utility / VIN / VIN Read.
3. WRITE VIN
(a) Confirm the vehicle VIN.
(b) Connect the Techstream to the DLC3.
(c) Turn the ignition switch to ON.
(d) Turn the Techstream on.
(e) Enter the following menus: Powertrain / Engine and ECT / Utility / VIN / VIN Write.
Page 3019
Accelerator Pedal Position Sensor: Diagrams
Page 3558
(a) Measure the voltage and resistance according to the value(s) in the table below.
HINT Check from the rear of the connector while it is connected to the air conditioning amplifier.
* If the result is not as specified, the ECU may have a malfunction.
7. CHECK INTEGRATION CONTROL AND PANEL ASSEMBLY
(a) Disconnect the J37 integration control and panel assembly connector.
(b) Measure the voltage and resistance according to the value(s) in the table below.
* If the result is not as specified, there may be a malfunction on the wire harness side.
CAN Communication System
CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: TERMINALS OF ECU
HINT Operating the ignition switch, any switches or any doors triggers related ECU and sensor
communication with the CAN, which causes resistance variation.
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
(a) Disconnect the cable from the negative (-) battery terminal before measuring the resistances of
the main wire and the branch wire.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
NOTICE: Before measuring the resistance, leave the vehicle for at least 1 minute and do not
operate the ignition switch, any switches or doors. If
Page 4161
Page 6571
Auxiliary Power Outlet Switch: Service and Repair Installation
OTHER SYSTEM: INVERTER MAIN SWITCH (for CrewMax): INSTALLATION
1. INSTALL INVERTER MAIN SWITCH
(a) Attach the 2 claws to install the main switch.
2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Floor Shift Type)/Installation
3. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation
4. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Installation
5. INSTALL FRONT DOOR SCUFF PLATE LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining
(For Double Cab)/Installation
Page 2549
Required Tools & Equipment
Repair Procedure Overview
^ Confirm noise is coming from the rear of the vehicle and changes with vehicle speed.
^ Install ChaSSiSEAR(TM) (or equivalent) and isolate the noise to the rear wheel bearing.
^ Remove the rear axle shaft assembly.
^ Install new rear wheel bearing brake caliper bracket and seals.
^ Reinstall rear axle shaft assembly and confirm the noise is no longer present.
Repair Procedure
1. Test drive the vehicle and confirm the customer complaint.
Does the noise increase and decrease with vehicle speed?
^ YES - Go to step 2.
^ NO - This TSB does NOT apply. Refer to the Repair Manual for further diagnosis.
Page 7592
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: ELECTRONIC
CIRCUIT INSPECTION PROCEDURE
1. BASIC INSPECTION
(a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS
(1) Unless otherwise stated, all resistance measurements should be made at an ambient
temperature of 20°C (68°F). Resistance measurements
may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been
running. Measurements should be made after the engine has cooled down.
(b) HANDLING CONNECTORS
(1) When disconnecting a connector, first squeeze the mating halves tightly together to release the
lock, and then press the lock claw and
separate the connector.
(2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly
and separate it.
(3) Before connecting a connector, check that there are no deformed, damaged, loose or missing
terminals.
(4) When connecting a connector, press firmly until it locks with a "click" sound.
(5) If checking a connector with a TOYOTA electrical tester, check the connector from the backside
(harness side) using a mini test lead.
NOTICE: *
As a waterproof connector cannot be checked from the backside, check it by connecting a
sub-harness.
* Do not damage the terminals by moving the inserted tester needle.
(c) CHECKING CONNECTORS
(1) Checking when a connector is connected: Squeeze the connectors together to confirm that they
are fully connected and locked.
(2) Checking when a connector is disconnected: Check by pulling the wire harness lightly from the
backside of the connector. Look for
unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for
corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or
deformed terminals.
(3) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a
female terminal, and check for ample tension
Recall 11V185000 - TPMS Non-Compliance
Tire Pressure Module: All Technical Service Bulletins Recall 11V185000 - TPMS Non-Compliance
VEHICLE MAKE/MODEL: MODEL YEAR(S) Toyota/FJ Cruiser 2011
Toyota/Tundra 2009-2011
MANUFACTURER: Gulf States Toyota, Inc.
MFR'S REPORT DATE: March 16, 2011
NHTSA CAMPAIGN ID NUMBER: 11V185000
NHTSA ACTION NUMBER: N/A
COMPONENT: Tires: Pressure Monitoring and Regulating Systems
POTENTIAL NUMBER OF UNITS AFFECTED: 1,489
SUMMARY: Gulf States Toyota is recalling certain model year 2011 FJ Cruiser and model year
2009-2011 Tundra vehicles for failing to comply with the requirements of Federal Motor Vehicle
Safety Standard No. 138, "Tire Pressure Monitoring Systems." The TPMS on some vehicles may
not have been properly calibrated and as a result the low tire pressure warning lamp may not
illuminate should the inflation pressure in one or more of the vehicle's tires fall below the threshold
for when the low tire pressure warning lamp should illuminate.
CONSEQUENCE: Drivers will not receive a warning from the tire pressuring monitor that one or
more tires are underinflated increasing the risk that a vehicle will be driven with one or more
underinflated tires and increasing the risk of a tire failure that may lead to a crash.
REMEDY: Dealers will recalibrate the tire pressure monitoring system in accordance with the
regulation free of charge. The safety recall is expected to begin during April 2011. Owners may
contact Gulf State Toyota Customer Assistance Center toll free at 1-800-444-1074 Monday through
Thursday, 8:30 AM to 5:00 PM, or Friday 8:30 AM to 4:00 PM Central Standard Time.
NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle
Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov.
Page 7627
Symbols Used Within Diagrams
Symbols Used Within Diagrams
Diagrams
Variable Valve Timing Actuator Position Sensor: Diagrams
Page 1411
(a) Set the battery in the vehicle. Then move the stay onto the battery and tighten the nut to fix the
battery in place.
(b) Connect the cable to the positive (+) battery terminal.
3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
4. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
Components
SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for CrewMax):
COMPONENTS
Drivetrain - Front Driveshaft Ticking Noise In 4WD
Drive/Propeller Shaft: All Technical Service Bulletins Drivetrain - Front Driveshaft Ticking Noise In
4WD
T-SB-0045-10
January 27, 2010
Front Propeller Shaft Parts Label Delaminating - Ticking Noise
Service Category Drivetrain
Section Drive Shaft/Propeller Shaft
Market USA
Applicability
Introduction
Some 2008 - 2010 model year 4WD Sequoia and 2007 - 2010 model year 4WD Tundra vehicles
may have a ticking noise present only when in 4WD. Production changes have been made to
correct this condition. Follow the procedure in this bulletin to address this condition.
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60
months or 60,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Repair Procedure
1. Confirm there is a ticking noise only present in 4WD.
Page 8007
Air Bag Control Module: Diagrams
Page 8826
A/T - Torque Converter Bolt Installation Precautions
Flex Plate: Technical Service Bulletins A/T - Torque Converter Bolt Installation Precautions
T-SB-0014-11
February 17, 2011
Torque Converter Bolt Installation
Service Category Drivetrain
Section Automatic Transmission/Transaxle
Market USA
Applicability
Introduction
The purpose of this TSB is to provide information regarding the installation of the correct torque
converter bolts during automatic transmission/transaxle assembly replacement. Incorrect torque
converter bolts or missing washers can cause damage to the torque converter assembly. Use the
information in this bulletin when installing an automatic transmission/transaxle assembly.
NOTE
Not all applications will use washers on the torque converter bolts.
Warranty Information
Installation Procedure
^ When removing torque converter bolts and washers take special care that the same bolts and
washers are used when installing the torque converter.
^ Using an incorrect size bolt or washer may cause damage to the torque converter assembly.
Page 2088
Driver Side J/B - Cowl Side Left
Page 3862
Power Steering Pressure Switch: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: POWER STEERING OIL PRESSURE SWITCH:
INSTALLATION
1. INSTALL POWER STEERING OIL PRESSURE SWITCH
(a) Install a new O-ring to the power steering oil pressure switch.
(b) Apply a light coat of engine oil to the O-ring of the power steering oil pressure switch.
NOTICE: *
When reusing the power steering oil pressure switch, inspect the O-ring.
* If the O-ring has scratches or cuts, replace the power steering oil pressure switch.
(c) Using SST, install the power steering oil pressure switch.
SST : 09922-10010
without SST - Torque : 21 Nm (210 kgf-cm, 15 ft-lbf)
with SST - Torque : 15 Nm (148 kgf-cm, 11 ft-lbf)
HINT *
Use a torque wrench with a fulcrum length of 30 cm (11.8 in.). When using a torque wrench with a
fulcrum length that is not 30 cm (11.8 in.), calculate the torque specification for the torque wrench
and SST based on the "without SST" torque specification See: Service Precautions
* Make sure SST and the torque wrench are connected in a straight line.
(d) Connect the oil pressure switch connector.
2. INSTALL FAN AND GENERATOR V BELT
(a) Install the fan and generator V belt See: Engine, Cooling and Exhaust/Engine/Drive Belts,
Mounts, Brackets and Accessories/Drive
Belt/Service and Repair/Installation.
3. ADD POWER STEERING FLUID
4. BLEED POWER STEERING FLUID See: Steering and Suspension/Steering/Testing and
Inspection/Component Tests and General
Diagnostics/Power Steering System/On-Vehicle Inspection
5. INSPECT FOR POWER STEERING FLUID LEAK
6. CHECK FLUID LEVEL See: Steering and Suspension/Steering/Testing and
Inspection/Component Tests and General Diagnostics/Power
Steering System/On-Vehicle Inspection
7. INSTALL FRONT FENDER APRON SEAL RH See: Engine, Cooling and Exhaust/Exhaust
System/Exhaust Manifold/Service and
Repair/Installation
8. INSTALL FRONT WHEEL See: Steering and Suspension/Suspension/Suspension Strut / Shock
Absorber/Service and Repair/Removal and
Replacement/Front Shock Absorber/Installation
Side Airbag Sensor
Impact Sensor: Diagrams Side Airbag Sensor
Page 3245
* In the DTC check, it is very important to determine whether the problem indicated by the DTC is
either: 1) still occurring; or 2) occurred in the past but has since returned to normal. In addition, the
DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs
should be checked before and after confirmation of symptoms (i.e., whether or not problem
symptoms exist) to determine current system conditions, as shown in the flowchart below.
* Never skip the DTC check. Failing to check DTCs may, depending on the case, result in
unnecessary troubleshooting for systems operating normally or lead to repairs not related to the
problem. Follow the procedures listed in the flowchart in the correct order.
* The following flowchart shows how to proceed with troubleshooting using the DTC check.
Directions from the flowchart will indicate how to proceed either to DTC troubleshooting or to the
troubleshooting of each problem symptom.
1. DTC CHECK
NEXT -- Continue to next step.
2. MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR MEMORY
NEXT -- Continue to next step.
3. SYMPTOM CONFIRMATION
B -- Go to step 5 A -- Continue to next step.
4. SIMULATION TEST USING SYMPTOM SIMULATION METHODS
NEXT -- Continue to next step.
5. DTC CHECK
B -- TROUBLESHOOTING OF PROBLEM INDICATED BY DTC A -- Continue to next step.
6. SYMPTOM CONFIRMATION
Components
Ambient Temperature Sensor / Switch HVAC: Service and Repair Components
AIR CONDITIONING: AMBIENT TEMPERATURE SENSOR: COMPONENTS
Page 6848
Page 1603
Standard resistance:
(4) If the resistance is not as specified, repair or replace the harness or connector.
(c) Check the 4WD control switch.
(1) Turn the ignition switch OFF.
(2) Connect the L1 switch connector.
(3) Connect the A25 and A26 ECU connectors.
(4) Measure the voltage according to the value(s) in the table below.
Standard voltage:
(5) If the voltage is not as specified, check the 4WD control ECU.
(d) Check the 4WD control ECU.
(1) Disconnect the L1 switch connector.
(2) Measure the voltage according to the value(s) in the table below.
Page 4916
9. REMOVE TRANSMISSION CONTROL SWITCH (P POSITION)
(a) Remove the 2 screws and switch from the column shift control shift lever retainer.
Reassembly
A760F AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY (for Column Shift Type):
REASSEMBLY
1. INSTALL TRANSMISSION CONTROL SWITCH (P POSITION)
(a) Install the switch to the column shift control shift lever retainer with the 2 screws.
2. INSTALL TRANSMISSION CONTROL SWITCH (S POSITION)
(a) Apply MP grease to the switch as shown in the illustration.
(b) Install the switch to the column shift control shift lever retainer with the 2 screws.
Page 2371
(4) for Fuel Pipe Clamp Type:
Install the fuel pipe clamp to the connector.
(5) for Fuel Hose Connector Cover Type:
Attach the lock claw to the connector by pushing down on the cover, as shown in the illustration.
(6) Check that there is no fuel leakage.
3. CHECK FOR FUEL LEAK
(a) Check that there are no fuel leaks after performing maintenance anywhere on the fuel system
See: Powertrain Management/Fuel Delivery and
Air Induction/Testing and Inspection.
Locations
Relay Box: Locations
Engine Compartment
Page 8200
Child Restraint: Service and Repair Child Restraint Seat Anchor Bracket (for Regular Cab)
Components
SEAT BELT: CHILD RESTRAINT SEAT ANCHOR BRACKET (for Regular Cab): COMPONENTS
Removal
SEAT BELT: CHILD RESTRAINT SEAT ANCHOR BRACKET (for Regular Cab): REMOVAL
HINT Move the seat to the foremost position before performing this procedure.
Page 6384
Page 6115
Starter Motor: Overhaul
Disassembly
1UR-FE STARTING: STARTER (for 1.6 kW Type): DISASSEMBLY
1. REMOVE MAGNET STARTER SWITCH ASSEMBLY
(a) Remove the nut and disconnect the lead wire from the magnet starter switch.
(b) Remove the 2 nuts from the starter drive housing while holding the magnet starter switch.
(c) Pull the magnet starter switch and while lifting the front part of the magnet starter switch,
release the plunger hook from the drive lever and
remove the magnet starter switch.
2. REMOVE STARTER YOKE ASSEMBLY
(a) Using a T25 "TORX" socket wrench, remove the 2 bolts.
(b) Pull out the starter yoke together with the starter commutator end frame.
(c) Remove the 2 screws and commutator end frame from the starter yoke.
(d) Pull the starter yoke out of the starter commutator end frame.
Page 4584
Remove the blown fuse and disconnect all loads of the fuse.
Connect a test light in place of the fuse.
Establish conditions in which the test light comes on.
Example:
- [A] - Ignition SW on
- [B] - Ignition SW and SW1 on
- [C] - Ignition SW, SW1 and Relay on (Connect the Relay) and SW2 off (or Disconnect SW2)
Disconnect and reconnect the connectors while watching the test light.
Page 8900
Double Cab)/Removal
5. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH
6. REMOVE REAR DOOR SCUFF PLATE RH
(a) Remove the front door scuff plate See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Removal.
HINT The procedures listed below are for the LH side.
7. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY RH See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Double Cab)/Removal
8. REMOVE DOOR CONTROL RECEIVER
(a) Disconnect the door control receiver connector.
(b) Remove the bolt and receiver.
Installation
DOOR LOCK: DOOR CONTROL RECEIVER (for Double Cab): INSTALLATION
1. INSTALL DOOR CONTROL RECEIVER
(a) Install the receiver with the bolt.
(b) Connect the door control receiver connector.
2. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY RH
3. INSTALL REAR DOOR SCUFF PLATE RH
(a) Install rear door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double
Cab)/Installation.
HINT The procedures listed below are for the LH side.
4. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH
5. INSTALL REAR SEAT ASSEMBLY See: Body and Frame/Seats/Service and Repair/Removal
and Replacement/Rear Seat Assembly (for
Double Cab)/Installation
6. INSTALL SEAT FLOOR BOX See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Rear Seat Assembly (for Double
Page 6025
Torque : 4.6 Nm (47 kgf-cm, 41 in-lbf)
6. INSTALL GENERATOR PULLEY
SST : 09820-63011
09820-06010
09820-06021
HINT
(a) Clamp the generator housing stay in a vise.
(b) Install SST 1-A to the pulley shaft.
(c) Install SST 1-B to SST 1-A.
(d) Install the pulley onto the rotor shaft by tightening the pulley nut by hand.
(e) Hold SST 1-A with a torque wrench, and tighten SST 1-B clockwise to the specified torque.
Torque : 39 Nm (398 kgf-cm, 29 ft-lbf)
NOTICE: Check that SST is secured to the rotor shaft.
(f) Insert SST 2, and attach the pulley nut to SST 2.
(g) Tighten the pulley nut by turning SST 1-A in the direction shown in the illustration.
Page 6797
(a) For an open circuit in the wire harness in Fig. 1, check the resistance or voltage, as described
below.
(b) Check the resistance.
(1) Disconnect connectors A and C and measure the resistance between them.
Standard resistance (Fig. 2):
HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally.
If the results match the examples above, an open circuit exists between terminal 1 of connector A
and terminal 1 of connector C.
(2) Disconnect connector B and measure the resistance between the connectors.
Standard resistance (Fig. 3):
* If the results match the examples above, an open circuit exists between terminal 1 of connector
B2 and terminal 1 of connector C.
(c) Check the voltage.
Page 5051
Standard preload (at starting):
* If the preload is greater than the maximum, replace the bearing spacer.
* If the preload is less than the minimum, retighten the nut with 13 N*m (130 kgf*cm, 9 ft.*lbf) of
torque at a time until the specified preload is reached.
Torque : 441 Nm (4497 kgf-cm, 325 ft-lb for less)
* If the maximum torque is exceeded while retightening the nut, replace the bearing spacer and
repeat the preload adjusting procedure.
HINT Do not loosen the pinion nut to reduce the preload.
25. INSPECT TOTAL PRELOAD
(a) Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in
contact.
Standard total preload (at starting):
Standard drive pinion preload plus 0.24 to 0.46 N*m (3 to 4 kgf*cm, 3 to 4 in.*lbf)
26. INSPECT DIFFERENTIAL RING GEAR BACKLASH
(a) Using a dial indicator, check the backlash of the ring gear.
Standard backlash:
0.10 to 0.20 mm (0.00394 to 0.00788 in.)
* If the backlash is not as specified, adjust the side bearing preload or repair as necessary.
Page 8264
14. INSTALL REAR SEAT CUSHION COVER WITH PAD LH See: Body and Frame/Seats/Service
and Repair/Overhaul/Rear Seat Assembly (for
Crewmax LH Side)/Reassembly
15. CONNECT REAR CENTER SEAT OUTER BELT ASSEMBLY
(a) Connect the seat belt anchor with the bolt.
Torque : 42 Nm (428 kgf-cm, 31 ft-lbf)
HINT The rear No. 1 seat inner belt is fixed with the same bolt as the rear center seat outer belt's
anchor. Therefore, connect it when installing the rear No. 1 seat inner belt.
16. INSTALL REAR SEAT ASSEMBLY LH See: Body and Frame/Seats/Service and
Repair/Removal and Replacement/Rear Seat Assembly (for
Crewmax LH Side)/Installation
17. CONNECT REAR SEAT INNER BELT ASSEMBLY See: Rear Seat Inner Belt Assembly (for
CrewMax)/Installation
Components
SEAT BELT: REAR CENTER SEAT OUTER BELT ASSEMBLY (for Double Cab): COMPONENTS
Page 9011
[A] For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
"Case1" Raise the terminal retainer up to the temporary lock position.
CAN Communication System
Body Control Module: Locations CAN Communication System
CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: PARTS LOCATION
Page 8124
Page 9245
Rear Door Panel: Service and Repair Rear Door (for Double Cab)
Up to 11/2009
ENGINE HOOD / DOOR: REAR DOOR (for Double Cab): COMPONENTS
Page 2005
[A] For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
"Case1" Raise the terminal retainer up to the temporary lock position.
Page 5052
HINT Perform the measurements at 3 or more positions around the circumference of the ring gear.
27. INSPECT RUNOUT OF REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY
(a) Using a dial indicator, measure the runout of the companion flange vertically and laterally.
Maximum runout:
* If the runout is greater than the maximum, replace the companion flange.
28. STAKE REAR DRIVE PINION NUT
(a) Using a chisel and hammer, stake the nut.
29. INSTALL REAR DIFFERENTIAL BEARING ADJUSTING NUT LOCK
(a) Install 2 new adjusting locks onto the bearing caps with the 2 bolts.
Torque : 13 Nm (130 kgf-cm, 9 ft-lbf)
(b) Bend the nut locks.
Disassembly
DIFFERENTIAL: FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD): DISASSEMBLY
1. REMOVE AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR
(a) Remove the 4 bolts.
Components
Transmission Speed Sensor: Service and Repair Components
A760F AUTOMATIC TRANSMISSION: SPEED SENSOR: COMPONENTS
Engine - Snow Ingestion Into Air Cleaner Box
Front Fender Liner: Customer Interest Engine - Snow Ingestion Into Air Cleaner Box
T-SB-0396-09
December 8, 2009
Snow Entry Into Air Cleaner Box
Service Category Engine/Hybrid System
Section Intake/Exhaust
Market USA
Applicability
Introduction
Some Sequoia and Tundra vehicles operated in areas with significant snow volume may
experience snow accumulation in the air cleaner box which can cause the lid to fracture. The air
cleaner lid and fender liner have been revised to reduce accumulation.
Parts Information
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for
36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Production Change Information
Page 935
10. REMOVE DAMPER SERVO SUB-ASSEMBLY
(a) Disconnect the 2 connectors.
(b) Remove the 4 screws and damper servo.
(c) Remove the damper servo.
(1) Detach the claw and remove the main plate.
(2) Remove the 2 screws and damper servo.
(d) Remove the damper servo.
Page 3414
NOTICE: *1: MIL turns on only during VSC or ABS failure status.
Page 7702
Control Assembly: Service and Repair Air Conditioning Panel (for Floor Shift Type)
Components
AIR CONDITIONING: AIR CONDITIONING PANEL (for Floor Shift Type): COMPONENTS
Page 626
Remote Switch: Service and Repair Installation
AUDIO / VISUAL: STEERING PAD SWITCH: INSTALLATION
1. INSTALL STEERING PAD SWITCH ASSEMBLY
(a) Attach the 4 pins to install the switch with the 2 screws.
(b) Connect the connector.
2. INSTALL LOWER NO. 3 STEERING WHEEL COVER See: Restraint Systems/Air Bag
Systems/Air Bag/Service and Repair/Removal and
Replacement/Steering Pad/Installation
3. INSTALL LOWER NO. 2 STEERING WHEEL COVER See: Restraint Systems/Air Bag
Systems/Air Bag/Service and Repair/Removal and
Replacement/Steering Pad/Installation
4. INSTALL STEERING PAD See: Restraint Systems/Air Bag Systems/Air Bag/Service and
Repair/Removal and Replacement/Steering
Pad/Installation
5. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
6. INSPECT STEERING PAD See: Restraint Systems/Air Bag Systems/Air Bag/Service and
Repair/Removal and Replacement/Steering
Pad/Installation
7. CHECK SRS WARNING LIGHT See: Restraint Systems/Air Bag Systems/Air Bag/Service and
Repair/Removal and Replacement/Steering
Pad/Installation
Page 6475
Establish conditions in which voltage is present at the check point.
Example:
- [A] - Ignition SW on
- [B] - Ignition SW and SW1 on
- [C] - Ignition SW, SW1 and Relay on (SW2 off)
Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or component terminal.
This check can be done with a test light instead of a voltmeter.
Electronic Circuit Inspection Procedure
Page 1408
(e) Connect the holder (with connectors).
(f) Check that the waterproof sheet is properly set.
2. INSTALL FRONT CONSOLE BOX See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal
and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation
3. INSTALL REAR CONSOLE BOX ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation
4. INSTALL CONSOLE BOX CARPET
5. INSTALL REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
6. INSTALL UPPER CONSOLE REAR PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
7. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding
/ Trim/Dashboard / Instrument Panel/Service
and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
8. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation
9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
10. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
Components
SUPPLEMENTAL RESTRAINT SYSTEM: FRONT AIRBAG SENSOR: COMPONENTS
Page 1054
Door Switch: Diagrams Rear Door Courtesy Switch
Page 8331
Impact Sensor: Diagrams Door Side Airbag Sensor
Page 8778
Tweeter
Page 86
Power Seat Control Module: Diagrams
Page 6919
Establish conditions in which voltage is present at the check point.
Example:
- [A] - Ignition SW on
- [B] - Ignition SW and SW1 on
- [C] - Ignition SW, SW1 and Relay on (SW2 off)
Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or component terminal.
This check can be done with a test light instead of a voltmeter.
Electronic Circuit Inspection Procedure
Page 6600
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: ELECTRONIC
CIRCUIT INSPECTION PROCEDURE
1. BASIC INSPECTION
(a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS
(1) Unless otherwise stated, all resistance measurements should be made at an ambient
temperature of 20°C (68°F). Resistance measurements
may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been
running. Measurements should be made after the engine has cooled down.
(b) HANDLING CONNECTORS
(1) When disconnecting a connector, first squeeze the mating halves tightly together to release the
lock, and then press the lock claw and
separate the connector.
(2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly
and separate it.
(3) Before connecting a connector, check that there are no deformed, damaged, loose or missing
terminals.
(4) When connecting a connector, press firmly until it locks with a "click" sound.
(5) If checking a connector with a TOYOTA electrical tester, check the connector from the backside
(harness side) using a mini test lead.
NOTICE: *
As a waterproof connector cannot be checked from the backside, check it by connecting a
sub-harness.
* Do not damage the terminals by moving the inserted tester needle.
(c) CHECKING CONNECTORS
(1) Checking when a connector is connected: Squeeze the connectors together to confirm that they
are fully connected and locked.
(2) Checking when a connector is disconnected: Check by pulling the wire harness lightly from the
backside of the connector. Look for
unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for
corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or
deformed terminals.
(3) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a
female terminal, and check for ample tension
Engine Controls - ECM Update For Shift Performance
Engine Control Module: Customer Interest Engine Controls - ECM Update For Shift Performance
T-SB-0285-10
October 12, 2010
ECM Calibration: Enhancement to Shifting Performance
Service Category Drivetrain
Section Automatic Transmission/Transaxle
Market USA
Applicability
Introduction
Some vehicles may exhibit the following shifting conditions:
^ Harsh shift on acceleration below 20 mph during the 2-1 downshift.
^ Excessive lock-up operation at freeway speeds about 50 - 60 mph, sometimes referred to as
"busy shifting".
The Engine Control Module/ECM (SAE term: Powertrain Control Module/PCM) calibration has
been revised. Use the following repair procedure to address these conditions.
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Federal Emission Warranty. This warranty is in effect for
96 months or 80,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Page 6371
Page 9244
Up to 11/2009
Yaw Rate Sensor: Locations Up to 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 5340
Transmission Mode Switch: Diagrams Tow/Haul Pattern Select Switch
Diagrams
Television / Monitor: Diagrams
Components
Rear Vision Camera: Service and Repair Components
PARK ASSIST / MONITORING: TELEVISION CAMERA: COMPONENTS
Locations
Steering Control Module: Locations
Instrument Panel (Floor Shift)
Instrument Panel (Column Shift)
Page 4808
Actuator: Diagrams
Page 3965
Required Tools & Equipment
Repair Procedure
1. Using TIS Techstream check if DTC P0418, P0419, P2440, P2441, P2442, P2443, P2446
and/or P2447 are present.
2. Using Techstream perform the manual Air Injection Test (options 1 and 2) to verify if the signal
from the air injection control driver is reaching the
air pumps.
^ The pumps should be heard turning on at this point and there should be battery voltage on pin 2
of the pumps during this test.
^ If there is NO voltage refer to the Repair Manual for air injection control driver diagnosis.
Refer to the Technical Information System (TIS) 2010 model year Tundra Repair Manual:
3. If during the test voltage is present at the pump and the pump is NOT running or the Air
Pressure (gauge) value did NOT increase from 0 to 1 psi on
TIS Techstream with the pump running remove the air pump assemblies for inspection.
Refer to TIS 2010 model year Tundra Repair Manual:
4. With the pumps removed from the vehicle verify if there is liquid or evidence that liquid entered
the pumps.
^ YES - If there is liquid evidence go to step 5.
^ NO - If there is NO evidence of liquid go to step 7.
5. If liquid is present replace the affected pump assembly.
Refer to TIS 2010 model year Tundra Repair Manual:
Page 6836
Junction Connector
Page 4548
Ignition Relay: Testing and Inspection
1UR-FE ENGINE CONTROL SYSTEM: IGNITION RELAY NO. 2: ON-VEHICLE INSPECTION
1. REMOVE INTEGRATION RELAY
(a) Remove the engine room relay block cover.
(b) Using a screwdriver, detach the 2 claws and remove the integration relay from the engine room
relay block.
HINT Tape the screwdriver tip before use.
(c) Disconnect the 3 connectors.
2. INSPECT INTEGRATION RELAY (IG2)
NOTICE: *
Some relays are built into the integration relay. The integration relay cannot be disassembled. If
there is a malfunction in the circuit of the integration relay, replace the integration relay.
* The internal circuit of the integration relay is as shown in the illustration below. Inspect the
integration relay using the following procedures.
(a) Measure the resistance of the IG2 MAIN fuse.
(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(2) If the result is not as specified, replace the IG2 MAIN fuse.
(b) Measure the resistance of the ignition relay No. 2 (IG2).
Page 7898
Solar Sensor: Service and Repair Removal
AIR CONDITIONING: SOLAR SENSOR (for Automatic Air Conditioning System): REMOVAL
1. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY
(a) for Column Shift Type:
Remove the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Column Shift Type)/Removal.
(b) for Floor Shift Type:
Remove the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Floor Shift Type)/Removal.
2. REMOVE AUTOMATIC LIGHT CONTROL SENSOR (SOLAR SENSOR)
(a) Detach the 2 claws.
(b) Disconnect the connector and remove the sensor.
Components
Cargo Lamp Switch: Service and Repair Components
LIGHTING: CARGO LIGHT SWITCH: COMPONENTS
Page 6780
Page 2648
3. INSTALL INLET RADIATOR HOSE
(a) Install the inlet radiator hose.
HINT The direction of each hose clamp is indicated in the illustration.
4. INSTALL AIR CLEANER ASSEMBLY See: Powertrain Management/Ignition System/Ignition
Coil/Service and Repair/Installation
5. ADD ENGINE COOLANT See: Coolant/Service and Repair
6. INSPECT FOR COOLANT LEAK See: Testing and Inspection
7. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine/Service and Repair/Removal and
Replacement/Engine Assembly/Installation
8. INSTALL NO. 1 ENGINE UNDER COVER See: Engine/Engine Lubrication/Engine Oil/Service
and Repair/Replacement
Page 5029
Removal
DIFFERENTIAL: FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD): REMOVAL
1. REMOVE FRONT WHEELS
2. REMOVE NO. 1 ENGINE UNDER COVER See: Engine, Cooling and Exhaust/Engine/Drive
Belts, Mounts, Brackets and Accessories/Drive
Belt/Service and Repair/Removal
3. DRAIN DIFFERENTIAL OIL See: Fluid - Differential/Service and Repair
4. REMOVE FRONT PROPELLER SHAFT ASSEMBLY
(a) Remove the front propeller shaft See: Drive/Propeller Shafts, Bearings and
Joints/Drive/Propeller Shaft/Service and Repair/Removal and
Page 5647
Wheel Speed Sensor: Diagrams Rear Speed Sensor
Components
Actuator: Service and Repair Components
DIFFERENTIAL: AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR (for 4WD):
COMPONENTS
Page 356
Mongoose MFC Software and Driver MUST be installed before Mongoose MFC selection will be
available.
See TIS - Diagnostics - Scantool page for additional information.
^ If using TIS Techstream select TIS Techstream VIM (this is the default).
4. Click OK.
Operation Procedure
1. Verify the vehicle's applicability for recalibration and locate desired calibration file.
A. Connect Techstream and establish a vehicle connection.
B. Click the Health Check button on the System Select tab.
Page 8493
Keyless Entry Module: Service and Repair Door Control Receiver (for Double Cab)
Components
DOOR LOCK: DOOR CONTROL RECEIVER (for Double Cab): COMPONENTS
Page 1200
Oxygen Sensor: Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 7196
(c) Align the notch of the front side plate with the notch of the front housing, and install the front
side plate.
NOTICE: Make sure that the front side plate is installed facing in the correct direction.
4. INSTALL VANE PUMP CAM RING
(a) Coat the cam ring with the power steering fluid.
(b) Align the notch of the cam ring with the notch of the front side plate, and install the cam ring
with the inscribed mark facing upward.
NOTICE: Make sure that the cam ring is installed facing in the correct direction.
5. INSTALL VANE PUMP ROTOR
(a) Install the vane pump rotor.
Engine Controls - Techstream(R) ECU Re-Flash
Procedure
Engine Control Module: All Technical Service Bulletins Engine Controls - Techstream(R) ECU
Re-Flash Procedure
T-SB-0064-10
February 4, 2010
Techstream ECU Flash Reprogramming Procedure
Service Category Engine/Hybrid System
Section Engine Control
Market USA
Applicability
TSB SUPERSESSION NOTICE
The information contained in this TSB supersedes TSB No. SS002-07.
^ Applicability has been updated to include 2009 - 2011 model year Toyota vehicles.
^ A new section, Techstream Preparation, has been added.
^ Techstream Lite has been added as an option in Required Tools & Materials.
^ Process Overview and Operation Procedure sections have been updated.
TSB No. SS002-07 is Obsolete and any printed versions should be discarded. Be sure to review
the entire content of this service bulletin before proceeding.
Introduction
Flash reprogramming allows the ECU software to be updated without replacing the ECU. Flash
calibration updates for specific vehicle models/ECUs are released as field-fix procedures described
in individual service bulletins. This bulletin details the Techstream ECU flash reprogramming
process and outlines use of the Technical Information System (TIS) and the Calibration Update
Wizard (CUW). Flash calibration updates can only be applied to the vehicle/ECU combination for
which they are intended. ECUs have internal security that will not allow them to be programmed
with another ECU's information.
ECU
Electronic Control Unit (ECU) is a Toyota term used to describe integrated computerized devices
responsible for managing the operation of a system or subsystem. For the purposes of this bulletin,
the term "ECU" is used as a generic label for the following SAE J1930 standard references:
^ Powertrain Control Module (PCM)
Page 4935
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Installation
13. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Installation
14. INSTALL FRONT DOOR SCUFF PLATE LH (for Double Cab, CrewMax) See: Body and
Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Installation
15. INSTALL FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Installation
16. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Page 6833
Page 4742
Parts Information
Required Tools & Equipment
Repair Procedure
1. Confirm the condition matches the Introduction.
Page 3521
Standard resistance:
NG -- CHECK FOR SHORT TO GND IN CAN BUS WIRE (SKID CONTROL ECU WITH
ACTUATOR) OK -- Continue to next step.
10. CHECK FOR SHORT TO GND IN CAN BUS WIRE (NO. 1 JUNCTION CONNECTOR STEERING ANGLE SENSOR)
(a) Disconnect the J87 No. 1 junction connector connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- CHECK FOR SHORT TO GND IN CAN BUS WIRE (STEERING ANGLE SENSOR) OK -Continue to next step.
11. CHECK FOR SHORT TO GND IN CAN BUS WIRE (NO. 1 JUNCTION CONNECTOR POWER STEERING ECU)
NOTICE: For vehicles without a power steering ECU, go to "CHECK FOR SHORT TO GND IN
CAN BUS WIRE (NO. 1 JUNCTION CONNECTOR - CENTER AIRBAG SENSOR)".
(a) Disconnect the J115 No. 1 junction connector connector.
Page 2837
(b) Install the connector holder block cover.
4. INSTALL AIR CLEANER ASSEMBLY See: Ignition System/Ignition Coil/Service and
Repair/Installation
5. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Installation
Page 3690
When using Techstream Lite, select Generic J2534 Interface. Then click Next.
E. Confirm the following:
^ PC is connected to VIM.
^ VIM is connected to DLC3 connector.
^ Ignition is ON and engine is OFF or "READY" OFF (hybrid vehicles).
Page 1098
Headlamp Dimmer Switch: Service and Repair Installation
LIGHTING: HEADLIGHT DIMMER SWITCH: INSTALLATION
1. INSTALL HEADLIGHT DIMMER SWITCH ASSEMBLY
(a) Insert the headlight dimmer switch assembly onto the steering column while making sure that
the switch's protrusions align with the shaft's
cutout parts.
(b) While loosening the band clamp, attach the claw to install the headlight dimmer switch
assembly.
(c) Connect the connector.
2. INSTALL WINDSHIELD WIPER SWITCH ASSEMBLY
(a) Attach the claw to install the windshield wiper switch.
(b) Connect the connectors.
3. INSTALL SPIRAL CABLE SUB-ASSEMBLY See: Restraint Systems/Air Bag
Systems/Clockspring Assembly / Spiral Cable/Service and
Repair/Installation
4. INSTALL TILT AND TELESCOPIC MANUAL SWITCH (for Power Tilt and Power Telescopic
Steering Column) See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering
Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Installation
5. INSTALL UPPER STEERING COLUMN COVER (for Manual Tilt) See: Steering and
Suspension/Steering/Steering Column/Service and
Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Installation
6. INSTALL UPPER STEERING COLUMN COVER (for Manual Tilt and Manual Telescopic
Steering Column) See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering
Column Assembly (for Manual Tilt and Manual Telescopic Steering Column)/Installation
7. INSTALL UPPER STEERING COLUMN COVER (for Power Tilt and Power Telescopic Steering
Column) See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering
Column Assembly (for Power Tilt and Power
Page 3152
(4) Connect the engine wire harness clamp.
3. INSTALL AIR CLEANER ASSEMBLY
(a) Install the air cleaner with the 2 bolts.
Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)
(b) Tighten the hose clamp.
Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf)
(c) Connect the ventilation hose and vacuum hose.
(d) Connect the MAF meter connector and clamp.
4. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Installation
Page 5825
Electronic Brake Control Module: Diagrams
Page 8263
First install the bolt A, and then install the nut B.
for bolt A - Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)
for nut B - Torque : 42 Nm (428 kgf-cm, 31 ft-lbf)
(b) Install the belt sensor with the 3 nuts.
for nut C - Torque : 6.0 Nm (61 kgf-cm, 53 in-lbf)
2. INSTALL REAR SEAT SHOULDER BELT HOLE COVER
(a) Install the seat belt as shown in the illustration.
(b) Install the cover with the screw.
3. INSTALL REAR SEATBACK HINGE COVER See: Body and Frame/Seats/Service and
Repair/Overhaul/Rear Seat Assembly (for Crewmax
LH Side)/Reassembly
4. INSTALL CENTER RECLINING ADJUSTER INSIDE COVER See: Body and
Frame/Seats/Service and Repair/Overhaul/Rear Seat Assembly
(for Crewmax LH Side)/Reassembly
5. INSTALL REAR SEATBACK COVER WITH PAD See: Body and Frame/Seats/Service and
Repair/Overhaul/Rear Seat Assembly (for
Crewmax LH Side)/Reassembly
6. INSTALL LOWER REAR SEATBACK COVER SUB-ASSEMBLY LH See: Body and
Frame/Seats/Service and Repair/Overhaul/Rear Seat
Assembly (for Crewmax LH Side)/Reassembly
7. INSTALL REAR SEAT LOCK CONTROL LEVER SUB-ASSEMBLY LH See: Body and
Frame/Seats/Service and Repair/Overhaul/Rear Seat
Assembly (for Crewmax LH Side)/Reassembly
8. INSTALL REAR SEATBACK LOCK STRIKER COVER LH See: Body and Frame/Seats/Service
and Repair/Overhaul/Rear Seat Assembly
(for Crewmax LH Side)/Reassembly
9. INSTALL REAR SEAT HEADREST SUPPORT See: Body and Frame/Seats/Service and
Repair/Overhaul/Rear Seat Assembly (for Crewmax
LH Side)/Reassembly
10. INSTALL CENTER REAR SEAT HEADREST ASSEMBLY
11. INSTALL REAR SEAT HEADREST ASSEMBLY LH
12. INSTALL REAR SEAT ARMREST ASSEMBLY See: Body and Frame/Seats/Service and
Repair/Overhaul/Rear Seat Assembly (for Crewmax
LH Side)/Reassembly
13. INSTALL REAR SEATBACK BOARD LH See: Body and Frame/Seats/Service and
Repair/Overhaul/Rear Seat Assembly (for Crewmax LH
Side)/Reassembly
Diagram Information and Instructions
Relay Box: Diagram Information and Instructions
Wiring Color Codes
Abbreviations Used Within Diagrams
Abbreviations Used Within Diagrams
Recall 10V017000: Accelerator Pedal Sticking
Accelerator Pedal Position Sensor: All Technical Service Bulletins Recall 10V017000: Accelerator
Pedal Sticking
VEHICLE MAKE/MODEL: MODEL YEAR(S): Toyota/Avalon 2005-2010 Toyota/Camry 2007-2010
Toyota/Corolla 2009-2010 Toyota/Corolla Matrix 2009-2010 Toyota/Highlander 2010 Toyota/ RAV4
2009-2010 Toyota/Sequoia 2008-2010 Toyota/Tundra 2007-2010 MANUFACTURER: Toyota
Motor North America, Inc.
MFR'S REPORT DATE: January 21, 2010
NHTSA CAMPAIGN ID NUMBER: 10V017000
NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Accelerator Assembly:
Pedal/Linkage
POTENTIAL NUMBER OF UNITS AFFECTED: ?
SUMMARY: Toyota is recalling certain model year 2005-2010 Avalon, model year 2007-2010
Camry, model year 2009-2010 Corolla, Corolla Matrix, RAV4, model year 2010 Highlander, model
year 2008-2010 Sequoia, and model year 2007-2010 Tundra. due to the manner in which the
friction lever interacts with the sliding surface of the accelerator pedal inside the pedal sensor
assembly, the sliding surface of the lever may become smooth during vehicle operation. In this
condition, if condensation occurs on the surface, as may occur from heater operation (without A/C)
when the pedal assembly is cold, the friction when the accelerator pedal is operated may increase,
which may result in the accelerator pedal becoming harder to depress, slower to return, or, in the
worst case, mechanically stuck in a partially depressed position.
CONSEQUENCE: The accelerator pedal may become hard to depress, slow to return to idle, or, in
the worst case, mechanically stuck in a partially depressed position, increasing the risk of a crash.
REMEDY: Toyota has not yet provided a remedy plan or an owner notification schedule. Owners
may contact Toyota at 1-800-331-4331.
NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle
Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov.
Page 3093
(2) CONNECTORS
Slightly shake the connector vertically and horizontally.
(3) WIRE HARNESS
Slightly shake the wire harness vertically and horizontally.
HINT The connector joint and fulcrum of the vibration are the major areas that should be checked
thoroughly.
(b) HEAT METHOD:
When a malfunction seems to occur when the area in question is heated.
(1) Heat the component that is the possible cause of the malfunction with a hair dryer or similar
device. Check if the malfunction occurs.
NOTICE: *
Do not heat to more than 60°C (140°F). Exceeding this temperature may damage components.
* Do not apply heat directly to the parts in the ECU.
(c) WATER SPRINKLING METHOD:
When a malfunction seems to occur on a rainy day or in high-humidity.
(1) Sprinkle water onto the vehicle and check if the malfunction occurs.
NOTICE: *
Never sprinkle water directly into the engine compartment. Indirectly change the temperature and
humidity by spraying water onto the front of the radiator.
* Never apply water directly onto the electronic components.
HINT If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU
or connections. Look for evidence of corrosion or short circuits. Proceed with caution during water
tests.
(d) HIGH ELECTRICAL LOAD METHOD:
When a malfunction seems to occur when the electrical load is excessive.
(1) Turn on the heater blower, headlights, rear window defogger and all other electrical loads.
Check if the malfunction reoccurs.
5. DIAGNOSTIC TROUBLE CODE CHART
Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate
section's Diagnostic Trouble Code Chart. Use the chart to determine the trouble area and the
proper inspection procedure. A description of each of the chart's columns is below.
Page 6653
(a) for AC Power Supply:
Connect the clamp.
(b) Install the bezel with the 4 screws.
5. INSTALL NO. 2 CONSOLE BOX REGISTER ASSEMBLY See: Body and Frame/Seats/Service
and Repair/Overhaul/Front Seat Assembly (for
Center Seat)/Reassembly
6. INSTALL NO. 1 CONSOLE BOX REGISTER ASSEMBLY See: Body and Frame/Seats/Service
and Repair/Overhaul/Front Seat Assembly (for
Center Seat)/Reassembly
7. INSTALL CENTER SEATBACK PANEL See: Body and Frame/Seats/Service and
Repair/Overhaul/Front Seat Assembly (for Center
Seat)/Reassembly
Components
OTHER SYSTEM: POWER OUTLET SOCKET (for CrewMax Floor Shift Type): COMPONENTS
Page 2431
Repair Procedure
Page 8130
Seat Occupant Classification Module - Air Bag: Service and Repair Removal
SUPPLEMENTAL RESTRAINT SYSTEM: OCCUPANT CLASSIFICATION ECU: REMOVAL
1. REMOVE FRONT SEAT ASSEMBLY RH
(a) Remove the front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Manual
Seat)/Removal.
2. REMOVE OCCUPANT CLASSIFICATION ECU
(a) Disconnect the connector.
(b) Detach the claw and remove the ECU from the seat.
Page 810
Steering Angle Sensor: Service and Repair Removal
BRAKE CONTROL: STEERING ANGLE SENSOR: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to disable the SRS system.
2. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
3. REMOVE LOWER NO. 3 STEERING WHEEL COVER See: Restraint Systems/Air Bag
Systems/Air Bag/Service and Repair/Removal and
Replacement/Steering Pad/Removal
4. REMOVE LOWER NO. 2 STEERING WHEEL COVER See: Restraint Systems/Air Bag
Systems/Air Bag/Service and Repair/Removal and
Replacement/Steering Pad/Removal
5. REMOVE STEERING PAD See: Restraint Systems/Air Bag Systems/Air Bag/Service and
Repair/Removal and Replacement/Steering
Pad/Removal
6. REMOVE STEERING WHEEL ASSEMBLY See: Steering and Suspension/Steering/Steering
Column/Service and Repair/Removal and
Replacement/Steering Column Assembly (for Manual Tilt)/Removal
7. REMOVE LOWER STEERING COLUMN COVER See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Removal and
Replacement/Steering Column Assembly (for Manual Tilt)/Removal
8. REMOVE UPPER STEERING COLUMN COVER See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Removal and
Replacement/Steering Column Assembly (for Manual Tilt)/Removal
9. REMOVE SPIRAL CABLE SUB-ASSEMBLY See: Restraint Systems/Air Bag
Systems/Clockspring Assembly / Spiral Cable/Service and
Repair/Removal
10. REMOVE STEERING ANGLE SENSOR See: Restraint Systems/Air Bag Systems/Clockspring
Assembly / Spiral Cable/Service and
Repair/Removal
Page 7589
Release the locking lug from terminal and pull the terminal out from rear.
INSTALL TERMINAL TO CONNECTOR
Insert the terminal.
HINT: Make sure the terminal is positioned correctly.
Insert the terminal until the locking lug locks firmly.
Insert the terminal with terminal retainer in the temporary lock position.
Page 4986
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) Apply 12 V battery voltage to the shift solenoid valve and check that the valve moves and
makes an operating noise.
OK:
(c) If the result is not as specified, replace the solenoid valve.
5. INSPECT SHIFT SOLENOID VALVE S4
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) Apply 12 V battery voltage to the shift solenoid valve and check that the valve moves and
makes an operating noise.
OK:
Page 5543
Four Wheel Drive Selector Switch: Diagrams
Page 1090
Headlamp Dimmer Switch: Diagrams
Page 844
Torque : 11 Nm (107 kgf-cm, 8 ft-lbf)
(b) Connect the speed sensor connector (labeled C).
NOTICE: Securely connect the connector.
4. INSTALL REAR WHEEL See: Steering and Suspension/Suspension/Suspension Strut / Shock
Absorber/Service and Repair/Removal and
Replacement/Rear Shock Absorber/Installation
5. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
6. CHECK SPEED SENSOR SIGNAL
(a) Check the speed sensor signal See: Brakes and Traction Control/Antilock Brakes / Traction
Control Systems/Testing and Inspection/Scan
Tool Testing and Procedures/Test Mode Procedure.
Page 6271
"Case2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 4782
4. Attach the Authorized Vehicle Modification Label.
Modifications to ECU calibrations MUST be recorded and properly displayed on the vehicle using
the Authorized Modification Label.
Techstream Preparation
Selecting the TIS Techstream VIM or the Mongoose MFC VIM.
Techstream software requires a VIM selection before you can use the Mongoose MFC VIM.
If using TIS Techstream no changes are needed.
Perform the following:
1. Select Setup from the Techstream Main Menu screen.
2. Select VIM Select from the Setup drop down menu.
3. Select the correct Interface Setup from the drop down list.
^ If using Techstream Lite select Mongoose MFC.
NOTE
Page 7041
Alignment: Service and Repair
SUSPENSION: FRONT WHEEL ALIGNMENT: ADJUSTMENT
NOTICE: For vehicles equipped with VSC, if wheel alignment has been adjusted, and if suspension
or underbody components have been removed/installed or replaced, be sure to perform the
following initialization procedure in order for the system to function normally:
* Check that the steering wheel is in the centered position.
* Disconnect the negative battery terminal for more than 2 seconds.
* Reconnect the negative battery terminal.
* Perform zero point calibration of the yaw rate and deceleration sensor and test mode inspection
See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Testing and
Inspection/Programming and Relearning
1. INSPECT TIRE
(a) Inspect the tires See: Wheels and Tires/Testing and Inspection/Component Tests and General
Diagnostics.
2. MEASURE VEHICLE HEIGHT
NOTICE: Before inspecting the wheel alignment, adjust the vehicle height to the specification.
(a) Press down on the vehicle several times to stabilize the suspension, and then measure the
vehicle height.
Standard vehicle height (unloaded vehicle):
for Regular Cab of Standard Deck
Page 6767
AJ9-JI2
Page 8527
(a) Detach the 4 clips.
(b) Disconnect the connector and remove the panel.
11. REMOVE GLASS BREAKAGE SENSOR MICROPHONE
(a) Detach the 2 claws and remove the sensor.
Installation
THEFT DETERRENT: GLASS BREAKAGE SENSOR (for Floor Shift Type): INSTALLATION
1. INSTALL GLASS BREAKAGE SENSOR MICROPHONE
(a) Attach the 2 claws to install the sensor.
2. INSTALL INTEGRATION CONTROL AND PANEL ASSEMBLY
Page 1323
(1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be
checked by conducting a voltage check.
With each connector still connected, measure the voltage between the body ground and these
terminals (in this order): 1) terminal 1 of connector A; 2) terminal 1 of connector B; and 3) terminal
1 of connector C.
Standard voltage (Fig. 4):
* If the results match the examples above, an open circuit exists in the wire harness between
terminal 1 of connector B and terminal 1 of connector C.
3. CHECK FOR SHORT CIRCUIT
(a) If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance
check with the body ground (below).
(b) Check the resistance with the body ground.
(1) Disconnect connectors A and C and measure the resistance.
Standard resistance (Fig. 6):
HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally.
If your results match the examples above, a short circuit exists between terminal 1 of connector A
and terminal 1 of connector C.
Engine Control System - SFI System
Crankshaft Position Sensor: Locations Engine Control System - SFI System
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 7447
Tire Pressure Sensor: Service and Repair Removal
TIRE AND WHEEL: TIRE PRESSURE WARNING VALVE AND TRANSMITTER: REMOVAL
1. REMOVE TIRE
2. REMOVE TIRE PRESSURE WARNING VALVE AND TRANSMITTER
(a) Remove the valve core and cap, and release the air from the tire.
(b) After ensuring that a sufficient amount of air has been released, remove the nut and washer
that is used to secure the tire pressure warning
valve and transmitter. Then drop the tire pressure warning valve and transmitter inside the tire.
HINT Keep the removed cap, valve core, nut and washer.
(c) Disengage the bead using the shoe of a tire remover.
NOTICE: Be careful as the tire pressure warning valve and transmitter may become damaged due
to interference between the sensor and tire bead.
(d) Remove the bead on the upper side.
(e) Take out the tire pressure warning valve and transmitter from the tire, then remove the bead on
the lower side.
HINT *
The grommet is a non-reusable part.
* Check that there are no cracks or damage on the grommet. If any damage is found, replace the
washer and nut.
Page 8820
* The procedures listed below are for the LH side.
1. INSTALL FRONT NO. 3 SPEAKER ASSEMBLY (for 10 Speakers)
(a) Attach the 3 claws to install the speaker to the bracket.
NOTICE: Do not touch the cone part of the speaker.
(b) Install the speaker with bracket to the lower frame bracket garnish with the 3 screws.
2. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY
(a) Temporarily install the speaker by attaching the claws of the speaker to the door panel.
(b) Install the speaker with the 4 screws.
NOTICE: Do not touch the cone part of the speaker.
HINT Install the screws in the order shown in the illustration.
(c) Connect the connector.
3. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH See: Body and Frame/Doors,
Hood and Trunk/Doors/Front Door/Service and
Repair/Front Door (for Double Cab)/Reassembly
4. INSTALL FRONT DOOR ARMREST COVER LH
5. INSTALL COURTESY LIGHT ASSEMBLY See: Body and Frame/Doors, Hood and
Trunk/Doors/Front Door/Service and Repair/Front Door
(for Double Cab)/Reassembly
6. INSTALL FRONT UPPER ARMREST BASE PANEL LH See: Body and Frame/Doors, Hood and
Trunk/Doors/Front Door/Service and
Repair/Front Door (for Double Cab)/Reassembly
7. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH See: Body and Frame/Doors,
Hood and Trunk/Doors/Front Door/Service and
Page 5961
when inserting and after full engagement.
NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal.
(d) REPAIR METHOD OF CONNECTOR TERMINAL
(1) If there is any foreign matter on the terminal, clean the contact point using an air gun or cloth.
Never rub the contact point using sandpaper
as the plating may come off.
(2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is
gold-plated (gold color), use a gold-plated female
terminal; if it is silver-plated (silver color), use a silver-plated female terminal.
(3) Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock
into the housing, the housing may have to be
replaced.
(e) HANDLING OF WIRE HARNESS
(1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be
restored in the same way.
(2) Never twist, pull or slacken the wire harness more than necessary.
(3) The wire harness should never come into contact with a high temperature part, or rotating,
moving, vibrating or sharp-edged parts. Avoid
contact with panel edges, screw tips and other sharp items.
(4) When installing parts, never pinch the wire harness.
(5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with
vinyl tape.
2. CHECK FOR OPEN CIRCUIT
Page 2100
J/B No.3 Inner Circuit
J/B No.4 Inner Circuit
J/B No.5 Inner Circuit
Page 7667
ND-OIL 8 or equivalent
(c) Install the O-ring on the cooler refrigerant suction hose.
(d) Connect the cooler refrigerant suction hose on the cooler compressor with the bolt.
Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)
4. CONNECT DISCHARGE HOSE
(a) Remove the attached vinyl tape from the cooler refrigerant discharge hose.
(b) Sufficiently apply compressor oil to a new O-ring and the fitting surface of the cooler
compressor.
Compressor oil:
ND-OIL 8 or equivalent
(c) Install the O-ring on the cooler refrigerant discharge hose.
(d) Connect the cooler refrigerant discharge hose on the cooler compressor with the bolt.
Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)
5. INSTALL FAN AND GENERATOR V BELT See: Engine, Cooling and Exhaust/Engine/Drive
Belts, Mounts, Brackets and Accessories/Drive
Belt/Service and Repair/Installation
6. INSTALL FENDER APRON MUDGUARD SEAL LH
(a) Install the seal with the 6 clips.
7. CHARGE REFRIGERANT See: Service and Repair
8. WARM UP ENGINE See: Service and Repair
9. CHECK FOR REFRIGERANT GAS LEAK See: Service and Repair
Page 6037
Removal and Replacement
Power Steering Pump: Removal and Replacement
Components
POWER STEERING: VANE PUMP (for 1UR-FE): COMPONENTS
Removal
Page 378
Engine Control Module: Locations
Engine Compartment
Page 8149
Seat Position Sensor: Testing and Inspection
SUPPLEMENTAL RESTRAINT SYSTEM: SEAT POSITION SENSOR: ON-VEHICLE
INSPECTION
1. CHECK SEAT POSITION SENSOR (VEHICLE NOT INVOLVED IN COLLISION)
(a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnosis System.
2. CHECK SEAT POSITION SENSOR (VEHICLE INVOLVED IN COLLISION)
(a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnosis System.
(b) Even if the airbag was not deployed, check if there is any damage to the seat position sensor. If
there are any defects as mentioned below,
replace the seat position sensor with a new one:
* Cracks, dents or chips on the sensor housing.
* Cracks or other damage to the connector.
CAUTION: For removal and installation procedures of the seat position sensor, be sure to follow
the correct procedure.
Page 4127
Ultrasonic Sensor (for Front Side)
Parking Assist Distance Sensor: Service and Repair Ultrasonic Sensor (for Front Side)
Components
PARK ASSIST / MONITORING: ULTRASONIC SENSOR (for Front Side): COMPONENTS
Page 3589
(d) Enter the following menus: Powertrain / Engine and ECT / Trouble Codes.
(e) Check if any DTCs have been stored. Note down any DTCs.
(f) Clear DTCs See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/DTC
Check / Clear.
(g) Check if the MIL goes off.
OK:
MIL goes off.
NG -- CHECK HARNESS AND CONNECTOR (CHECK FOR SHORT IN WIRE HARNESS)
OK -- REPAIR CIRCUITS INDICATED BY OUTPUT DTCS See: Testing and Inspection/Diagnostic
Trouble Code Descriptions/Engine Control System - SFI System
3. CHECK HARNESS AND CONNECTOR (CHECK FOR SHORT IN WIRE HARNESS)
(a) Disconnect the ECM connector.
(b) Turn the ignition switch to ON.
(c) Check that the MIL is not illuminated.
OK:
MIL is not illuminated.
NG -- CHECK HARNESS AND CONNECTOR (COMBINATION METER - ECM)
OK -- REPLACE ECM See: Engine Control Module/Service and Repair/Removal
4. CHECK HARNESS AND CONNECTOR (COMBINATION METER - ECM)
Child Restraint Seat Anchor Bracket (for Double Cab)
Child Restraint: Service and Repair Child Restraint Seat Anchor Bracket (for Double Cab)
Components
SEAT BELT: CHILD RESTRAINT SEAT ANCHOR BRACKET (for Double Cab): COMPONENTS
Removal
SEAT BELT: CHILD RESTRAINT SEAT ANCHOR BRACKET (for Double Cab): REMOVAL
1. REMOVE REAR SEAT ASSEMBLY
Page 1406
Removal
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift
Type): REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal
3. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding
/ Trim/Dashboard / Instrument
Locations
Oxygen Sensor Relay: Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 5424
Control Module: Locations JF1A Transfer Case
JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION
Page 8230
(2) Place the front seat outer belt in a plastic bag, tie the end tightly and dispose of it in the same
way as other general parts.
Page 1745
This TSB applies to all Sequoia and Tundra vehicles equipped with lUR-FE (4.6L) 2UZ-FE (4.7L)
and 3UR-FE/FBE (5.7L) engines produced BEFORE the Production Change Effective VINs shown.
Repair Procedure
1. Remove and replace the air cleaner lid.
2. Remove and replace the front right hand (RH) fender liner.
Components
Engine Temperature Sensor: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: ENGINE COOLANT TEMPERATURE SENSOR:
COMPONENTS
Page 8463
Alarm Module: Service and Repair Installation
THEFT DETERRENT: THEFT WARNING ECU: INSTALLATION
1. INSTALL GLASS BREAKAGE SENSOR ECU
(a) Install the ECU with the nut.
(b) Install the junction block with the 2 nuts.
(c) Connect the connectors.
2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH
(a) for Column Shift Type:
Remove the instrument panel finish panel See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument
Panel Safety Pad (for Column Shift Type)/Installation.
(b) for Floor Shift Type:
Remove the instrument panel finish panel See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument
Panel Safety Pad (for Floor Shift Type)/Installation.
3. INSTALL INSTRUMENT SIDE PANEL LH
Page 9023
(2) Disconnect connector B and measure the resistance.
Standard resistance (Fig. 7):
* If the results match the examples above, a short circuit exists between terminal 1 of connector B2
and terminal 1 of connector C.
4. CHECK AND REPLACE ECU
NOTICE: *
The connector should not be disconnected from the ECU. Perform the inspection from the backside
of the connector on the wire harness side.
* When no measuring condition is specified, perform the inspection with the engine stopped and
the ignition switch ON.
* Check that the connectors are fully seated. Check for loose, corroded or broken wires.
(a) First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be
faulty. Temporarily replace the ECU with a
normally functioning one and check if the symptoms occur. If the trouble symptoms disappear,
replace the original ECU.
(1) Measure the resistance between the ECU ground terminal and body ground.
Standard resistance:
Below 1 Ohms
(2) Disconnect the ECU connector. Check the ground terminal on the ECU side and wire harness
side for bending, corrosion or foreign matter.
Lastly, check the contact pressure of the female terminals.
Page 1627
Page 6306
J/B No.3 Inner Circuit
J/B No.4 Inner Circuit
J/B No.5 Inner Circuit
Page 559
Heated Glass Element Relay: Locations Window Defogger System
WINDSHIELD / WINDOWGLASS: WINDOW DEFOGGER SYSTEM: PARTS LOCATION
Page 4160
Page 8163
Air Bag Control Module: Diagrams
Page 2723
Removal
1UR-FE EXHAUST: EXHAUST PIPE (for Regular Cab Standard Deck): REMOVAL
CAUTION: *
Wear protective gloves when removing the exhaust pipe.
* The exhaust pipe is extremely hot immediately after the engine has stopped.
* Confirm that the exhaust pipe has cooled down before removing it.
1. REMOVE TAILPIPE ASSEMBLY
(a) Remove the bolt, clamp and gasket.
(b) Disconnect the tailpipe from the exhaust pipe support.
2. REMOVE CENTER EXHAUST PIPE ASSEMBLY
(a) Remove the 4 bolts.
(b) Disconnect the center exhaust pipe from the 3 exhaust pipe supports.
(c) Remove the center exhaust pipe from the front exhaust pipe and front No. 3 exhaust pipe.
Page 9121
(1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be
checked by conducting a voltage check.
With each connector still connected, measure the voltage between the body ground and these
terminals (in this order): 1) terminal 1 of connector A; 2) terminal 1 of connector B; and 3) terminal
1 of connector C.
Standard voltage (Fig. 4):
* If the results match the examples above, an open circuit exists in the wire harness between
terminal 1 of connector B and terminal 1 of connector C.
3. CHECK FOR SHORT CIRCUIT
(a) If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance
check with the body ground (below).
(b) Check the resistance with the body ground.
(1) Disconnect connectors A and C and measure the resistance.
Standard resistance (Fig. 6):
HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally.
If your results match the examples above, a short circuit exists between terminal 1 of connector A
and terminal 1 of connector C.
Page 1215
SST : 09224-00010
without SST - Torque : 44 Nm (449 kgf-cm, 32 ft-lbf)
with SST - Torque : 40 Nm (408 kgf-cm, 30 ft-lbf)
HINT *
Use a torque wrench with a fulcrum length of 30 cm (11.8 in.). When using a torque wrench with a
fulcrum length that is not 30 cm (11.8 in.), calculate the torque specification for the torque wrench
and SST based on the "without SST" torque specification See: Service Precautions
* Make sure SST and the wrench are connected in a straight line.
3. INSTALL PROPELLER SHAFT HEAT INSULATOR (for 4WD) See: Transmission and
Drivetrain/Drive/Propeller Shafts, Bearings and
Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Front Propeller Shaft
Assembly/Installation
4. INSPECT FOR EXHAUST GAS LEAK See: Engine, Cooling and Exhaust/Exhaust
System/Exhaust Manifold/Service and Repair/Installation
Page 5947
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Page 5948
Use a volt/ohmmeter with high impedance (10 kohms/V minimum) for troubleshooting of the
electrical circuit.
Disconnection of Male and Female Connectors
DISCONNECTION OF MALE AND FEMALE CONNECTORS
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Finding A Short Circuit
FINDING A SHORT CIRCUIT
Page 1688
*: for 5 leaf spring
Standard Caster Inclination
for Regular Cab of Standard Deck
Page 1064
Removal
LIGHTING: REAR DOOR COURTESY SWITCH: REMOVAL
HINT *
Use the same procedures for the RH and LH side.
* The procedures listed below are for the LH side.
1. REMOVE REAR DOOR COURTESY SWITCH
(a) Remove the bolt.
Page 8799
Speaker: Service and Repair Front Door Speaker (for CrewMax)
Components
AUDIO / VISUAL: FRONT DOOR SPEAKER (for CrewMax): COMPONENTS
Page 1321
when inserting and after full engagement.
NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal.
(d) REPAIR METHOD OF CONNECTOR TERMINAL
(1) If there is any foreign matter on the terminal, clean the contact point using an air gun or cloth.
Never rub the contact point using sandpaper
as the plating may come off.
(2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is
gold-plated (gold color), use a gold-plated female
terminal; if it is silver-plated (silver color), use a silver-plated female terminal.
(3) Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock
into the housing, the housing may have to be
replaced.
(e) HANDLING OF WIRE HARNESS
(1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be
restored in the same way.
(2) Never twist, pull or slacken the wire harness more than necessary.
(3) The wire harness should never come into contact with a high temperature part, or rotating,
moving, vibrating or sharp-edged parts. Avoid
contact with panel edges, screw tips and other sharp items.
(4) When installing parts, never pinch the wire harness.
(5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with
vinyl tape.
2. CHECK FOR OPEN CIRCUIT
Page 8526
(a) for Regular Cab:
Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular Cab)/Removal.
(b) for Double Cab:
Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Removal.
(c) for CrewMax:
Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for CrewMax)/Removal.
2. REMOVE COWL SIDE TRIM BOARD LH
(a) for Regular Cab:
Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular Cab)/Removal.
(b) for Double Cab:
Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Removal.
(c) for CrewMax:
Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for CrewMax)/Removal.
3. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal
4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Floor Shift Type)/Removal
5. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
6. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal
7. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding
/ Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
8. REMOVE REAR UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
9. REMOVE CENTER LOWER INSTRUMENT PANEL FINISH PANEL See: Body and
Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
10. REMOVE INTEGRATION CONTROL AND PANEL ASSEMBLY
Page 8131
Seat Occupant Classification Module - Air Bag: Service and Repair Installation
SUPPLEMENTAL RESTRAINT SYSTEM: OCCUPANT CLASSIFICATION ECU: INSTALLATION
1. INSTALL OCCUPANT CLASSIFICATION ECU
(a) Check that the ignition switch is OFF.
(b) Check that the cable is disconnected from the battery negative (-) terminal.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
(c) Attach the claw and install the occupant classification ECU to the seat.
NOTICE: *
If the ECU has been dropped, or there are any cracks, dents or other defects in the case, bracket
or connector, replace it with a new one.
* When installing the ECU, be careful that the SRS wiring does not interfere with other parts and
that it is not pinched between other parts.
(d) Check that there is no looseness in the installation parts of the ECU.
2. INSTALL FRONT SEAT ASSEMBLY RH
(a) Install the front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Manual
Seat)/Installation.
Page 6991
Relay Box: Connector Views
Engine Room R/B, J/B - Engine Compartment Left
Page 8367
(a) Set the battery in the vehicle. Then move the stay onto the battery and tighten the nut to fix the
battery in place.
(b) Connect the cable to the positive (+) battery terminal.
3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
4. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Air Bag Systems/Testing and Inspection/Initial Inspection
and Diagnostic Overview/Diagnosis System.
Components
SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for CrewMax):
COMPONENTS
Page 3317
NG -- REPLACE RELAY OK -- Continue to next step.
3. CHECK HARNESS AND CONNECTOR (ECM - BODY GROUND)
(a) Disconnect the ECM connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR OK -- Continue to next step.
4. INSPECT ECM (IGSW VOLTAGE)
(a) Disconnect the ECM connectors.
(b) Turn the ignition switch to ON.
(c) Measure the voltage according to the value(s) in the table below.
Page 6842
Page 2812
(a) Remove the AM2 fuse, IG2 MAIN fuse, EFI NO. 1 fuse and IGN fuse from the engine room
relay block.
(b) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
NG -- CHECK FOR SHORT IN ALL HARNESSES AND CONNECTORS CONNECTED TO FUSE
AND REPLACE FUSE OK -- Continue to next step.
2. INSPECT RELAY (IG2, EFI)
(a) Remove the integration relay from the engine room relay block.
(b) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
Page 9018
Establish conditions in which voltage is present at the check point.
Example:
- [A] - Ignition SW on
- [B] - Ignition SW and SW1 on
- [C] - Ignition SW, SW1 and Relay on (SW2 off)
Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or component terminal.
This check can be done with a test light instead of a voltmeter.
Electronic Circuit Inspection Procedure
Page 1131
Accelerator Pedal Position Sensor: Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Locations
Air Flow Meter/Sensor: Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 1977
Engine Room R/B, J/B - Engine Compartment Left
Page 8091
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
4. REMOVE UPPER CONSOLE REAR PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
5. REMOVE REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
6. REMOVE CONSOLE BOX CARPET
7. REMOVE REAR CONSOLE BOX ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal
8. REMOVE FRONT CONSOLE BOX See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal
and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal
9. REMOVE CENTER AIRBAG SENSOR ASSEMBLY
(a) Disconnect the holder (with connectors).
(b) Remove the 3 bolts and airbag sensor.
Installation
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift
Type): INSTALLATION
1. INSTALL CENTER AIRBAG SENSOR ASSEMBLY
(a) Check that the ignition switch is OFF.
(b) Check that the cable is disconnected from the battery negative (-) terminal.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
(c) Install the airbag sensor with the 3 bolts.
Torque : 18 Nm (184 kgf-cm, 13 ft-lbf)
NOTICE: *
If the center airbag sensor has been dropped, or there are any cracks, dents or other defects in the
case, bracket or connector, replace it with a new one.
* When installing the center airbag sensor, be careful that the SRS wiring does not interfere with
other parts and that it is not pinched between other parts.
(d) Check that there is no looseness in the installation parts of the center airbag sensor.
Page 6586
Auxiliary Power Outlet: Diagnostic Aids
Continuity and Resistance Check
CONTINUITY AND RESISTANCE CHECK
Disconnect the battery terminal or wire so there is no voltage between the check points.
Contact the two leads of an ohmmeter to each of the check points.
Locations
Headlamp Switch: Locations
LIGHTING: LIGHTING SYSTEM: PARTS LOCATION
Diagrams
Alarm System Transponder: Diagrams
Engine Controls - Techstream(R) ECU Re-Flash
Procedure
PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls Techstream(R) ECU Re-Flash Procedure
T-SB-0064-10
February 4, 2010
Techstream ECU Flash Reprogramming Procedure
Service Category Engine/Hybrid System
Section Engine Control
Market USA
Applicability
TSB SUPERSESSION NOTICE
The information contained in this TSB supersedes TSB No. SS002-07.
^ Applicability has been updated to include 2009 - 2011 model year Toyota vehicles.
^ A new section, Techstream Preparation, has been added.
^ Techstream Lite has been added as an option in Required Tools & Materials.
^ Process Overview and Operation Procedure sections have been updated.
TSB No. SS002-07 is Obsolete and any printed versions should be discarded. Be sure to review
the entire content of this service bulletin before proceeding.
Introduction
Flash reprogramming allows the ECU software to be updated without replacing the ECU. Flash
calibration updates for specific vehicle models/ECUs are released as field-fix procedures described
in individual service bulletins. This bulletin details the Techstream ECU flash reprogramming
process and outlines use of the Technical Information System (TIS) and the Calibration Update
Wizard (CUW). Flash calibration updates can only be applied to the vehicle/ECU combination for
which they are intended. ECUs have internal security that will not allow them to be programmed
with another ECU's information.
ECU
Electronic Control Unit (ECU) is a Toyota term used to describe integrated computerized devices
responsible for managing the operation of a system or subsystem. For the purposes of this bulletin,
the term "ECU" is used as a generic label for the following SAE J1930 standard references:
^ Powertrain Control Module (PCM)
Page 1367
Air Bag Deactivation Switch: Service and Repair Curtain Shield Airbag Cutoff Switch
Components
SUPPLEMENTAL RESTRAINT SYSTEM: CURTAIN SHIELD AIRBAG CUTOFF SWITCH:
COMPONENTS
Removal
SUPPLEMENTAL RESTRAINT SYSTEM: CURTAIN SHIELD AIRBAG CUTOFF SWITCH:
REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Removal
3. REMOVE FRONT DOOR SCUFF PLATE LH (for Double Cab, CrewMax) See: Body and
Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Removal
4. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Removal
5. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal
6. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Removal
7. REMOVE CURTAIN SHIELD AIRBAG CUTOFF SWITCH
(a) Disconnect the connector.
Page 689
(2) If the result is not as specified, replace the outer mirror switch.
3. INSPECT OUTER MIRROR SWITCH ASSEMBLY (w/ Memory)
(a) Inspect the outer mirror switch.
(1) Select "L" on the left/right adjustment switch.
(2) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(3) If the result is not as specified, replace the outer mirror switch.
(4) Select "R" on the left/right adjustment switch.
(5) Using an ohmmeter, measure the resistance and check the results in accordance with the
value(s) in the table below.
Standard resistance:
Page 7024
*: for 5 leaf spring
Standard Wheel Angle
for Regular Cab of Standard Deck
Page 6323
AJ9-JI2
Page 5790
Parking Brake Warning Switch: Service and Repair Reassembly
PARKING BRAKE: PARKING BRAKE PEDAL: REASSEMBLY
1. INSTALL PARKING BRAKE SWITCH ASSEMBLY
(a) Install the switch with the screw.
Torque : 0.9 Nm (9 kgf-cm, 8 in-lbf)
Locations
Steering Column Control Module: Locations
Instrument Panel (Floor Shift)
Instrument Panel (Column Shift)
Locations
Four Wheel Drive Selector Switch: Locations
JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION
Page 1830
Parts Information
Calibration Information
Required Tools & Equipment
Repair Procedure
Page 5605
BRAKE CONTROL: BRAKE ACTUATOR: INSTALLATION
NOTICE: In case of replacing the skid control ECU, perform the zero point calibration of the
steering angle sensor, master cylinder pressure sensor, and yaw rate and deceleration sensor See:
Testing and Inspection/Programming and Relearning
1. INSTALL VSC ACTUATOR WITH ACTUATOR BRACKET ASSEMBLY
(a) Install the VSC actuator with actuator bracket with the 3 nuts.
NOTICE: Do not drop the actuator. If dropped, replace it.
(b) Tighten the 3 nuts uniformly in alphabetical order.
Torque : 22 Nm (224 kgf-cm, 16 ft-lbf)
2. CONNECT BRAKE TUBE
(a) Set each brake line to the correct position on the brake actuator as shown in the illustration.
HINT *
*1: FR RH
* *2: FR LH
* *3: RR RH
* *4: RR LH
* *5: FR Master Cylinder
* *6: RR Master Cylinder
(b) Install a new clamp onto the VSC actuator bracket.
(c) Using a union nut wrench, connect the 4 brake tubes.
Torque : 15 Nm (155 kgf-cm, 11 ft-lbf)
NOTICE:
Component Tests and General Diagnostics
Acceleration/Deceleration Sensor: Component Tests and General Diagnostics
BRAKE CONTROL: YAW RATE AND DECELERATION SENSOR: INSPECTION
1. CHECK YAW RATE SENSOR
(a) Check the yaw rate sensor.
Under any of the following conditions, replace the sensor with a new one:
* The surface of the sensor is cracked, dented, or chipped.
* The connector is scratched, cracked, or damaged.
* The sensor has been dropped.
Page 5627
Traction Control Relay: Testing and Inspection
BRAKE CONTROL: STOP LIGHT CONTROL RELAY: ON-VEHICLE INSPECTION
1. CHECK STOP LIGHT CONTROL RELAY
(a) Remove the stop light control relay from the engine room relay block.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(c) If the result is not as specified, replace the relay.
(d) Install the stop light control relay.
Power Source Control ECU
Power Distribution Module: Diagrams Power Source Control ECU
Page 6465
Remove the blown fuse and disconnect all loads of the fuse.
Connect a test light in place of the fuse.
Establish conditions in which the test light comes on.
Example:
- [A] - Ignition SW on
- [B] - Ignition SW and SW1 on
- [C] - Ignition SW, SW1 and Relay on (Connect the Relay) and SW2 off (or Disconnect SW2)
Disconnect and reconnect the connectors while watching the test light.
Page 5271
Removal
PROPELLER SHAFT: PROPELLER SHAFT ASSEMBLY (for 4WD): REMOVAL
1. REMOVE PROPELLER SHAFT HEAT INSULATOR BRACKET SUB-ASSEMBLY
Page 1085
Headlamp Alignment Switch: Service and Repair Removal
LIGHTING: HEADLIGHT LEVELING SWITCH: REMOVAL
1. REMOVE FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Removal
2. REMOVE FRONT DOOR SCUFF PLATE LH (for Double Cab, CrewMax) See: Body and
Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Removal
3. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Removal
4. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal
5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Removal
6. REMOVE HEADLIGHT LEVELING SWITCH
(a) Detach the 2 claws and remove the switch.
Page 9168
1. Wrap a pry bar with a soft shop towel then gently pull the step pad in an upward motion from
front to back using the pry bar to assist.
Be careful NOT to damage the chrome/painted surface.
2. If the plastic posts break off when the step pad is removed and stay in the tube use a punch and
hammer to punch the plastic bits into the tube. Use an
air gun to blow the posts out through the end of the tube.
3. Discard the step pad.
4. Using a pair of pliers pull out the old stainless post retainers (12 pieces) and discard.
5. Install the new post retainers into the holes in the tube.
6. Line up the replacement step posts with the holes in the post retainers.
7. Using the palm of your hand push firmly down in all post locations.
Then using a rubber mallet strike the pad along its entire length to ensure it is seated properly.
Page 2683
Thermostat: Service and Repair Removal
1UR-FE COOLING: THERMOSTAT: REMOVAL
HINT If the thermostat was not installed, cooling efficiency would decrease. Even if the engine
tends to overheat, do not remove the thermostat.
1. REMOVE NO. 1 ENGINE UNDER COVER See: Engine/Engine Lubrication/Engine Oil/Service
and Repair/Replacement
2. DRAIN ENGINE COOLANT See: Coolant/Service and Repair
3. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine/Service and Repair/Removal and
Replacement/Engine Assembly/Removal
4. REMOVE AIR CLEANER ASSEMBLY See: Powertrain Management/Ignition System/Ignition
Coil/Service and Repair/Removal
5. REMOVE AIR TUBE SUB-ASSEMBLY LH
(a) Disconnect the 2 connectors.
(b) Disconnect the water by-pass hose.
(c) Disconnect the 2 wire harness clamps and air hose.
(d) Remove the bolt and disconnect the air tube LH from the water inlet housing.
(e) Disconnect the vacuum sensor connector and clamp.
(f) Remove the 2 bolts and disconnect the air hose from the air switching valve LH.
(g) Remove the air tube LH.
6. DISCONNECT OUTLET RADIATOR HOSE
(a) Disconnect the radiator hose.
7. REMOVE WATER INLET SUB-ASSEMBLY WITH THERMOSTAT
(a) Remove the 3 nuts, water inlet with thermostat and gasket.
Page 5200
(l) If the boots are stretched or contracted, correct them.
(m)Install the inboard joint boot clamps in the same manner as the outboard side.
HINT Adjust the clearance of the inboard joint boot clamps.
Standard clearance:
6. INSPECT FRONT DRIVE SHAFT ASSEMBLY See: Testing and Inspection/Component Tests
and General Diagnostics/Front Drive Shaft
Assembly
Disassembly
AXLE: REAR AXLE SHAFT: DISASSEMBLY
1. REMOVE REAR AXLE SHAFT SNAP RING
(a) Using a snap ring expander, remove the snap ring.
2. REMOVE REAR AXLE SHAFT
(a) Using SST and a press, press out the rear axle shaft.
SST : 09521-25011
SST : 09521-60010
(b) Remove the rear axle bearing inner retainer from the axle hub.
(c) Remove the rear axle shaft washer from the axle hub.
Page 6532
Establish conditions in which voltage is present at the check point.
Example:
- [A] - Ignition SW on
- [B] - Ignition SW and SW1 on
- [C] - Ignition SW, SW1 and Relay on (SW2 off)
Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or component terminal.
This check can be done with a test light instead of a voltmeter.
Electronic Circuit Inspection Procedure
Procedures
Seat Belt: Procedures
Front Seat Outer Belt Assembly (for CrewMax)
SEAT BELT: FRONT SEAT OUTER BELT ASSEMBLY (for CrewMax): DISPOSAL
HINT When scrapping vehicles equipped with a seat belt pretensioner or disposing of a front seat
outer belt (with seat belt pretensioner), always first activate the seat belt pretensioner in
accordance with the procedures described below. If any abnormality occurs during activation of the
seat belt pretensioner, contact the SERVICE DEPARTMENT of TOYOTA MOTOR SALES, U.S.A.,
INC.
CAUTION:
* Never dispose of a front seat outer belt that has a non-activated pretensioner.
* The seat belt pretensioner produces a loud, exploding sound when it activates. Perform the
operation where it will not be a nuisance to nearby people.
* When activating a front seat outer belt (with seat belt pretensioner), stand at least 10 m (32.8 ft.)
away from the front seat outer belt.
* Use gloves and safety glasses when handling a front seat outer belt with an activated
pretensioner.
* Always wash your hands with water after completing the disposal.
* Do not apply water to a front seat outer belt that has an activated pretensioner.
* Perform procedures in a place away from electrical interference.
* When activating the seat belt pretensioner, always use the specified SST (SRS airbag
deployment tool).
1. DISPOSE OF FRONT SEAT OUTER BELT ASSEMBLY (WHEN INSTALLED IN VEHICLE)
HINT Prepare a battery to activate the seat belt pretensioner.
(a) Check if SST is functioning properly.
SST : 09082-00700
CAUTION: When activating the seat belt pretensioner, always use the specified SST.
Page 660
Power Door Lock Switch: Locations Wireless Door Lock Control System
DOOR LOCK: WIRELESS DOOR LOCK CONTROL SYSTEM: PARTS LOCATION
Page 3328
(c) WAVEFORM 2:
HINT The wavelength varies in accordance with the engine operating conditions.
(d) WAVEFORM 3:
HINT In the Data List, item O2S B1 S2 and O2S B2 S2 shows the ECM input values from the
heated oxygen sensor.
(e) WAVEFORM 4:
Page 2985
Power Steering Pressure Switch: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: POWER STEERING OIL PRESSURE SWITCH:
REMOVAL
1. REMOVE FAN AND GENERATOR V BELT
(a) Remove the fan and generator V belt See: Engine, Cooling and Exhaust/Engine/Drive Belts,
Mounts, Brackets and Accessories/Drive
Belt/Service and Repair/Removal.
2. REMOVE FRONT WHEEL
3. REMOVE FRONT FENDER APRON SEAL RH See: Engine, Cooling and Exhaust/Exhaust
System/Exhaust Manifold/Service and
Repair/Removal
4. DRAIN POWER STEERING FLUID
5. REMOVE POWER STEERING OIL PRESSURE SWITCH
(a) Disconnect the power steering oil pressure switch connector.
(b) Remove the power steering oil pressure switch.
(c) Remove the O-ring.
Page 1922
Fluid - Differential: Fluid Type Specifications
Differential Oil
Type ........................................................................................................................ Toyota Genuine
Differential Gear Oil LT 75W-85 GL-5 or equivalent
Page 9034
Trailer Connector: Electrical Diagrams
Trailer Towing Part 1
Page 2948
Manifold Pressure/Vacuum Sensor: Testing and Inspection
1UR-FE ENGINE CONTROL SYSTEM: MANIFOLD ABSOLUTE PRESSURE SENSOR:
INSPECTION
1. INSPECT MANIFOLD ABSOLUTE PRESSURE SENSOR
(a) Check the resistance.
(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(2) If the result is not as specified, replace the manifold absolute pressure sensor.
Page 7189
(a) Remove the bolt and separate the pressure feed tube.
(b) Remove the gasket.
8. REMOVE VANE PUMP ASSEMBLY
(a) Remove the 2 bolts and vane pump assembly.
Installation
POWER STEERING: VANE PUMP (for 1UR-FE): INSTALLATION
1. INSTALL VANE PUMP ASSEMBLY
HINT Before performing the following procedures, move the spacer until the vane pump can be
installed.
(a) Install the vane pump with the 2 bolts.
Torque : 28 Nm (286 kgf-cm, 21 ft-lbf)
2. CONNECT PRESSURE FEED TUBE
Page 2764
C. Choose desired ECU group(s) in the Health Check dialog box.
D. Click Next.
E. Click Continue to view Health Check results.
F. Available calibration updates are indicated by a link in the Cal. Update? column. Click the link to
access the appropriate service bulletin on TIS.
NOTE
^ Note any DTCs stored in Systems that will be flash reprogrammed.
^ Clicking the link will automatically launch TIS and perform a calibration search.
G. Log in to TIS. (If already logged in skip this step.)
H. To review the TSB and access the calibration file click the service bulletin link in the Document
Title column of the Calibration Search Result
portlet.
Page 5037
(b) If the bearing is damaged during removal, replace it.
19. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING
(a) Using a brass bar and hammer, tap out the bearing (outer race).
(b) If the bearing is damaged during removal, replace it.
20. REMOVE DIFFERENTIAL RING GEAR
(a) Place matchmarks on the ring gear and differential case.
(b) Remove the 12 ring gear set bolts.
(c) Using a plastic-faced hammer, tap on the ring gear to separate it from the differential case.
21. INSPECT REAR DIFFERENTIAL CASE ASSEMBLY RUNOUT
HINT If the ring gear runout is within the specified value (see "INSPECT RUNOUT OF
DIFFERENTIAL RING GEAR" procedure), this inspection is not necessary.
(a) Install the differential case to the differential carrier.
(b) Inspect the differential case runout.
Locations
Cargo Lamp Relay: Locations
LIGHTING: LIGHTING SYSTEM: PARTS LOCATION
Page 4145
Page 9102
Components
Tire Pressure Monitor Receiver / Transponder: Service and Repair Components
TIRE AND WHEEL: TIRE PRESSURE WARNING RECEIVER: COMPONENTS
Page 393
HINT *: The ECM terminal voltage is constant regardless of the output voltage from the sensor.
(b) WAVEFORM 1:
Page 3091
* In the DTC check, it is very important to determine whether the problem indicated by the DTC is
either: 1) still occurring; or 2) occurred in the past but has since returned to normal. In addition, the
DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs
should be checked before and after confirmation of symptoms (i.e., whether or not problem
symptoms exist) to determine current system conditions, as shown in the flowchart below.
* Never skip the DTC check. Failing to check DTCs may, depending on the case, result in
unnecessary troubleshooting for systems operating normally or lead to repairs not related to the
problem. Follow the procedures listed in the flowchart in the correct order.
* The following flowchart shows how to proceed with troubleshooting using the DTC check.
Directions from the flowchart will indicate how to proceed either to DTC troubleshooting or to the
troubleshooting of each problem symptom.
1. DTC CHECK
NEXT -- Continue to next step.
2. MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR MEMORY
NEXT -- Continue to next step.
3. SYMPTOM CONFIRMATION
B -- Go to step 5 A -- Continue to next step.
4. SIMULATION TEST USING SYMPTOM SIMULATION METHODS
NEXT -- Continue to next step.
5. DTC CHECK
B -- TROUBLESHOOTING OF PROBLEM INDICATED BY DTC A -- Continue to next step.
6. SYMPTOM CONFIRMATION
Page 8319
Air Bag Deactivation Switch: Testing and Inspection Curtain Shield Airbag Cutoff Switch
SUPPLEMENTAL RESTRAINT SYSTEM: CURTAIN SHIELD AIRBAG CUTOFF SWITCH:
INSPECTION
1. INSPECT CURTAIN SHIELD AIRBAG CUTOFF SWITCH
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
Page 2852
Fuel Pump Control Unit: Locations Double Cab
Body
Page 1888
Page 2686
(e) Connect the 2 wire harness clamps.
HINT When installing the hose, make sure the paint mark and clip are as shown in the illustration.
(f) Connect the water by-pass hose and 2 connectors.
HINT When installing the hose, make sure the paint mark and clip are as shown in the illustration.
4. ADD ENGINE COOLANT See: Coolant/Service and Repair
5. INSPECT FOR COOLANT LEAK See: Testing and Inspection
6. INSTALL AIR CLEANER ASSEMBLY See: Powertrain Management/Ignition System/Ignition
Coil/Service and Repair/Installation
7. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine/Service and Repair/Removal and
Replacement/Engine Assembly/Installation
8. INSTALL NO. 1 ENGINE UNDER COVER See: Engine/Engine Lubrication/Engine Oil/Service
and Repair/Replacement
Page 465
(e) Connect the holder (with connectors).
(f) Check that the waterproof sheet is properly set.
2. INSTALL FRONT CONSOLE BOX See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal
and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation
3. INSTALL REAR CONSOLE BOX ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation
4. INSTALL CONSOLE BOX CARPET
5. INSTALL REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
6. INSTALL UPPER CONSOLE REAR PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
7. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding
/ Trim/Dashboard / Instrument Panel/Service
and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
8. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation
9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
10. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
Page 3801
Crankshaft Position Sensor: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: CRANKSHAFT POSITION SENSOR: INSTALLATION
1. INSTALL CRANKSHAFT POSITION SENSOR
(a) Install the sensor with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(b) Connect the sensor connector.
2. INSTALL CRANKSHAFT POSITION SENSOR PROTECTOR
(a) Install the sensor protector with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
Page 3452
ERROR: stackunderflow
OFFENDING COMMAND: ~
STACK:
Page 8960
Parking Assist Switch: Service and Repair Removal
PARK ASSIST / MONITORING: CLEARANCE SONAR MAIN SWITCH: REMOVAL
1. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Panel,
Gauges and Warning Indicators/Instrument Cluster
/ Carrier/Service and Repair/Combination Meter/Removal
2. REMOVE DRIVE MONITOR SWITCH
(a) Detach the 2 claws and remove the monitor switch.
Page 1929
Fluid - Transfer Case: Fluid Type Specifications
Transfer Oil
Type .....................................................................................................................................................
....................................... Gear oil API GL-4 or GL-5 Recommended viscosity ...................................
................................................................................................................................................ SAE
75W-90
Page 5194
Axle Shaft Assembly: Overhaul
Disassembly
DRIVE SHAFT: FRONT DRIVE SHAFT ASSEMBLY (for 4WD): DISASSEMBLY
1. REMOVE INBOARD JOINT BOOT CLAMP
(a) Using a side cutter, cut the 2 inboard joint boot clamps and remove them.
2. DISCONNECT INBOARD JOINT BOOT
(a) Disconnect the inboard joint boot from the inboard joint shaft.
3. REMOVE INBOARD JOINT SHAFT
(a) Place matchmarks on the inboard joint shaft and outboard joint shaft.
NOTICE: Do not punch the marks.
(b) Using a screwdriver, remove the snap ring from the outboard joint shaft.
(c) Remove the inboard joint shaft from the outboard joint shaft.
(d) Place matchmarks on the outboard joint shaft, inner race and cage.
NOTICE: Do not punch the marks.
(e) Remove the 6 balls.
(f) Slide the cage to the outboard joint side.
(g) Using a snap ring expander, remove the snap ring.
Page 6961
Page 6801
NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do
not operate the ignition switch, any other switches, or the doors.
(a) If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the
harness and connector.
(b) Connect the cable of the Techstream to the DLC3, turn the ignition switch ON and attempt to
use the tester. If the display indicates that a
communication error has occurred, there is a problem either with the vehicle or with the tester.
HINT *
If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of
the original vehicle.
* If communication is still not possible when the tester is connected to another vehicle, the problem
may be in the tester itself. Consult the Service Department listed in the tester's instruction manual.
How To Proceed With Troubleshooting
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: HOW TO
PROCEED WITH TROUBLESHOOTING
1. OPERATION FLOW
HINT Perform troubleshooting in accordance with the procedures below. The following is an outline
of basic troubleshooting procedures. Confirm the troubleshooting procedures for the circuit you are
working on before beginning troubleshooting.
1. VEHICLE BROUGHT TO WORKSHOP
NEXT -- Continue to next step.
2. CUSTOMER PROBLEM ANALYSIS
(a) Ask the customer about the conditions and environment when the problem occurred.
NEXT -- Continue to next step.
3. INSPECT BATTERY VOLTAGE
Standard voltage:
11 to 14 V
If the voltage is below 11 V, recharge or replace the battery before proceeding.
NEXT -- Continue to next step.
Cylinder Head Gasket (for Bank 1)
Cylinder Head Gasket: Service and Repair Cylinder Head Gasket (for Bank 1)
Components
1UR-FE ENGINE MECHANICAL: CYLINDER HEAD GASKET (for Bank 1): COMPONENTS
Removal
1UR-FE ENGINE MECHANICAL: CYLINDER HEAD GASKET (for Bank 1): REMOVAL
1. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH
(a) Remove the exhaust manifold LH See: Exhaust System/Exhaust Manifold/Service and
Repair/Removal.
2. REMOVE CAMSHAFTS (for Bank 1)
(a) Remove the camshafts See: Camshaft, Lifters and Push Rods/Camshaft/Service and
Repair/Camshaft (for Bank 1)/Removal.
3. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
(a) Remove the 16 valve rocker arms from the cylinder head.
HINT Arrange the removed parts in the correct order.
4. REMOVE VALVE LASH ADJUSTER ASSEMBLY
(a) Remove the 16 valve lash adjusters from the cylinder head.
HINT Arrange the removed parts in the correct order.
5. REMOVE VALVE STEM CAP
(a) Remove the 16 valve stem caps from the cylinder head.
HINT Arrange the removed parts in the correct order.
6. REMOVE CYLINDER HEAD SUB-ASSEMBLY LH
Page 8784
Speaker: Testing and Inspection Front Door Speaker (for Double Cab)
AUDIO / VISUAL: FRONT DOOR SPEAKER (for Double Cab): INSPECTION
1. INSPECT FRONT NO. 1 SPEAKER ASSEMBLY (for Standard)
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the speaker assembly.
2. INSPECT FRONT NO. 1 SPEAKER ASSEMBLY (for 10 Speakers)
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the speaker assembly.
3. INSPECT FRONT NO. 3 SPEAKER ASSEMBLY (for 10 Speakers)
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
Diagrams
Vacuum Brake Booster: Diagrams
Page 8122
Page 3549
resistance variation.
PROCEDURE
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
(a) Disconnect the cable from the negative (-) battery terminal before measuring the resistances of
the main wire and the branch wire.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
NEXT -- Continue to next step.
2. CHECK FOR OPEN IN CAN BUS WIRE (SKID CONTROL ECU WITH ACTUATOR BRANCH
WIRE)
(a) Disconnect the A17 skid control ECU with actuator connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE SKID CONTROL ECU BRANCH WIRE OR CONNECTOR (CANH,
CANL) OK -- Continue to next step.
3. CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU WITH ACTUATOR - BATTERY
AND BODY GROUND)
(a) Reconnect the cable to the negative (-) battery terminal before measuring the resistances of the
main wire and the branch wire.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
Page 8671
Release the locking lug from terminal and pull the terminal out from rear.
INSTALL TERMINAL TO CONNECTOR
Insert the terminal.
HINT: Make sure the terminal is positioned correctly.
Insert the terminal until the locking lug locks firmly.
Insert the terminal with terminal retainer in the temporary lock position.
Page 6278
(a) For an open circuit in the wire harness in Fig. 1, check the resistance or voltage, as described
below.
(b) Check the resistance.
(1) Disconnect connectors A and C and measure the resistance between them.
Standard resistance (Fig. 2):
HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally.
If the results match the examples above, an open circuit exists between terminal 1 of connector A
and terminal 1 of connector C.
(2) Disconnect connector B and measure the resistance between the connectors.
Standard resistance (Fig. 3):
* If the results match the examples above, an open circuit exists between terminal 1 of connector
B2 and terminal 1 of connector C.
(c) Check the voltage.
Page 9037
Trailer Towing Part 4
Page 3482
2. CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (MAIN BODY ECU)
(a) Disconnect the J2 main body ECU connector.
(b) Reconnect the cable to the negative (-) battery terminal.
(c) Select "CAN Bus Check" on the Techstream.
Result
B -- CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (SKID CONTROL ECU WITH
ACTUATOR) A -- Continue to next step.
3. CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (MAIN BODY ECU BRANCH
WIRE)
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE CAN BRANCH WIRE OR CONNECTOR (MAIN BODY ECU)
OK -- REPLACE MAIN BODY ECU
4. CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (SKID CONTROL ECU WITH
ACTUATOR)
(a) Disconnect the A17 skid control ECU with actuator connector.
(b) Reconnect the cable to the negative (-) battery terminal.
(c) Select "CAN Bus Check" on the Techstream.
Result
B -- CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (STEERING ANGLE SENSOR)
Rear Oil Seal
Seals and Gaskets: Service and Repair Rear Oil Seal
Components
JF1A TRANSFER: TRANSFER CASE REAR OIL SEAL: COMPONENTS
Replacement
JF1A TRANSFER: TRANSFER CASE REAR OIL SEAL: REPLACEMENT
1. DRAIN TRANSFER OIL See: Fluid - Transfer Case/Service and Repair
Page 6321
Multiple Junction Connector: Locations Wire and Wire In Instrument Panel [Floor Shift]
AJ1-TJ1
Page 1349
Knock Sensor: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: REMOVAL
1. REMOVE INTAKE MANIFOLD
(a) Remove the intake manifold See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service
and Repair/Removal.
2. REMOVE SEPARATOR CASE
(a) Remove the 4 bolts and separator case.
3. REMOVE KNOCK SENSOR
(a) Disconnect the 4 knock sensor connectors.
(b) Remove the 4 bolts and 4 knock sensors.
Page 5734
Hydraulic Control Assembly - Antilock Brakes: Locations From 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 6529
Push the terminal retainer down to the temporary lock position.
Symptom Related Diagnostic Procedures
Drive/Propeller Shaft: Symptom Related Diagnostic Procedures
PROPELLER SHAFT: PROPELLER SHAFT SYSTEM: PROBLEM SYMPTOMS TABLE
HINT Use the table below to help determine the cause of the problem symptom. The potential
causes of the symptoms are listed in order of probability in the "Suspected Area" column of the
table. Check each symptom by checking the suspected areas in the order they are listed. Replace
parts as necessary.
Page 7689
(a) Remove the bolt and disconnect the discharge hose from the cooler condenser.
NOTICE: *
When removing the bolt, do not allow any tools to contact the pipe.
* When removing the bolt, hold a part of the pipe near the connector.
(b) Remove the O-ring from the discharge hose.
NOTICE: Seal the openings of the disconnected parts using vinyl tape to prevent moisture and
foreign matter from entering them.
7. DISCONNECT AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY
(a) Remove the 2 bolts and air conditioning tube and accessory from the cooler condenser.
NOTICE: *
When removing the bolt, do not allow any tools to contact the pipe.
* When removing the bolt, hold a part of the pipe near the connector.
(b) Remove the O-ring from the air conditioning tube and accessory.
NOTICE: Seal the openings of the disconnected parts using vinyl tape to prevent moisture and
foreign matter from entering them.
8. REMOVE COOLER CONDENSER ASSEMBLY
(a) Remove the 2 bolts.
(b) Remove the cooler condenser, as shown in the illustration.
9. REMOVE COOLER DRYER
Page 8984
Ultrasonic Sensor: Service and Repair Glass Breakage Sensor (for Column Shift Type)
Components
THEFT DETERRENT: GLASS BREAKAGE SENSOR (for Column Shift Type): COMPONENTS
Removal
THEFT DETERRENT: GLASS BREAKAGE SENSOR (for Column Shift Type): REMOVAL
1. REMOVE FRONT DOOR SCUFF PLATE LH
Page 1849
load while reprogramming.
^ Confirm the hood is open and ensure under hood temperature does NOT exceed 158°F (70°C).
^ Confirm cable connections between the vehicle and Techstream are secure.
^ Do NOT disconnect or turn off Techstream or vehicle ignition during reprogramming.
^ Set parking brake.
^ Complete ALL flash calibration updates provided for each ECU.
^ If the battery's state of charge or capacity are in question, test with SST. No. 00002-8150-KIT
"Digital Battery Analyze," and follow TSB No. PG001-06, "Battery Maintenance for In-Stock
Vehicles & Pre-Delivery" or the appropriate "Maintenance for HV & Auxiliary Batteries" service
bulletin.
^ The GR8 Battery Diagnostic Station MUST be used in Power Supply Mode to maintain battery
voltage at 13.5 volts while flash reprogramming the vehicle. For details on how to use the GR8
Battery Diagnostic Station, refer to the GR8 Instruction Manual located on TIS, Diagnostics - Tools
& Equipment - Battery Diagnostics.
3C. Click Next to start the calibration update process.
D. When using TIS Techstream select Techstream VIM as the desired programming device. Then
click Next.
Page 5151
4. REMOVE FRONT DRIVE PINION COMPANION FLANGE FRONT NUT See: Differential
Carrier/Service and Repair/Overhaul/Front
Differential Carrier Assembly/Disassembly
5. REMOVE FRONT DRIVE PINION COMPANION FLANGE FRONT SUB-ASSEMBLY See:
Differential Carrier/Service and
Repair/Overhaul/Front Differential Carrier Assembly/Disassembly
6. REMOVE FRONT DIFFERENTIAL CARRIER OIL SEAL
(a) Using SST, remove the oil seal.
SST : 09308-10010
7. REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER
8. REMOVE FRONT DIFFERENTIAL CROSS SHAFT BEARING RETAINER See: Differential
Carrier/Service and Repair/Overhaul/Front
Differential Carrier Assembly/Disassembly
9. REMOVE FRONT DIFFERENTIAL CASE See: Differential Carrier/Service and
Repair/Overhaul/Front Differential Carrier
Assembly/Disassembly
10. REMOVE DIFFERENTIAL DRIVE PINION See: Differential Carrier/Service and
Repair/Overhaul/Front Differential Carrier
Assembly/Disassembly
11. REMOVE FRONT DRIVE PINION FRONT RADIAL BALL BEARING See: Differential
Carrier/Service and Repair/Overhaul/Front
Differential Carrier Assembly/Disassembly
12. REMOVE FRONT DIFFERENTIAL DRIVE PINION BEARING SPACER
13. INSTALL FRONT DIFFERENTIAL DRIVE PINION BEARING SPACER
(a) Install a new bearing spacer.
14. TEMPORARILY INSTALL DIFFERENTIAL DRIVE PINION
15. INSTALL FRONT DIFFERENTIAL CASE
16. INSTALL FRONT DIFFERENTIAL CROSS SHAFT BEARING RETAINER See: Differential
Carrier/Service and Repair/Overhaul/Front
Differential Carrier Assembly/Reassembly
17. INSTALL FRONT DRIVE PINION FRONT RADIAL BALL BEARING See: Differential
Carrier/Service and Repair/Overhaul/Front
Differential Carrier Assembly/Reassembly
18. INSTALL FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER
19. INSTALL FRONT DIFFERENTIAL CARRIER OIL SEAL
(a) Using SST and a hammer, tap in a new oil seal.
Page 8343
Removal
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift
Type): REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal
3. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding
/ Trim/Dashboard / Instrument
Page 5124
D. Fill the bracket with Loctite 5040 (or equivalent) until sealant can be seen coming out of the
bracket opening. Allow sealant to setup for 12
minutes.
E. Inspect surrounding area for damage.
2. Test drive the vehicle to confirm the repair.
Page 8581
Replacement/Rear Bumper (for Resin Type Bumper)/Installation
7. INSTALL REAR BUMPER PLATE RH (for Steel Type Bumper) See: Body and
Frame/Bumper/Rear Bumper/Service and Repair/Removal and
Replacement/Rear Bumper (for Steel Type Bumper)/Installation
8. INSTALL REAR BUMPER PLATE LH (for Steel Type Bumper) See: Body and
Frame/Bumper/Rear Bumper/Service and Repair/Removal and
Replacement/Rear Bumper (for Steel Type Bumper)/Installation
9. INSTALL REAR BUMPER PAD SUB-ASSEMBLY (for Steel Type Bumper) See: Body and
Frame/Bumper/Rear Bumper/Service and
Repair/Removal and Replacement/Rear Bumper (for Steel Type Bumper)/Installation
10. INSTALL LICENSE PLATE LIGHT ASSEMBLY RH (for Steel Type Bumper) See: Body and
Frame/Bumper/Rear Bumper/Service and
Repair/Removal and Replacement/Rear Bumper (for Resin Type Bumper)/Installation
11. INSTALL LICENSE PLATE LIGHT ASSEMBLY RH (for Resin Type Bumper) See: Body and
Frame/Bumper/Rear Bumper/Service and
Repair/Removal and Replacement/Rear Bumper (for Resin Type Bumper)/Installation
12. INSTALL LICENSE PLATE LIGHT ASSEMBLY LH (for Steel Type Bumper) See: Body and
Frame/Bumper/Rear Bumper/Service and
Repair/Removal and Replacement/Rear Bumper (for Steel Type Bumper)/Installation
13. INSTALL LICENSE PLATE LIGHT ASSEMBLY LH (for Resin Type Bumper) See: Body and
Frame/Bumper/Rear Bumper/Service and
Repair/Removal and Replacement/Rear Bumper (for Resin Type Bumper)/Installation
14. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Page 7369
(b) Temporarily install the shock absorber, cushion and retainer with the nut.
(c) Temporarily install the lower side of the shock absorber with the bolt and nut.
2. STABILIZE SUSPENSION
(a) Lower the vehicle.
(b) Press down on the vehicle several times to stabilize the suspension.
3. TIGHTEN REAR SHOCK ABSORBER ASSEMBLY LH
(a) Tighten the bolt and 2 nuts.
Upper side - Torque : 28 Nm (286 kgf-cm, 21 ft-lbf)
Lower side - Torque : 90 Nm (918 kgf-cm, 66 ft-lbf)
4. INSTALL REAR WHEEL
for Aluminum Wheel - Torque : 131 Nm (1336 kgf-cm, 97 ft-lbf)
for Steel Wheel - Torque : 209 Nm (2131 kgf-cm, 154 ft-lbf)
5. REMOVE SAFETY STANDS
Disposal
SUSPENSION: REAR SHOCK ABSORBER: DISPOSAL
1. DISPOSE OF SHOCK ABSORBER ASSEMBLY REAR
Page 3095
Ignition Switch: Connector Views
Locations
Overdrive Switch: Locations
A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS
LOCATION
Locations
Shift Interlock Control Module: Locations
Instrument Panel (Floor Shift)
Instrument Panel (Column Shift)
Page 3398
(1) The branch wire is a wire harness which diverges from the main wire to an ECU or sensor.
(c) Termination circuits
(1) The termination circuits is a circuit which converts the communication current of the CAN
communication into the bus voltage. It consists
of a resistor and condenser. 2 termination circuits are necessary on a bus.
(d) CAN J/C
(1) The CAN J/C is designed so that it can be used with CAN communication which has a
termination circuit and CAN communication which
does not have a termination circuit.
3. CIRCUIT DESCRIPTION
(a) The V bus and MS bus each have termination circuits with 120 Ohms x 2 of resistance. High
speed communication at 500 kbps and 250 kbps
is possible.
4. ECU OR SENSOR WHICH COMMUNICATE VIA CAN COMMUNICATION SYSTEM
HINT *
*1: w/ Bus Buffer ECU
* *2: w/ 4WD
* *3: w/ Power Steering ECU
* *4: w/ Seat Memory
(a) ECM
(b) Skid control ECU with actuator
(c) Combination meter ECU
(d) Center airbag sensor
(e) Air conditioning amplifier
(f) Steering angle sensor
(g) Bus buffer ECU*1
(h) 4WD control ECU*2
(i) Main body ECU
(j) Power steering ECU*3
(k) Front power seat ECU and switch LH*4
(l) Outer mirror control ECU*4
(m)Multiplex tilt and telescopic ECU*4
5. DIAGNOSTIC CODES FOR CAN COMMUNICATION SYSTEM
(a) DTCs for the CAN communication system are as follows: U0073, U0100, U0114, U0123,
U0124, U0126, U0129, U0199, U0208, U1002,
U1115, B1499, and B2621
6. NOTES REGARDING TROUBLESHOOTING
(a) Trouble in the CAN bus (communication line) can be checked through the DLC3 (except when
there is a wire break other than in the branch
wire of the DLC3).
NOTICE: Do not connect the tester directly to the DLC3. Be sure to use a service wire.
(b) DTCs regarding the CAN communication system can be checked using the Techstream.
Page 8366
(b) Loosen the nut, move the stay off the battery, and remove the battery.
3. REMOVE FRONT AIRBAG SENSOR
(a) Remove the nut and front airbag sensor from the body.
(b) Disconnect the connector.
Installation
SUPPLEMENTAL RESTRAINT SYSTEM: FRONT AIRBAG SENSOR: INSTALLATION
1. INSTALL FRONT AIRBAG SENSOR
(a) Check that the ignition switch is OFF.
(b) Check that the cable is disconnected from the battery negative (-) terminal.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
(c) Connect the connector.
(d) Install the front airbag sensor with the nut.
Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)
NOTICE: *
If the front airbag sensor has been dropped, or there are any cracks, dents or other defects in the
case, bracket or connector, replace it with a new one.
* When installing the front airbag sensor, be careful that the SRS wiring does not interfere with
other parts and that it is not pinched between other parts.
(e) Check that there is no looseness in the installation parts of the front airbag sensor.
2. INSTALL BATTERY
Page 685
Service and Repair
Fuel Pressure Release: Service and Repair
1UR-FE FUEL: FUEL SYSTEM: PRECAUTION
CAUTION: *
Before working on the fuel system, disconnect the cable from the negative (-) battery terminal.
* Do not smoke or be near an open flame when working on the fuel system.
* Keep gasoline away from rubber and leather parts.
1. DISCHARGE FUEL SYSTEM PRESSURE
CAUTION: *
Do not disconnect any part of the fuel system until you have discharged the fuel system pressure.
* After discharging the fuel pressure, place a cloth or equivalent over fittings as you separate them
to reduce the risk of fuel spray on yourself or in the engine compartment.
(a) Disconnect the cable from the negative (-) battery terminal.
(b) Disconnect the 2 fuel pump ECU connectors.
(c) Connect the cable to the negative (-) battery terminal.
(d) Start the engine. After the engine has stopped on its own, turn the ignition switch OFF.
HINT DTC P0171/0174 (system too lean) may be set.
(e) Crank the engine again, then check that the engine does not start.
(f) Loosen the fuel tank cap, then discharge the pressure in the fuel tank completely.
(g) Connect the 2 fuel pump ECU connectors.
2. FUEL SYSTEM
(a) When disconnecting the high fuel pressure line, a large amount of gasoline will spill out. Follow
these procedures.
(1) Perform the "DISCHARGE FUEL SYSTEM PRESSURE" procedures above.
(2) Put a container under the connecting part of the pressure line.
(3) Slowly loosen the connection.
(4) Disconnect the connection.
(5) Plug the connection with a rubber plug.
(b) Observe these precautions when removing and installing the injectors:
Page 8369
Locations
Actuator: Locations
JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION
Diagrams
Brake Fluid Level Sensor/Switch: Diagrams
Page 6007
Battery: Specifications
SERVICE SPECIFICATIONS: 1UR-FE CHARGING: SERVICE DATA
Page 279
when inserting and after full engagement.
NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal.
(d) REPAIR METHOD OF CONNECTOR TERMINAL
(1) If there is any foreign matter on the terminal, clean the contact point using an air gun or cloth.
Never rub the contact point using sandpaper
as the plating may come off.
(2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is
gold-plated (gold color), use a gold-plated female
terminal; if it is silver-plated (silver color), use a silver-plated female terminal.
(3) Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock
into the housing, the housing may have to be
replaced.
(e) HANDLING OF WIRE HARNESS
(1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be
restored in the same way.
(2) Never twist, pull or slacken the wire harness more than necessary.
(3) The wire harness should never come into contact with a high temperature part, or rotating,
moving, vibrating or sharp-edged parts. Avoid
contact with panel edges, screw tips and other sharp items.
(4) When installing parts, never pinch the wire harness.
(5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with
vinyl tape.
2. CHECK FOR OPEN CIRCUIT
Page 3571
Information Bus: Tools and Equipment CAN Communication
PREPARATION: CAN COMMUNICATION: RECOMMENDED TOOLS
Page 4516
Crankshaft Position Sensor: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: CRANKSHAFT POSITION SENSOR: REMOVAL
1. REMOVE CRANKSHAFT POSITION SENSOR PROTECTOR
(a) Remove the 2 bolts and sensor protector.
2. REMOVE CRANKSHAFT POSITION SENSOR
(a) Disconnect the sensor connector.
(b) Remove the bolt and sensor.
Page 904
Ambient Temperature Sensor / Switch HVAC: Testing and Inspection
AIR CONDITIONING: AMBIENT TEMPERATURE SENSOR: INSPECTION
1. INSPECT AMBIENT TEMPERATURE SENSOR
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NOTICE: *
Touching the sensor even slightly may change the resistance value. Hold the connector of the
sensor.
* When measuring the resistance, the sensor temperature must be the same as the ambient
temperature.
HINT As the temperature increases, the resistance decreases (see the graph).
(b) If the result is not as specified, replace the ambient temperature sensor.
Page 5672
Yaw Rate Sensor: Service and Repair Installation
BRAKE CONTROL: YAW RATE AND DECELERATION SENSOR: INSTALLATION
1. INSTALL YAW RATE SENSOR
(a) Connect the sensor connector (labeled A), and then attach the clamp (labeled B) to the hole of
the sensor bracket.
(b) Install the yaw rate sensor with the 2 nuts (labeled C).
Torque : 13 Nm (127 kgf-cm, 9 ft-lbf)
NOTICE: *
Make sure that the sensor is oriented correctly.
* If the sensor is dropped, replace it.
* Securely connect the connector.
* When installing the sensor, make sure to avoid impacts to the sensor.
2. INSTALL CENTER FRONT SEAT (for Center Seat) See: Body and Frame/Seats/Service and
Repair/Removal and Replacement/Front Seat
Assembly (for Center Seat)/Installation
3. INSTALL CONSOLE BOX ASSEMBLY (for Separate Seat Type)
(a) Install the console box See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and
Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation.
4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
5. PERFORM YAW RATE SENSOR ZERO POINT CALIBRATION
(a) Perform the yaw rate sensor zero point calibration See: Testing and Inspection/Programming
and Relearning.
6. CHECK YAW RATE SENSOR SIGNAL
(a) Check the yaw rate sensor signal See: Testing and Inspection/Scan Tool Testing and
Procedures/Test Mode Procedure.
Page 1712
(c) * for 5 leaf spring
Standard caster inclination (unloaded vehicle):
for Regular Cab of Standard Deck
Page 6901
Symbols Used Within Diagrams
Symbols Used Within Diagrams
Components
Parking Assist Control Module: Service and Repair Components
PARK ASSIST / MONITORING: CLEARANCE WARNING ECU: COMPONENTS
Page 9252
Up to 11/2009
ENGINE HOOD / DOOR: REAR DOOR (for Double Cab): DISASSEMBLY
REAR DOOR TRIM BOARD SUB-ASSEMBLY LH
1. REMOVE REAR DOOR INSIDE HANDLE BEZEL PLUG LH
(a) Using a screwdriver, detach the 4 claws and remove the inside handle bezel.
Page 9069
(2) Disconnect connector B and measure the resistance.
Standard resistance (Fig. 7):
* If the results match the examples above, a short circuit exists between terminal 1 of connector B2
and terminal 1 of connector C.
4. CHECK AND REPLACE ECU
NOTICE: *
The connector should not be disconnected from the ECU. Perform the inspection from the backside
of the connector on the wire harness side.
* When no measuring condition is specified, perform the inspection with the engine stopped and
the ignition switch ON.
* Check that the connectors are fully seated. Check for loose, corroded or broken wires.
(a) First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be
faulty. Temporarily replace the ECU with a
normally functioning one and check if the symptoms occur. If the trouble symptoms disappear,
replace the original ECU.
(1) Measure the resistance between the ECU ground terminal and body ground.
Standard resistance:
Below 1 Ohms
(2) Disconnect the ECU connector. Check the ground terminal on the ECU side and wire harness
side for bending, corrosion or foreign matter.
Lastly, check the contact pressure of the female terminals.
Components
Engine Temperature Sensor: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: ENGINE COOLANT TEMPERATURE SENSOR:
COMPONENTS
Page 6603
(1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be
checked by conducting a voltage check.
With each connector still connected, measure the voltage between the body ground and these
terminals (in this order): 1) terminal 1 of connector A; 2) terminal 1 of connector B; and 3) terminal
1 of connector C.
Standard voltage (Fig. 4):
* If the results match the examples above, an open circuit exists in the wire harness between
terminal 1 of connector B and terminal 1 of connector C.
3. CHECK FOR SHORT CIRCUIT
(a) If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance
check with the body ground (below).
(b) Check the resistance with the body ground.
(1) Disconnect connectors A and C and measure the resistance.
Standard resistance (Fig. 6):
HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally.
If your results match the examples above, a short circuit exists between terminal 1 of connector A
and terminal 1 of connector C.
Page 6298
J/B No.5 - Instrument Panel Center
Page 5759
16. REMOVE NO. 1 PARKING BRAKE CABLE ASSEMBLY (for 3700 mm [12 ft. 1.7 in.]
Wheelbase Type)
(a) Remove the adjustment nut and lock nut (labeled A).
(b) Remove the bolt (labeled B) and cable retainer.
(c) Remove the 2 nuts (labeled C) and 2 clamps from the body.
(d) Disconnect the 2 clamps (labeled D) from the No. 1 parking brake cable.
(e) Remove the 2 bolts (labeled E) and No. 1 parking brake cable from the inside of the vehicle.
NOTICE: Do not bend and twist the parking brake cable.
(f) Remove the 3 bolts (labeled F) and No. 1 cable support bracket.
Page 8806
4. REMOVE FRONT UPPER ARMREST BASE PANEL LH See: Body and Frame/Doors, Hood
and Trunk/Doors/Front Door/Service and
Repair/Front Door (for Double Cab)/Disassembly
5. REMOVE FRONT DOOR ARMREST COVER LH
6. REMOVE COURTESY LIGHT ASSEMBLY See: Body and Frame/Doors, Hood and
Trunk/Doors/Front Door/Service and Repair/Front Door
(for Double Cab)/Disassembly
7. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH See: Body and Frame/Doors,
Hood and Trunk/Doors/Front Door/Service and
Repair/Front Door (for Double Cab)/Disassembly
8. REMOVE FRONT NO. 1 SPEAKER ASSEMBLY
(a) Disconnect the speaker connector.
(b) Remove the 4 screws and speaker.
NOTICE: Do not touch the cone part of the speaker.
9. REMOVE FRONT NO. 3 SPEAKER ASSEMBLY (for 10 Speakers)
(a) Remove the 3 screws and speaker with bracket.
(b) Detach the 3 claws and remove the speaker from the bracket.
NOTICE: Do not touch the cone part of the speaker.
Installation
AUDIO / VISUAL: FRONT DOOR SPEAKER (for Double Cab): INSTALLATION
HINT *
Use the same procedures for the LH side and RH side.
Page 8278
Removal
SEAT BELT: REAR SEAT OUTER BELT ASSEMBLY (for CrewMax): REMOVAL
HINT *
Use the same procedures for the LH side and RH side.
* The procedures listed below are for the LH side.
1. REMOVE REAR SEAT ASSEMBLY
(a) Remove the rear seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Rear Seat Assembly (for Double
Cab)/Removal.
2. REMOVE BACK PANEL TRIM RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for
CrewMax)/Removal
Page 9224
Page 308
J/B No.3 Inner Circuit
J/B No.4 Inner Circuit
J/B No.5 Inner Circuit
Page 4903
4. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Removal
5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Removal
6. REMOVE LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY See: Restraint
Systems/Air Bag Systems/Air Bag/Service and
Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Removal
7. REMOVE STEERING PAD (w/o Steering Pad Switch) See: Restraint Systems/Air Bag
Systems/Air Bag/Service and Repair/Removal and
Replacement/Steering Pad/Removal
8. REMOVE STEERING PAD (w/ Steering Pad Switch) See: Restraint Systems/Air Bag
Systems/Air Bag/Service and Repair/Removal and
Replacement/Steering Pad/Removal
9. REMOVE STEERING WHEEL ASSEMBLY See: Steering and Suspension/Steering/Steering
Column/Service and Repair/Removal and
Replacement/Steering Column Assembly (for Power Tilt and Power Telescopic Steering
Column)/Removal
10. REMOVE LOWER STEERING COLUMN COVER See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Removal and
Replacement/Steering Column Assembly (for Power Tilt and Power Telescopic Steering
Column)/Removal
11. REMOVE UPPER STEERING COLUMN COVER See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Removal and
Replacement/Steering Column Assembly (for Power Tilt and Power Telescopic Steering
Column)/Removal
12. REMOVE TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY See:
Steering and Suspension/Steering/Steering
Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Power Tilt
and Power Telescopic Steering Column)/Removal
13. REMOVE COLUMN SHIFT ASSEMBLY
(a) Move the shift lever to N.
(b) Disconnect the column shift transmission control cable end from the column shift.
(c) Disconnect the connector and detach the harness clamp.
Page 1936
Engine Oil: Fluid Type Specifications
Grade ...................................................................................................................................................
..................................... ILSAC multigrade engine oil
4.6L V8 ................................................................................................................................................
............................................................... SAE 0W-20
5.7L V8 ................................................................................................................................................
.............................................. SAE 5W-20 or 0W-20
Page 8052
NOTICE: Do not turn the spiral cable with steering sensor by the airbag wire harness.
(d) Rotate the spiral cable with steering sensor clockwise approximately 2.5 turns to align the
marks.
NOTICE: Do not turn the spiral cable with spiral sensor by the airbag wire harness.
HINT The spiral cable with steering sensor will rotate approximately 2.5 turns to both the left and
right from the center.
5. INSTALL STEERING WHEEL ASSEMBLY See: Steering and Suspension/Steering/Steering
Column/Service and Repair/Removal and
Replacement/Steering Column Assembly (for Manual Tilt)/Installation
6. INSTALL STEERING PAD See: Air Bag/Service and Repair/Removal and Replacement/Steering
Pad/Installation
7. INSTALL LOWER NO. 3 STEERING WHEEL COVER See: Air Bag/Service and
Repair/Removal and Replacement/Steering Pad/Installation
8. INSTALL LOWER NO. 2 STEERING WHEEL COVER See: Air Bag/Service and
Repair/Removal and Replacement/Steering Pad/Installation
9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
10. INSPECT STEERING PAD See: Air Bag/Service and Repair/Removal and
Replacement/Steering Pad/Installation
11. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
Page 7774
(a) Install the evaporator to the blower case (front side).
(b) Install the blower case (back side).
(c) Install the 6 screws and attach the 4 claws.
(d) Install the packing, as shown in the illustration.
4. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY
Locations
Tire Pressure Sensor: Locations
TIRE AND WHEEL: TIRE PRESSURE WARNING SYSTEM: PARTS LOCATION
Page 3494
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- CHECK FOR SHORT IN CAN BUS WIRES (POWER STEERING ECU) OK -- Continue to
next step.
12. CHECK FOR SHORT IN CAN BUS WIRES (NO. 1 JUNCTION CONNECTOR - CENTER
AIRBAG SENSOR)
(a) Disconnect the J83 No. 1 junction connector connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- CHECK FOR SHORT IN CAN BUS WIRES (CENTER AIRBAG SENSOR)
OK -- REPAIR OR REPLACE NO. 1 JUNCTION CONNECTOR
13. CHECK FOR SHORT IN CAN BUS WIRES (COMBINATION METER ECU)
(a) Disconnect the J28 combination meter ECU connector.
Components
Power Distribution Module: Service and Repair Components
OTHER SYSTEM: VOLTAGE INVERTER (for CrewMax): COMPONENTS
Initial Inspection and Diagnostic Overview
Shifter A/T: Initial Inspection and Diagnostic Overview
SHIFT LEVER ASSEMBLY (for Column Shift Type)
A760F AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY (for Column Shift Type):
ON-VEHICLE INSPECTION
1. INSPECT SHIFT LEVER POSITION
(a) When moving the shift lever from P to R with the ignition switch ON and the brake pedal
depressed, make sure that it moves smoothly and
correctly into position.
(b) Start the engine and make sure that the vehicle moves forward after moving the shift lever from
N to D and moves in reverse after moving the
shift lever to R.
If the operation cannot be performed as specified, inspect the park/neutral position switch
assembly and check the shift lever assembly installation condition.
SHIFT LEVER ASSEMBLY (for Floor Shift Type)
A760F AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY (for Floor Shift Type):
ON-VEHICLE INSPECTION
1. INSPECT SHIFT LEVER POSITION
(a) When moving the shift lever from P to R with the ignition switch ON and the brake pedal
depressed, make sure that it moves smoothly and
correctly into position.
(b) Check that the shift lever does not stop when moving the shift lever from R to P, and check that
the shift lever does not stick when moving the
shift lever from D to S.
(c) Start the engine and make sure that the vehicle moves forward after moving the shift lever from
N to D and moves in reverse after moving the
shift lever to R.
If the operation cannot be performed as specified, inspect the park/neutral position switch
assembly and check the shift lever assembly installation condition.
Page 5028
Page 7813
Control Module HVAC: Locations Air Conditioning System (for Manual Air Conditioning System)
AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Manual Air Conditioning System):
PARTS LOCATION
Page 6501
Relay Box: Electrical Diagrams
Engine Room R/B And Engine Room J/B Inner Circuit
Page 8297
The customer (individual requiring the extender) must visit a Toyota dealership to have the required
measurements made and to complete the Seat Belt Extender Worksheet. The worksheet will allow
the proper fitting and selection of a Seat Belt Extender for the customer. The dealership personnel
will then determine the applicable part number and place an order through Dealer Daily.
The dealership service department will complete the Seat Belt Extender Customer Information
Label attached to the part and review the "Owner Instructions" with the customer. The dealership
should give a copy of the completed worksheet and Owner Instructions to the customer and keep
the originals in the customer's file. To assure utmost owner satisfaction, it is recommended that
dealerships designate one person to coordinate all activities related to the Seat Belt Extender
issue. It is recommended that dealerships do NOT stock Seat Belt Extenders due to the need for
proper fitting to individual customers.
This bulletin contains the following information:
^ Procedure and Sample Label
^ Application Charts
Page 3735
HINT The wavelength becomes shorter as the vehicle speed increases.
(k) WAVEFORM 10:
HINT The duty ratio varies depending on the throttle actuator operation.
(l) WAVEFORM 11:
HINT The duty ratio varies depending on the throttle actuator operation.
(m)WAVEFORM 12:
Page 5463
Page 8663
Remove the blown fuse and disconnect all loads of the fuse.
Connect a test light in place of the fuse.
Establish conditions in which the test light comes on.
Example:
- [A] - Ignition SW on
- [B] - Ignition SW and SW1 on
- [C] - Ignition SW, SW1 and Relay on (Connect the Relay) and SW2 off (or Disconnect SW2)
Disconnect and reconnect the connectors while watching the test light.
Page 4401
Fuel Gauge Sender: Diagrams
Page 6918
Push the secondary locking device or terminal retainer in to the full lock position.
CONNECT CONNECTOR
Voltage Check
VOLTAGE CHECK
Engine Control System - SFI System
Crankshaft Position Sensor: Locations Engine Control System - SFI System
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 3786
Camshaft Position Sensor: Locations Ignition System
1UR-FE IGNITION: IGNITION SYSTEM: PARTS LOCATION
Page 6823
Front Door Wire
Page 8655
Symbols Used Within Diagrams
Symbols Used Within Diagrams
Engine Controls - ECM Update For Shift Performance
Engine Control Module: All Technical Service Bulletins Engine Controls - ECM Update For Shift
Performance
T-SB-0285-10
October 12, 2010
ECM Calibration: Enhancement to Shifting Performance
Service Category Drivetrain
Section Automatic Transmission/Transaxle
Market USA
Applicability
Introduction
Some vehicles may exhibit the following shifting conditions:
^ Harsh shift on acceleration below 20 mph during the 2-1 downshift.
^ Excessive lock-up operation at freeway speeds about 50 - 60 mph, sometimes referred to as
"busy shifting".
The Engine Control Module/ECM (SAE term: Powertrain Control Module/PCM) calibration has
been revised. Use the following repair procedure to address these conditions.
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Federal Emission Warranty. This warranty is in effect for
96 months or 80,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Locations
Four Wheel Drive Selector Switch: Locations
JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION
Page 9311
Lower Side Moulding / Trim: Service and Repair Removal
EXTERIOR: SIDE MOULDING: REMOVAL
HINT *
Use the same procedures for the RH side and LH side.
* The procedures listed below are for the LH side.
* When removing the moulding, heat the vehicle body and moulding using a heat light.
Standard heating temperature:
NOTICE: Do not heat the vehicle body and moulding excessively.
1. REMOVE LOWER NO. 1 SIDE PANEL MOULDING LH
(a) Detach the 2 clips and remove the moulding.
Page 6378
Page 5386
Page 6334
Page 1270
Air Flow Meter/Sensor: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: INSTALLATION
1. INSTALL MASS AIR FLOW METER
(a) Install the MAF meter with the 2 screws.
Torque : 1.7 Nm (17 kgf-cm, 15 in-lbf)
(b) Connect the MAF connector.
Page 4123
Page 8485
Hood Sensor/Switch (For Alarm): Diagrams
Page 4619
Knock Sensor: Diagrams
Page 3277
^ Calibration ID(s) [Refer to the Calibration Identification Chart for the NEW CALIBRATION ID]
^ Dealer Code
^ Repair Date
^ Change Authority [This TSB number]
B. Affix the Authorized Modifications Label to the vehicle at the location shown in Figure 1. The
Authorized Modifications Label is available
through the MDC P/N 00451-00001-LBL.
Page 4371
(m)Measure the fuel pressure.
Standard fuel pressure:
281 to 287 kPa (2.87 to 2.93 kgf/cm2, 41 to 42 psi)
(n) If the pressure is not as specified, check the fuel pump, pressure regulator and/or injectors.
(o) Stop the engine.
(p) Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped.
Standard fuel pressure:
147 kPa (1.5 kgf/cm2, 21 psi) or higher
(q) If the pressure is not as specified, check the fuel pump, pressure regulator and/or injectors.
(r) After checking the fuel pressure, disconnect the cable from the negative (-) battery terminal and
carefully remove SST and the fuel tube
connector to prevent gasoline from spraying.
(s) Reconnect the fuel tube (fuel tube connector).
(t) Check for fuel leak.
(1) Check that there are no fuel leaks after performing maintenance anywhere on the system.
If there are fuel leaks, repair or replace parts as necessary.
Page 2967
Oxygen Sensor: Testing and Inspection Air Fuel Ratio Sensor
1UR-FE ENGINE CONTROL SYSTEM: AIR FUEL RATIO SENSOR: ON-VEHICLE INSPECTION
1. INSPECT AIR FUEL RATIO SENSOR
(a) Disconnect the 2 sensor connectors.
(b) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(c) If the result is not as specified, replace the air fuel ratio sensor.
(d) Connect the 2 sensor connectors.
Locations
Steering Column Control Module: Locations
Instrument Panel (Floor Shift)
Instrument Panel (Column Shift)
Page 7654
3. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE
HINT The diagnostic system in the TOYOTA TUNDRA has various functions.
* The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU
memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a
previous malfunction's DTC can be checked by a technician during troubleshooting.
* Another function is the Input Signal Check, which checks if the signals from various switches are
sent to the ECU correctly.
* By using these functions, the problem areas can be narrowed down and troubleshooting is more
effective. Diagnostic functions are incorporated in the following systems in the TOYOTA TUNDRA.
Page 8377
Door/Service and Repair/Front Door (for Double Cab)/Disassembly
4. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH (for Front Side) See: Body
and Frame/Doors, Hood and
Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly
5. REMOVE COURTESY LIGHT ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood
and Trunk/Doors/Front Door/Service and
Repair/Front Door (for Double Cab)/Disassembly
6. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Disassembly
7. REMOVE FRONT SIDE AIRBAG SENSOR
(a) Disconnect the connector.
(b) Remove the screw and side airbag sensor.
8. REMOVE REAR SEAT ASSEMBLY (for Rear Side)
(a) Remove the rear seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Rear Seat Assembly (for Double
Cab)/Removal.
9. REMOVE REAR DOOR SCUFF PLATE LH (for Rear Side) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and Repair/Roof
Headlining (For Double Cab)/Removal
10. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH (for Rear Side)
11. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY LH (for Rear Side) See: Body and
Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal
12. REMOVE REAR SIDE AIRBAG SENSOR
(a) Remove the bolt and side airbag sensor.
(b) Disconnect the connector.
Installation
SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Double Cab):
INSTALLATION
1. INSTALL FRONT SIDE AIRBAG SENSOR
(a) Check that the ignition switch is OFF.
(b) Check that the cable is disconnected from the battery negative (-) terminal.
CAUTION:
Engine - Controls - Non-Linear Acceleration From A Stop
PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine - Controls Non-Linear Acceleration From A Stop
T-SB-0273-10
September 28, 2010
Non-Linear Acceleration from a Stop
Service Category Engine/Hybrid System
Section Engine Control
Market USA
Applicability
Introduction
Some 2010 model year Tundra vehicles with the 1UR-FE (4.6 L) engine may exhibit non-linear
acceleration from a stop under certain conditions of low engine rpm with high engine load. The
Engine Control Module/ECM (SAE term: Powertrain Control Module/PCM) logic has been revised
to address this condition. Use the following repair procedure to recalibrate the ECM (PCM).
Calibration Information
Warranty Information
Applicable Warranty
^ This repair is covered under the Toyota Federal Emission Warranty. This warranty is in effect for
96 months or 80,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Page 6594
"Case1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (/\ Mark) and pull the terminal retainer
up to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Page 5017
Actuator: Service and Repair Installation
DIFFERENTIAL: AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR (for 4WD):
INSTALLATION
1. INSTALL AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR
(a) Remove any old FIPG material and be careful not to drop oil on the contact surfaces of the
differential tube and actuator.
(b) Clean the contact surfaces with any residual FIPG material using gasoline or alcohol.
(c) Apply seal packing to the differential tube as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
HINT Install the actuator within 10 minutes of applying seal packing.
(d) Clean the threads of the 4 bolts and retainer bolt holes with toluene or trichloroethylene.
(e) Install the actuator onto the differential tube.
(f) Apply adhesive to 2 to 3 threads of each bolt end.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
(g) Install the 4 bolts.
Torque : 21 Nm (210 kgf-cm, 15 ft-lbf)
(h) Connect the actuator hose.
(i) Connect the actuator connector.
2. INSTALL NO. 1 ENGINE UNDER COVER See: Engine, Cooling and Exhaust/Engine/Drive
Belts, Mounts, Brackets and Accessories/Drive
Belt/Service and Repair/Installation
3. INSPECT AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR
(a) Inspect the automatic disconnecting differential actuator See: Transfer Case/Testing and
Inspection/Component Tests and General
Diagnostics/Touch Select 2-4 and High-Low System.
Page 6808
6. PROBLEM SYMPTOMS TABLE
When a "Normal" code is output during a DTC check but the problem is still occurring, use the
Problem Symptoms Table. The suspected areas (circuits or parts) for each problem symptom are
in the table. The suspected areas are listed in order of probability. A description of each of the
chart's columns is below.
HINT In some cases, the problem is not detected by the diagnostic system even though a problem
symptom is present. It is possible that the problem is occurring outside the detection range of the
diagnostic system, or that the problem is occurring in a completely different system.
7. CIRCUIT INSPECTION
A description of the main areas of each circuit inspection is below.
Page 5888
Steering Angle Sensor: Service and Repair Installation
BRAKE CONTROL: STEERING ANGLE SENSOR: INSTALLATION
1. INSTALL STEERING ANGLE SENSOR See: Restraint Systems/Air Bag Systems/Clockspring
Assembly / Spiral Cable/Service and
Repair/Installation
2. INSTALL SPIRAL CABLE SUB-ASSEMBLY See: Restraint Systems/Air Bag
Systems/Clockspring Assembly / Spiral Cable/Service and
Repair/Installation
3. INSTALL UPPER STEERING COLUMN COVER See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Removal and
Replacement/Steering Column Assembly (for Manual Tilt)/Installation
4. INSTALL LOWER STEERING COLUMN COVER See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Removal and
Replacement/Steering Column Assembly (for Manual Tilt)/Installation
5. ADJUST SPIRAL CABLE See: Restraint Systems/Air Bag Systems/Clockspring Assembly /
Spiral Cable/Service and Repair/Installation
6. INSTALL STEERING WHEEL ASSEMBLY See: Steering and Suspension/Steering/Steering
Column/Service and Repair/Removal and
Replacement/Steering Column Assembly (for Manual Tilt)/Installation
7. INSTALL STEERING PAD See: Restraint Systems/Air Bag Systems/Air Bag/Service and
Repair/Removal and Replacement/Steering
Pad/Installation
8. INSTALL LOWER NO. 3 STEERING WHEEL COVER See: Restraint Systems/Air Bag
Systems/Air Bag/Service and Repair/Removal and
Replacement/Steering Pad/Installation
9. INSTALL LOWER NO. 2 STEERING WHEEL COVER See: Restraint Systems/Air Bag
Systems/Air Bag/Service and Repair/Removal and
Replacement/Steering Pad/Installation
10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
11. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
Page 6812
Page 3375
Push the secondary locking device or terminal retainer in to the full lock position.
CONNECT CONNECTOR
Voltage Check
VOLTAGE CHECK
Up to 11/2009
Brake Fluid Pump Relay: Locations Up to 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 3361
Page 1930
Fluid - Transfer Case: Testing and Inspection
JF1A TRANSFER: TRANSFER OIL: ON-VEHICLE INSPECTION
1. CHECK TRANSFER OIL
(a) Remove the filler plug and gasket.
(b) Check that the oil level is between 0 to 5.0 mm (0 to 0.197 in.) from the bottom lip of the filler
plug hole.
(c) If the result is not as specified, add transfer oil.
Oil grade:
GL-4 or GL-5
Viscosity:
SAE 75W-90
Standard capacity:
1.1 +/- 0.06 liters (1.2 +/- 0.06 US qts, 1.0 +/- 0.05 Imp. qts)
NOTICE: *
After changing the oil, drive the vehicle and check the oil level again.
* Too much or too little oil will lead to transfer problems.
(d) When the oil level is too low, check for oil leak.
(e) Install a new gasket into the filler plug and then tighten the plug.
2. ADD TRANSFER OIL
(a) Remove the filler plug and gasket.
(b) Pour oil so that the oil level is between 0 to 5.0 mm (0 to 0.197 in.) from the bottom lip of the
case plug (for filler) hole.
NOTICE: *
When adding oil, pour it slowly.
* Add oil a little at a time, waiting several minutes between each addition of oil.
(c) Wait approximately 5 minutes and check that the oil level has not changed.
(d) Install a new gasket and the filler plug.
Torque : 37 Nm (377 kgf-cm, 27 ft-lbf)
Up to 11/2009
Hose/Line HVAC: Service and Repair Up to 11/2009
AIR CONDITIONING: REFRIGERANT LINE: COMPONENTS
Page 463
Removal
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift
Type): REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal
3. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding
/ Trim/Dashboard / Instrument
Page 2647
Radiator Cooling Fan: Service and Repair Installation
1UR-FE COOLING: FAN: INSTALLATION
1. INSTALL FAN
(a) Install the fan to the fluid coupling with the 4 nuts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
2. INSTALL FAN SHROUD
(a) Install the fan pulley to the fan bracket.
(b) Place the fan shroud together with the fluid coupling fan between the radiator and engine.
NOTICE: Be careful not to damage the radiator core
(c) Temporarily install the fluid coupling fan to the fan bracket with the 4 nuts. Tighten the nuts as
much as possible by hand.
(d) Attach the shroud's claws to the radiator as shown in the illustration.
(e) Install the shroud with the 2 bolts.
Torque : 6.5 Nm (66 kgf-cm, 58 in-lbf)
(f) w/ Trailer Towing System:
(f) Pass the 2 hoses through the flexible hose clamp and close the clamp as shown in the
illustration.
(g) Connect the reservoir hose to the upper radiator tank.
(h) Install the fan and generator V-belt See: Engine/Drive Belts, Mounts, Brackets and
Accessories/Drive Belt/Service and Repair/Installation.
(i) Tighten the 4 nuts of the fluid coupling fan.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
Page 1431
(a) Disconnect the holder (with connectors).
(b) Remove the 3 bolts and airbag sensor.
Installation
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Column
Shift Type): INSTALLATION
1. INSTALL CENTER AIRBAG SENSOR ASSEMBLY
(a) Check that the ignition switch is OFF.
(b) Check that the cable is disconnected from the battery negative (-) terminal.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
(c) Install the airbag sensor with the 3 bolts.
Torque : 18 Nm (184 kgf-cm, 13 ft-lbf)
NOTICE: *
If the center airbag sensor has been dropped, or there are any cracks, dents or other defects in the
case, bracket or connector, replace it with a new one.
* When installing the center airbag sensor, be careful that the SRS wiring does not interfere with
other parts and that it is not pinched between other parts.
(d) Check that there is no looseness in the installation parts of the center airbag sensor.
(e) Connect the holder (with connectors).
(f) Check that the waterproof sheet is properly set.
2. INSTALL CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service
and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
NOTICE: Some systems need to be initialized after the cable is reconnected See: Testing and
Inspection/Programming and Relearning
4. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
Page 6409
Page 5132
D. Fill the bracket with Loctite 5040 (or equivalent) until sealant can be seen coming out of the
bracket opening. Allow sealant to setup for 12
minutes.
E. Inspect surrounding area for damage.
2. Test drive the vehicle to confirm the repair.
Page 4542
Knock Sensor: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: REMOVAL
1. REMOVE INTAKE MANIFOLD
(a) Remove the intake manifold See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service
and Repair/Removal.
2. REMOVE SEPARATOR CASE
(a) Remove the 4 bolts and separator case.
3. REMOVE KNOCK SENSOR
(a) Disconnect the 4 knock sensor connectors.
(b) Remove the 4 bolts and 4 knock sensors.
Components
Tire Pressure Warning Reset Switch: Service and Repair Components
TIRE AND WHEEL: TIRE PRESSURE WARNING RESET SWITCH: COMPONENTS
Page 891
Page 2994
Transmission Position Switch/Sensor: Diagrams
Page 8316
Air Bag Deactivation Switch: Diagrams Curtain Airbag Cutoff Switch
Page 2715
Page 5527
Transmission Speed Sensor: Testing and Inspection
A760F AUTOMATIC TRANSMISSION: SPEED SENSOR: INSPECTION
1. INSPECT SPEED SENSOR NT
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) If the result is not as specified, replace the sensor.
2. INSPECT SPEED SENSOR SP2
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) If the result is not as specified, replace the sensor.
Page 2314
(b) Uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.
(c) Uniformly loosen and remove the 18 bearing cap bolts in the sequence shown in the illustration.
NOTICE: Uniformly loosen the bolts while keeping the camshaft level.
(d) Remove the 6 bearing caps.
HINT Arrange the removed parts in the correct order.
(e) Remove the No. 1 and No. 2 camshafts.
13. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH
(a) Remove the camshaft housing by prying between the cylinder head and camshaft housing with
a screwdriver.
HINT Tape the screwdriver tip before use.
NOTICE: Be careful not to damage the contact surfaces of the cylinder head and camshaft
housing.
Installation
1UR-FE ENGINE MECHANICAL: CAMSHAFT (for Bank 2): INSTALLATION
1. INSTALL CAMSHAFT BEARING CAP RH
Page 5908
Wheel Speed Sensor: Diagrams Rear Speed Sensor
Body/Frame - Choppy Ride Condition
Body / Frame Mount Bushing: All Technical Service Bulletins Body/Frame - Choppy Ride Condition
T-SB-0369-10
December 23, 2010
Choppy Ride (Tundra D-Cab Short Bed)
Service Category Suspension
Section Rear Suspension
Market USA
Applicability
Introduction
Some 2007 - 2010 Tundra vehicles may exhibit a body vibration when driving under certain road
conditions. A newly designed cab mount has been developed to help improve this condition.
NOTE
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for
36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Front Door Courtesy Switch
Door Switch: Testing and Inspection Front Door Courtesy Switch
LIGHTING: FRONT DOOR COURTESY SWITCH: INSPECTION
1. INSPECT FRONT DOOR COURTESY SWITCH
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the switch.
Page 2717
(d) Remove the 2 gaskets from the front exhaust pipes.
3. REMOVE PROPELLER SHAFT HEAT INSULATOR (for 4WD) See: Transmission and
Drivetrain/Drive/Propeller Shafts, Bearings and
Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Front Propeller Shaft
Assembly/Removal
4. REMOVE HEATED OXYGEN SENSOR (for Bank 1 Sensor 2) See: Powertrain
Management/Computers and Control Systems/Oxygen
Sensor/Service and Repair/Heated Oxygen Sensor/Removal
5. REMOVE FRONT NO. 2 EXHAUST PIPE ASSEMBLY
(a) Disconnect the air fuel ratio sensor connector.
(b) Remove the 3 nuts.
(c) Disconnect the front No. 2 exhaust pipe from the exhaust pipe support to remove it.
(d) Remove the gasket.
6. REMOVE HEATED OXYGEN SENSOR (for Bank 2 Sensor 2) See: Powertrain
Management/Computers and Control Systems/Oxygen
Sensor/Service and Repair/Heated Oxygen Sensor/Removal
7. REMOVE FRONT EXHAUST PIPE ASSEMBLY
(a) Disconnect the air fuel ratio sensor connector.
(b) Remove the 3 nuts and the front exhaust pipe from the exhaust manifold RH.
(c) Remove the gasket.
8. REMOVE AIR FUEL RATIO SENSOR (for Bank 1 Sensor 1)
(a) Using SST, remove the sensor.
SST : 09224-00010
9. REMOVE AIR FUEL RATIO SENSOR (for Bank 2 Sensor 1) See: Powertrain
Management/Computers and Control Systems/Oxygen
Sensor/Service and Repair/Air Fuel Ratio Sensor/Removal
10. REMOVE MONOLITHIC CONVERTER PROTECTOR (for Bank 1)
Page 6553
J/B No.3 - Instrument Panel Right
Testing and Inspection
Fuel Filler Cap: Testing and Inspection
1UR-FE EMISSION CONTROL: FUEL TANK CAP: INSPECTION
1. INSPECT FUEL TANK CAP ASSEMBLY
(a) Visually check if the cap and/or gasket are deformed or damaged.
(b) If the result is not as specified, replace the fuel tank cap assembly or gasket.
Page 3840
Oxygen Sensor: Diagrams Heated Oxygen Sensor
Components
Steering Angle Sensor: Service and Repair Components
BRAKE CONTROL: STEERING ANGLE SENSOR: COMPONENTS
Locations
Ignition Relay: Locations
MULTIPLEX COMMUNICATION: LIN COMMUNICATION SYSTEM: PARTS LOCATION
Page 7772
(c) Remove the blower case (back side).
(d) Remove the evaporator from the blower case (front side).
16. REMOVE NO. 1 COOLER THERMISTOR
(a) Remove the No. 1 cooler thermistor.
17. REMOVE COOLER EXPANSION VALVE
(a) Using a 4 mm hexagon wrench, remove the 2 bolts.
(b) Remove the tube and accessory and 2 O-rings.
(c) Remove the cooler expansion valve and 2 O-rings from the cooler evaporator.
Reassembly
Page 8730
4. Refer to the applicable model and model year in the table for part replacement.
5. Register the new XM Receiver Radio Identification Number (RID).
A. Be prepared with the VIN OLD Radio Identification Number (RID) and NEW Radio Identification
Number (RID).
B. Call the XM Radio Listener line at 1-800-967-2346.
C. Provide the necessary information and the representative will complete the request.
D. If the customer has an active account confirm XM Satellite Radio service has been refreshed
and the radio is active. Once you can listen to
channels 4, 11, and 41 you know the activation was successful.
Page 8685
(c) Low power mode:
(1) If a garage door opener switch is held for 100 seconds or more, the garage door opener will
enter low power mode to economize on power
consumption. When the garage door opener has entered low power mode, the LED turns off.
Page 3372
"Case2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 75
(a) Remove the front door scuff plate See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Removal.
HINT The procedures listed below are for the LH side.
5. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP RH
6. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY RH See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Removal
7. REMOVE FRONT QUARTER TRIM PANEL ASSEMBLY RH See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Removal
8. REMOVE DOOR CONTROL RECEIVER
(a) Disconnect the door control receiver connector.
(b) Remove the bolt and receiver.
Installation
DOOR LOCK: DOOR CONTROL RECEIVER (for Regular Cab): INSTALLATION
1. INSTALL DOOR CONTROL RECEIVER
(a) Install the receiver with the bolt.
(b) Connect the door control receiver connector.
2. INSTALL FRONT QUARTER TRIM PANEL ASSEMBLY RH See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Installation
3. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY RH See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Installation
4. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH
5. INSTALL FRONT DOOR SCUFF PLATE RH
(a) Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular
Cab)/Installation.
HINT The procedures listed below are for the LH side.
Page 341
Parts Information
Calibration Information
Required Tools & Equipment
Repair Procedure
Page 9305
1. Heat the double-sided tape remaining on the body with an infrared lamp or equivalent.
HINT: 1. Heat the tape to 40 to 60 degrees C for approximately 1 to 2 minutes.
2. Wipe off the remaining double-sided tape using a clean cloth or equivalent.
HINT: 1. If a name plate is installed without thoroughly removing the remaining double-sided tape
from the body, the name plate will not adhere
Page 6377
Removal and Replacement
Axle Shaft Assembly: Removal and Replacement
Components
DRIVE SHAFT: FRONT DRIVE SHAFT ASSEMBLY (for 4WD): COMPONENTS
Page 7590
Push the secondary locking device or terminal retainer in to the full lock position.
CONNECT CONNECTOR
Voltage Check
VOLTAGE CHECK
Page 5101
5. Replace the affected oil baffle.
A. Using a double nut configuration remove 2 axle housing stud bolts to allow the oil baffle to be
removed. See Figures 3 and 4 and attached video
below for reference.
B. Use a 10 mm 1.25 thread chaser or cleaner to carefully clean the axle housing threads.
NOTICE
After cleaning the axle housing threads be sure to thoroughly clean out the axle housing of any
debris to prevent damage to the differential assembly.
C. Replace the oil baffle and fully seat the new baffle against the upper and lower tabs. See Figure
5 for reference.
D. Using a double nut configuration install the new axle housing stud bolts until they are fully
seated.
Torque: 36 N*m (373 kgf*cm, 27 ft*lbf)
6. Install the rear differential and axle shafts.
Take special care not to damage the oil baffle or axle seals when installing the axle shaft assembly.
Refer to TIS applicable model year Tundra Repair Manual:
7. Test drive the vehicle and confirm proper operation.
Page 3413
Page 4659
Page 8283
6. INSTALL BACK PANEL TRIM LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for
CrewMax)/Installation
7. INSTALL BACK PANEL TRIM RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for
CrewMax)/Installation
8. INSTALL REAR SEAT ASSEMBLY
(a) Install the rear seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Rear Seat Assembly (for Crewmax LH
Side)/Installation.
Components
SEAT BELT: REAR SEAT OUTER BELT ASSEMBLY (for Double Cab): COMPONENTS
Page 1752
(4) for Fuel Pipe Clamp Type:
Install the fuel pipe clamp to the connector.
(5) for Fuel Hose Connector Cover Type:
Attach the lock claw to the connector by pushing down on the cover, as shown in the illustration.
(6) Check that there is no fuel leakage.
3. CHECK FOR FUEL LEAK
(a) Check that there are no fuel leaks after performing maintenance anywhere on the fuel system
See: Powertrain Management/Fuel Delivery and
Air Induction/Testing and Inspection.
Page 8834
Page 2041
Driver Side J/B Inner Circuit
Page 3234
Establish conditions in which voltage is present at the check point.
Example:
- [A] - Ignition SW on
- [B] - Ignition SW and SW1 on
- [C] - Ignition SW, SW1 and Relay on (SW2 off)
Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or component terminal.
This check can be done with a test light instead of a voltmeter.
Electronic Circuit Inspection Procedure
Page 5917
(e) Attach the 3 clips (labeled F).
NOTICE: *
When installing the clips, do not twist the wire harness.
* When installing the clips, securely insert them as shown in the illustration.
(f) Connect the speed sensor connector (labeled G).
NOTICE: Securely connect the connector.
7. INSTALL FRONT WHEEL See: Steering and Suspension/Suspension/Suspension Strut / Shock
Absorber/Service and Repair/Removal and
Replacement/Front Shock Absorber/Installation
8. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
9. CHECK SPEED SENSOR SIGNAL
(a) Check the speed sensor signal See: Antilock Brakes / Traction Control Systems/Testing and
Inspection/Scan Tool Testing and
Procedures/Test Mode Procedure.
Page 3240
General Information
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: GENERAL
INFORMATION
* A large number of ECU controlled systems are used in the TOYOTA TUNDRA. In general, ECU
controlled systems are considered to be very intricate, requiring a high level of technical knowledge
to troubleshoot. However, most problem checking procedures only involve inspecting the ECU
controlled system's circuits one by one. An adequate understanding of the system and a basic
knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and
necessary repairs.
1. TROUBLESHOOTING PROCEDURES
* The troubleshooting procedures consist of diagnosis procedures for when a DTC is stored and
diagnosis procedures for when no DTC is stored. The basic idea is explained in the following table.
* Vehicle systems are complex and use many ECUs that are difficult to inspect independently.
Therefore, a process of elimination is used, where components that can be inspected individually
are inspected, and if no problems are found in these components, the related ECU is identified as
the problem and replaced.
* It is extremely important to ask the customer about the environment and the conditions present
when the problem occurred (Customer Problem Analysis). This makes it possible to simulate the
conditions and confirm the symptom. If the symptom cannot be confirmed or the DTC does not
recur, the malfunctioning part may not be identified using the troubleshooting procedure, and the
ECU for the related system may be replaced even though it is not defective. If this happens, the
original problem will not be solved.
* In order to prevent endless expansion of troubleshooting procedures, the troubleshooting
procedures are written with the assumption that multiple malfunctions do not occur simultaneously
for a single problem symptom.
* To identify the malfunctioning part, troubleshooting procedures narrow down the target by
separating components, ECUs and wire harnesses during the inspection. If the wire harness is
identified as the cause of the problem, it is necessary to inspect not only the connections to
components and ECUs but also all of the wire harness connectors between the component and the
ECU.
DIAGNOSTIC TESTER
2. DESCRIPTION
System data and the Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector
3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the Techstream* to
check for a malfunction and perform repairs.
HINT *: Techstream is the name for the diagnostic tester in North America.
3. DATA LINK CONNECTOR 3 (DLC3)
(a) The vehicle's ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of
the DLC3 complies with SAE J1962 and
matches the ISO 15765-4 format.
Page 5414
Four Wheel Drive Selector Switch: Service and Repair Removal
JF1A TRANSFER: 4WD CONTROL SWITCH: REMOVAL
1. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Panel,
Gauges and Warning Indicators/Instrument Cluster
/ Carrier/Service and Repair/Combination Meter/Removal
2. REMOVE 4WD CONTROL SWITCH
(a) Detach the 3 claws to remove the switch.
Page 4528
(4) Connect the engine wire harness clamp.
3. INSTALL AIR CLEANER ASSEMBLY
(a) Install the air cleaner with the 2 bolts.
Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)
(b) Tighten the hose clamp.
Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf)
(c) Connect the ventilation hose and vacuum hose.
(d) Connect the MAF meter connector and clamp.
4. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Installation
Page 6637
(a) for AC Power Supply:
Connect the clamp.
(b) Install the bezel with the 4 screws.
5. INSTALL NO. 2 CONSOLE BOX REGISTER ASSEMBLY See: Body and Frame/Seats/Service
and Repair/Overhaul/Front Seat Assembly (for
Center Seat)/Reassembly
6. INSTALL NO. 1 CONSOLE BOX REGISTER ASSEMBLY See: Body and Frame/Seats/Service
and Repair/Overhaul/Front Seat Assembly (for
Center Seat)/Reassembly
7. INSTALL CENTER SEATBACK PANEL See: Body and Frame/Seats/Service and
Repair/Overhaul/Front Seat Assembly (for Center
Seat)/Reassembly
Page 7707
21. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Installation
22. INSTALL FRONT DOOR SCUFF PLATE LH
(a) for Regular Cab:
Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Floor Shift Type)/Removal.
(b) for Double Cab:
Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Floor Shift Type)/Installation.
(c) for CrewMax:
Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Floor Shift Type)/Installation.
23. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
24. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Reading and Clearing Diagnostic Trouble
Codes/Check Mode Procedure.
Page 1822
J. When Cal 1 has completed the update process turn ignition OFF for a minimum of 10 seconds.
Then click Next.
K. Turn ignition to the ON position. Then click Start.
L. Do NOT disturb the vehicle during flash reprogramming.
Components
Control Module HVAC: Service and Repair Components
AIR CONDITIONING: AIR CONDITIONING AMPLIFIER: COMPONENTS
Page 289
If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness
or connector in that circuit in the past. Check the wire harness and connectors.
B -- SYSTEM NORMAL
A -- TROUBLESHOOTING OF EACH PROBLEM SYMPTOM
The problem is still occurring in a place other than the diagnostic circuit (the DTC displayed first is
either for a past problem or a secondary problem).
4. SYMPTOM SIMULATION
HINT The most difficult case in troubleshooting is when no problem symptoms occur. In such a
case, a thorough problem analysis must be carried out. A simulation of the same or similar
conditions and environment in which the problem occurred in the customer's vehicle should be
carried out. No matter how much skill or experience a technician has, troubleshooting without
confirming the problem symptoms will lead to important repairs being overlooked and mistakes or
delays.
For example:
With a problem that only occurs when the engine is cold or as a result of vibration caused by the
road during driving, the problem can never be determined if the symptoms are being checked on a
stationary vehicle or on a vehicle with a warmed-up engine. Vibration, heat or water penetration
(moisture) is difficult to reproduce. The symptom simulation tests below are effective substitutes for
the conditions and can be applied on a stationary vehicle.
Important points in the symptom simulation test:
In the symptom simulation test, the problem symptoms as well as the problem area or parts must
be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then,
connect the tester and carry out the symptom simulation test, judging whether the circuit being
tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the
problem symptoms table for each system to narrow down the possible causes.
To reproduce DTCs, it is necessary to satisfy the respective DTC detection conditions.
(a) VIBRATION METHOD:
When a malfunction seems to occur as a result of vibration.
(1) PART AND SENSOR
Apply slight vibration with a finger to the part of the sensor suspected to be the cause of the
problem, and check whether or not the malfunction occurs.
NOTICE: Applying strong vibration to relays may open them.
Page 3833
Applicable Vehicles
Page 8144
Seat Occupant Sensor: Diagrams Rear Occupant Classification Sensor
Page 7188
POWER STEERING: VANE PUMP (for 1UR-FE): REMOVAL
1. REMOVE RADIATOR ASSEMBLY
(a) Remove the radiator assembly See: Engine, Cooling and Exhaust/Cooling
System/Radiator/Service and Repair/Removal.
2. DRAIN POWER STEERING FLUID
3. SEPARATE HARNESS BRACKET
(a) Remove the bolt and separate the bracket.
4. DISCONNECT NO. 1 OIL RESERVOIR TO PUMP HOSE
(a) Detach the clip and disconnect the hose.
5. DISCONNECT POWER STEERING OIL PRESSURE SENSOR CONNECTOR
(a) Disconnect the oil pressure sensor connector.
6. DISCONNECT SOLENOID VALVE CONNECTOR
(a) Disconnect the solenoid valve connector.
7. SEPARATE PRESSURE FEED TUBE
Page 822
Traction Control Switch: Service and Repair Installation
BRAKE CONTROL: VSC OFF SWITCH: INSTALLATION
1. INSTALL VSC OFF SWITCH
(a) Attach the 2 claws to install the VSC OFF switch into the lower instrument panel finish panel
LH.
(b) Connect the VSC OFF switch connector.
2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Installation
3. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Installation
4. INSTALL FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Installation
5. INSTALL FRONT DOOR SCUFF PLATE LH (for Double Cab, CrewMax) See: Body and
Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Installation
Page 8805
Removal
AUDIO / VISUAL: FRONT DOOR SPEAKER (for Double Cab): REMOVAL
HINT *
Use the same procedures for the LH side and RH side.
* The procedures listed below are for the LH side.
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE FRONT LOWER DOOR FRAME BRACKET GARNISH LH See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Disassembly
3. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH See: Body and Frame/Doors,
Hood and Trunk/Doors/Front Door/Service and
Repair/Front Door (for Double Cab)/Disassembly
Page 3030
Air Flow Meter/Sensor: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: REMOVAL
1. REMOVE MASS AIR FLOW METER
(a) Disconnect the MAF connector.
(b) Remove the 2 screws and MAF meter.
Components
Brake Pedal Assy: Service and Repair Components
BRAKE: BRAKE PEDAL: COMPONENTS
Components
Knock Sensor: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: COMPONENTS
Page 2359
Standard Bearing Center Wall Thickness:
Other Journals:
Main Bearing Clearance, Standard & Limit
Page 3629
(2) If the result is not as specified, replace the integration relay.
3. INSTALL INTEGRATION RELAY See: Ignition System/Ignition Relay/Testing and Inspection
Page 6541
3. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE
HINT The diagnostic system in the TOYOTA TUNDRA has various functions.
* The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU
memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a
previous malfunction's DTC can be checked by a technician during troubleshooting.
* Another function is the Input Signal Check, which checks if the signals from various switches are
sent to the ECU correctly.
* By using these functions, the problem areas can be narrowed down and troubleshooting is more
effective. Diagnostic functions are incorporated in the following systems in the TOYOTA TUNDRA.
Page 4719
Four Wheel Drive Selector Switch: Service and Repair Removal
JF1A TRANSFER: 4WD CONTROL SWITCH: REMOVAL
1. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Panel,
Gauges and Warning Indicators/Instrument Cluster
/ Carrier/Service and Repair/Combination Meter/Removal
2. REMOVE 4WD CONTROL SWITCH
(a) Detach the 3 claws to remove the switch.
Page 5600
Hydraulic Control Assembly - Antilock Brakes: Locations From 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Components
Camshaft Position Sensor: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT POSITION SENSOR: COMPONENTS
Locations
Tire Pressure Warning Reset Switch: Locations
TIRE AND WHEEL: TIRE PRESSURE WARNING SYSTEM: PARTS LOCATION
Page 3117
SST : 09268-31012
90467-13001
95336-08070
09268-41500
09268-41120
SST : 09268-45014
09268-41200
09268-41220
(g) Wipe off any gasoline.
(h) Reconnect the cable to the negative (-) battery terminal.
(i) Operate the fuel pump.
(1) Connect the Techstream to the DLC3.
(2) Turn the ignition switch to ON.
NOTICE: Do not start the engine.
(3) Turn the Techstream main switch ON.
(4) Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump /
Speed.
(j) Measure the fuel pressure.
Standard fuel pressure:
281 to 287 kPa (2.87 to 2.93 kgf/cm2, 41 to 42 psi)
(k) If the pressure is higher than the specification, replace the fuel pressure regulator.
If the pressure is lower than the specification, check the fuel hoses and connections, fuel pump,
fuel filter and fuel pressure regulator assembly.
(l) Start the engine.
Page 1500
Ignition Switch: Testing and Inspection
1UR-FE STARTING: IGNITION SWITCH: INSPECTION
1. INSPECT IGNITION SWITCH ASSEMBLY
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) If the result is not as specified, replace the ignition switch assembly.
Page 787
Braking Sensor/Switch: Diagrams
Page 178
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Page 4037
6. In some instances where water has entered the system DTCs P2440/P2441/P2442/P2443 may
set.
Refer to TIS 2010 model year Tundra Repair Manual to diagnose and inspect the emission control
valves if necessary:
7. If there is NO liquid found in the air pump assemblies or the DTC is still present after
replacement inspect the air injection system.
Refer to TIS 2010 model year Tundra Repair Manual:
8. Clear the DTC and road test the vehicle to confirm the condition has been corrected.
Page 2559
Page 5735
Hydraulic Control Assembly - Antilock Brakes: Testing and Inspection
BRAKE CONTROL: BRAKE ACTUATOR: ON-VEHICLE INSPECTION
1. CONNECT TECHSTREAM
(a) Connect the Techstream to the DLC3.
(b) Start the engine and run it at idle.
(c) Select the Active Test mode on the Techstream.
HINT Refer to the Techstream operator's manual for further details.
2. INSPECT ACTUATOR MOTOR OPERATION
(a) With the motor relay on, check the actuator motor operation noise.
(b) Turn the motor relay off.
(c) Depress the brake pedal and hold it for about 15 seconds. Check that the pedal does not go
down any further while holding it.
(d) With the motor relay on, check that the pedal could have pulsations.
NOTICE: Do not keep the motor relay on for more than 5 seconds continuously. When operating it
consecutively, wait more than 20 seconds between each operation.
(e) Turn the motor relay off and release the brake pedal.
3. INSPECT WHEEL OPERATION
NOTICE: Never turn on a solenoid that is not described below.
(a) With the brake pedal depressed, perform the following operations.
(b) Turn the ABS Solenoid (SFRH) and ABS Solenoid (SFRR) on simultaneously, and check that
the pedal cannot be depressed.
NOTICE: Do not keep the solenoid on for more than 10 seconds continuously. When operating it
consecutively, wait more than 20 seconds between each operation.
(c) Turn the ABS Solenoid (SFRH) and ABS Solenoid (SFRR) off simultaneously, and check that
the pedal can be depressed.
(d) Turn the motor relay on and check that the pedal returns.
NOTICE: Do not keep the motor relay on for more than 5 seconds continuously. When operating it
consecutively, wait more than 20 seconds between each operation.
(e) Turn the motor relay off and release the brake pedal.
(f) Using the procedure above, check the solenoids of the other wheels.
HINT LEFT Front wheel LH: ABS Solenoid (SFLH), ABS Solenoid (SFLR)
RIGHT Rear wheel RH: ABS Solenoid (SRRH), ABS Solenoid (SRRR)
LEFT Rear wheel LH: ABS Solenoid (SRLH), ABS Solenoid (SRLR)
(g) Clear the DTCs See: Antilock Brakes / Traction Control Systems/Testing and
Inspection/Reading and Clearing Diagnostic Trouble Codes.
Page 7768
(a) Remove the filter.
5. REMOVE NO. 2 AIR DUCT SUB-ASSEMBLY
(a) Remove the screw and duct.
6. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY
(a) Remove the 2 screws and amplifier.
7. REMOVE BLOWER WITH FAN MOTOR SUB-ASSEMBLY
(a) Remove the 3 screws and motor.
8. REMOVE AIR DUCT
(a) Remove the 2 screws and duct.
9. REMOVE DAMPER SERVO SUB-ASSEMBLY
Diagrams
Steering Angle Sensor: Diagrams
Page 553
Control Module: Service and Repair Installation
JF1A TRANSFER: 4WD CONTROL ECU: INSTALLATION
1. INSTALL 4WD CONTROL ECU
(a) Install the ECU with the bolt.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
(b) Connect the 2 ECU connectors.
2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Installation
3. INSTALL INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
4. INSTALL COWL SIDE TRIM BOARD RH
(a) Install the cowl side trim board RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Installation.
HINT Use the same procedures described for the LH side.
5. INSTALL FRONT DOOR SCUFF PLATE RH (for Regular Cab)
(a) Install the front door scuff plate RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Installation.
HINT Use the same procedures described for the LH side.
6. INSTALL FRONT DOOR SCUFF PLATE RH (for Double Cab, for CrewMax)
(a) Install the front door scuff plate RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Installation.
HINT Use the same procedures described for the LH side.
Locations
Power Distribution Module: Locations
Instrument Panel (Floor Shift)
Instrument Panel (Column Shift)
Page 7294
SST : 09631-20081
NOTICE: Be careful not to damage the control valve rings.
(e) To prevent the control valve upper oil seal lip from getting damaged, wind vinyl tape around the
serrated portion of the control valve.
(f) Coat the control valve upper oil seal lip with power steering fluid.
(g) Install the control valve onto the control valve housing.
NOTICE: Be careful not to damage the control valve ring and control valve upper oil seal lip.
(h) Apply grease to the needle roller bearing.
(i) Install a new O-ring onto the control valve housing.
(j) Wind vinyl tape around the serrated portion of the control valve.
(k) Install the control valve w/ control valve housing onto the rack housing with the 2 bolts.
Torque : 21 Nm (214 kgf-cm, 14 ft-lbf)
9. INSTALL STEERING GEAR RACK GUIDE
(a) Install the rack guide.
(b) Install the rack guide spring.
(c) Apply adhesive to 2 or 3 threads of the rack guide spring cap.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
(d) Provisionally install the rack guide spring cap.
Components
Variable Valve Timing Actuator Position Sensor: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: VVT SENSOR: COMPONENTS
Page 2459
(e) Disconnect the purge line hose from the purge VSV.
(f) Disconnect the vacuum switching valve connector (for ACIS).
(g) Disconnect the vacuum hose.
(h) Remove the bolt and disconnect the wire harness from the wire harness bracket.
(i) Detach the 3 wire harness clamps from the 3 wire harness brackets.
(j) Detach the 4 clamps from the fuel tube.
(k) Disconnect the fuel tube from the fuel delivery pipe RH See: Powertrain Management/Fuel
Delivery and Air Induction/Service Precautions.
(l) Disconnect the fuel tube from the fuel delivery pipe LH See: Powertrain Management/Fuel
Delivery and Air Induction/Service Precautions.
(m)Remove the 2 nuts, 8 bolts, intake manifold and 2 gaskets.
8. REMOVE FUEL TUBE SUB-ASSEMBLY
(a) Remove the bolt and fuel tube from the intake manifold.
Components
Crankshaft Main Bearing Seal: Service and Repair Components
1UR-FE ENGINE MECHANICAL: REAR CRANKSHAFT OIL SEAL: COMPONENTS
Page 2763
Mongoose MFC Software and Driver MUST be installed before Mongoose MFC selection will be
available.
See TIS - Diagnostics - Scantool page for additional information.
^ If using TIS Techstream select TIS Techstream VIM (this is the default).
4. Click OK.
Operation Procedure
1. Verify the vehicle's applicability for recalibration and locate desired calibration file.
A. Connect Techstream and establish a vehicle connection.
B. Click the Health Check button on the System Select tab.
Page 1704
Standard difference:
0 +/-1 mm (0 +/-0.0394 in.) or less
(e) Tighten the tie rod end lock nuts.
Torque : 82 Nm (836 kgf-cm, 60 ft-lbf)
(f) Place the boots on the seats and install the clips.
HINT Make sure that the boots are not twisted.
5. INSPECT WHEEL ANGLE
(a) Turn the steering wheel to the left and right full lock positions, and measure the turning angle.
Standard wheel angle (unloaded vehicle):
for Regular Cab of Standard Deck
Standard wheel angle (unloaded vehicle):
for Regular Cab of Long Deck
Power Steering Oil Pressure Sensor
Power Steering Pressure Switch: Diagrams Power Steering Oil Pressure Sensor
Components
Variable Valve Timing Actuator Position Sensor: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: VVT SENSOR: COMPONENTS
Page 3852
SST : 09224-00010
without SST - Torque : 44 Nm (449 kgf-cm, 32 ft-lbf)
with SST - Torque : 40 Nm (408 kgf-cm, 30 ft-lbf)
HINT *
Use a torque wrench with a fulcrum length of 30 cm (11.8 in.). When using a torque wrench with a
fulcrum length that is not 30 cm (11.8 in.), calculate the torque specification for the torque wrench
and SST based on the "without SST" torque specification See: Service Precautions
* Make sure SST and the wrench are connected in a straight line.
3. INSTALL PROPELLER SHAFT HEAT INSULATOR (for 4WD) See: Transmission and
Drivetrain/Drive/Propeller Shafts, Bearings and
Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Front Propeller Shaft
Assembly/Installation
4. INSPECT FOR EXHAUST GAS LEAK See: Engine, Cooling and Exhaust/Exhaust
System/Exhaust Manifold/Service and Repair/Installation
Components
Neutral Safety Switch: Service and Repair Components
A760F AUTOMATIC TRANSMISSION: PARK / NEUTRAL POSITION SWITCH: COMPONENTS
Page 6912
[A] For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
"Case1" Raise the terminal retainer up to the temporary lock position.
Page 5962
(a) For an open circuit in the wire harness in Fig. 1, check the resistance or voltage, as described
below.
(b) Check the resistance.
(1) Disconnect connectors A and C and measure the resistance between them.
Standard resistance (Fig. 2):
HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally.
If the results match the examples above, an open circuit exists between terminal 1 of connector A
and terminal 1 of connector C.
(2) Disconnect connector B and measure the resistance between the connectors.
Standard resistance (Fig. 3):
* If the results match the examples above, an open circuit exists between terminal 1 of connector
B2 and terminal 1 of connector C.
(c) Check the voltage.
Page 3374
Release the locking lug from terminal and pull the terminal out from rear.
INSTALL TERMINAL TO CONNECTOR
Insert the terminal.
HINT: Make sure the terminal is positioned correctly.
Insert the terminal until the locking lug locks firmly.
Insert the terminal with terminal retainer in the temporary lock position.
Components
Thermostat: Service and Repair Components
1UR-FE COOLING: THERMOSTAT: COMPONENTS
Page 6272
Push the terminal retainer down to the temporary lock position.
Page 6617
Connectors
Locations: The locations of components, connectors, ground points, and splices referred to within
these diagrams can be found at Vehicle Locations. See: Locations
Power Outlet [12V]
Page 1076
Hazard Warning Switch: Service and Repair Removal
LIGHTING: HAZARD WARNING SWITCH: REMOVAL
1. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Panel,
Gauges and Warning Indicators/Instrument Cluster
/ Carrier/Service and Repair/Combination Meter/Removal
2. REMOVE HAZARD WARNING SWITCH
(a) Detach the 2 claws and remove the switch.
Page 5478
Actuator: Diagrams
Engine - Controls - Non-Linear Acceleration From A Stop
Engine Control Module: Customer Interest Engine - Controls - Non-Linear Acceleration From A
Stop
T-SB-0273-10
September 28, 2010
Non-Linear Acceleration from a Stop
Service Category Engine/Hybrid System
Section Engine Control
Market USA
Applicability
Introduction
Some 2010 model year Tundra vehicles with the 1UR-FE (4.6 L) engine may exhibit non-linear
acceleration from a stop under certain conditions of low engine rpm with high engine load. The
Engine Control Module/ECM (SAE term: Powertrain Control Module/PCM) logic has been revised
to address this condition. Use the following repair procedure to recalibrate the ECM (PCM).
Calibration Information
Warranty Information
Applicable Warranty
^ This repair is covered under the Toyota Federal Emission Warranty. This warranty is in effect for
96 months or 80,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Page 3958
6. In some instances where water has entered the system DTCs P2440/P2441/P2442/P2443 may
set.
Refer to TIS 2010 model year Tundra Repair Manual to diagnose and inspect the emission control
valves if necessary:
7. If there is NO liquid found in the air pump assemblies or the DTC is still present after
replacement inspect the air injection system.
Refer to TIS 2010 model year Tundra Repair Manual:
8. Clear the DTC and road test the vehicle to confirm the condition has been corrected.
Page 6181
HINT Tape the screwdriver tip before use.
10. REMOVE REAR POWER OUTLET SOCKET COVER (for Double Cab)
(a) Detach the 2 claws and remove the power outlet socket cover.
Installation
OTHER SYSTEM: CENTER POWER OUTLET SOCKET (for Column Shift Type): INSTALLATION
1. INSTALL REAR POWER OUTLET SOCKET COVER (for Double Cab)
(a) Attach the 2 claws to install the power outlet socket cover.
2. INSTALL REAR POWER OUTLET SOCKET ASSEMBLY (for Double Cab)
(a) Attach the claw to install the power outlet socket.
3. INSTALL CENTER SEATBACK PANEL (for Double Cab) See: Body and Frame/Seats/Service
and Repair/Overhaul/Front Seat Assembly (for
Center Seat)/Reassembly
4. INSTALL POWER OUTLET SOCKET COVER
(a) Attach the 2 claws to install the power outlet socket cover.
5. INSTALL POWER OUTLET SOCKET ASSEMBLY
Drivetrain - Front End Grinding Noise In 4WD
Differential Mount: All Technical Service Bulletins Drivetrain - Front End Grinding Noise In 4WD
T-SB-0338-09
Rev1
September 16, 2009
Grinding Noise When in 4WD
Service Category Drivetrain
Section Axle/Differential
Market USA
Applicability
March 10, 2010 Rev1:
^ Applicability has been updated to include 2008 - 2010 model year Sequoia vehicles.
^ Production Change Information has been added.
Any previous printed versions of this service bulletin should be discarded.
Introduction
Some 2008 - 2010 model year Sequoia and 2007 - 2010 model year Tundra vehicles may exhibit a
grinding noise from the front of the vehicle while in 4WD. An updated differential support bolt is
available to address this condition. Follow the repair procedure in this bulletin to inspect and
replace the differential support bolt.
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for
36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Tools and Equipment
Valve Spring: Tools and Equipment
Valve Spring Depressor
AST tool# TOY 160
Valve Spring Depressor used for Toyota Engines.
- Made of Aluminum
toyota valve springs depressor Contact AST for pricing.
Assenmacher Specialty Tools 1-800-525-2943
Page 7194
(a) Remove the front side plate from the front housing.
(b) Using a screwdriver, remove the O-ring from the front side plate.
HINT Tape the screwdriver tip before use.
(c) Remove the O-ring from the front housing.
8. REMOVE VANE PUMP HOUSING OIL SEAL
(a) Using a screwdriver and piece of cloth, pry out the oil seal.
NOTICE: Be careful not to damage the front housing.
Reassembly
POWER STEERING: VANE PUMP (for 1UR-FE): REASSEMBLY
NOTICE: When installing parts, coat the parts indicated by arrows with power steering fluid See:
Removal and Replacement/Components
1. INSTALL VANE PUMP HOUSING OIL SEAL
(a) Coat the lip of a new oil seal with power steering fluid.
Page 3748
Main Relay (Computer/Fuel System): Testing and Inspection
1UR-FE ENGINE CONTROL SYSTEM: CIRCUIT OPENING RELAY: ON-VEHICLE INSPECTION
1. REMOVE CIRCUIT OPENING RELAY (C/OPN)
(a) Remove the circuit opening relay from the engine room relay block.
2. INSPECT CIRCUIT OPENING RELAY
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) If the result is not as specified, replace the circuit opening relay.
3. INSTALL CIRCUIT OPENING RELAY
(a) Install the circuit opening relay to the engine room relay block.
Page 8869
Alarm Module: Diagrams Glass Breakage Sensor ECU
Page 7643
Release the locking lug from terminal and pull the terminal out from rear.
INSTALL TERMINAL TO CONNECTOR
Insert the terminal.
HINT: Make sure the terminal is positioned correctly.
Insert the terminal until the locking lug locks firmly.
Insert the terminal with terminal retainer in the temporary lock position.
Page 6497
J/B No.4 - Instrument Panel Center
Page 8840
(a) Attach the 4 clips and claw to install the speaker panel.
7. INSTALL FRONT PILLAR GARNISH RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Installation
8. INSTALL FRONT PILLAR GARNISH LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Installation
9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Components
AUDIO / VISUAL: INSTRUMENT PANEL SPEAKER (for Regular Cab): COMPONENTS
Page 6229
Diode: Diagrams Diode (Starting)
Page 2234
Required Tools & Equipment
Repair Procedure Overview
^ Confirm noise is coming from the rear of the vehicle and changes with vehicle speed.
^ Install ChaSSiSEAR(TM) (or equivalent) and isolate the noise to the rear wheel bearing.
^ Remove the rear axle shaft assembly.
^ Install new rear wheel bearing brake caliper bracket and seals.
^ Reinstall rear axle shaft assembly and confirm the noise is no longer present.
Repair Procedure
1. Test drive the vehicle and confirm the customer complaint.
Does the noise increase and decrease with vehicle speed?
^ YES - Go to step 2.
^ NO - This TSB does NOT apply. Refer to the Repair Manual for further diagnosis.
Page 8810
CrewMax)/Removal
3. REMOVE BACK PANEL GARNISH LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for
CrewMax)/Removal
4. REMOVE NO. 1 BOX SPEAKER ASSEMBLY
(a) Disconnect the connector.
(b) Remove the 3 bolts and box speaker.
Installation
AUDIO / VISUAL: FLOOR SPEAKER (for CrewMax): INSTALLATION
1. INSTALL NO. 1 BOX SPEAKER ASSEMBLY
(a) Install the box speaker with the 3 bolts.
(b) Connect the connector.
2. INSTALL BACK PANEL GARNISH LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for
CrewMax)/Installation
3. INSTALL BACK PANEL GARNISH RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for
CrewMax)/Installation
4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Components
AUDIO / VISUAL: FLOOR SPEAKER (for Double Cab): COMPONENTS
Page 2479
NOTICE: *
Ensure that no oil is on the mounting surface of the cylinder head.
* Gently place the cylinder head in order not to damage the gasket with the bottom part of the
head.
HINT The cylinder head bolts are tightened in 3 progressive steps.
(b) Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.
(c) Step 1:
(1) Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 10 cylinder head bolts with
the plate washers in several steps, in the
sequence shown in the illustration.
Torque : 36 Nm (367 kgf-cm, 27 ft-lbf)
(d) Step 2:
(1) Mark each cylinder head bolt head with paint as shown in the illustration.
(2) Tighten the cylinder head bolts another 90° in the sequence shown in step 1.
(e) Step 3:
(1) Tighten the cylinder head bolts an additional 90° in the sequence shown in step 1.
(2) Check that the painted marks are now facing rearward.
(f) Install and uniformly tighten the 2 bolts in the sequence shown in the illustration.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
5. INSTALL VALVE STEM CAP
(a) Apply a light coat of engine oil to the valve stem caps.
Locations
Cruise Control Switch: Locations
CRUISE CONTROL: CRUISE CONTROL SYSTEM: PARTS LOCATION
Page 7077
Steering Column Control Module: Service and Repair Removal
STEERING COLUMN: MULTIPLEX TILT AND TELESCOPIC ECU (for Power Tilt and Power
Telescopic Steering Column): REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE UPPER STEERING COLUMN COVER
(a) Remove the 2 screws.
HINT Turn the steering wheel to the right and left as necessary to remove the 2 screws.
(b) Detach the 4 clips.
(c) Detach the claw to remove the upper steering column cover.
3. REMOVE LOWER STEERING COLUMN COVER
(a) Detach the 2 claws to remove the lower steering column cover.
4. REMOVE HOOD LOCK CONTROL LEVER SUB-ASSEMBLY See: Body and Frame/Doors,
Hood and Trunk/Hood/Hood Latch Release
Cable/Service and Repair/Removal
5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Removal
Page 6976
Establish conditions in which voltage is present at the check point.
Example:
- [A] - Ignition SW on
- [B] - Ignition SW and SW1 on
- [C] - Ignition SW, SW1 and Relay on (SW2 off)
Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or component terminal.
This check can be done with a test light instead of a voltmeter.
Electronic Circuit Inspection Procedure
Page 3067
Ignition Switch: Diagnostic Aids
Continuity and Resistance Check
CONTINUITY AND RESISTANCE CHECK
Disconnect the battery terminal or wire so there is no voltage between the check points.
Contact the two leads of an ohmmeter to each of the check points.
Page 4596
when inserting and after full engagement.
NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal.
(d) REPAIR METHOD OF CONNECTOR TERMINAL
(1) If there is any foreign matter on the terminal, clean the contact point using an air gun or cloth.
Never rub the contact point using sandpaper
as the plating may come off.
(2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is
gold-plated (gold color), use a gold-plated female
terminal; if it is silver-plated (silver color), use a silver-plated female terminal.
(3) Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock
into the housing, the housing may have to be
replaced.
(e) HANDLING OF WIRE HARNESS
(1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be
restored in the same way.
(2) Never twist, pull or slacken the wire harness more than necessary.
(3) The wire harness should never come into contact with a high temperature part, or rotating,
moving, vibrating or sharp-edged parts. Avoid
contact with panel edges, screw tips and other sharp items.
(4) When installing parts, never pinch the wire harness.
(5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with
vinyl tape.
2. CHECK FOR OPEN CIRCUIT
Page 8606
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for
36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Required Tools & Equipment
Parts Information
Repair Procedure
Page 2397
(b) Remove the oil filter drain plug.
(c) Install the pipe to the oil filter cap.
HINT Use a container to catch the draining oil.
NOTICE: If the O-ring is removed with the drain plug, install the O-ring together with the pipe.
(d) Check that oil is drained from the oil filter. Then disconnect the pipe and remove the O-ring, as
shown in the illustration.
(e) Using SST, remove the oil filter cap.
SST : 09228-06501
NOTICE: Do not remove the oil filter bracket clip.
Page 3522
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- CHECK FOR SHORT TO GND IN CAN BUS WIRE (POWER STEERING ECU)
OK -- REPAIR OR REPLACE NO. 1 JUNCTION CONNECTOR
12. CHECK FOR SHORT TO GND IN CAN BUS WIRE (NO. 1 JUNCTION CONNECTOR CENTER AIRBAG SENSOR)
(a) Disconnect the J83 No. 1 junction connector connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
Components
Central Control Module: Service and Repair Components
AUDIO / VISUAL: MULTI-MEDIA INTERFACE ECU: COMPONENTS
Page 6168
(2) CONNECTORS
Slightly shake the connector vertically and horizontally.
(3) WIRE HARNESS
Slightly shake the wire harness vertically and horizontally.
HINT The connector joint and fulcrum of the vibration are the major areas that should be checked
thoroughly.
(b) HEAT METHOD:
When a malfunction seems to occur when the area in question is heated.
(1) Heat the component that is the possible cause of the malfunction with a hair dryer or similar
device. Check if the malfunction occurs.
NOTICE: *
Do not heat to more than 60°C (140°F). Exceeding this temperature may damage components.
* Do not apply heat directly to the parts in the ECU.
(c) WATER SPRINKLING METHOD:
When a malfunction seems to occur on a rainy day or in high-humidity.
(1) Sprinkle water onto the vehicle and check if the malfunction occurs.
NOTICE: *
Never sprinkle water directly into the engine compartment. Indirectly change the temperature and
humidity by spraying water onto the front of the radiator.
* Never apply water directly onto the electronic components.
HINT If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU
or connections. Look for evidence of corrosion or short circuits. Proceed with caution during water
tests.
(d) HIGH ELECTRICAL LOAD METHOD:
When a malfunction seems to occur when the electrical load is excessive.
(1) Turn on the heater blower, headlights, rear window defogger and all other electrical loads.
Check if the malfunction reoccurs.
5. DIAGNOSTIC TROUBLE CODE CHART
Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate
section's Diagnostic Trouble Code Chart. Use the chart to determine the trouble area and the
proper inspection procedure. A description of each of the chart's columns is below.
Page 2421
Oil Filter: Service and Repair Replacement
1UR-FE LUBRICATION: OIL AND OIL FILTER: REPLACEMENT
CAUTION: *
Prolonged and repeated contact with engine oil will result in the removal of natural oils from the
skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially
harmful contaminants which may cause skin cancer.
* Precautions should be taken when replacing engine oil to minimize the risk of your skin making
contact with used engine oil. Protective clothing and gloves that cannot be penetrated by oil should
be worn. The skin should be washed with soap and water, or use waterless hand cleaner, to
remove any used engine oil thoroughly. Do not use gasoline, thinners, or solvents.
* In order to protect the environment, used oil and used oil filters must be disposed of at designated
disposal sites.
1. DRAIN ENGINE OIL
(a) Remove the oil filler cap.
(b) Remove the oil pan drain plug and gasket, and drain the engine oil into a container.
(c) Install a new gasket and the oil pan drain plug.
Torque : 40 Nm (408 kgf-cm, 30 ft-lbf)
2. REMOVE NO. 1 ENGINE UNDER COVER
(a) Remove the 3 screws and 5 bolts.
(b) Unhook the engine under cover from the vehicle body as shown in the illustration.
3. REMOVE OIL FILTER ELEMENT
(a) Connect a hose with an inside diameter of 15 mm (0.591 in.) to the pipe.
Page 51
Keyless Entry Module: Service and Repair Door Control Receiver (for Regular Cab)
Components
DOOR LOCK: DOOR CONTROL RECEIVER (for Regular Cab): COMPONENTS
Page 4658
Transfer Case Actuator: Locations JF1A Transfer Case
JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION
Page 5648
Wheel Speed Sensor: Diagrams Front Speed Sensor
Page 2617
(4) Connect the engine wire harness clamp.
3. INSTALL AIR CLEANER ASSEMBLY
(a) Install the air cleaner with the 2 bolts.
Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)
(b) Tighten the hose clamp.
Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf)
(c) Connect the ventilation hose and vacuum hose.
(d) Connect the MAF meter connector and clamp.
4. INSTALL V-BANK COVER SUB-ASSEMBLY See: Service and Repair/Removal and
Replacement/Engine Assembly/Installation
Page 6540
4. SYMPTOM CONFIRMATION AND DTC (INCLUDING FREEZE FRAME DATA) CHECK
(a) Visually check the wire harnesses, connectors and fuses for open and short circuits.
(b) Warm up the engine to the normal operating temperature.
(c) Confirm the problem symptoms and conditions, and check for DTCs.
B -- Go to step 6 A -- Continue to next step.
5. DTC CHART
(a) Check the results obtained in the DTC check. Then find the output DTC in the DTC chart. Look
at the "Trouble Area" column for a list of
potentially malfunctioning circuits and / or parts.
NEXT -- Go to step 7
6. PROBLEM SYMPTOMS TABLE
(a) Check the results obtained in the symptom confirmation. Then find the problem symptoms in
the problem symptoms table. Look at the
"Suspected Area" column for a list of potentially malfunctioning circuits and / or parts.
NEXT -- Continue to next step.
7. CIRCUIT INSPECTION OR PARTS INSPECTION
(a) Confirm the malfunctioning circuit or part.
NEXT -- Continue to next step.
8. ADJUST, REPAIR OR REPLACE
(a) Adjust, repair or replace the malfunctioning circuit or parts.
NEXT -- Continue to next step.
9. CONFIRMATION TEST
(a) After the adjustment, repairs or replacement, confirm that the malfunction no longer exists. If the
malfunction does not reoccur, perform a
confirmation test under the same conditions and in the same environment as when the malfunction
occurred the first time.
NEXT -- END
2. CUSTOMER PROBLEM ANALYSIS
HINT *
In troubleshooting, confirm that the problem symptoms have been accurately identified.
Preconceptions should be discarded in order to make an accurate judgment. To clearly understand
what the problem symptoms are, it is extremely important to ask the customer about the problem
and the conditions at the time the malfunction occurred.
* Gather as much information as possible for reference. Past problems that seem unrelated may
also help in some cases.
* The following 5 questions are important points in the problem analysis:
Locations
Trailer Towing Relay: Locations
Engine Room R/B, J/B - Engine Compartment Left
Page 8356
Page 3363
Information Bus: Diagnostic Aids
Continuity and Resistance Check
CONTINUITY AND RESISTANCE CHECK
Disconnect the battery terminal or wire so there is no voltage between the check points.
Contact the two leads of an ohmmeter to each of the check points.
Page 2624
Water Pump: Testing and Inspection
1UR-FE COOLING: WATER PUMP: ON-VEHICLE INSPECTION
1. INSPECT WATER PUMP ASSEMBLY
(a) Visually check the air hole and drain hole for coolant leakage.
(b) If leakage is found, replace the water pump assembly.
(c) Turn the pulley and check that the water pump bearing moves smoothly and quietly.
(d) If necessary, replace the water pump assembly.
Specifications
Axle Nut: Specifications
FRONT AXLE HUB NUT LH (for 4WD)
Using a 39 mm socket wrench, install the hub nut.
Torque..................................................................................................................................................
...............................338 Nm (3446 kgf-cm, 249 ft-lbf)
Page 8607
1. Please compare customer's iPod(TM) with the compatible models table listed below. If the
customers' iPod(TM) is NOT listed, this TSB does NOT
apply.
2. Verify the condition.
NOTE
If USB device error occurs during every use, visually inspect the port.
3. Verify the error condition continues when using a known good USB cable.
4. Replace the Multi-Media Interface ECU by following procedures in the Repair Manual.
Page 2307
2. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH
(a) Install the valve rocker arms as shown in the illustration.
(b) Apply seal packing in a continuous line as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Standard seal diameter:
3.5 to 4.0 mm (0.138 to 0.157 in.)
NOTICE: *
Remove any oil from the contact surface.
* Install the camshaft housing within 3 minutes and tighten the bolts within 15 minutes after
applying seal packing.
(c) Install the camshaft housing, and install the 18 bolts in the order shown in the illustration.
for bolt A - Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
except bolt A - Torque : 30 Nm (306 kgf-cm, 22 ft-lbf)
NOTICE: *
Do not start the engine for at least 2 hours after the installation.
Page 8595
Rear Vision Camera: Service and Repair Installation
PARK ASSIST / MONITORING: TELEVISION CAMERA: INSTALLATION
HINT A bolt without a torque specification is shown in the standard bolt chart See:
Specifications/Mechanical Specifications/Standard Bolt - Specified Torque For Standard Bolts
1. INSTALL TELEVISION CAMERA ASSEMBLY
(a) Attach the 3 clamps and install the television camera with the 2 bolts.
(b) Connect the television camera connector.
2. INSTALL TAIL GATE SERVICE HOLE COVER See: Body and Frame/Tailgate/Service and
Repair/Tail Gate/Installation
3. CHECK TELEVISION CAMERA ASSEMBLY ANGLE
(a) Move the shift lever to R and check that the rear view image in the display has no lines or
distortion and has good color.
Page 1640
2. CHECK POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY (w/ Jam Protection
Function)
(a) Remove the power window regulator master switch See: Service and Repair/Power Window
Master Switch/Removal.
(b) Reconnect the switch connector.
(c) Measure the voltage according to the value(s) in the table below.
Standard voltage:
Page 1813
Mongoose MFC Software and Driver MUST be installed before Mongoose MFC selection will be
available.
See TIS - Diagnostics - Scantool page for additional information.
^ If using TIS Techstream select TIS Techstream VIM (this is the default).
4. Click OK.
Operation Procedure
1. Verify the vehicle's applicability for recalibration and locate desired calibration file.
A. Connect Techstream and establish a vehicle connection.
B. Click the Health Check button on the System Select tab.
Page 300
J/B No.5 - Instrument Panel Center
Page 2417
Repair Procedure
Page 6193
(a) for AC Power Supply:
Connect the clamp.
(b) Install the bezel with the 4 screws.
5. INSTALL NO. 2 CONSOLE BOX REGISTER ASSEMBLY See: Body and Frame/Seats/Service
and Repair/Overhaul/Front Seat Assembly (for
Center Seat)/Reassembly
6. INSTALL NO. 1 CONSOLE BOX REGISTER ASSEMBLY See: Body and Frame/Seats/Service
and Repair/Overhaul/Front Seat Assembly (for
Center Seat)/Reassembly
7. INSTALL CENTER SEATBACK PANEL See: Body and Frame/Seats/Service and
Repair/Overhaul/Front Seat Assembly (for Center
Seat)/Reassembly
Page 1687
for CrewMax of standard deck
Page 8605
This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown.
Power Seat Switch (w/o Seat Position Memory System)
Power Seat Switch: Service and Repair Power Seat Switch (w/o Seat Position Memory System)
Components
SEAT: POWER SEAT SWITCH (w/o Seat Position Memory System): COMPONENTS
Page 9236
Page 3480
NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR OK -- Continue to next step.
3. CHECK INTEGRATION CONTROL AND PANEL ASSEMBLY (OPERATION)
(a) Temporarily replace the integration control and panel assembly with a new or normally
functioning one.
(1) For Column Shift Type, refer to the following procedures See: Heating and Air
Conditioning/Control Assembly/Service and
Repair/Air Conditioning Panel (for Column Shift Type)/Removal.
(2) For Floor Shift Type, refer to the following procedures See: Heating and Air
Conditioning/Control Assembly/Service and Repair/Air
Conditioning Panel (for Floor Shift Type)/Removal.
(b) Check that the malfunction disappears.
OK:
Malfunction disappears.
NG -- REPLACE AIR CONDITIONING AMPLIFIER ASSEMBLY See: Heating and Air
Conditioning/Control Module HVAC/Service and Repair/Removal
OK -- END (INTEGRATION CONTROL AND PANEL ASSEMBLY IS DEFECTIVE)
Open In One Side of CAN Branch Line
CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: Open in One Side of CAN Branch
Line - Open in One Side of CAN Branch Line
DESCRIPTION
If 2 or more ECUs and/or sensors do not appear on the Techstream's "CAN Bus Check" screen,
one side of the CAN branch wire may be open. (One side of the CANH [branch wire]/CANL [branch
wire] of the ECU and/or sensor is open.)
HINT *
*1: w/ Bus Buffer ECU
* *2: w/ 4WD
* *3: w/ Power Steering ECU
WIRING DIAGRAM
Page 1004
Installation Procedure
1. Insert the tip of the fuel sender unit upper cover into the hole on the fuel sender unit lower cover
(2 places).
2. Fasten the tab of the fuel sender unit upper cover to the lip on the fuel sender unit lower cover (1
place).
Page 2004
DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector.
Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
Page 6020
NOTICE: To prevent damage to the rotor shaft, do not loosen the pulley nut more than one-half
turn.
(g) Remove SST 2 from the generator.
(h) Turn SST 1-B, and remove SST 1-A and B.
(i) Remove the pulley nut and pulley.
2. REMOVE GENERATOR REAR END COVER
(a) Place the generator on the pulley.
(b) Remove the 3 nuts and end cover.
(c) Remove the terminal insulator.
3. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY
(a) Remove the 2 screws and brush holder.
Page 328
1. Test drive the vehicle and confirm there is a harsh shift on acceleration below 20 mph and or
excessive lock-up operation at freeway speeds about 50
- 60 mph.
2. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in
Figure 1. Confirm if the ECM (PCM) calibration has
been updated. If the calibration ID listed is NOT the latest ECM (PCM) calibration - go to step 3.
3. Flash reprogram the ECM (PCM).
NOTE
^ The GR8 Battery Diagnostic Station MUST be used in Power Supply Mode to maintain battery
voltage at 13.5 volts while flash reprogramming the vehicle.
^ For details on how to use the GR8 Battery Diagnostic Station, refer to the GR8 Instruction Manual
located on the Technical Information System (TIS), Diagnostics - Battery.
Follow the procedures outlined in TSB No. T-SB-0064-10, "Techstream ECU Flash
Reprogramming Procedure", and flash the ECM (PCM) with the NEW calibration file update.
4. Start the engine and warm it up to normal operating temperature before test driving.
5. Test drive the vehicle to confirm proper vehicle operation and ECM (PCM) initial learning. Refer
to the Technical Information System (TIS) 2010
Tundra Repair Manual:
Drivetrain - Automatic Transmission/Transaxle - "A760E / A760F Automatic
Transmission/Transaxle: Automatic Transmission System: Initialization"
6. Install the Authorized Modifications Label.
A. Using a permanent marker enter the following information on the label:
^ ECM part number [Refer to the Parts Information section for the CURRENT PART NUMBER]
Page 4212
Page 4124
Page 3118
(m)Measure the fuel pressure.
Standard fuel pressure:
281 to 287 kPa (2.87 to 2.93 kgf/cm2, 41 to 42 psi)
(n) If the pressure is not as specified, check the fuel pump, pressure regulator and/or injectors.
(o) Stop the engine.
(p) Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped.
Standard fuel pressure:
147 kPa (1.5 kgf/cm2, 21 psi) or higher
(q) If the pressure is not as specified, check the fuel pump, pressure regulator and/or injectors.
(r) After checking the fuel pressure, disconnect the cable from the negative (-) battery terminal and
carefully remove SST and the fuel tube
connector to prevent gasoline from spraying.
(s) Reconnect the fuel tube (fuel tube connector).
(t) Check for fuel leak.
(1) Check that there are no fuel leaks after performing maintenance anywhere on the system.
If there are fuel leaks, repair or replace parts as necessary.
Page 917
(a) Detach the 2 claws and remove the sensor.
Page 226
Page 9393
5. Pull the carpet back in the rear of the cab and remove the body plugs to expose the cab mount
bolts.
6. Remove the cab mount bolts by pulling them through the hole and discard. New bolts will be
used in their place.
Page 2450
Intake Manifold: Locations
1UR-FE INTAKE: INTAKE SYSTEM: PARTS LOCATION
Page 9248
From 11/2009
ENGINE HOOD / DOOR: REAR DOOR (for Double Cab): COMPONENTS
Page 7879
Refrigerant Pressure Sensor / Switch: Diagrams
Page 6936
Engine Room R/B, J/B - Engine Compartment Left
Page 3533
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- CONNECT CONNECTOR
OK -- REPLACE NO. 1 JUNCTION CONNECTOR
5. CONNECT CONNECTOR
(a) Reconnect the J94 No. 1 junction connector connector.
NEXT -- Continue to next step.
6. CHECK FOR OPEN IN CAN BUS MAIN WIRE (NO. 2 JUNCTION CONNECTOR - ECM)
(a) Disconnect the J113 No. 2 junction connector connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- CONNECT CONNECTOR OK -- Continue to next step.
7. CHECK FOR OPEN IN CAN BUS MAIN WIRE (NO. 1 JUNCTION CONNECTOR - NO. 2
JUNCTION CONNECTOR)
(a) Measure the resistance according to the value(s) in the table below.
Page 3116
Fuel Pressure: Testing and Inspection
1UR-FE FUEL: FUEL SYSTEM: ON-VEHICLE INSPECTION
1. CHECK FUEL PUMP OPERATION AND FOR FUEL LEAK
(a) Connect the Techstream to the DLC3.
(b) Turn the ignition switch to ON.
NOTICE: Do not start the engine.
(c) Turn the Techstream main switch ON.
(d) Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump /
Speed.
(e) Check the fuel pump operation.
(1) Check for pressure in the fuel inlet tube from the fuel line. Check that the sound of fuel flowing
in the fuel tank can be heard.
If there is no sound, check the integration relay, fuel pump, ECM and wiring connector.
(f) Check for fuel leak.
(1) Check that there are no fuel leaks after performing maintenance anywhere on the system.
If there are fuel leaks, repair or replace parts as necessary.
2. CHECK FUEL PRESSURE
(a) Check that the battery voltage is 11 to 14 V.
(b) Perform the "DISCHARGE FUEL SYSTEM PRESSURE" procedures See: Fuel Delivery and Air
Induction/Service Precautions.
(c) Disconnect the cable from the negative (-) battery terminal.
(d) Remove the fuel pipe clamp from the fuel tube connector.
(e) Pinch and pull the fuel tube (fuel tube connector) to disconnect it.
CAUTION: *
Always read the precautions See: Fuel Delivery and Air Induction/Service Precautions before
disconnecting the fuel tube connector (quick type).
* The fuel tube may spray fuel as a result of pressure that remains in it. Do not allow fuel to be
sprayed in the engine compartment.
(f) Install SST (pressure gauge) as shown in the illustration.
Page 4309
load while reprogramming.
^ Confirm the hood is open and ensure under hood temperature does NOT exceed 158°F (70°C).
^ Confirm cable connections between the vehicle and Techstream are secure.
^ Do NOT disconnect or turn off Techstream or vehicle ignition during reprogramming.
^ Set parking brake.
^ Complete ALL flash calibration updates provided for each ECU.
^ If the battery's state of charge or capacity are in question, test with SST. No. 00002-8150-KIT
"Digital Battery Analyze," and follow TSB No. PG001-06, "Battery Maintenance for In-Stock
Vehicles & Pre-Delivery" or the appropriate "Maintenance for HV & Auxiliary Batteries" service
bulletin.
^ The GR8 Battery Diagnostic Station MUST be used in Power Supply Mode to maintain battery
voltage at 13.5 volts while flash reprogramming the vehicle. For details on how to use the GR8
Battery Diagnostic Station, refer to the GR8 Instruction Manual located on TIS, Diagnostics - Tools
& Equipment - Battery Diagnostics.
3C. Click Next to start the calibration update process.
D. When using TIS Techstream select Techstream VIM as the desired programming device. Then
click Next.
Page 9131
6. PROBLEM SYMPTOMS TABLE
When a "Normal" code is output during a DTC check but the problem is still occurring, use the
Problem Symptoms Table. The suspected areas (circuits or parts) for each problem symptom are
in the table. The suspected areas are listed in order of probability. A description of each of the
chart's columns is below.
HINT In some cases, the problem is not detected by the diagnostic system even though a problem
symptom is present. It is possible that the problem is occurring outside the detection range of the
diagnostic system, or that the problem is occurring in a completely different system.
7. CIRCUIT INSPECTION
A description of the main areas of each circuit inspection is below.
Page 4070
(f) Connect the connector.
(g) Connect the wire harness clamp bracket with the nut.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
Page 7575
Page 4910
1. INSTALL TRANSMISSION FLOOR SHIFT ASSEMBLY
(a) Install the floor shift with the 4 bolts. Tighten the bolts in the order shown in the illustration.
Torque : 14 Nm (143 kgf-cm, 10 ft-lbf)
(b) Connect the transmission control cable to the shift lever retainer, and install a new clip.
(c) Connect the control cable end to the shift lever.
NOTICE: Make sure to connect the cable end so that the inner cable is not twisted. Confirm that
the ridged side of the cable end is facing upward.
(d) Connect the 2 connectors.
2. INSTALL FRONT CONSOLE BOX See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal
and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation
3. INSTALL REAR CONSOLE BOX ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation
4. INSTALL CONSOLE BOX CARPET
5. INSTALL REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
6. INSTALL REAR UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
Page 5100
^ Inspect the axles and rear differential axle housing oil baffles.
^ Install new rear differential axle housing oil baffle(s).
^ Reinstall rear axle shaft and differential and confirm proper operation.
Repair Procedure
1. Test drive the vehicle and confirm the condition. Is the noise loudest from the rear of the vehicle?
^ YES - Go to step 2.
^ NO - This TSB does NOT apply. Refer to the Repair Manual for further diagnosis.
2. Install ChassisEAR(TM) (or equivalent) on the vehicle and attempt to isolate the source of the
noise. Is the noise loudest from the rear differential
area?
^ YES - Go to step 3.
^ NO - This TSB does NOT apply. Refer to the Repair Manual for further diagnosis.
3. Remove the rear axle shafts and rear differential.
Refer to the Technical Information System (TIS) applicable model year Tundra Repair Manual:
4. Inspect the rear axle housing oil baffles and axle shafts.
Are the rear axle housing baffle(s) deformed or are there wear marks on the axle shaft(s)
assembly? See Figures 1 and 2 for reference.
^ YES - Go to step 5.
^ NO - This TSB does NOT apply. Refer to the Repair Manual for further diagnosis.
Page 6958
Symbols Used Within Diagrams
Symbols Used Within Diagrams
Page 1496
If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness
or connector in that circuit in the past. Check the wire harness and connectors.
B -- SYSTEM NORMAL
A -- TROUBLESHOOTING OF EACH PROBLEM SYMPTOM
The problem is still occurring in a place other than the diagnostic circuit (the DTC displayed first is
either for a past problem or a secondary problem).
4. SYMPTOM SIMULATION
HINT The most difficult case in troubleshooting is when no problem symptoms occur. In such a
case, a thorough problem analysis must be carried out. A simulation of the same or similar
conditions and environment in which the problem occurred in the customer's vehicle should be
carried out. No matter how much skill or experience a technician has, troubleshooting without
confirming the problem symptoms will lead to important repairs being overlooked and mistakes or
delays.
For example:
With a problem that only occurs when the engine is cold or as a result of vibration caused by the
road during driving, the problem can never be determined if the symptoms are being checked on a
stationary vehicle or on a vehicle with a warmed-up engine. Vibration, heat or water penetration
(moisture) is difficult to reproduce. The symptom simulation tests below are effective substitutes for
the conditions and can be applied on a stationary vehicle.
Important points in the symptom simulation test:
In the symptom simulation test, the problem symptoms as well as the problem area or parts must
be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then,
connect the tester and carry out the symptom simulation test, judging whether the circuit being
tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the
problem symptoms table for each system to narrow down the possible causes.
To reproduce DTCs, it is necessary to satisfy the respective DTC detection conditions.
(a) VIBRATION METHOD:
When a malfunction seems to occur as a result of vibration.
(1) PART AND SENSOR
Apply slight vibration with a finger to the part of the sensor suspected to be the cause of the
problem, and check whether or not the malfunction occurs.
NOTICE: Applying strong vibration to relays may open them.
Locations
Transmission Temperature Sensor/Switch: Locations
A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS
LOCATION
Front Occupant Classification Sensor
Seat Occupant Sensor: Diagrams Front Occupant Classification Sensor
Page 6316
AJ9-JI2
Page 5849
Acceleration/Deceleration Sensor: Service and Repair Removal
BRAKE CONTROL: YAW RATE AND DECELERATION SENSOR: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to disable the SRS system.
2. REMOVE CENTER FRONT SEAT ASSEMBLY (for Center Seat) See: Body and
Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Center Seat)/Removal
3. REMOVE CONSOLE BOX ASSEMBLY (for Separate Seat Type)
(a) Remove the console box See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and
Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal.
4. REMOVE YAW RATE SENSOR
(a) Remove the 2 nuts (labeled A) and sensor.
(b) Disconnect the sensor connector (labeled B), and then detach the clamp (labeled C) from the
sensor bracket.
Recall 11V185000 - TPMS Non-Compliance
Tire Pressure Module: All Technical Service Bulletins Recall 11V185000 - TPMS Non-Compliance
VEHICLE MAKE/MODEL: MODEL YEAR(S) Toyota/FJ Cruiser 2011
Toyota/Tundra 2009-2011
MANUFACTURER: Gulf States Toyota, Inc.
MFR'S REPORT DATE: March 16, 2011
NHTSA CAMPAIGN ID NUMBER: 11V185000
NHTSA ACTION NUMBER: N/A
COMPONENT: Tires: Pressure Monitoring and Regulating Systems
POTENTIAL NUMBER OF UNITS AFFECTED: 1,489
SUMMARY: Gulf States Toyota is recalling certain model year 2011 FJ Cruiser and model year
2009-2011 Tundra vehicles for failing to comply with the requirements of Federal Motor Vehicle
Safety Standard No. 138, "Tire Pressure Monitoring Systems." The TPMS on some vehicles may
not have been properly calibrated and as a result the low tire pressure warning lamp may not
illuminate should the inflation pressure in one or more of the vehicle's tires fall below the threshold
for when the low tire pressure warning lamp should illuminate.
CONSEQUENCE: Drivers will not receive a warning from the tire pressuring monitor that one or
more tires are underinflated increasing the risk that a vehicle will be driven with one or more
underinflated tires and increasing the risk of a tire failure that may lead to a crash.
REMEDY: Dealers will recalibrate the tire pressure monitoring system in accordance with the
regulation free of charge. The safety recall is expected to begin during April 2011. Owners may
contact Gulf State Toyota Customer Assistance Center toll free at 1-800-444-1074 Monday through
Thursday, 8:30 AM to 5:00 PM, or Friday 8:30 AM to 4:00 PM Central Standard Time.
NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle
Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov.
Page 9032
6. PROBLEM SYMPTOMS TABLE
When a "Normal" code is output during a DTC check but the problem is still occurring, use the
Problem Symptoms Table. The suspected areas (circuits or parts) for each problem symptom are
in the table. The suspected areas are listed in order of probability. A description of each of the
chart's columns is below.
HINT In some cases, the problem is not detected by the diagnostic system even though a problem
symptom is present. It is possible that the problem is occurring outside the detection range of the
diagnostic system, or that the problem is occurring in a completely different system.
7. CIRCUIT INSPECTION
A description of the main areas of each circuit inspection is below.
Page 307
Driver Side J/B Inner Circuit
Page 3510
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO SKID CONTROL ECU
WITH ACTUATOR (CANH, CANL)
OK -- REPLACE SKID CONTROL ECU WITH ACTUATOR See: Brakes and Traction
Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock
Brakes/Service and Repair/Removal and Replacement/Removal
16. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (STEERING ANGLE SENSOR)
(a) Disconnect the J6 steering angle sensor connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO STEERING ANGLE
SENSOR (CANH, CANL)
OK -- REPLACE STEERING ANGLE SENSOR
17. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (POWER STEERING ECU)
(a) Disconnect the J101 power steering ECU connector.
Page 7736
(a) Disconnect the connector.
(b) Remove the 3 screws and damper servo.
14. REMOVE COOLING UNIT DAMPER SERVO SUB-ASSEMBLY (for Automatic Air Conditioning
System)
(a) Disconnect the connector.
(b) Remove the 3 screws and damper servo.
15. REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY
(a) Remove the 3 screws and plate.
(b) Detach the 3 claws and remove the heater clamp.
(c) Remove the heater radiator unit.
16. REMOVE NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY
Page 48
Removal
DOOR LOCK: DOOR CONTROL RECEIVER (for Double Cab): REMOVAL
1. REMOVE LUGGAGE COMPARTMENT SIDE COVER SUB-ASSEMBLY LH See: Body and
Frame/Seats/Service and Repair/Removal and
Replacement/Rear Seat Assembly (for Double Cab)/Removal
2. REMOVE LUGGAGE COMPARTMENT SIDE COVER SUB-ASSEMBLY RH See: Body and
Frame/Seats/Service and Repair/Removal and
Replacement/Rear Seat Assembly (for Double Cab)/Removal
3. REMOVE SEAT FLOOR BOX See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Rear Seat Assembly (for Double
Cab)/Removal
4. REMOVE REAR SEAT ASSEMBLY See: Body and Frame/Seats/Service and Repair/Removal
and Replacement/Rear Seat Assembly (for
Page 9209
Page 445
(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(2) If the result is not as specified, replace the integration relay.
3. INSTALL INTEGRATION RELAY
(a) Connect the 3 connectors.
(b) Install the integration relay to the engine room relay block.
(c) Install the engine room relay block cover.
Page 4517
Crankshaft Position Sensor: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: CRANKSHAFT POSITION SENSOR: INSTALLATION
1. INSTALL CRANKSHAFT POSITION SENSOR
(a) Install the sensor with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(b) Connect the sensor connector.
2. INSTALL CRANKSHAFT POSITION SENSOR PROTECTOR
(a) Install the sensor protector with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
Page 907
Ambient Temperature Sensor / Switch HVAC: Service and Repair Removal
AIR CONDITIONING: AMBIENT TEMPERATURE SENSOR: REMOVAL
1. REMOVE AMBIENT TEMPERATURE SENSOR
(a) Disconnect the connector.
(b) Using a screwdriver, detach the clamp and remove the ambient temperature sensor.
HINT Tape the screwdriver tip before use.
Page 3493
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- CHECK FOR SHORT IN CAN BUS WIRES (SKID CONTROL ECU WITH ACTUATOR) OK
-- Continue to next step.
10. CHECK FOR SHORT IN CAN BUS WIRES (NO. 1 JUNCTION CONNECTOR - STEERING
ANGLE SENSOR)
(a) Disconnect the J87 No. 1 junction connector connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- CHECK FOR SHORT IN CAN BUS WIRES (STEERING ANGLE SENSOR) OK -- Continue
to next step.
11. CHECK FOR SHORT IN CAN BUS WIRES (NO. 1 JUNCTION CONNECTOR - POWER
STEERING ECU)
NOTICE: For vehicles without a power steering ECU, go to "CHECK FOR SHORT IN CAN BUS
WIRES (NO. 1 JUNCTION CONNECTOR - CENTER AIRBAG SENSOR)".
(a) Disconnect the J115 No. 1 junction connector connector.
Components
Evaporator Temperature Sensor / Switch: Service and Repair Components
AIR CONDITIONING: FRONT EVAPORATOR TEMPERATURE SENSOR: COMPONENTS
Page 1467
Page 3815
Knock Sensor: Testing and Inspection
1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: INSPECTION
1. INSPECT KNOCK SENSOR
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) If the result is not as specified, replace the knock sensor.
Page 278
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: ELECTRONIC
CIRCUIT INSPECTION PROCEDURE
1. BASIC INSPECTION
(a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS
(1) Unless otherwise stated, all resistance measurements should be made at an ambient
temperature of 20°C (68°F). Resistance measurements
may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been
running. Measurements should be made after the engine has cooled down.
(b) HANDLING CONNECTORS
(1) When disconnecting a connector, first squeeze the mating halves tightly together to release the
lock, and then press the lock claw and
separate the connector.
(2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly
and separate it.
(3) Before connecting a connector, check that there are no deformed, damaged, loose or missing
terminals.
(4) When connecting a connector, press firmly until it locks with a "click" sound.
(5) If checking a connector with a TOYOTA electrical tester, check the connector from the backside
(harness side) using a mini test lead.
NOTICE: *
As a waterproof connector cannot be checked from the backside, check it by connecting a
sub-harness.
* Do not damage the terminals by moving the inserted tester needle.
(c) CHECKING CONNECTORS
(1) Checking when a connector is connected: Squeeze the connectors together to confirm that they
are fully connected and locked.
(2) Checking when a connector is disconnected: Check by pulling the wire harness lightly from the
backside of the connector. Look for
unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for
corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or
deformed terminals.
(3) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a
female terminal, and check for ample tension
Page 8374
Locations
Air Flow Meter/Sensor: Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Diode (Starting)
Starter Motor: Diagrams Diode (Starting)
Center Airbag Sensor Assembly (for Column Shift Type)
Impact Sensor: Testing and Inspection Center Airbag Sensor Assembly (for Column Shift Type)
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Column
Shift Type): ON-VEHICLE INSPECTION
1. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION)
(a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnosis System.
2. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND
AIRBAG HAS NOT DEPLOYED)
(a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnosis System.
3. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND
AIRBAG IS DEPLOYED)
(a) Replace the center airbag sensor.
CAUTION: For removal and installation procedures of the center airbag sensor, be sure to follow
the correct procedure.
HINT The center airbag sensor should be replaced after any of the airbags has deployed, as it has
been subjected to the impact.
Page 5951
DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector.
Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
Page 9003
Page 5409
Four Wheel Drive Selector Switch: Testing and Inspection
JF1A TRANSFER: 4WD CONTROL SWITCH: ON-VEHICLE INSPECTION
1. INSPECT 4WD CONTROL SWITCH
(a) Check the harness and connector (ECU - battery and body ground).
(1) Measure the voltage and resistance according to the value(s) in the table below.
Standard voltage:
(2) If there is a malfunction, inspect the harness or connector. If the harness is malfunctioning,
repair or replace harness or connector. If the
harness or connector is normal, replace the 4WD control ECU See: Control Module/Service and
Repair/Removal.
Standard resistance:
(3) If there is a malfunction, repair or replace the harness or connector.
(b) Check the harness and connector (switch - ECU).
(1) Disconnect the A25 ECU connector.
(2) Disconnect the L1 switch connector.
(3) Measure the resistance according to the value(s) in the table below.
Standard resistance:
Page 6359
3. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE
HINT The diagnostic system in the TOYOTA TUNDRA has various functions.
* The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU
memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a
previous malfunction's DTC can be checked by a technician during troubleshooting.
* Another function is the Input Signal Check, which checks if the signals from various switches are
sent to the ECU correctly.
* By using these functions, the problem areas can be narrowed down and troubleshooting is more
effective. Diagnostic functions are incorporated in the following systems in the TOYOTA TUNDRA.
Page 9028
EFI Relay
Fuel Pump Relay: Testing and Inspection EFI Relay
1UR-FE ENGINE CONTROL SYSTEM: EFI RELAY: ON-VEHICLE INSPECTION
1. REMOVE INTEGRATION RELAY See: Ignition System/Ignition Relay/Testing and Inspection
2. INSPECT INTEGRATION RELAY (EFI)
NOTICE: *
Some relays are built into the integration relay. The integration relay cannot be disassembled. If
there is a malfunction in the circuit of the integration relay, replace the integration relay.
* The internal circuit of the integration relay is as shown in the illustration below. Inspect the
integration relay using the following procedures.
(a) Measure the resistance of the EFI No. 1 fuse.
(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(2) If the result is not as specified, replace the EFI No. 1 fuse.
(b) Measure the resistance of the EFI relay.
(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
Page 1034
Page 184
"Case2" Open the secondary locking device.
[B] For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray
Gray or White : Black
Page 2615
(4) Remove the 2 bolts and disconnect the water by-pass pipe.
(5) Remove the 4 bolts and 4 ignition coils.
4. REMOVE SPARK PLUG
(a) Using a 16 mm plug wrench, remove the 8 spark plugs.
Diagrams
Amplifier: Diagrams
Page 9214
Page 2638
Coolant: Service and Repair
1UR-FE COOLING: COOLANT: REPLACEMENT
1. REMOVE NO. 1 ENGINE UNDER COVER See: Engine/Engine Lubrication/Engine Oil/Service
and Repair/Replacement
2. DRAIN ENGINE COOLANT
CAUTION: Do not remove the radiator cap while the engine and radiator are still hot. Pressurized,
hot engine coolant and steam may be released and cause serious burns.
HINT Collect the coolant in a container and dispose of it according to the regulations in your area.
(a) Loosen the radiator drain cock plug.
(b) Remove the radiator cap. Then drain the coolant from the radiator.
(c) Loosen the 2 cylinder block drain cock plugs. Then drain the coolant from the engine.
(d) Tighten the 2 cylinder block drain cock plugs.
Torque : 13 Nm (130 kgf-cm, 9 ft-lbf)
(e) Tighten the radiator drain cock plug by hand.
3. ADD ENGINE COOLANT
(a) Add engine coolant.
Standard Capacity:
NOTICE: Do not substitute plain water for engine coolant.
HINT TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to
the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high
quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life
hybrid organic acid technology (coolant with long-life hybrid organic acid technology is a
combination of low phosphates and organic acids).
LIN Communication System
Information Bus: Description and Operation LIN Communication System
MULTIPLEX COMMUNICATION: LIN COMMUNICATION SYSTEM: SYSTEM DIAGRAM
MULTIPLEX COMMUNICATION: LIN COMMUNICATION SYSTEM: SYSTEM DESCRIPTION
1. LIN COMMUNICATION SYSTEM DESCRIPTION
* The LIN communication system is used for communication between the components below.
* The LIN communication system has a component as a control master.
(a) Window and Sliding Roof Components that Use LIN Communication Bus (for CrewMax)
(1) Main Body ECU (Driver Side Junction Block)*1
(2) Power Window Regulator Master Switch Assembly*2
(3) Front Power Window Regulator Motor Assembly LH*2
(4) Front Power Window Regulator Motor Assembly RH*2
(5) Sliding Roof Drive Gear Sub-assembly (Sliding Roof ECU)*3
HINT *
*1: Control master
* *2: for Power Window Control System (w/ Jam Protection Function)
* *3: w/ Sliding Roof System
(b) Heater Components that Use LIN Communication
(1) Air Conditioning Amplifier Assembly (A/C ECU)*
HINT *: Control master
(2) Integration Control and Panel Assembly
2. LIN COMMUNICATION SYSTEM DTCs
The control master component shown below outputs LIN communication system DTCs when there
is a malfunction in the LIN communication. If a LIN communication stops, the control master of that
part of the LIN communication system outputs DTCs.
(a) Main Body ECU (Driver Side Junction Block)
Page 6090
Neutral Safety Switch: Service and Repair Installation
A760F AUTOMATIC TRANSMISSION: PARK / NEUTRAL POSITION SWITCH: INSTALLATION
1. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY
(a) Install the switch to the manual valve shaft.
(b) Temporarily install the bolt.
(c) Install a new lock washer and the nut.
Torque : 6.9 Nm (70 kgf-cm, 61 in-lbf)
(d) Temporarily install the control shaft lever RH.
(e) Turn the control shaft lever RH counterclockwise until it stops, and then turn it clockwise 2
notches to set it to the N position.
(f) Align the groove with the neutral basic line.
Page 2399
(g) Apply a small amount of engine oil to a new drain plug O-ring, and install it to the oil filter cap.
NOTICE: Before installing the O-ring, remove any dirt or foreign matter from the installation surface
of the oil filter cap.
(h) Install the oil filter drain plug.
Torque : 13 Nm (127 kgf-cm, 9 ft-lbf)
NOTICE: Be careful that the O-ring does not get caught between any surrounding parts.
5. ADD ENGINE OIL
(a) Add fresh oil.
Standard Oil Grade (for USA):
Standard Oil Grade (for Canada):
Standard Oil Capacity:
(b) Install the oil filler cap.
6. INSPECT FOR OIL LEAK
(a) Start the engine. Make sure that there are no oil leaks from the area that was worked on.
7. CHECK ENGINE OIL LEVEL See: Testing and Inspection
8. INSTALL NO. 1 ENGINE UNDER COVER
Page 2822
Page 9340
Front Fender Liner: Service and Repair Removal
EXTERIOR: FENDER LINER (for Front Side): REMOVAL
HINT *
Use the same procedures for the RH side and LH side.
* The procedures listed below are for the LH side.
1. REMOVE FENDER APRON MUDGUARD SEAL LH
(a) for Steel Type Bumper:
Remove the fender apron mudguard seal.
(1) w/ Side Step:
Remove the side step See: Auxiliary Step / Running Board/Service and Repair/Removal and
Replacement/Removal.
(2) w/ Front Fender Mudguard:
Remove the fender mudguard See: Spoilers, Flaps, and Air Dams/Mud Flap/Service and
Repair/Removal.
(3) Remove the 18 clips and fender apron mudguard.
(b) for Resin Type Bumper:
Remove the fender apron mudguard seal.
(1) w/ Side Step:
Remove the side step See: Auxiliary Step / Running Board/Service and Repair/Removal and
Replacement/Removal.
(2) w/ Front Fender Mudguard:
Remove the fender mudguard See: Spoilers, Flaps, and Air Dams/Mud Flap/Service and
Repair/Removal.
(3) Using a screwdriver, remove the pin hold clip.
(4) Remove the 17 clips and fender apron mudguard.
Page 3684
4. Attach the Authorized Vehicle Modification Label.
Modifications to ECU calibrations MUST be recorded and properly displayed on the vehicle using
the Authorized Modification Label.
Techstream Preparation
Selecting the TIS Techstream VIM or the Mongoose MFC VIM.
Techstream software requires a VIM selection before you can use the Mongoose MFC VIM.
If using TIS Techstream no changes are needed.
Perform the following:
1. Select Setup from the Techstream Main Menu screen.
2. Select VIM Select from the Setup drop down menu.
3. Select the correct Interface Setup from the drop down list.
^ If using Techstream Lite select Mongoose MFC.
NOTE
Page 8024
Air Bag Deactivation Switch: Locations Occupant Classification System
SUPPLEMENTAL RESTRAINT SYSTEM: OCCUPANT CLASSIFICATION SYSTEM: PARTS
LOCATION
Page 8946
Removal
PARK ASSIST / MONITORING: ULTRASONIC SENSOR (for Front Side): REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE FRONT END PANEL LH (for Resin Type Bumper) See: Body and
Frame/Bumper/Front Bumper/Service and Repair/Removal and
Replacement/Front Bumper (for Resin Type Bumper)/Removal
3. REMOVE FRONT END PANEL RH (for Resin Type Bumper) See: Body and
Frame/Bumper/Front Bumper/Service and Repair/Removal and
Replacement/Front Bumper (for Resin Type Bumper)/Removal
4. REMOVE FRONT BUMPER COVER (for Resin Type Bumper) See: Body and
Frame/Bumper/Front Bumper/Service and Repair/Removal and
Replacement/Front Bumper (for Resin Type Bumper)/Removal
5. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH (for Steel Type Bumper)
See: Body and Frame/Bumper/Front
Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Steel Type
Bumper)/Removal
6. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH (for Steel Type Bumper)
See: Body and Frame/Bumper/Front
Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Steel Type
Bumper)/Removal
7. REMOVE FRONT END PANEL LH (for Steel Type Bumper) See: Body and
Frame/Bumper/Front Bumper/Service and Repair/Removal and
Replacement/Front Bumper (for Steel Type Bumper)/Removal
8. REMOVE FRONT END PANEL RH (for Steel Type Bumper) See: Body and
Frame/Bumper/Front Bumper/Service and Repair/Removal and
Replacement/Front Bumper (for Steel Type Bumper)/Removal
9. REMOVE FRONT LOWER BUMPER COVER (for Steel Type Bumper) See: Body and
Frame/Bumper/Front Bumper/Service and
Repair/Removal and Replacement/Front Bumper (for Steel Type Bumper)/Removal
10. REMOVE FRONT BUMPER BAR (for Steel Type Bumper) See: Body and
Frame/Bumper/Front Bumper/Service and Repair/Removal and
Replacement/Front Bumper (for Steel Type Bumper)/Removal
11. REMOVE NO. 1 ULTRASONIC SENSOR
(a) While pushing down on the lever with a finger to release the one claw, detach the claw on the
other side to remove the ultrasonic sensor.
Page 4833
Required Tools & Equipment
Important Information
^ 100,000 Mile Maintenance Interval - Inspection only; ATF-WS does NOT require any flushing or
changing during the life of the vehicle.
^ The use of Genuine Toyota ATF-WS is recommended.
^ The use of additives or aftermarket fluids that are considered compatible or substitutes may result
in shift concerns and damage to the internal transmission components.
^ ATF-WS is NOT compatible with T-IV or Dexron ATF.
^ Containers storing Toyota ATF-WS should ALWAYS be sealed - If exposed to the atmosphere,
ATF-WS may absorb moisture and potentially cause shift concerns if used in operation.
^ One time use only.
^ When performing repairs on ATF-WS equipped transaxles, it is important to use only new, clean
ATF-WS when refilling the ATM.
^ ATF-WS equipped ATMs may use the overflow type procedure - Any fluid drained from the
overflow plug should be discarded following proper local regulations and never reused. Failure to
do so could result in shift concerns and damage to the internal transmission components.
Recall 10V017000: Accelerator Pedal Sticking
Accelerator Pedal Position Sensor: Recalls Recall 10V017000: Accelerator Pedal Sticking
VEHICLE MAKE/MODEL: MODEL YEAR(S): Toyota/Avalon 2005-2010 Toyota/Camry 2007-2010
Toyota/Corolla 2009-2010 Toyota/Corolla Matrix 2009-2010 Toyota/Highlander 2010 Toyota/ RAV4
2009-2010 Toyota/Sequoia 2008-2010 Toyota/Tundra 2007-2010 MANUFACTURER: Toyota
Motor North America, Inc.
MFR'S REPORT DATE: January 21, 2010
NHTSA CAMPAIGN ID NUMBER: 10V017000
NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Accelerator Assembly:
Pedal/Linkage
POTENTIAL NUMBER OF UNITS AFFECTED: ?
SUMMARY: Toyota is recalling certain model year 2005-2010 Avalon, model year 2007-2010
Camry, model year 2009-2010 Corolla, Corolla Matrix, RAV4, model year 2010 Highlander, model
year 2008-2010 Sequoia, and model year 2007-2010 Tundra. due to the manner in which the
friction lever interacts with the sliding surface of the accelerator pedal inside the pedal sensor
assembly, the sliding surface of the lever may become smooth during vehicle operation. In this
condition, if condensation occurs on the surface, as may occur from heater operation (without A/C)
when the pedal assembly is cold, the friction when the accelerator pedal is operated may increase,
which may result in the accelerator pedal becoming harder to depress, slower to return, or, in the
worst case, mechanically stuck in a partially depressed position.
CONSEQUENCE: The accelerator pedal may become hard to depress, slow to return to idle, or, in
the worst case, mechanically stuck in a partially depressed position, increasing the risk of a crash.
REMEDY: Toyota has not yet provided a remedy plan or an owner notification schedule. Owners
may contact Toyota at 1-800-331-4331.
NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle
Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov.
Page 1974
Engine Room R/B, J/B - Engine Compartment Left
Page 5138
Fluid - Differential: Service and Repair
DIFFERENTIAL: DIFFERENTIAL OIL: REPLACEMENT
1. DRAIN DIFFERENTIAL OIL
(a) Stop the vehicle on a level place.
(b) for Front Differential:
(1) Using a 10 mm hexagon wrench, remove the filler plug and gasket.
(2) Using a 10 mm hexagon wrench, remove the drain plug and gasket, and drain the oil.
(3) Using a 10 mm hexagon wrench, install a new gasket and the drain plug.
Torque : 39 Nm (398 kgf-cm, 29 ft-lbf)
(c) for Rear Differential:
(1) Remove the filler plug and gasket.
(2) Remove the drain plug and gasket, and drain the oil.
(3) Install a new gasket and the drain plug.
Torque : 49 Nm (500 kgf-cm, 36 ft-lbf)
2. ADD DIFFERENTIAL OIL
(a) Add differential oil so that the oil level is between 0 to 5 mm (0 to 0.197 in.) from the bottom lip
of the differential filler plug hole.
NOTICE: *
Too much or too little oil will lead to differential problems.
* After changing the oil, drive the vehicle and then check the oil level again.
Oil type:
Front differential capacity:
Rear differential capacity:
Page 6152
Push the terminal retainer down to the temporary lock position.
Page 2706
12. REMOVE FRONT NO. 3 FLOOR HEAT INSULATOR
(a) Remove the 4 nuts and front floor heat insulator.
13. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY
(a) Remove the 4 nuts and EGR pipe.
(b) Remove the 2 gaskets.
14. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR
(a) Remove the 3 bolts and heat insulator.
15. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH
(a) Remove the 9 nuts, exhaust manifold and 2 gaskets.
16. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
(a) Remove the 3 bolts and heat insulator.
Page 3399
(c) The CAN communication system cannot detect trouble in the branch line of the DLC3 even
though the DLC3 is also connected to the CAN
communication system.
7. HOW TO DISTINGUISH CAN J/C CONNECTOR
(a) In the CAN communication system, the shape of all connectors connected to the CAN J/C is the
same. The connectors connected to the CAN
J/C can be distinguished by the colors of the bus line and the connecting side of the connector.
HINT See "TERMINALS OF ECU" See: Testing and Inspection/Pinout Values and Diagnostic
Parameters/CAN Communication System for bus line color or the type of connecting surface.
Page 2074
(2) Disconnect connector B and measure the resistance.
Standard resistance (Fig. 7):
* If the results match the examples above, a short circuit exists between terminal 1 of connector B2
and terminal 1 of connector C.
4. CHECK AND REPLACE ECU
NOTICE: *
The connector should not be disconnected from the ECU. Perform the inspection from the backside
of the connector on the wire harness side.
* When no measuring condition is specified, perform the inspection with the engine stopped and
the ignition switch ON.
* Check that the connectors are fully seated. Check for loose, corroded or broken wires.
(a) First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be
faulty. Temporarily replace the ECU with a
normally functioning one and check if the symptoms occur. If the trouble symptoms disappear,
replace the original ECU.
(1) Measure the resistance between the ECU ground terminal and body ground.
Standard resistance:
Below 1 Ohms
(2) Disconnect the ECU connector. Check the ground terminal on the ECU side and wire harness
side for bending, corrosion or foreign matter.
Lastly, check the contact pressure of the female terminals.
Page 5651
(d) Remove the 3 bolts (labeled E), 3 harness clamps (labeled F) and sensor wire.
4. REMOVE FRONT SPEED SENSOR LH
(a) Remove the hexagon socket head cap bolt (labeled A) and speed sensor (labeled B) from the
knuckle.
5. REMOVE FRONT SKID CONTROL SENSOR CLAMP LH
(a) Remove the bolt (labeled C) and skid control sensor clamp (labeled D) from the knuckle.
6. REMOVE FRONT SKID CONTROL SENSOR WIRE RH
(a) Disconnect the connector (labeled A) from the front speed sensor.
(b) Detach the 3 clips (labeled B) and remove the clamp bolt (labeled C).
Page 5060
(a) Check that the differential case is not damaged.
If the differential case is damaged, replace it.
24. REMOVE FRONT DIFFERENTIAL SIDE GEAR NEEDLE ROLLER BEARING
(a) Using a brass bar and hammer, tap out the 2 bearings.
25. REMOVE DIFFERENTIAL CLUTCH HUB
(a) Using a snap ring expander, remove the snap ring.
(b) Remove the differential clutch hub.
26. REMOVE DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL
(a) Using SST, tap out the oil seal.
SST : 09308-00010
27. REMOVE DIFFERENTIAL SIDE GEAR SHAFT SUB-ASSEMBLY RH
(a) Using a snap ring expander, remove the snap ring.
(b) Using a plastic-faced hammer, tap out the side gear shaft.
Locations
Hood Sensor/Switch (For Alarm): Locations
THEFT DETERRENT: THEFT DETERRENT SYSTEM: PARTS LOCATION
Page 8690
Integrated Accessory Switch Assembly: Testing and Inspection
METER: DRIVE MONITOR SWITCH: INSPECTION
1. INSPECT DRIVE MONITOR SWITCH
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(a) If the result is not as specified, replace the monitor switch.
(b) Inspect the switch illumination.
(1) Connect the battery's positive (+) lead to terminal 1 (ILL+) and the negative (-) lead to terminal 6
(ILL-).
(2) Check that the light comes on.
OK:
LED comes on.
(3) If the result is not as specified, replace the monitor switch.
Page 8824
3. INSTALL FRONT DOOR ARMREST COVER LH
4. INSTALL COURTESY LIGHT ASSEMBLY (w/ Power Window) See: Body and Frame/Doors,
Hood and Trunk/Doors/Front Door/Service and
Repair/Front Door (for Regular Cab)/Reassembly
5. INSTALL FRONT DOOR WINDOW REGULATOR HANDLE ASSEMBLY (w/o Power Window)
See: Body and Frame/Doors, Hood and
Trunk/Doors/Front Door/Service and Repair/Front Door (for Regular Cab)/Reassembly
6. INSTALL FRONT UPPER ARMREST BASE PANEL LH (w/ Power Window) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Regular Cab)/Reassembly
7. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH See: Body and Frame/Doors,
Hood and Trunk/Doors/Front Door/Service and
Repair/Front Door (for Regular Cab)/Reassembly
8. INSTALL FRONT LOWER DOOR FRAME BRACKET GARNISH LH See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Regular Cab)/Reassembly
9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Components
AUDIO / VISUAL: INSTRUMENT PANEL SPEAKER (for CrewMax): COMPONENTS
Page 2937
Knock Sensor: Diagrams
Page 7593
when inserting and after full engagement.
NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal.
(d) REPAIR METHOD OF CONNECTOR TERMINAL
(1) If there is any foreign matter on the terminal, clean the contact point using an air gun or cloth.
Never rub the contact point using sandpaper
as the plating may come off.
(2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is
gold-plated (gold color), use a gold-plated female
terminal; if it is silver-plated (silver color), use a silver-plated female terminal.
(3) Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock
into the housing, the housing may have to be
replaced.
(e) HANDLING OF WIRE HARNESS
(1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be
restored in the same way.
(2) Never twist, pull or slacken the wire harness more than necessary.
(3) The wire harness should never come into contact with a high temperature part, or rotating,
moving, vibrating or sharp-edged parts. Avoid
contact with panel edges, screw tips and other sharp items.
(4) When installing parts, never pinch the wire harness.
(5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with
vinyl tape.
2. CHECK FOR OPEN CIRCUIT
Page 7479
Tire Pressure Module: Service and Repair Removal
TIRE AND WHEEL: TIRE PRESSURE WARNING ECU: REMOVAL
NOTICE: *
It is necessary to perform initialization See: Testing and Inspection/Programming and
Relearning/Initialization after registration See: Testing and Inspection/Programming and
Relearning/Registration of the transmitter IDs into the tire pressure warning ECU after the ECU has
been replaced.
* When replacing the tire pressure warning ECU, read the transmitter IDs stored in the old ECU
using the intelligent tester or Techstream and write them down before removal.
1. REMOVE FRONT DOOR SCUFF PLATE RH (for Regular Cab)
(a) Remove the front door scuff plate RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Removal.
HINT Use the same procedures described for the LH side.
2. REMOVE FRONT DOOR SCUFF PLATE RH (for Double Cab, for CrewMax)
(a) Remove the front door scuff plate RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Removal.
HINT Use the same procedures described for the LH side.
3. REMOVE COWL SIDE TRIM BOARD RH
(a) Remove the cowl side trim board RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Removal.
HINT Use the same procedures described for the LH side.
4. REMOVE INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal
5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and
Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument
Panel Safety Pad (for Column Shift Type)/Removal
6. REMOVE TIRE PRESSURE WARNING ECU
(a) Disconnect the ECU connector.
(b) Remove the 2 nuts and ECU.
Page 5919
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to disable the SRS system.
2. REMOVE REAR WHEEL
3. REMOVE REAR SPEED SENSOR LH
(a) Disconnect the speed sensor connector (labeled A).
(b) Remove the nut (labeled B) and speed sensor (labeled C).
4. REMOVE REAR SPEED SENSOR RH
(a) Disconnect the speed sensor connector (labeled A).
(b) Remove the nut (labeled B) and speed sensor (labeled C).
5. REMOVE SKID CONTROL SENSOR WIRE
(a) Disconnect the sensor connector (labeled A).
(b) Detach the 7 clips (labeled B).
(c) Remove the bolt (labeled C).
(d) Remove the nut (labeled D) and skid control sensor wire.
Installation
BRAKE CONTROL: REAR SPEED SENSOR: INSTALLATION
Page 6266
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION: Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC
terminals are touched, the IC may be destroyed by static electricity.)
When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact with the terminals of leads from the IC, etc. of the
replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown on the left.
DISCONNECT CONNECTOR
Page 7688
Condenser HVAC: Service and Repair Removal
AIR CONDITIONING: CONDENSER: REMOVAL
1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM See: Service and Repair
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
3. REMOVE FRONT BUMPER COVER
(a) for Steel Type Bumper:
Remove front bumper cover See: Body and Frame/Bumper/Front Bumper/Service and
Repair/Removal and Replacement/Front Bumper (for Steel Type Bumper)/Removal.
(b) for Resin Type Bumper:
Remove front bumper cover See: Body and Frame/Bumper/Front Bumper/Service and
Repair/Removal and Replacement/Front Bumper (for Resin Type Bumper)/Removal.
4. DISCONNECT OIL COOLER HOSE (w/ Air Cooled Transmission Oil Cooler)
(a) Using pliers, grip the claws of the clip and slide the clip.
(b) Disconnect the 2 oil cooler hoses.
5. REMOVE RADIATOR ASSEMBLY
(a) for 1GR-FE:
Remove the radiator See: Engine, Cooling and Exhaust/Cooling System/Radiator/Service and
Repair/Removal.
(b) for 1UR-FE:
Remove the radiator See: Engine, Cooling and Exhaust/Cooling System/Radiator/Service and
Repair/Removal.
(c) for 3UR-FE:
Remove the radiator See: Engine, Cooling and Exhaust/Cooling System/Radiator/Service and
Repair/Removal.
(d) for 3UR-FBE:
Remove the radiator See: Engine, Cooling and Exhaust/Cooling System/Radiator/Service and
Repair/Removal.
6. DISCONNECT DISCHARGE HOSE
Page 6237
Engine Room R/B, J/B - Engine Compartment Left
Page 1436
Seat Belt Buckle Switch: Diagrams
Page 1924
(b) for Rear Differential:
(1) Install a new gasket and the filler plug.
Torque : 49 Nm (500 kgf-cm, 36 ft-lbf)
(c) for Front Differential:
(1) Using a 10 mm hexagon wrench, install a new gasket and the filler plug.
Torque : 39 Nm (398 kgf-cm, 29 ft-lbf)
Page 9406
Grille: Overhaul
Disassembly
EXTERIOR: RADIATOR GRILLE: DISASSEMBLY
1. REMOVE RADIATOR GRILLE (OR FRONT PANEL) EMBLEM
(a) Detach the 3 claws and remove the radiator grille (or front panel) emblem.
2. REMOVE RADIATOR GRILLE PROTECTOR
(a) Remove the radiator grille protector.
Reassembly
EXTERIOR: RADIATOR GRILLE: REASSEMBLY
HINT When installing the radiator grille protector, heat the radiator grille surface using a heat light.
Standard:
NOTICE: Do not heat the radiator grille excessively.
1. INSTALL RADIATOR GRILLE PROTECTOR
(a) Clean the radiator grille sub-assembly surface.
(1) Using a heat light, heat the radiator grille sub-assembly surface.
(2) Remove the double-sided tape from the radiator grille sub-assembly surface.
(3) Wipe off any tape adhesive residue with cleaner.
(b) Install a new radiator grille protector.
Page 1327
4. SYMPTOM CONFIRMATION AND DTC (INCLUDING FREEZE FRAME DATA) CHECK
(a) Visually check the wire harnesses, connectors and fuses for open and short circuits.
(b) Warm up the engine to the normal operating temperature.
(c) Confirm the problem symptoms and conditions, and check for DTCs.
B -- Go to step 6 A -- Continue to next step.
5. DTC CHART
(a) Check the results obtained in the DTC check. Then find the output DTC in the DTC chart. Look
at the "Trouble Area" column for a list of
potentially malfunctioning circuits and / or parts.
NEXT -- Go to step 7
6. PROBLEM SYMPTOMS TABLE
(a) Check the results obtained in the symptom confirmation. Then find the problem symptoms in
the problem symptoms table. Look at the
"Suspected Area" column for a list of potentially malfunctioning circuits and / or parts.
NEXT -- Continue to next step.
7. CIRCUIT INSPECTION OR PARTS INSPECTION
(a) Confirm the malfunctioning circuit or part.
NEXT -- Continue to next step.
8. ADJUST, REPAIR OR REPLACE
(a) Adjust, repair or replace the malfunctioning circuit or parts.
NEXT -- Continue to next step.
9. CONFIRMATION TEST
(a) After the adjustment, repairs or replacement, confirm that the malfunction no longer exists. If the
malfunction does not reoccur, perform a
confirmation test under the same conditions and in the same environment as when the malfunction
occurred the first time.
NEXT -- END
2. CUSTOMER PROBLEM ANALYSIS
HINT *
In troubleshooting, confirm that the problem symptoms have been accurately identified.
Preconceptions should be discarded in order to make an accurate judgment. To clearly understand
what the problem symptoms are, it is extremely important to ask the customer about the problem
and the conditions at the time the malfunction occurred.
* Gather as much information as possible for reference. Past problems that seem unrelated may
also help in some cases.
* The following 5 questions are important points in the problem analysis:
Page 1214
(b) Using SST, remove the sensor.
SST : 09224-00010
Installation
1UR-FE ENGINE CONTROL SYSTEM: HEATED OXYGEN SENSOR: INSTALLATION
1. INSTALL HEATED OXYGEN SENSOR (for Bank 2 Sensor 2)
(a) Install the sensor to the exhaust pipe by hand.
(b) Using SST, tighten the sensor.
SST : 09224-00010
without SST - Torque : 44 Nm (449 kgf-cm, 32 ft-lbf)
with SST - Torque : 40 Nm (408 kgf-cm, 30 ft-lbf)
HINT *
Use a torque wrench with a fulcrum length of 30 cm (11.8 in.). When using a torque wrench with a
fulcrum length that is not 30 cm (11.8 in.), calculate the torque specification for the torque wrench
and SST based on the "without SST" torque specification See: Service Precautions
* Make sure SST and the wrench are connected in a straight line.
2. INSTALL HEATED OXYGEN SENSOR (for Bank 1 Sensor 2)
(a) Install the sensor to the exhaust pipe by hand.
(b) Using SST, tighten the sensor.
Page 3535
D -- REPLACE ECM See: Engine Control Module/Service and Repair/Removal
C -- REPLACE ECM See: Engine Control Module/Service and Repair/Removal
B -- REPLACE ECM See: Engine Control Module/Service and Repair/Removal
A -- REPLACE ECM
10. CONNECT CONNECTOR
(a) Reconnect the J84 No. 1 junction connector connector.
NEXT -- Continue to next step.
11. CHECK FOR OPEN IN CAN BUS MAIN WIRE (COMBINATION METER ECU - NO. 1
JUNCTION CONNECTOR)
(a) Disconnect the J28 combination meter ECU connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE CAN MAIN WIRE CONNECTED TO COMBINATION METER ECU
(COMBINATION METER ECU - NO. 1 JUNCTION CONNECTOR)
OK -- REPLACE COMBINATION METER ASSEMBLY
Air Conditioning Amplifier Communication Stop Mode
CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: Air Conditioning Amplifier
Communication Stop Mode - Air Conditioning Amplifier Communication Stop Mode
DESCRIPTION
WIRING DIAGRAM
Page 499
(a) Attach the claw to install the upper steering column cover.
(b) Attach the 4 clips to install the upper steering cover onto the instrument panel cluster finish
panel.
(c) Install the 2 screws.
Torque : 2.0 Nm (20 kgf-cm, 18 in-lbf)
HINT Turn the steering wheel to the right and left as necessary to install the 2 screws.
8. INSPECT SRS WARNING LIGHT
(a) Inspect the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
9. CONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
Page 9166
Refer to the service kit instruction sheet for further detail.
Page 8223
(3) Move SST at least 10 m (32.8 ft.) away from the front of the vehicle.
(4) Close all the doors and windows of the vehicle.
HINT Leave a gap in one of the windows for inserting SST wire harness.
NOTICE: Take care not to damage SST wire harness.
(5) Connect SST's red clip to the battery's positive (+) terminal and the black clip to the negative (-)
terminal.
(e) Activate the seat belt pretensioner.
(1) Confirm that no one is inside the vehicle or within 10 m (32.8 ft.) of the vehicle.
(2) Press SST activation switch to activate the seat belt pretensioner.
HINT The seat belt pretensioner operates at the same time SST activation switch's LED
illuminates.
(f) Dispose of the front seat outer belt (with the seat belt pretensioner).
CAUTION: *
Do not touch the front seat outer belt for at least 30 minutes after the seat belt pretensioner has
been activated. It is very hot.
* Use gloves and safety glasses when handling a front seat outer belt whose pretensioner has
been activated.
* Always wash your hands with water after completing the disposal.
* Do not apply water to a front seat outer belt that has an activated pretensioner.
HINT When scrapping a vehicle, activate the seat belt pretensioner, and then scrap the vehicle with
the activated front seat outer belt installed.
2. DISPOSE OF FRONT SEAT OUTER BELT ASSEMBLY (WHEN NOT INSTALLED IN
VEHICLE)
CAUTION: Be sure to follow the procedures listed below when activating the seat belt pretensioner.
(a) Remove the front seat outer belt.
(1) Wind the seat belt with the retractor.
(2) When the seat belt is sufficiently wound, cut the seat belt approximately 100 mm (3.94 in.) from
the retractor, as shown in the illustration.
HINT The seat belt is designed so that winding the seat belt before pretensioner activation will
decrease the pulling power of the seat belt during pretensioner activation.
Page 1851
Then click Next.
F. Verify correct current calibration and new calibration information. Then click Next.
NOTE
^ The total number of calibration IDs in the calibration file corresponds to the number of
reprogrammable processors in the ECU.
^ Each calibration file may contain up to three separate calibrations.
Page 1304
Page 6370
Page 2025
(2) CONNECTORS
Slightly shake the connector vertically and horizontally.
(3) WIRE HARNESS
Slightly shake the wire harness vertically and horizontally.
HINT The connector joint and fulcrum of the vibration are the major areas that should be checked
thoroughly.
(b) HEAT METHOD:
When a malfunction seems to occur when the area in question is heated.
(1) Heat the component that is the possible cause of the malfunction with a hair dryer or similar
device. Check if the malfunction occurs.
NOTICE: *
Do not heat to more than 60°C (140°F). Exceeding this temperature may damage components.
* Do not apply heat directly to the parts in the ECU.
(c) WATER SPRINKLING METHOD:
When a malfunction seems to occur on a rainy day or in high-humidity.
(1) Sprinkle water onto the vehicle and check if the malfunction occurs.
NOTICE: *
Never sprinkle water directly into the engine compartment. Indirectly change the temperature and
humidity by spraying water onto the front of the radiator.
* Never apply water directly onto the electronic components.
HINT If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU
or connections. Look for evidence of corrosion or short circuits. Proceed with caution during water
tests.
(d) HIGH ELECTRICAL LOAD METHOD:
When a malfunction seems to occur when the electrical load is excessive.
(1) Turn on the heater blower, headlights, rear window defogger and all other electrical loads.
Check if the malfunction reoccurs.
5. DIAGNOSTIC TROUBLE CODE CHART
Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate
section's Diagnostic Trouble Code Chart. Use the chart to determine the trouble area and the
proper inspection procedure. A description of each of the chart's columns is below.
Page 1144
Air Flow Meter/Sensor: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: INSTALLATION
1. INSTALL MASS AIR FLOW METER
(a) Install the MAF meter with the 2 screws.
Torque : 1.7 Nm (17 kgf-cm, 15 in-lbf)
(b) Connect the MAF connector.
Page 706
Page 1405
Impact Sensor: Service and Repair
Components
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift
Type): COMPONENTS
Page 1444
Seat Occupant Sensor: Locations Seat Belt Warning System
SEAT BELT: SEAT BELT WARNING SYSTEM: PARTS LOCATION
Page 6352
when inserting and after full engagement.
NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal.
(d) REPAIR METHOD OF CONNECTOR TERMINAL
(1) If there is any foreign matter on the terminal, clean the contact point using an air gun or cloth.
Never rub the contact point using sandpaper
as the plating may come off.
(2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is
gold-plated (gold color), use a gold-plated female
terminal; if it is silver-plated (silver color), use a silver-plated female terminal.
(3) Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock
into the housing, the housing may have to be
replaced.
(e) HANDLING OF WIRE HARNESS
(1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be
restored in the same way.
(2) Never twist, pull or slacken the wire harness more than necessary.
(3) The wire harness should never come into contact with a high temperature part, or rotating,
moving, vibrating or sharp-edged parts. Avoid
contact with panel edges, screw tips and other sharp items.
(4) When installing parts, never pinch the wire harness.
(5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with
vinyl tape.
2. CHECK FOR OPEN CIRCUIT
Components
Traction Control Switch: Service and Repair Components
BRAKE CONTROL: VSC OFF SWITCH: COMPONENTS
Page 4074
Leak Detection Pump: Diagrams
Page 3520
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- CHECK FOR SHORT TO GND IN CAN BUS WIRE (MAIN BODY ECU) OK -- Continue to
next step.
9. CHECK FOR SHORT TO GND IN CAN BUS WIRE (NO. 1 JUNCTION CONNECTOR - SKID
CONTROL ECU WITH ACTUATOR)
(a) Disconnect the A46 No. 1 junction connector connector.
(b) Measure the resistance according to the value(s) in the table below.
Page 4955
(a) Disconnect the No. 4 oil cooler inlet hose and No. 4 oil cooler outlet hose from the cooler
condenser.
(b) Remove the bolt and No. 2 oil cooler tube together with the 2 oil cooler hoses.
(c) Remove the No. 4 oil cooler inlet hose and No. 4 oil cooler outlet hose from the No. 2 oil cooler
tube.
9. REMOVE OIL COOLER TUBE (w/ Trailer Towing System)
(a) Remove the 2 bolts and oil cooler tube.
Page 6931
If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness
or connector in that circuit in the past. Check the wire harness and connectors.
B -- SYSTEM NORMAL
A -- TROUBLESHOOTING OF EACH PROBLEM SYMPTOM
The problem is still occurring in a place other than the diagnostic circuit (the DTC displayed first is
either for a past problem or a secondary problem).
4. SYMPTOM SIMULATION
HINT The most difficult case in troubleshooting is when no problem symptoms occur. In such a
case, a thorough problem analysis must be carried out. A simulation of the same or similar
conditions and environment in which the problem occurred in the customer's vehicle should be
carried out. No matter how much skill or experience a technician has, troubleshooting without
confirming the problem symptoms will lead to important repairs being overlooked and mistakes or
delays.
For example:
With a problem that only occurs when the engine is cold or as a result of vibration caused by the
road during driving, the problem can never be determined if the symptoms are being checked on a
stationary vehicle or on a vehicle with a warmed-up engine. Vibration, heat or water penetration
(moisture) is difficult to reproduce. The symptom simulation tests below are effective substitutes for
the conditions and can be applied on a stationary vehicle.
Important points in the symptom simulation test:
In the symptom simulation test, the problem symptoms as well as the problem area or parts must
be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then,
connect the tester and carry out the symptom simulation test, judging whether the circuit being
tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the
problem symptoms table for each system to narrow down the possible causes.
To reproduce DTCs, it is necessary to satisfy the respective DTC detection conditions.
(a) VIBRATION METHOD:
When a malfunction seems to occur as a result of vibration.
(1) PART AND SENSOR
Apply slight vibration with a finger to the part of the sensor suspected to be the cause of the
problem, and check whether or not the malfunction occurs.
NOTICE: Applying strong vibration to relays may open them.
Page 2932
Engine Temperature Sensor: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: ENGINE COOLANT TEMPERATURE SENSOR:
REMOVAL
1. REMOVE NO. 1 ENGINE UNDER COVER See: Engine, Cooling and Exhaust/Engine/Engine
Lubrication/Engine Oil/Service and
Repair/Replacement
2. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Removal
3. DRAIN ENGINE COOLANT See: Engine, Cooling and Exhaust/Cooling System/Coolant/Service
and Repair
4. REMOVE ENGINE COOLANT TEMPERATURE SENSOR
(a) Disconnect the sensor connector.
(b) Using a 19 mm ball joint lock nut wrench, remove the sensor.
(c) Remove the gasket from the sensor.
Page 3261
Parts Information
Calibration Information
Required Tools & Equipment
Repair Procedure
Page 4083
(a) Connect the No. 8 water by-pass hose.
HINT The direction of the hose clamp is indicated in the illustration.
6. INSTALL NO. 3 WATER BY-PASS PIPE SUB-ASSEMBLY
(a) Install the No. 3 water by-pass pipe with the 2 bolts and connect the hose.
HINT The direction of the hose clamp is indicated in the illustration.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(b) Connect the No. 4 water by-pass hose.
7. INSTALL INTAKE MANIFOLD ASSEMBLY
(a) Install the intake manifold See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service
and Repair/Installation.
Page 7014
Auxiliary Power Outlet Switch: Service and Repair Removal
OTHER SYSTEM: INVERTER MAIN SWITCH (for CrewMax): REMOVAL
1. REMOVE FRONT DOOR SCUFF PLATE LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining
(For Double Cab)/Removal
2. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for
CrewMax)/Removal
3. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal
4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Floor Shift Type)/Removal
5. REMOVE INVERTER MAIN SWITCH
(a) Detach the 2 claws and remove the main switch.
Page 936
(1) Detach the claw and remove the main plate.
(2) Remove the 2 screws and damper servo.
11. REMOVE DAMPER SERVO SUB-ASSEMBLY
(a) Disconnect the connector.
(b) Remove the 3 screws and damper servo.
12. REMOVE BLOWER CASE SUB-ASSEMBLY
(a) Remove the 3 screws.
(b) Detach the 2 claws and remove the case.
13. REMOVE BLOWER DAMPER SERVO SUB-ASSEMBLY
Locations
Accessory Relay: Locations
Instrument Panel (Floor Shift)
Instrument Panel (Column Shift)
Components
Variable Valve Timing Actuator Position Sensor: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: VVT SENSOR: COMPONENTS
Page 5106
Actuator: Diagrams
Page 4792
J. When Cal 1 has completed the update process turn ignition OFF for a minimum of 10 seconds.
Then click Next.
K. Turn ignition to the ON position. Then click Start.
L. Do NOT disturb the vehicle during flash reprogramming.
Page 2639
(b) Slowly pour coolant into the radiator reservoir until it reaches the FULL line.
(c) Install the reservoir cap.
(d) Press the inlet and outlet radiator hoses several times by hand, and then check the coolant
level. If the coolant level is low, add coolant.
(e) Install the radiator cap.
(f) Start the engine and warm it up until the thermostat opens.
HINT The thermostat opening timing can be confirmed by pressing the radiator inlet hose by hand,
and checking when the engine coolant starts to flow inside the hose.
(g) Maintain the engine speed at 2000 to 2500 rpm.
NOTICE: *
Make sure that the radiator reservoir still has some coolant in it.
* Pay attention to the needle of the water temperature meter. Make sure that the needle does not
show an abnormally high temperature.
* If there is not enough coolant, the engine may burn out or overheat.
* Immediately after starting the engine, if the radiator reservoir does not have any coolant, perform
the following: 1) stop the engine, 2) wait until the coolant has cooled down, and 3) add coolant until
the coolant is filled to the FULL line.
* Run the engine at 2000 rpm until the coolant level has stabilized.
(h) Press the inlet and outlet radiator hoses several times by hand to bleed air.
CAUTION: *
Wear protective gloves.
* Be careful as the radiator hoses are hot.
* Keep your hands away from the fan.
(i) Stop the engine, and wait until the engine coolant cools down to ambient temperature.
CAUTION: Do not remove the radiator cap while the engine and radiator are still hot. Pressurized,
hot engine coolant and steam may be released and cause serious burns.
(j) Check that the coolant level is between the FULL and LOW lines.
If the coolant level is below the LOW line, repeat all of the procedures above.
If the coolant level is above the FULL line, drain coolant so that the coolant level is between the
FULL and LOW lines.
4. INSPECT FOR COOLANT LEAK See: Testing and Inspection
5. INSTALL NO. 1 ENGINE UNDER COVER See: Engine/Engine Lubrication/Engine Oil/Service
and Repair/Replacement
Page 2119
(h) It is extremely dangerous to perform any work on a vehicle raised on a jack alone, even for
work that can be finished quickly. Safety stands
must be used to support the vehicle.
Page 8250
(c) Detach the 7 clips and 2 claws, and remove the pillar garnish.
8. REMOVE CENTER PILLAR GARNISH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Removal
9. REMOVE FRONT SEAT OUTER BELT ASSEMBLY
(a) Remove the nut and shoulder anchor.
(b) Disconnect the pretensioner connector as shown in the illustration.
(c) Remove the 2 bolts and seat belt.
Installation
SEAT BELT: FRONT SEAT OUTER BELT ASSEMBLY (for Double Cab): INSTALLATION
HINT *
Use the same procedures for the LH side and RH side.
* The procedures listed below are for the LH side.
1. INSTALL FRONT SEAT OUTER BELT ASSEMBLY
Page 388
Page 7866
(a) Remove the packing.
(b) Remove the 6 screws and detach the 4 claws.
(c) Remove the blower case (back side).
(d) Remove the evaporator from the blower case (front side).
17. REMOVE NO. 1 COOLER THERMISTOR
(a) Remove the No. 1 cooler thermistor.
Page 7084
Steering Control Module: Diagrams
Fuel System - Fuel Sending Unit Upper Cover
Replacement
Fuel Gauge Sender: Technical Service Bulletins Fuel System - Fuel Sending Unit Upper Cover
Replacement
T-SB-0399-09
December 23, 2009
Fuel Sending Unit Upper Cover Installation
Service Category Engine/Hybrid System
Section Fuel System
Market USA
Applicability
Introduction
A Fuel Sending Unit Upper Cover has been developed as a separate service part for 2007-2010
MY Tundra vehicles to allow for individual replacement. This bulletin supplements the Repair
Manual by providing the installation procedures and part number details for this component.
Vehicles produced after the production change below utilize this replaceable Fuel Sending Unit
Upper Cover.
Production Change Information
This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown.
Page 2665
(c) Remove the drain cock plug.
(d) Remove the O-ring.
Page 6354
(1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be
checked by conducting a voltage check.
With each connector still connected, measure the voltage between the body ground and these
terminals (in this order): 1) terminal 1 of connector A; 2) terminal 1 of connector B; and 3) terminal
1 of connector C.
Standard voltage (Fig. 4):
* If the results match the examples above, an open circuit exists in the wire harness between
terminal 1 of connector B and terminal 1 of connector C.
3. CHECK FOR SHORT CIRCUIT
(a) If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance
check with the body ground (below).
(b) Check the resistance with the body ground.
(1) Disconnect connectors A and C and measure the resistance.
Standard resistance (Fig. 6):
HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally.
If your results match the examples above, a short circuit exists between terminal 1 of connector A
and terminal 1 of connector C.
Page 192
when inserting and after full engagement.
NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal.
(d) REPAIR METHOD OF CONNECTOR TERMINAL
(1) If there is any foreign matter on the terminal, clean the contact point using an air gun or cloth.
Never rub the contact point using sandpaper
as the plating may come off.
(2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is
gold-plated (gold color), use a gold-plated female
terminal; if it is silver-plated (silver color), use a silver-plated female terminal.
(3) Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock
into the housing, the housing may have to be
replaced.
(e) HANDLING OF WIRE HARNESS
(1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be
restored in the same way.
(2) Never twist, pull or slacken the wire harness more than necessary.
(3) The wire harness should never come into contact with a high temperature part, or rotating,
moving, vibrating or sharp-edged parts. Avoid
contact with panel edges, screw tips and other sharp items.
(4) When installing parts, never pinch the wire harness.
(5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with
vinyl tape.
2. CHECK FOR OPEN CIRCUIT
Page 3966
6. In some instances where water has entered the system DTCs P2440/P2441/P2442/P2443 may
set.
Refer to TIS 2010 model year Tundra Repair Manual to diagnose and inspect the emission control
valves if necessary:
7. If there is NO liquid found in the air pump assemblies or the DTC is still present after
replacement inspect the air injection system.
Refer to TIS 2010 model year Tundra Repair Manual:
8. Clear the DTC and road test the vehicle to confirm the condition has been corrected.
Page 8477
Alarm System Transponder: Service and Repair Installation
ENGINE IMMOBILISER: TRANSPONDER KEY AMPLIFIER: INSTALLATION
1. INSTALL TRANSPONDER KEY AMPLIFIER
(a) Align the transponder key amplifier with the installation position of the upper bracket with the
amplifier inclined.
(b) Push the transponder key amplifier and install it to the upper bracket.
NOTICE: Do not push the amplifier upward with excessive force.
2. INSTALL LOWER STEERING COLUMN COVER
(a) Attach the 2 claws to install the lower steering column cover.
(b) Install the 2 screws.
Removal and Replacement
Shifter A/T: Removal and Replacement
Components
A760F AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY (for Column Shift Type):
COMPONENTS
Locations
Transmission Speed Sensor: Locations
A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS
LOCATION
Page 4312
^ Figure 17 shows an example of the update procedure for a two-processor ECU.
G. Turn ignition OFF. Then click Next.
H. Confirm the following:
^ Ignition is ON and engine is OFF or "READY" OFF (hybrid vehicles).
^ Hood is open.
^ All accessories are OFF.
^ Battery voltage is above 11.4 volts.
NOTICE
Verify the vehicle is connected to a battery charger before continuing - If battery voltage falls below
11.4 volts, ECU damage may occur.
Page 7455
Tire Pressure Warning Reset Switch: Diagrams
Page 4406
Fuel Gauge Sender: Service and Repair Fuel Sending Unit Cover
Fuel Sending Unit Upper Cover Installation
Introduction
A Fuel Sending Unit Upper Cover has been developed as a separate service part for 2007-2010
MY Tundra vehicles to allow for individual replacement. This bulletin supplements the Repair
Manual by providing the installation procedures and part number details for this component.
Vehicles produced after the production change below utilize this replaceable Fuel Sending Unit
Upper Cover.
Production Change Information
This information applies to vehicles produced BEFORE the Production Change Effective VINs
shown below.
Production Change Information (Continued)
Parts Information
Warranty Information
Page 7363
(a) Remove the nut and bolt from the shock absorber lower side.
NOTICE: To prevent the shock absorber with coil spring from falling, leave the bolt inserted.
(b) Remove the 4 nuts.
(c) Remove the bolt (lower side) and shock absorber with coil spring.
Installation
SUSPENSION: FRONT SHOCK ABSORBER: INSTALLATION
HINT *
Use the same procedures for the RH side and LH side.
* The procedures listed below are for the LH side.
* A bolt without a torque specification is shown in the standard bolt chart See:
Specifications/Mechanical Specifications/Standard Bolt - Specified Torque For Standard Bolts
1. TEMPORARILY INSTALL FRONT SHOCK ABSORBER WITH COIL SPRING
(a) Temporarily install the upper side of the shock absorber to the chassis frame with the 4 nuts.
(b) Temporarily install the lower side of the shock absorber to the lower suspension arm with the
bolt, washer and nut.
2. STABILIZE SUSPENSION
(a) Lower the vehicle.
Page 686
Power Mirror Switch: Diagrams
Page 2422
(b) Remove the oil filter drain plug.
(c) Install the pipe to the oil filter cap.
HINT Use a container to catch the draining oil.
NOTICE: If the O-ring is removed with the drain plug, install the O-ring together with the pipe.
(d) Check that oil is drained from the oil filter. Then disconnect the pipe and remove the O-ring, as
shown in the illustration.
(e) Using SST, remove the oil filter cap.
SST : 09228-06501
NOTICE: Do not remove the oil filter bracket clip.
Specifications
Alignment: Specifications
SERVICE SPECIFICATIONS: SUSPENSION: SERVICE DATA
Stanard Vehicle Height
for Regular Cab of Standard Deck
for Regular Cab of Long Deck
for Double Cab of Standard Deck
Page 3219
Page 2281
Parts Information
Required Tools & Equipment
Additional TIS Techstream units may be ordered by calling Approved Dealer Equipment (ADE).
TSB Overview
1. Confirm that DTC P0012 and/or P0022 is stored in the ECM.
2. Diagnose the Oil Control Valves (OCVs) for proper operation.
3. If the OCVs operate correctly replace both intake VVTi gear assemblies following the Repair
Manual.
Diagnostic Procedure
1. Using TIS Techstream confirm that DTC P0012 and/or P0022 is stored in the ECM.
2. Remove the affected Oil Control Valve (OCV) and inspect for debris in the valve or evidence that
the valve is stuck.
3. Check valve operation by applying positive (+) battery voltage to terminal 1 and negative (-)
battery voltage to terminal 2. Valve should move
quickly when voltage is applied. If NOT valve should be replaced.
4. Reinstall the OCVs warm up the engine to over 167°F (75°C) and perform an Active Test using
Tech stream.
Powertrain / Engine and ECT / Active Test / Control the WT System (Bank 1) or (Bank 2)
5. If there is NO debris and the OCV moves with battery voltage and Active Test functions Replace both intake VVTi gears following the repair
procedure below.
Repair Procedure
1. Replace both intake VVTi gears.
Page 6834
Page 8961
Parking Assist Switch: Service and Repair Installation
PARK ASSIST / MONITORING: CLEARANCE SONAR MAIN SWITCH: INSTALLATION
1. INSTALL DRIVE MONITOR SWITCH
(a) Attach the 2 claws to install the monitor switch.
2. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Panel,
Gauges and Warning Indicators/Instrument Cluster
/ Carrier/Service and Repair/Combination Meter/Installation
Locations
Temperature Sensor/Switch: Locations
JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION
Initial Inspection and Diagnostic Overview
Neutral Safety Switch: Initial Inspection and Diagnostic Overview
A760F AUTOMATIC TRANSMISSION: PARK / NEUTRAL POSITION SWITCH: ON-VEHICLE
INSPECTION
1. INSPECT PARK/NEUTRAL POSITION SWITCH ASSEMBLY
(a) Apply the parking brake and turn the ignition switch to ON.
(b) Depress the brake pedal and check that the engine starts when the shift lever is in N or P, but
does not start when the shift lever is in other
positions.
(c) Check that the back-up light illuminates and the reverse warning buzzer sounds when the shift
lever is in R, but do not function when the shift
lever is in other positions.
Page 9304
Page 8814
Removal
AUDIO / VISUAL: FRONT DOOR SPEAKER (for CrewMax): REMOVAL
HINT *
Use the same procedures for the LH side and RH side.
* The procedures listed below are for the LH side.
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE FRONT LOWER DOOR FRAME BRACKET GARNISH LH See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for CrewMax)/Disassembly
3. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH See: Body and Frame/Doors,
Hood and Trunk/Doors/Front Door/Service and
Repair/Front Door (for CrewMax)/Disassembly
Page 2101
J/B No.6 Assembly Inner Circuit
Page 6535
(a) For an open circuit in the wire harness in Fig. 1, check the resistance or voltage, as described
below.
(b) Check the resistance.
(1) Disconnect connectors A and C and measure the resistance between them.
Standard resistance (Fig. 2):
HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally.
If the results match the examples above, an open circuit exists between terminal 1 of connector A
and terminal 1 of connector C.
(2) Disconnect connector B and measure the resistance between the connectors.
Standard resistance (Fig. 3):
* If the results match the examples above, an open circuit exists between terminal 1 of connector
B2 and terminal 1 of connector C.
(c) Check the voltage.
Page 2084
Relay Box: Connector Views
Engine Room R/B, J/B - Engine Compartment Left
Page 4605
* In the DTC check, it is very important to determine whether the problem indicated by the DTC is
either: 1) still occurring; or 2) occurred in the past but has since returned to normal. In addition, the
DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs
should be checked before and after confirmation of symptoms (i.e., whether or not problem
symptoms exist) to determine current system conditions, as shown in the flowchart below.
* Never skip the DTC check. Failing to check DTCs may, depending on the case, result in
unnecessary troubleshooting for systems operating normally or lead to repairs not related to the
problem. Follow the procedures listed in the flowchart in the correct order.
* The following flowchart shows how to proceed with troubleshooting using the DTC check.
Directions from the flowchart will indicate how to proceed either to DTC troubleshooting or to the
troubleshooting of each problem symptom.
1. DTC CHECK
NEXT -- Continue to next step.
2. MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR MEMORY
NEXT -- Continue to next step.
3. SYMPTOM CONFIRMATION
B -- Go to step 5 A -- Continue to next step.
4. SIMULATION TEST USING SYMPTOM SIMULATION METHODS
NEXT -- Continue to next step.
5. DTC CHECK
B -- TROUBLESHOOTING OF PROBLEM INDICATED BY DTC A -- Continue to next step.
6. SYMPTOM CONFIRMATION
Capacity Specifications
Fluid - A/T: Capacity Specifications
Automatic Transmission Fluid Capacities:
With tow package:
2WD .....................................................................................................................................................
.......................................................... 12.3 qt (11.6L) 4WD .................................................................
.............................................................................................................................................. 11.9 qt
(11.3L)
Without tow package:
2WD .....................................................................................................................................................
.......................................................... 11.7 qt (11.7L) 4WD .................................................................
.............................................................................................................................................. 11.4 qt
(10.8L)
Locations
Temperature Sensor/Switch: Locations
JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION
Page 2604
(3) Check for dirt or mud on the pipe and around the connector before disconnection. Clean if
necessary.
(4) Pinch the connector and disconnect the connector and pipe.
(5) If the connector and the pipe are stuck together, pinch the connector, push and pull the pipe to
disconnect the pipe and pull it out.
NOTICE: Do not use any tools.
(6) Check for dirt or mud on the seal surface of the disconnected pipe. Clean if necessary.
(7) To protect the disconnected pipe and connector from damage and contamination, cover it with a
plastic bag.
(e) Observe these precautions when connecting the fuel tube connector (for Quick Type).
(1) Check that there is no damage or contamination in the connected part of the pipe.
(2) Align the axis of the connector with the axis of the pipe. Push the pipe into the connector until
the connector makes a "click" sound. If the
connection is tight, apply a small amount of fresh spindle oil or gasoline on the tip of the pipe.
(3) After having finished the connection, try to pull apart the pipe and the connector to confirm that
they are securely connected.
Page 4008
(4) Check that air flows from port A to port B.
If the result is not as specified, replace the air switching valve.
Diagrams
Shift Interlock Solenoid: Diagrams
Page 2720
Install the monolithic converter protector within the angle range specified in the illustration.
5. INSTALL AIR FUEL RATIO SENSOR (for Bank 1 Sensor 1)
(a) Install the sensor to the No. 2 exhaust pipe by hand.
(b) Using SST, tighten the sensor.
SST : 09224-00010
without SST - Torque : 44 Nm (449 kgf-cm, 32 ft-lbf)
with SST - Torque : 40 Nm (408 kgf-cm, 30 ft-lbf)
HINT *
Use a torque wrench with a fulcrum length of 30 cm (11.8 in.). If using a torque wrench with a
length that is not 30 cm (11.8 in.), calculate the torque specification for the torque wrench and SST
based on the "without SST" torque specification See: Service Precautions
* Make sure SST and the wrench are connected in a straight line.
6. INSTALL AIR FUEL RATIO SENSOR (for Bank 2 Sensor 1) See: Powertrain
Management/Computers and Control Systems/Oxygen
Sensor/Service and Repair/Air Fuel Ratio Sensor/Installation
7. INSTALL FRONT EXHAUST PIPE ASSEMBLY
(a) Install a new gasket and the front exhaust pipe to the exhaust manifold RH with 3 new nuts.
Torque : 54 Nm (554 kgf-cm, 40 ft-lbf)
(b) Connect the air fuel ratio sensor connector.
8. INSTALL HEATED OXYGEN SENSOR (for Bank 2 Sensor 2) See: Powertrain
Management/Computers and Control Systems/Oxygen
Sensor/Service and Repair/Heated Oxygen Sensor/Installation
9. INSTALL FRONT NO. 2 EXHAUST PIPE ASSEMBLY
(a) Connect the front No. 2 exhaust pipe to the exhaust pipe support.
(b) Install a new gasket and the front No. 2 exhaust pipe to the exhaust manifold LH with 3 new
nuts.
Page 4438
Main Relay (Computer/Fuel System): Testing and Inspection
1UR-FE ENGINE CONTROL SYSTEM: CIRCUIT OPENING RELAY: ON-VEHICLE INSPECTION
1. REMOVE CIRCUIT OPENING RELAY (C/OPN)
(a) Remove the circuit opening relay from the engine room relay block.
2. INSPECT CIRCUIT OPENING RELAY
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) If the result is not as specified, replace the circuit opening relay.
3. INSTALL CIRCUIT OPENING RELAY
(a) Install the circuit opening relay to the engine room relay block.
Page 2097
Driver Side J/B Inner Circuit
Page 5637
Traction Control Switch: Service and Repair Removal
BRAKE CONTROL: VSC OFF SWITCH: REMOVAL
1. REMOVE FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Removal
2. REMOVE FRONT DOOR SCUFF PLATE LH (for Double Cab, CrewMax) See: Body and
Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Removal
3. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Removal
4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Removal
5. REMOVE VSC OFF SWITCH
(a) Disconnect the VSC OFF switch connector.
(b) Using a screwdriver, detach the 2 claws and remove the VSC OFF switch from the lower
instrument panel finish panel LH.
Page 2709
for nut A - Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
except nut A - Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
4. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR
(a) Install the heat insulator with the 3 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
5. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY
(a) Install 2 new gaskets.
(b) Install the EGR pipe with the 4 nuts, and tighten the nuts in the sequence shown in the
illustration.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
6. INSTALL FRONT NO. 3 FLOOR HEAT INSULATOR
(a) Install the front floor heat insulator with the 4 bolts.
Torque : 5.5 Nm (56 kgf-cm, 49 in-lbf)
7. INSTALL FRONT NO. 4 FLOOR HEAT INSULATOR
(a) Install the front floor heat insulator with the 4 bolts.
Page 805
Steering Angle Sensor: Programming and Relearning
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: CALIBRATION
PERFORM INITIALIZATION OF STEERING ANGLE SENSOR
NOTICE: Complete the adjustment of the steering wheel and wheel alignment, and then initialize
the steering angle sensor. If the order is reversed, the steering wheel and wheel alignment will
become misaligned.
(a) Check that the steering wheel is in the centered position.
(b) Disconnect the negative battery terminal for more than 2 seconds.
NOTICE: After the ignition switch is turned OFF, the navigation system requires approximately 90
seconds to record various types of memory and settings. As a result, after turning the ignition
switch OFF, wait 90 seconds or more before disconnecting the cable from the negative (-) battery
terminal.
(c) Reconnect the negative battery terminal.
Page 7159
Tire Pressure Warning Reset Switch: Testing and Inspection
TIRE AND WHEEL: TIRE PRESSURE WARNING RESET SWITCH: INSPECTION
1. CHECK TIRE PRESSURE WARNING RESET SWITCH
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the switch.
Page 1172
Engine Temperature Sensor: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: ENGINE COOLANT TEMPERATURE SENSOR:
INSTALLATION
1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR
(a) Install a new gasket to the sensor.
(b) Using a 19 mm ball joint lock nut wrench, install the sensor.
Torque : 20 Nm (200 kgf-cm, 14 ft-lbf)
NOTICE: Use the formula to calculate special torque values for situations where ball joint lock nut
wrench is combined with a torque wrench See: Service Precautions
(c) Connect the sensor connector.
2. ADD ENGINE COOLANT See: Engine, Cooling and Exhaust/Cooling System/Coolant/Service
and Repair
3. INSPECT FOR COOLANT LEAK See: Engine, Cooling and Exhaust/Cooling System/Testing
and Inspection
4. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Installation
5. INSTALL NO. 1 ENGINE UNDER COVER See: Engine, Cooling and Exhaust/Engine/Engine
Lubrication/Engine Oil/Service and
Repair/Replacement
Engine Controls - Techstream(R) ECU Re-Flash
Procedure
Engine Control Module: All Technical Service Bulletins Engine Controls - Techstream(R) ECU
Re-Flash Procedure
T-SB-0064-10
February 4, 2010
Techstream ECU Flash Reprogramming Procedure
Service Category Engine/Hybrid System
Section Engine Control
Market USA
Applicability
TSB SUPERSESSION NOTICE
The information contained in this TSB supersedes TSB No. SS002-07.
^ Applicability has been updated to include 2009 - 2011 model year Toyota vehicles.
^ A new section, Techstream Preparation, has been added.
^ Techstream Lite has been added as an option in Required Tools & Materials.
^ Process Overview and Operation Procedure sections have been updated.
TSB No. SS002-07 is Obsolete and any printed versions should be discarded. Be sure to review
the entire content of this service bulletin before proceeding.
Introduction
Flash reprogramming allows the ECU software to be updated without replacing the ECU. Flash
calibration updates for specific vehicle models/ECUs are released as field-fix procedures described
in individual service bulletins. This bulletin details the Techstream ECU flash reprogramming
process and outlines use of the Technical Information System (TIS) and the Calibration Update
Wizard (CUW). Flash calibration updates can only be applied to the vehicle/ECU combination for
which they are intended. ECUs have internal security that will not allow them to be programmed
with another ECU's information.
ECU
Electronic Control Unit (ECU) is a Toyota term used to describe integrated computerized devices
responsible for managing the operation of a system or subsystem. For the purposes of this bulletin,
the term "ECU" is used as a generic label for the following SAE J1930 standard references:
^ Powertrain Control Module (PCM)
Page 6368
Engine - MIL ON/DTC's P0012/P0022 Set
Variable Valve Timing Actuator: All Technical Service Bulletins Engine - MIL ON/DTC's
P0012/P0022 Set
T-SB-0019-10
January 20, 2010
MIL "ON" DTC P0012 and/or P0022
Service Category Engine/Hybrid System
Section Engine Control
Market USA
Applicability
Introduction
Some 2010 model year Sequoia and Tundra vehicles may exhibit a MIL "ON" condition for
Diagnostic Trouble Code (DTC) P0012 and/or P0022 ( Camshaft Position "A" - Timing
Over-Retarded Bank 1/2).
Please refer to the following repair procedure to address this condition.
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60
months or 60,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Production Change Information
Page 5279
*1: for 5 leaf spring
*2: includes Off road package
* If the measured angle is not within the specification, adjust it with the bearing washer (See
"Adjust Propeller Shaft Angle").
(b) Measure the No. 2 joint angle.
(1) Using SST, measure and record the angle of the propeller shaft (D).
SST : 09370-50010
(2) Subtract the angle of the propeller shaft (D) from the angle of the intermediate shaft (C) to
calculate the No. 2 joint angle.
No. 2 joint angle:
Page 6631
Auxiliary Power Outlet: Service and Repair Power Outlet Socket (for Column Shift Type)
Components
OTHER SYSTEM: POWER OUTLET SOCKET (for Column Shift Type): COMPONENTS
Removal
OTHER SYSTEM: POWER OUTLET SOCKET (for Column Shift Type): REMOVAL
1. REMOVE FRONT DOOR SCUFF PLATE LH (for Double Cab)
Page 7891
Solar Sensor: Service and Repair Installation
AIR CONDITIONING: SOLAR SENSOR (for Automatic Air Conditioning System): INSTALLATION
1. INSTALL AUTOMATIC LIGHT CONTROL SENSOR (SOLAR SENSOR)
(a) Connect the connector.
(b) Attach the 2 claws to install the sensor.
2. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY
(a) for Column Shift Type:
Install the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column
Shift Type)/Installation.
(b) for Floor Shift Type:
Install the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation.
Page 6644
(a) Disconnect the connector.
(b) Using a screwdriver, detach the 5 claws and remove the console box bezel.
HINT Tape the screwdriver tip before use.
3. REMOVE POWER OUTLET SOCKET ASSEMBLY
(a) Using a screwdriver, detach the claw and remove the power outlet socket.
HINT Tape the screwdriver tip before use.
4. REMOVE POWER OUTLET SOCKET COVER
(a) Detach the 2 claws and remove the power outlet socket cover.
5. REMOVE REAR CONSOLE END PANEL SUB-ASSEMBLY (for Double Cab) See: Body and
Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Floor Shift Type)/Removal
6. REMOVE REAR POWER OUTLET SOCKET ASSEMBLY (for Double Cab)
(a) Using a screwdriver, detach the claw and remove the power outlet socket.
HINT Tape the screwdriver tip before use.
Page 3507
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- CHECK FOR SHORT TO B+ IN CAN BUS WIRE (POWER STEERING ECU) OK -- Continue
to next step.
12. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (NO. 1 JUNCTION CONNECTOR - CENTER
AIRBAG SENSOR)
(a) Disconnect the J83 No. 1 junction connector connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- CHECK FOR SHORT TO B+ IN CAN BUS WIRE (CENTER AIRBAG SENSOR)
Page 2061
DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector.
Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
Page 5344
Transmission Position Switch/Sensor: Diagrams
Recall - Floor Mat/Accelerator Pedal Interferance
Technical Service Bulletin # SSC90L Date: 091001
Page 7630
Page 104
Brake Fluid Pump Relay: Locations From 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Locations
Ignition Relay: Locations
MULTIPLEX COMMUNICATION: LIN COMMUNICATION SYSTEM: PARTS LOCATION
Page 492
Steering Column Control Module: Diagrams
Page 2319
(b) RH:
(1) Using a wrench to hold the hexagonal portion of the No. 1 camshaft, tighten the camshaft timing
gear with the bolt.
Torque : 100 Nm (1020 kgf-cm, 74 ft-lbf)
(2) Using a wrench to hold the hexagonal portion of the No. 2 camshaft, tighten the camshaft timing
exhaust gear with the bolt.
Torque : 100 Nm (1020 kgf-cm, 74 ft-lbf)
13. CHECK NO. 1 CYLINDER TO TDC / COMPRESSION See: Service and
Repair/Overhaul/Reassembly
14. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY
(a) Install the timing chain cover See: Engine Lubrication/Oil Pump/Service and Repair/Removal
and Replacement/Installation.
15. INSPECT IGNITION TIMING See: Testing and Inspection/Engine
16. INSPECT ENGINE IDLE SPEED See: Testing and Inspection/Engine
Page 2799
^ Power Supply Mode is used to maintain battery voltage at 13.5 volts while flash reprogramming
the vehicle.
^ For details on how to use the GR8 Battery Diagnostic Station, refer to the located on TIS,
Diagnostics - Tools & Equipment - Battery Diagnostics.
3. Click the appropriate calibration ID and reprogram the vehicle's ECU with Techstream.
A. After reviewing the procedures outlined in the selected TSB, click the appropriate calibration ID
link by matching the vehicle's current
calibration ID to the Previous Calibration ID in the Calibration Identification Chart.
NOTE
^ Calibration files are embedded as live links in the service bulletin.
^ Some vehicles require special preparation - please review the selected TSB carefully.
B. Click Open to load calibration file information.
Techstream pulls calibration files as needed to ensure the latest calibration file is used. Do NOT
save calibrations locally on the hard drive or other media.
NOTICE
Errors during the flash reprogramming process can permanently damage the vehicle ECU.
Minimize the risk by following the steps below.
^ Battery voltage MUST NOT FALL BELOW 11.4 volts during reprogramming. Confirm battery
voltage is higher than 11.4 volts, but be sure voltage DOES NOT RISE ABOVE 16.0 volts during
reprogramming.
^ Turn OFF all vehicle accessories (e.g. audio system, A/C, interior lights, DRL, etc.). Do NOT add
to or significantly change the vehicle's electrical
Page 5595
Electronic Brake Control Module: Diagrams
Page 174
Heated Oxygen Sensor
Oxygen Sensor: Testing and Inspection Heated Oxygen Sensor
1UR-FE ENGINE CONTROL SYSTEM: HEATED OXYGEN SENSOR: ON-VEHICLE
INSPECTION
1. CHECK HEATED OXYGEN SENSOR
(a) Disconnect the heated oxygen sensor connector.
(b) Measure the heater resistance according to the value(s) in the table below.
Standard Resistance:
(c) If the result is not as specified, replace the heated oxygen sensor.
(d) Connect the heated oxygen sensor connector.
Page 605
Removal
PARK ASSIST / MONITORING: ULTRASONIC SENSOR (for Rear Side): REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE LICENSE PLATE LIGHT ASSEMBLY LH (for Resin Type Bumper) See: Body and
Frame/Bumper/Rear Bumper/Service and
Repair/Removal and Replacement/Rear Bumper (for Resin Type Bumper)/Removal
3. REMOVE LICENSE PLATE LIGHT ASSEMBLY LH (for Steel Type Bumper) See: Body and
Frame/Bumper/Rear Bumper/Service and
Repair/Removal and Replacement/Rear Bumper (for Steel Type Bumper)/Removal
Page 5758
(a) for Regular Cab Standard Deck:
Remove the front No. 2 exhaust pipe See: Engine, Cooling and Exhaust/Exhaust System/Exhaust
Pipe/Service and Repair/Exhaust Pipe (for Regular Cab Standard Deck)/Removal.
(b) except Regular Cab Standard Deck:
Remove the front No. 2 exhaust pipe See: Engine, Cooling and Exhaust/Exhaust System/Exhaust
Pipe/Service and Repair/Exhaust Pipe (Except Regular Cab Standard Deck)/Removal.
13. REMOVE FRONT NO. 2 EXHAUST PIPE ASSEMBLY (for 3UR-FE)
(a) for Regular Cab Standard Deck:
Remove the front No. 2 exhaust pipe See: Engine, Cooling and Exhaust/Exhaust System/Exhaust
Pipe/Service and Repair/Exhaust Pipe (for Regular Cab Standard Deck)/Removal.
(b) except Regular Cab Standard Deck:
Remove the front No. 2 exhaust pipe See: Engine, Cooling and Exhaust/Exhaust System/Exhaust
Pipe/Service and Repair/Exhaust Pipe (Except Regular Cab Standard Deck)/Removal.
14. REMOVE FRONT NO. 2 EXHAUST PIPE ASSEMBLY (for 3UR-FBE)
(a) except Regular Cab Standard Deck:
Remove the front No. 2 exhaust pipe See: Engine, Cooling and Exhaust/Exhaust System/Exhaust
Pipe/Service and Repair/Exhaust Pipe (Except Regular Cab Standard Deck)/Removal.
15. REMOVE NO. 1 PARKING BRAKE CABLE ASSEMBLY (for 3220 mm [10 ft. 6.8 in.]
Wheelbase Type)
(a) Remove the adjustment nut and lock nut (labeled A).
(b) Remove the bolt (labeled B) and cable retainer.
(c) Remove the nut (labeled C) and clamp from the body.
(d) Disconnect the clamp (labeled D) from the No. 1 parking brake cable.
(e) Remove the 2 bolts (labeled E) and No. 1 parking brake cable from the inside of the vehicle.
NOTICE: Do not bend and twist the parking brake cable.
(f) Remove the 3 bolts (labeled F) and No. 1 cable support bracket.
Engine Control System - SFI System
Crankshaft Position Sensor: Locations Engine Control System - SFI System
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 876
Cruise Control Switch: Service and Repair Installation
CRUISE CONTROL: CRUISE CONTROL MAIN SWITCH: INSTALLATION
1. INSTALL CRUISE CONTROL MAIN SWITCH
(a) Install the switch, as shown in the illustration.
(b) Install the 2 screws.
(c) Connect the connector.
2. INSTALL STEERING PAD (w/ Steering Pad Switch) See: Restraint Systems/Air Bag
Systems/Air Bag/Service and Repair/Removal and
Replacement/Steering Pad/Installation
3. INSTALL STEERING PAD (w/o Steering Pad Switch) See: Restraint Systems/Air Bag
Systems/Air Bag/Service and Repair/Removal and
Replacement/Steering Pad/Installation
4. INSTALL LOWER NO. 3 STEERING WHEEL COVER See: Restraint Systems/Air Bag
Systems/Air Bag/Service and Repair/Removal and
Replacement/Steering Pad/Installation
5. INSTALL LOWER NO. 2 STEERING WHEEL COVER See: Restraint Systems/Air Bag
Systems/Air Bag/Service and Repair/Removal and
Replacement/Steering Pad/Installation
6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
7. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
Service and Repair
Cabin Air Filter: Service and Repair
Step 1. Turn the engine switch off.
Step 2. Open the glove box.
Step 3. Remove the tray.
Page 4588
"Case2" Open the secondary locking device.
[B] For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray
Gray or White : Black
Page 8614
This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown.
Page 8095
(a) Set the battery in the vehicle. Then move the stay onto the battery and tighten the nut to fix the
battery in place.
(b) Connect the cable to the positive (+) battery terminal.
3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
4. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
Components
SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for CrewMax):
COMPONENTS
Page 3182
Air Flow Meter/Sensor: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: REMOVAL
1. REMOVE MASS AIR FLOW METER
(a) Disconnect the MAF connector.
(b) Remove the 2 screws and MAF meter.
Page 3299
J. When Cal 1 has completed the update process turn ignition OFF for a minimum of 10 seconds.
Then click Next.
K. Turn ignition to the ON position. Then click Start.
L. Do NOT disturb the vehicle during flash reprogramming.
Page 7971
* The front seat side airbag becomes extremely hot when the airbag is deployed, so do not touch it
for at least 30 minutes after deployment.
* Use gloves and safety glasses when handling a front seat side airbag with a deployed airbag.
* Do not apply water to a front seat side airbag with a deployed airbag.
* Always wash your hands with water after completing the operation.
(1) Remove the front seat side airbag from the tire.
(2) Place the front seat side airbag in a plastic bag, tie it tightly and dispose of it in the same way as
other general parts.
Page 6591
DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector.
Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
Page 4434
Fuel Pump Relay: Testing and Inspection Fuel Pump Relay
1UR-FE ENGINE CONTROL SYSTEM: FUEL PUMP RELAY: ON-VEHICLE INSPECTION
1. REMOVE FUEL PUMP RELAY (F/PMP)
(a) Remove the fuel pump relay from the engine room relay block.
2. INSPECT FUEL PUMP RELAY
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) If the result is not as specified, replace the fuel pump relay.
3. INSTALL FUEL PUMP RELAY
(a) Install the fuel pump relay to the engine room relay block.
Page 5296
09954-04010
09957-04010
09958-04011
SST : 09955-04100
NOTICE: Pull out the spider bearing until the SST claws contact the shaft's universal joint yoke.
(h) Clamp the protruding universal joint spider bearing in a vise.
(i) Using a brass bar and hammer, tap the shaft yoke to remove the universal joint spider bearing.
NOTICE: Do not tap the shaft tube.
HINT Use the same removal procedure for the universal joint spider bearing on the opposite side.
(j) Using SST, pull out the universal joint spider bearing from the flange yoke.
SST : 09331-60010
SST : 09950-40011
09951-04010
09952-04010
09953-04020
09954-04010
Page 6376
Floor Wire
Page 6238
Engine Room R/B, J/B - Engine Compartment Left
Page 4246
This TSB applies to all Sequoia and Tundra vehicles equipped with lUR-FE (4.6L) 2UZ-FE (4.7L)
and 3UR-FE/FBE (5.7L) engines produced BEFORE the Production Change Effective VINs shown.
Repair Procedure
1. Remove and replace the air cleaner lid.
2. Remove and replace the front right hand (RH) fender liner.
Page 8141
Page 3088
4. SYMPTOM CONFIRMATION AND DTC (INCLUDING FREEZE FRAME DATA) CHECK
(a) Visually check the wire harnesses, connectors and fuses for open and short circuits.
(b) Warm up the engine to the normal operating temperature.
(c) Confirm the problem symptoms and conditions, and check for DTCs.
B -- Go to step 6 A -- Continue to next step.
5. DTC CHART
(a) Check the results obtained in the DTC check. Then find the output DTC in the DTC chart. Look
at the "Trouble Area" column for a list of
potentially malfunctioning circuits and / or parts.
NEXT -- Go to step 7
6. PROBLEM SYMPTOMS TABLE
(a) Check the results obtained in the symptom confirmation. Then find the problem symptoms in
the problem symptoms table. Look at the
"Suspected Area" column for a list of potentially malfunctioning circuits and / or parts.
NEXT -- Continue to next step.
7. CIRCUIT INSPECTION OR PARTS INSPECTION
(a) Confirm the malfunctioning circuit or part.
NEXT -- Continue to next step.
8. ADJUST, REPAIR OR REPLACE
(a) Adjust, repair or replace the malfunctioning circuit or parts.
NEXT -- Continue to next step.
9. CONFIRMATION TEST
(a) After the adjustment, repairs or replacement, confirm that the malfunction no longer exists. If the
malfunction does not reoccur, perform a
confirmation test under the same conditions and in the same environment as when the malfunction
occurred the first time.
NEXT -- END
2. CUSTOMER PROBLEM ANALYSIS
HINT *
In troubleshooting, confirm that the problem symptoms have been accurately identified.
Preconceptions should be discarded in order to make an accurate judgment. To clearly understand
what the problem symptoms are, it is extremely important to ask the customer about the problem
and the conditions at the time the malfunction occurred.
* Gather as much information as possible for reference. Past problems that seem unrelated may
also help in some cases.
* The following 5 questions are important points in the problem analysis:
Page 5050
0.05 to 0.95 mm (0.00197 to 0.0374 in.)
HINT Connect 2 SST with vinyl tape.
(b) Coat the lip of the oil seal with MP grease.
23. INSTALL REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY
(a) Using SST, install the companion flange.
SST : 09950-30012
09951-03010
09953-03010
09954-03010
09956-03030
SST : 09955-03050
24. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD
(a) Coat the threads of a new nut with hypoid gear oil.
(b) Using SST to hold the companion flange.
SST : 09330-00021
09330-00030
(c) Tighten the nut until the standard preload is reached.
Torque : 441 Nm (4497 kgf-cm, 325 ft-lb for less)
(d) Using a torque wrench, measure the preload of the backlash between the drive pinion and ring
gear.
Locations
Shift Interlock Control Module: Locations
Instrument Panel (Floor Shift)
Instrument Panel (Column Shift)
Page 6463
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Page 8076
NOTICE: *
If the front airbag sensor has been dropped, or there are any cracks, dents or other defects in the
case, bracket or connector, replace it with a new one.
* When installing the front airbag sensor, be careful that the SRS wiring does not interfere with
other parts and that it is not pinched between other parts.
(e) Check that there is no looseness in the installation parts of the front airbag sensor.
2. INSTALL BATTERY
(a) Set the battery in the vehicle. Then move the stay onto the battery and tighten the nut to fix the
battery in place.
(b) Connect the cable to the positive (+) battery terminal.
3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
4. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
Page 2707
17. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH
(a) Remove the 9 nuts, exhaust manifold and 2 gaskets.
Page 4067
Evaporative Emission Control Canister: Service and Repair Removal
1UR-FE EMISSION CONTROL: CANISTER: REMOVAL
1. REMOVE CANISTER ASSEMBLY
(a) Remove the nut and disconnect the wire harness clamp bracket.
(b) Disconnect the connector.
(c) Disconnect the purge line hose.
(d) Disconnect the air inlet line hose.
(1) Push the hose firmly toward the canister side.
(2) Pinch the hose (portion A) as shown in the illustration.
(3) Pull out the hose.
NOTICE: *
Do not use any tools in this procedure.
* Check for any dirt and foreign matter contamination in the canister and around the hose. Clean if
necessary. Foreign matter may damage the O-rings or cause leaks in the seal between the
canister and hose.
(e) Disconnect the vent line hose.
(1) Pinch the retainer and then raise it.
NOTICE: *
Do not use any tools in this procedure.
* Check for any dirt and foreign matter contamination in the valve and around the connector. Clean
if necessary. Foreign matter may damage the O-rings or cause leaks in the seal between the valve
and connector.
Floor Speaker (for CrewMax)
Speaker: Testing and Inspection Floor Speaker (for CrewMax)
AUDIO / VISUAL: FLOOR SPEAKER (for CrewMax): INSPECTION
1. INSPECT NO. 1 BOX SPEAKER ASSEMBLY
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the speaker assembly.
Page 6750
J/B No.3 Inner Circuit
J/B No.4 Inner Circuit
J/B No.5 Inner Circuit
Page 5284
(a) Install the insulator bracket with the 2 bolts.
Torque : 30 Nm (306 kgf-cm, 22 ft-lbf)
Components
PROPELLER SHAFT: FRONT PROPELLER SHAFT ASSEMBLY: COMPONENTS
Page 3092
If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness
or connector in that circuit in the past. Check the wire harness and connectors.
B -- SYSTEM NORMAL
A -- TROUBLESHOOTING OF EACH PROBLEM SYMPTOM
The problem is still occurring in a place other than the diagnostic circuit (the DTC displayed first is
either for a past problem or a secondary problem).
4. SYMPTOM SIMULATION
HINT The most difficult case in troubleshooting is when no problem symptoms occur. In such a
case, a thorough problem analysis must be carried out. A simulation of the same or similar
conditions and environment in which the problem occurred in the customer's vehicle should be
carried out. No matter how much skill or experience a technician has, troubleshooting without
confirming the problem symptoms will lead to important repairs being overlooked and mistakes or
delays.
For example:
With a problem that only occurs when the engine is cold or as a result of vibration caused by the
road during driving, the problem can never be determined if the symptoms are being checked on a
stationary vehicle or on a vehicle with a warmed-up engine. Vibration, heat or water penetration
(moisture) is difficult to reproduce. The symptom simulation tests below are effective substitutes for
the conditions and can be applied on a stationary vehicle.
Important points in the symptom simulation test:
In the symptom simulation test, the problem symptoms as well as the problem area or parts must
be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then,
connect the tester and carry out the symptom simulation test, judging whether the circuit being
tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the
problem symptoms table for each system to narrow down the possible causes.
To reproduce DTCs, it is necessary to satisfy the respective DTC detection conditions.
(a) VIBRATION METHOD:
When a malfunction seems to occur as a result of vibration.
(1) PART AND SENSOR
Apply slight vibration with a finger to the part of the sensor suspected to be the cause of the
problem, and check whether or not the malfunction occurs.
NOTICE: Applying strong vibration to relays may open them.
Page 3239
(2) Disconnect connector B and measure the resistance.
Standard resistance (Fig. 7):
* If the results match the examples above, a short circuit exists between terminal 1 of connector B2
and terminal 1 of connector C.
4. CHECK AND REPLACE ECU
NOTICE: *
The connector should not be disconnected from the ECU. Perform the inspection from the backside
of the connector on the wire harness side.
* When no measuring condition is specified, perform the inspection with the engine stopped and
the ignition switch ON.
* Check that the connectors are fully seated. Check for loose, corroded or broken wires.
(a) First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be
faulty. Temporarily replace the ECU with a
normally functioning one and check if the symptoms occur. If the trouble symptoms disappear,
replace the original ECU.
(1) Measure the resistance between the ECU ground terminal and body ground.
Standard resistance:
Below 1 Ohms
(2) Disconnect the ECU connector. Check the ground terminal on the ECU side and wire harness
side for bending, corrosion or foreign matter.
Lastly, check the contact pressure of the female terminals.
Page 1806
2. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in
Figure 1. Confirm if the ECM (PCM) calibration has
been updated. If the calibration ID listed is NOT the latest ECM (PCM) calibration - go to step 3.
3. Flash reprogram the ECM (PCM).
NOTE
^ The GR8 Battery Diagnostic Station MUST be used in Power Supply Mode to maintain battery
voltage at 13.5 volts while flash reprogramming the vehicle.
^ For details on how to use the GR8 Battery Diagnostic Station, refer to the located on the
Technical Information System (TIS), Diagnostics - Battery
Follow the procedures outlined in TSB No. T-SB-0064-10, "Techstream ECU Flash
Reprogramming Procedure1⁄4 and flash the ECM (PCM) with the NEW calibration file update.
4. Install the Authorized Modifications Label.
A. Using a permanent marker enter the following information on the label:
^ ECM part number [Refer to the Parts Information section for the CURRENT PART NUMBER]
^ Calibration ID(s) [Refer to the Calibration Identification Chart for the NEW CALIBRATION ID]
^ Dealer Code
^ Repair Date
^ Change Authority [This TSB number]
B. Affix the Authorized Modifications Label to the vehicle at the location shown in Figure 1. The
Authorized Modifications Label is available
through the MDC P/N 00451-00001-LBL.
5. Test drive the vehicle to confirm proper vehicle operation.
Page 650
Page 9002
Page 8683
Garage Door Opener Transmitter: Programming and Relearning
GARAGE DOOR OPENER: GARAGE DOOR OPENER SYSTEM: REGISTRATION
1. REGISTER TRANSMITTER CODE
HINT *
The vehicle's garage door opener records transmitter codes for systems such as garage doors,
gates, entry gates, door locks, home lighting systems, security systems or other transmitter code
based systems.
* The garage door opener is built into the inner rear view mirror. If replacing the inner rear view
mirror, transmitter codes for any systems previously registered in the garage door opener must be
reregistered.
(a) Reregister systems in the garage door opener registration mode.
CAUTION: Do not perform transmitter code registration for a system if people or objects are near
the system. When registering transmitter codes for a system, injury or damage can occur because
the system may open, close, unlock or otherwise operate.
NOTICE: *
Before transmitter code registration, confirm that all the electrical systems (headlight, blower motor,
rear defogger, etc.) are turned off and no key is in the vehicle.
* The garage door opener cannot be used with systems that: 1) were manufactured before April 1,
1982; or 2) do not meet Federal Standards (for example, garage doors without a jam protection
function).
HINT *
3 transmitter codes can be registered with the garage door opener, one transmitter code for each
of the 3 garage door opener switches.
* Disconnecting the battery will not erase the transmitter codes registered with the garage door
opener.
* An attempt to overwrite a previously registered transmitter code with a new system's transmitter
code may fail. In this situation, the previously registered transmitter code will not be erased.
(1) Select a garage door opener switch for transmitter code registration.
(2) Press and hold the selected switch for 20 seconds. The garage door opener will enter
registration mode.
HINT Before entering registration mode, the LED illuminates. After entering registration mode, the
LED flashes at a cycle of 1 Hz. For a "rolling code" type system, after entering registration mode,
the LED flashes at a cycle of 8.8 Hz for 1.6 seconds, and then the LED flashes at a cycle of 1 Hz.
(3) After the garage door opener has entered registration mode, bring the original transmitter of the
system to be registered within 1 to 3 inches
of the garage door opener and press and hold one of the garage door opener switches. Then press
the original transmitter switch.
(4) If the transmitter code registration was successful, the LED of the garage door opener flashes
at a cycle of 5.6 Hz. If no malfunction
occurs, release both the garage door opener switch and the original transmitter switch.
HINT *
If transmitter code registration fails: 1) the original transmitter's battery may be low or need to be
replaced, or 2) the system you are trying to register may not be compatible with the garage door
opener.
Locations
Gear Sensor/Switch: Locations
JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION
Page 8736
^ This condition is NOT reception related. Switching modes will not correct the condition.
^ This condition affects XM ONLY - AM/FM reception is normal when this condition occurs. If
cycling the ignition key does NOT restore normal operation, this TSB does NOT apply.
Warranty Information
APPLICABLE WARRANTY
^ Toyota-supplied satellite radio component systems installed as original equipment are warranted
for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Toyota-supplied satellite radio components installed by a Toyota dealer are warranted for 12
months, regardless of mileage from the date of installation on the vehicle, or the remainder of the
applicable New Vehicle Limited Warranty for 36 months or 36,000 miles, whichever provides the
greater coverage.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Parts Information
Order parts through the Pioneer exchange program.
Service Exchange Part Identification
Countermeasure parts have a "P" marking on the parts label following the Toyota part number (see
Figure 1).
Required Tools & Equipment
NOTE
Page 3608
A/F and 02 Sensor Identification
Page 2164
Tire Pressure Warning Reset Switch: Diagrams
Page 2398
(f) Remove the oil filter element and O-ring from the oil filter cap.
NOTICE: Be sure to remove the O-ring for the cap by hand, without using any tools, to prevent
damage to the cap's O-ring groove.
4. INSTALL OIL FILTER ELEMENT
(a) Clean the inside of the oil filter cap, its threads and its O-ring groove.
(b) Apply a small amount of engine oil to a new O-ring and install it to the oil filter cap.
(c) Set a new oil filter element to the oil filter cap.
(d) Remove any dirt or foreign matter from the installation surface of the engine.
(e) Apply a small amount of engine oil to the O-ring again and temporarily install the oil filter cap.
(f) Using SST, tighten the oil filter cap.
SST : 09228-06501
Torque : 25 Nm (255 kgf-cm, 18 ft-lbf)
NOTICE: *
When tightening the oil filter cap, do not remove the oil filter bracket clip.
* Make sure that the oil filter is installed securely as shown in the illustration.
* Be careful that the O-ring does not get caught between any surrounding parts.
Page 427
Fuel Pump Control Unit: Service and Repair Removal
1UR-FE FUEL: FUEL PUMP ECU: REMOVAL
1. REMOVE FUEL PUMP ECU
(a) Disconnect the 2 fuel pump ECU connectors.
(b) Remove the 2 bolts and fuel pump ECU.
NOTICE: Make sure the fuel pump ECU is not subjected to physical shocks such as being
dropped, etc.
Page 2338
Refer to the Technical Information System (TIS) applicable model and model year Repair Manual:
2. Verify the vehicle has the proper coolant and oil levels.
3. Clear all DTCs and confirm the condition has been corrected.
Specifications
Wheel Fastener: Specifications
FRONT WHEEL
For Aluminum Wheel
Torque..................................................................................................................................................
.................................131 Nm (1336 kgf-cm, 97 ft-lbf)
For Steel Wheel
Torque..................................................................................................................................................
...............................209 Nm (2131 kgf-cm, 154 ft-lbf)
REAR WHEEL
For Aluminum Wheel
Torque..................................................................................................................................................
.................................131 Nm (1336 kgf-cm, 97 ft-lbf)
For Steel Wheel
Torque..................................................................................................................................................
...............................209 Nm (2131 kgf-cm, 154 ft-lbf)
Page 9124
NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do
not operate the ignition switch, any other switches, or the doors.
(a) If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the
harness and connector.
(b) Connect the cable of the Techstream to the DLC3, turn the ignition switch ON and attempt to
use the tester. If the display indicates that a
communication error has occurred, there is a problem either with the vehicle or with the tester.
HINT *
If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of
the original vehicle.
* If communication is still not possible when the tester is connected to another vehicle, the problem
may be in the tester itself. Consult the Service Department listed in the tester's instruction manual.
How To Proceed With Troubleshooting
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: HOW TO
PROCEED WITH TROUBLESHOOTING
1. OPERATION FLOW
HINT Perform troubleshooting in accordance with the procedures below. The following is an outline
of basic troubleshooting procedures. Confirm the troubleshooting procedures for the circuit you are
working on before beginning troubleshooting.
1. VEHICLE BROUGHT TO WORKSHOP
NEXT -- Continue to next step.
2. CUSTOMER PROBLEM ANALYSIS
(a) Ask the customer about the conditions and environment when the problem occurred.
NEXT -- Continue to next step.
3. INSPECT BATTERY VOLTAGE
Standard voltage:
11 to 14 V
If the voltage is below 11 V, recharge or replace the battery before proceeding.
NEXT -- Continue to next step.
Page 7986
(a) Check the SRS warning light See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
Components
SUPPLEMENTAL RESTRAINT SYSTEM: FRONT SEAT SIDE AIRBAG ASSEMBLY (except Fold
Down Seat Type): COMPONENTS
Removal
SUPPLEMENTAL RESTRAINT SYSTEM: FRONT SEAT SIDE AIRBAG ASSEMBLY (except Fold
Down Seat Type): REMOVAL
Page 5895
Traction Control Switch: Testing and Inspection
BRAKE CONTROL: VSC OFF SWITCH: INSPECTION
1. INSPECT VSC OFF SWITCH
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the VSC OFF switch.
Page 6537
(2) Disconnect connector B and measure the resistance.
Standard resistance (Fig. 7):
* If the results match the examples above, a short circuit exists between terminal 1 of connector B2
and terminal 1 of connector C.
4. CHECK AND REPLACE ECU
NOTICE: *
The connector should not be disconnected from the ECU. Perform the inspection from the backside
of the connector on the wire harness side.
* When no measuring condition is specified, perform the inspection with the engine stopped and
the ignition switch ON.
* Check that the connectors are fully seated. Check for loose, corroded or broken wires.
(a) First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be
faulty. Temporarily replace the ECU with a
normally functioning one and check if the symptoms occur. If the trouble symptoms disappear,
replace the original ECU.
(1) Measure the resistance between the ECU ground terminal and body ground.
Standard resistance:
Below 1 Ohms
(2) Disconnect the ECU connector. Check the ground terminal on the ECU side and wire harness
side for bending, corrosion or foreign matter.
Lastly, check the contact pressure of the female terminals.
Page 7997
(b) Pull out the steering pad from the steering wheel, as shown in the illustration. Then support the
steering pad with one hand.
NOTICE: When removing the steering pad, do not pull the airbag wire harness.
(c) Disconnect the 2 connectors and remove the steering pad.
NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness.
5. REMOVE STEERING PAD (w/o Steering Pad Switch)
(a) Using a T30 "TORX" socket wrench, loosen the 2 screws until the groove along the screw
circumference catches on the screw case.
(b) Pull out the steering pad from the steering wheel, as shown in the illustration. Then support the
steering pad with one hand.
NOTICE:
Page 5219
Required Tools & Equipment
Repair Procedure Overview
^ Confirm noise is coming from the rear of the vehicle and changes with vehicle speed.
^ Install ChaSSiSEAR(TM) (or equivalent) and isolate the noise to the rear wheel bearing.
^ Remove the rear axle shaft assembly.
^ Install new rear wheel bearing brake caliper bracket and seals.
^ Reinstall rear axle shaft assembly and confirm the noise is no longer present.
Repair Procedure
1. Test drive the vehicle and confirm the customer complaint.
Does the noise increase and decrease with vehicle speed?
^ YES - Go to step 2.
^ NO - This TSB does NOT apply. Refer to the Repair Manual for further diagnosis.
Locations
Neutral Safety Switch: Locations
1UR-FE STARTING: STARTING SYSTEM: PARTS LOCATION
Page 6186
5. INSTALL POWER OUTLET SOCKET ASSEMBLY
(a) Attach the claw to install the power outlet socket.
6. INSTALL CONSOLE BOX BEZEL
(a) Attach the 5 claws to install the console box bezel.
(b) Connect the connector.
7. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding
/ Trim/Dashboard / Instrument Panel/Service
and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
Page 3543
INSPECTION PROCEDURE
PROCEDURE
1. CHECK HARNESS AND CONNECTOR (ECM - BATTERY AND BODY GROUND)
(a) Disconnect the A24 and D74 ECM connectors.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(c) Measure the voltage according to the value(s) in the table below.
Standard voltage:
Front Seat Heater Switch
Seat Heater Switch: Diagrams Front Seat Heater Switch
Page 6098
Starter Motor: Diagrams Starter
Page 1224
Power Steering Pressure Switch: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: POWER STEERING OIL PRESSURE SWITCH:
REMOVAL
1. REMOVE FAN AND GENERATOR V BELT
(a) Remove the fan and generator V belt See: Engine, Cooling and Exhaust/Engine/Drive Belts,
Mounts, Brackets and Accessories/Drive
Belt/Service and Repair/Removal.
2. REMOVE FRONT WHEEL
3. REMOVE FRONT FENDER APRON SEAL RH See: Engine, Cooling and Exhaust/Exhaust
System/Exhaust Manifold/Service and
Repair/Removal
4. DRAIN POWER STEERING FLUID
5. REMOVE POWER STEERING OIL PRESSURE SWITCH
(a) Disconnect the power steering oil pressure switch connector.
(b) Remove the power steering oil pressure switch.
(c) Remove the O-ring.
Page 6706
Fuse Block: Diagnostic Aids
Continuity and Resistance Check
CONTINUITY AND RESISTANCE CHECK
Disconnect the battery terminal or wire so there is no voltage between the check points.
Contact the two leads of an ohmmeter to each of the check points.
Multiplex Communication
Information Bus: Tools and Equipment Multiplex Communication
PREPARATION: MULTIPLEX COMMUNICATION: RECOMMENDED TOOLS
Components
Wiring Harness: Service and Repair Components
A760F AUTOMATIC TRANSMISSION: TRANSMISSION WIRE: COMPONENTS
Page 1800
^ Calibration ID(s) [Refer to the Calibration Identification Chart for the NEW CALIBRATION ID]
^ Dealer Code
^ Repair Date
^ Change Authority [This TSB number]
B. Affix the Authorized Modifications Label to the vehicle at the location shown in Figure 1. The
Authorized Modifications Label is available
through the MDC P/N 00451-00001-LBL.
Initial Inspection and Diagnostic Overview
Neutral Safety Switch: Initial Inspection and Diagnostic Overview
A760F AUTOMATIC TRANSMISSION: PARK / NEUTRAL POSITION SWITCH: ON-VEHICLE
INSPECTION
1. INSPECT PARK/NEUTRAL POSITION SWITCH ASSEMBLY
(a) Apply the parking brake and turn the ignition switch to ON.
(b) Depress the brake pedal and check that the engine starts when the shift lever is in N or P, but
does not start when the shift lever is in other
positions.
(c) Check that the back-up light illuminates and the reverse warning buzzer sounds when the shift
lever is in R, but do not function when the shift
lever is in other positions.
Page 6869
Power Distribution Relay: Diagrams
Page 1198
Engine Bank Identification
Page 7895
Solar Sensor: Testing and Inspection
AIR CONDITIONING: SOLAR SENSOR (for Automatic Air Conditioning System): INSPECTION
1. INSPECT AUTOMATIC LIGHT CONTROL SENSOR (SOLAR SENSOR)
(a) Connect the battery's positive (+) lead to terminal 6 and the negative (-) lead to terminal 3, then
measure the voltage according to the value(s)
in the table below.
Standard voltage:
NOTICE: The connection procedure for using a digital tester such as a TOYOTA electrical tester is
shown above.
HINT *
As the inspection light is moved away from the sensor, the voltage decreases.
* Use an incandescent light for inspection. Bring it within 30 cm (11.8 in.) of the solar sensor.
(b) If the result is not as specified, replace the solar sensor.
Front Door Courtesy Switch
Door Switch: Testing and Inspection Front Door Courtesy Switch
LIGHTING: FRONT DOOR COURTESY SWITCH: INSPECTION
1. INSPECT FRONT DOOR COURTESY SWITCH
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the switch.
Page 4715
Standard resistance:
(4) If the resistance is not as specified, repair or replace the harness or connector.
(c) Check the 4WD control switch.
(1) Turn the ignition switch OFF.
(2) Connect the L1 switch connector.
(3) Connect the A25 and A26 ECU connectors.
(4) Measure the voltage according to the value(s) in the table below.
Standard voltage:
(5) If the voltage is not as specified, check the 4WD control ECU.
(d) Check the 4WD control ECU.
(1) Disconnect the L1 switch connector.
(2) Measure the voltage according to the value(s) in the table below.
Page 6865
Power Distribution Module: Service and Repair Installation
OTHER SYSTEM: VOLTAGE INVERTER (for CrewMax): INSTALLATION
1. INSTALL VOLTAGE INVERTER ASSEMBLY
(a) Connect the voltage inverter connector.
(b) Install the voltage inverter with the 2 bolts.
Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
2. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY LH See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (for CrewMax)/Installation
3. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH
4. INSTALL REAR DOOR SCUFF PLATE LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for
CrewMax)/Installation
5. INSTALL BACK PANEL TRIM LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for
CrewMax)/Installation
6. INSTALL BACK PANEL TRIM RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for
CrewMax)/Installation
Diagrams
Seat Memory Switch: Diagrams
Page 5959
Establish conditions in which voltage is present at the check point.
Example:
- [A] - Ignition SW on
- [B] - Ignition SW and SW1 on
- [C] - Ignition SW, SW1 and Relay on (SW2 off)
Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or component terminal.
This check can be done with a test light instead of a voltmeter.
Electronic Circuit Inspection Procedure
Page 6170
Auxiliary Power Outlet: Connector Views
Power Outlet Socket
Page 7693
(d) Connect the discharge hose on the cooler condenser with the bolt.
Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)
NOTICE: *
When tightening the bolt, do not allow any tools to contact the pipe.
* When tightening the bolt, hold a part of the pipe near the connector.
5. INSTALL RADIATOR ASSEMBLY
(a) for 1GR-FE:
Install the radiator See: Engine, Cooling and Exhaust/Cooling System/Radiator/Service and
Repair/Installation.
(b) for 1UR-FE:
Install the radiator See: Engine, Cooling and Exhaust/Cooling System/Radiator/Service and
Repair/Installation.
(c) for 3UR-FE:
Install the radiator See: Engine, Cooling and Exhaust/Cooling System/Radiator/Service and
Repair/Installation.
(d) for 3UR-FBE:
Install the radiator See: Engine, Cooling and Exhaust/Cooling System/Radiator/Service and
Repair/Installation.
6. CONNECT OIL COOLER HOSE (w/ Air Cooled Transmission Oil Cooler)
(a) Connect the 2 oil cooler hoses and attach the 2 clips.
7. INSTALL FRONT BUMPER COVER
(a) for Steel Type Bumper:
Install the front bumper cover See: Body and Frame/Bumper/Front Bumper/Service and
Repair/Removal and Replacement/Front Bumper (for Steel Type Bumper)/Installation.
(b) for Resin Type Bumper:
Install the front bumper cover See: Body and Frame/Bumper/Front Bumper/Service and
Repair/Removal and Replacement/Front Bumper (for Resin Type Bumper)/Installation.
8. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
9. CHARGE REFRIGERANT See: Service and Repair
10. WARM UP ENGINE See: Service and Repair
11. CHECK FOR REFRIGERANT GAS LEAK See: Service and Repair
12. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Reading and Clearing Diagnostic Trouble
Codes/Check Mode Procedure.
Page 6776
Symbols Used Within Diagrams
Symbols Used Within Diagrams
Page 6264
Use a volt/ohmmeter with high impedance (10 kohms/V minimum) for troubleshooting of the
electrical circuit.
Disconnection of Male and Female Connectors
DISCONNECTION OF MALE AND FEMALE CONNECTORS
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Finding A Short Circuit
FINDING A SHORT CIRCUIT
Page 7640
"Case1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (/\ Mark) and pull the terminal retainer
up to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Page 6592
[A] For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
"Case1" Raise the terminal retainer up to the temporary lock position.
Page 842
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to disable the SRS system.
2. REMOVE REAR WHEEL
3. REMOVE REAR SPEED SENSOR LH
(a) Disconnect the speed sensor connector (labeled A).
(b) Remove the nut (labeled B) and speed sensor (labeled C).
4. REMOVE REAR SPEED SENSOR RH
(a) Disconnect the speed sensor connector (labeled A).
(b) Remove the nut (labeled B) and speed sensor (labeled C).
5. REMOVE SKID CONTROL SENSOR WIRE
(a) Disconnect the sensor connector (labeled A).
(b) Detach the 7 clips (labeled B).
(c) Remove the bolt (labeled C).
(d) Remove the nut (labeled D) and skid control sensor wire.
Installation
BRAKE CONTROL: REAR SPEED SENSOR: INSTALLATION
Page 6803
3. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE
HINT The diagnostic system in the TOYOTA TUNDRA has various functions.
* The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU
memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a
previous malfunction's DTC can be checked by a technician during troubleshooting.
* Another function is the Input Signal Check, which checks if the signals from various switches are
sent to the ECU correctly.
* By using these functions, the problem areas can be narrowed down and troubleshooting is more
effective. Diagnostic functions are incorporated in the following systems in the TOYOTA TUNDRA.
Page 7314
1. REMOVE FRONT WHEEL
2. REMOVE FRONT SHOCK ABSORBER WITH COIL SPRING LH
(a) Remove the front shock absorber with coil spring See: Suspension Strut / Shock
Absorber/Service and Repair/Removal and
Replacement/Front Shock Absorber/Removal.
3. DISCONNECT SKID CONTROL SENSOR WIRE
(a) Remove the 2 bolts and disconnect the sensor wire from the steering knuckle and suspension
upper arm.
4. DISCONNECT STEERING KNUCKLE LH
(a) Support the front suspension lower arm LH with a jack.
(b) Remove the clip and the nut.
(c) Using SST, disconnect the upper ball joint from the steering knuckle.
SST : 09628-62011
5. REMOVE FRONT FENDER APRON SEAL LH
(a) Using a clip remover, remove the 6 clips and apron seal.
6. REMOVE FRONT FENDER APRON SEAL REAR LH
Page 5352
Transmission Speed Sensor: Service and Repair Removal
A760F AUTOMATIC TRANSMISSION: SPEED SENSOR: REMOVAL
1. REMOVE SPEED SENSOR NT
(a) Disconnect the sensor connector.
(b) Remove the bolt and sensor.
(c) Remove the O-ring from the sensor.
2. REMOVE SPEED SENSOR SP2
(a) Disconnect the sensor connector.
(b) Remove the bolt and sensor.
(c) Remove the O-ring from the sensor.
Front Lower Suspension Arm
Ball Joint: Testing and Inspection Front Lower Suspension Arm
SUSPENSION: FRONT LOWER SUSPENSION ARM: INSPECTION
1. INSPECT FRONT NO. 1 SUSPENSION ARM LOWER SUB-ASSEMBLY LH
(a) As shown in the illustration, move the ball joint stud back and forth 5 times before installing the
nut.
(b) Using a torque wrench, turn the nut continuously at a rate of 3 to 5 seconds per turn and take
the torque reading on the fifth turn.
Standard turning torque:
3.0 to 10.0 N*m (31 to 102 kgf*cm, 27 to 89 in.*lbf)
(c) Check for any cracks and grease leaks on the ball joint dust cover.
Page 316
Body Control Module: Locations LIN Communication System
MULTIPLEX COMMUNICATION: LIN COMMUNICATION SYSTEM: PARTS LOCATION
Page 2482
(b) Using a 10 mm bi-hexagon wrench, uniformly loosen the 10 cylinder head bolts in the sequence
shown in the illustration. Remove the 10
cylinder head bolts and plate washers.
HINT Be sure to arrange the removed parts for each installation position separately.
NOTICE: *
Be careful not to drop washers into the cylinder head.
* Head warpage or cracking could result from removing bolts in an incorrect order.
7. REMOVE CYLINDER HEAD GASKET RH
Installation
1UR-FE ENGINE MECHANICAL: CYLINDER HEAD GASKET (for Bank 2): INSTALLATION
1. INSPECT CYLINDER HEAD SET BOLT See: Testing and Inspection/Engine Unit
2. INSPECT CYLINDER HEAD SUB-ASSEMBLY RH See: Cylinder Head Assembly/Testing and
Inspection
3. INSTALL CYLINDER HEAD GASKET RH
(a) Check the piston protrusions for each cylinder.
(1) Clean the cylinder block with solvent.
(2) Set the piston of the cylinder to be measured to slightly ATDC.
(b) Place the cylinder head gasket on the cylinder block surface with the front face of the Lot No.
stamp upward.
NOTICE: *
Be careful of the installation direction.
* Make sure that no oil is on the front end (indicated by the arrows) of the cylinder head gasket.
4. INSTALL CYLINDER HEAD SUB-ASSEMBLY RH
(a) Place the cylinder head on the cylinder block.
NOTICE:
Page 4191
Page 7004
Driver Side J/B Inner Circuit
Page 6611
If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness
or connector in that circuit in the past. Check the wire harness and connectors.
B -- SYSTEM NORMAL
A -- TROUBLESHOOTING OF EACH PROBLEM SYMPTOM
The problem is still occurring in a place other than the diagnostic circuit (the DTC displayed first is
either for a past problem or a secondary problem).
4. SYMPTOM SIMULATION
HINT The most difficult case in troubleshooting is when no problem symptoms occur. In such a
case, a thorough problem analysis must be carried out. A simulation of the same or similar
conditions and environment in which the problem occurred in the customer's vehicle should be
carried out. No matter how much skill or experience a technician has, troubleshooting without
confirming the problem symptoms will lead to important repairs being overlooked and mistakes or
delays.
For example:
With a problem that only occurs when the engine is cold or as a result of vibration caused by the
road during driving, the problem can never be determined if the symptoms are being checked on a
stationary vehicle or on a vehicle with a warmed-up engine. Vibration, heat or water penetration
(moisture) is difficult to reproduce. The symptom simulation tests below are effective substitutes for
the conditions and can be applied on a stationary vehicle.
Important points in the symptom simulation test:
In the symptom simulation test, the problem symptoms as well as the problem area or parts must
be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then,
connect the tester and carry out the symptom simulation test, judging whether the circuit being
tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the
problem symptoms table for each system to narrow down the possible causes.
To reproduce DTCs, it is necessary to satisfy the respective DTC detection conditions.
(a) VIBRATION METHOD:
When a malfunction seems to occur as a result of vibration.
(1) PART AND SENSOR
Apply slight vibration with a finger to the part of the sensor suspected to be the cause of the
problem, and check whether or not the malfunction occurs.
NOTICE: Applying strong vibration to relays may open them.
Page 4405
(a) Remove the fuel suction with pump and gauge tube See: Fuel Pump/Service and
Repair/Removal and Replacement/Removal.
2. REMOVE FUEL SENDER GAUGE ASSEMBLY
(a) Disconnect the fuel sender gauge connector.
(b) Press down on the sender gauge claw labeled A. Then slide the sender gauge upward to
remove it.
Installation
1UR-FE FUEL: FUEL SENDER GAUGE ASSEMBLY: INSTALLATION
1. INSTALL FUEL SENDER GAUGE ASSEMBLY
(a) Set the sender gauge to the fuel sub tank. Then slide the sender gauge downward to install it.
(b) Connect the fuel sender gauge connector.
2. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY
(a) Install the fuel suction with pump and gauge tube See: Fuel Pump/Service and Repair/Removal
and Replacement/Installation.
Page 6329
Multiple Junction Connector: Locations Wire and Wire In Seat [Separate Seat]
PZ1-ZU1
PZ1-ZU1
Page 6268
[A] For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
"Case1" Raise the terminal retainer up to the temporary lock position.
Locations
Throttle Position Sensor: Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 355
4. Attach the Authorized Vehicle Modification Label.
Modifications to ECU calibrations MUST be recorded and properly displayed on the vehicle using
the Authorized Modification Label.
Techstream Preparation
Selecting the TIS Techstream VIM or the Mongoose MFC VIM.
Techstream software requires a VIM selection before you can use the Mongoose MFC VIM.
If using TIS Techstream no changes are needed.
Perform the following:
1. Select Setup from the Techstream Main Menu screen.
2. Select VIM Select from the Setup drop down menu.
3. Select the correct Interface Setup from the drop down list.
^ If using Techstream Lite select Mongoose MFC.
NOTE
Page 4283
M. Turn ignition OFF for a minimum of 10 seconds. Then click Next.
N. Turn ignition to the ON position. Then click Next.
0. Confirm all calibrations were updated as specified in the service bulletin. Then click Finish.
Page 7699
Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Column Shift Type)/Removal.
(c) for CrewMax:
Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Column Shift Type)/Removal.
4. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP LH (for Regular Cab)
5. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP LH (for Double cab, CrewMax)
6. REMOVE FRONT PILLAR GARNISH LH
7. REMOVE CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service
and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Removal
8. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal
9. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Removal
10. REMOVE LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY See: Restraint
Systems/Air Bag Systems/Air Bag/Service and
Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Removal
11. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and
Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column
Shift Type)/Removal
12. REMOVE FRONT ASH RECEPTACLE BOX SUB-ASSEMBLY
13. REMOVE LOWER INSTRUMENT CLUSTER FINISH PANEL See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column
Shift Type)/Removal
14. REMOVE INSTRUMENT PANEL CUP HOLDER ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column
Shift Type)/Removal
15. REMOVE INTEGRATION CONTROL AND PANEL ASSEMBLY
(a) Detach the 4 clips.
Page 7976
Removal
SUPPLEMENTAL RESTRAINT SYSTEM: CURTAIN SHIELD AIRBAG ASSEMBLY: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE ROOF HEADLINING ASSEMBLY
HINT *
Refer to the procedures up to "REMOVE ROOF HEADLINING ASSEMBLY" (for Double Cab) See:
Body and Frame/Interior
Page 3809
Engine Temperature Sensor: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: ENGINE COOLANT TEMPERATURE SENSOR:
INSTALLATION
1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR
(a) Install a new gasket to the sensor.
(b) Using a 19 mm ball joint lock nut wrench, install the sensor.
Torque : 20 Nm (200 kgf-cm, 14 ft-lbf)
NOTICE: Use the formula to calculate special torque values for situations where ball joint lock nut
wrench is combined with a torque wrench See: Service Precautions
(c) Connect the sensor connector.
2. ADD ENGINE COOLANT See: Engine, Cooling and Exhaust/Cooling System/Coolant/Service
and Repair
3. INSPECT FOR COOLANT LEAK See: Engine, Cooling and Exhaust/Cooling System/Testing
and Inspection
4. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Installation
5. INSTALL NO. 1 ENGINE UNDER COVER See: Engine, Cooling and Exhaust/Engine/Engine
Lubrication/Engine Oil/Service and
Repair/Replacement
Page 1357
Air Bag Deactivation Switch: Locations Occupant Classification System
SUPPLEMENTAL RESTRAINT SYSTEM: OCCUPANT CLASSIFICATION SYSTEM: PARTS
LOCATION
Page 9052
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Locations
Air Flow Meter/Sensor: Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 3897
Parts Information
Required Tools & Equipment
Additional TIS Techstream units may be ordered by calling Approved Dealer Equipment (ADE).
TSB Overview
1. Confirm that DTC P0012 and/or P0022 is stored in the ECM.
2. Diagnose the Oil Control Valves (OCVs) for proper operation.
3. If the OCVs operate correctly replace both intake VVTi gear assemblies following the Repair
Manual.
Diagnostic Procedure
1. Using TIS Techstream confirm that DTC P0012 and/or P0022 is stored in the ECM.
2. Remove the affected Oil Control Valve (OCV) and inspect for debris in the valve or evidence that
the valve is stuck.
3. Check valve operation by applying positive (+) battery voltage to terminal 1 and negative (-)
battery voltage to terminal 2. Valve should move
quickly when voltage is applied. If NOT valve should be replaced.
4. Reinstall the OCVs warm up the engine to over 167°F (75°C) and perform an Active Test using
Tech stream.
Powertrain / Engine and ECT / Active Test / Control the WT System (Bank 1) or (Bank 2)
5. If there is NO debris and the OCV moves with battery voltage and Active Test functions Replace both intake VVTi gears following the repair
procedure below.
Repair Procedure
1. Replace both intake VVTi gears.
Page 1641
Power Window Switch: Testing and Inspection Rear Power Window Switch
WINDSHIELD / WINDOWGLASS: REAR POWER WINDOW SWITCH: INSPECTION
1. INSPECT POWER WINDOW REGULATOR SWITCH ASSEMBLY
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
* If the result is not as specified, replace the regulator switch.
Page 8322
5. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Air Bag Systems/Testing and Inspection/Initial Inspection
and Diagnostic Overview/Diagnosis System
Page 8126
Seat Occupant Classification Module - Air Bag: Diagrams
Page 2034
J/B No.4 - Instrument Panel Center
Page 606
4. REMOVE LICENSE PLATE LIGHT ASSEMBLY RH (for Resin Type Bumper) See: Body and
Frame/Bumper/Rear Bumper/Service and
Repair/Removal and Replacement/Rear Bumper (for Resin Type Bumper)/Removal
5. REMOVE LICENSE PLATE LIGHT ASSEMBLY RH (for Steel Type Bumper) See: Body and
Frame/Bumper/Rear Bumper/Service and
Repair/Removal and Replacement/Rear Bumper (for Steel Type Bumper)/Removal
6. REMOVE REAR BUMPER PAD SUB-ASSEMBLY (for Steel Type Bumper) See: Body and
Frame/Bumper/Rear Bumper/Service and
Repair/Removal and Replacement/Rear Bumper (for Steel Type Bumper)/Removal
7. REMOVE REAR BUMPER PLATE LH (for Steel Type Bumper) See: Body and
Frame/Bumper/Rear Bumper/Service and Repair/Removal and
Replacement/Rear Bumper (for Steel Type Bumper)/Removal
8. REMOVE REAR BUMPER PLATE RH (for Steel Type Bumper) See: Body and
Frame/Bumper/Rear Bumper/Service and Repair/Removal and
Replacement/Rear Bumper (for Steel Type Bumper)/Removal
9. REMOVE REAR BUMPER COVER (for Resin Type Bumper) See: Body and
Frame/Bumper/Rear Bumper/Service and Repair/Removal and
Replacement/Rear Bumper (for Resin Type Bumper)/Removal
10. REMOVE REAR BUMPER BAR (for Steel Type Bumper) See: Body and Frame/Bumper/Rear
Bumper/Service and Repair/Removal and
Replacement/Rear Bumper (for Steel Type Bumper)/Removal
11. REMOVE NO. 1 ULTRASONIC SENSOR
(a) While pushing down on the lever with a finger to release the one claw, detach the claw on the
other side to remove the ultrasonic sensor.
HINT The type of claw on the top and bottom of the sensor are different. Observe the claws
carefully before removing the sensor.
12. REMOVE NO. 1 ULTRASONIC SENSOR RETAINER
(a) Detach the 2 claws and remove the sensor retainer from the rear bumper.
13. REMOVE NO. 2 ULTRASONIC SENSOR
(a) While pushing down on the lever with a finger to release the one claw, detach the claw on the
other side to remove the ultrasonic sensor.
Page 6139
Page 635
(a) for Regular Cab:
Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular Cab)/Removal.
(b) for Double Cab:
Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Removal.
(c) for CrewMax:
Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for CrewMax)/Removal.
2. REMOVE COWL SIDE TRIM BOARD LH
(a) for Regular Cab:
Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular Cab)/Removal.
(b) for Double Cab:
Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Removal.
(c) for CrewMax:
Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for CrewMax)/Removal.
3. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal
4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Floor Shift Type)/Removal
5. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
6. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal
7. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding
/ Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
8. REMOVE REAR UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
9. REMOVE CENTER LOWER INSTRUMENT PANEL FINISH PANEL See: Body and
Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
10. REMOVE INTEGRATION CONTROL AND PANEL ASSEMBLY
Page 3828
Manifold Pressure/Vacuum Sensor: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: MANIFOLD ABSOLUTE PRESSURE SENSOR:
INSTALLATION
1. INSTALL MANIFOLD ABSOLUTE PRESSURE SENSOR
(a) Install a new O-ring to the manifold absolute pressure sensor.
(b) Install the manifold absolute pressure sensor with the screw.
Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)
(c) Connect the manifold absolute pressure sensor connector.
2. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Installation
Page 9383
3. Loosen and remove the No.3 cab mount nut on the bottom of each cab mount. These will be
reused when installing the new No.3 cab mount bolts.
4. Loosen and remove the two bolts on top of each of the cab mounts and save them for reuse.
5. Pull the carpet back in the rear of the cab and remove the body plugs to expose the cab mount
bolts.
Page 1495
* In the DTC check, it is very important to determine whether the problem indicated by the DTC is
either: 1) still occurring; or 2) occurred in the past but has since returned to normal. In addition, the
DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs
should be checked before and after confirmation of symptoms (i.e., whether or not problem
symptoms exist) to determine current system conditions, as shown in the flowchart below.
* Never skip the DTC check. Failing to check DTCs may, depending on the case, result in
unnecessary troubleshooting for systems operating normally or lead to repairs not related to the
problem. Follow the procedures listed in the flowchart in the correct order.
* The following flowchart shows how to proceed with troubleshooting using the DTC check.
Directions from the flowchart will indicate how to proceed either to DTC troubleshooting or to the
troubleshooting of each problem symptom.
1. DTC CHECK
NEXT -- Continue to next step.
2. MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR MEMORY
NEXT -- Continue to next step.
3. SYMPTOM CONFIRMATION
B -- Go to step 5 A -- Continue to next step.
4. SIMULATION TEST USING SYMPTOM SIMULATION METHODS
NEXT -- Continue to next step.
5. DTC CHECK
B -- TROUBLESHOOTING OF PROBLEM INDICATED BY DTC A -- Continue to next step.
6. SYMPTOM CONFIRMATION
Page 5189
Removal
AXLE: REAR AXLE SHAFT: REMOVAL
HINT *
Use the same procedures for the LH side and RH side.
* The procedures listed below are for the LH side.
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE REAR WHEEL LH
3. DRAIN BRAKE FLUID See: Brakes and Traction Control/Hydraulic System/Brake
Hose/Line/Service and Repair/Rear Brake Flexible
Hose/Removal
Locations
Steering Column Control Module: Locations
Instrument Panel (Floor Shift)
Instrument Panel (Column Shift)
Page 7509
Tire Pressure Warning Reset Switch: Service and Repair Installation
TIRE AND WHEEL: TIRE PRESSURE WARNING RESET SWITCH: INSTALLATION
1. INSTALL TIRE PRESSURE WARNING RESET SWITCH
(a) Attach the 2 claws to install the reset switch.
(b) Connect the switch connector.
2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Installation
3. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
4. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Installation
5. INSTALL FRONT DOOR SCUFF PLATE LH (for Double Cab, for CrewMax) See: Body and
Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation
6. INSTALL FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Installation
Page 1681
for Regular Cab of Long Deck
for Double Cab of Standard Deck
Page 7925
(b) With the lower No. 1 instrument panel airbag removed from the vehicle, perform a visual check.
If there are any defects as mentioned below,
replace the lower No. 1 instrument panel airbag with a new one:
* Cuts, minute cracks or marked discoloration on the lower No. 1 instrument panel airbag.
* Cracks or other damage to the connector.
* Deformation or cracks on the instrument panel reinforcement.
CAUTION: For removal and installation procedures of the lower No. 1 instrument panel airbag, be
sure to follow the correct procedure.
Front Passenger Airbag Assembly
SUPPLEMENTAL RESTRAINT SYSTEM: FRONT PASSENGER AIRBAG ASSEMBLY:
ON-VEHICLE INSPECTION
1. CHECK FRONT PASSENGER AIRBAG ASSEMBLY (VEHICLE NOT INVOLVED IN
COLLISION)
(a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnosis System.
(b) With the front passenger airbag installed on the vehicle, perform a visual check. If there are any
defects as mentioned below, replace the
instrument panel with a new one:
Cuts, minute cracks or marked discoloration on the instrument panel around the front passenger
airbag.
2. CHECK FRONT PASSENGER AIRBAG ASSEMBLY (VEHICLE INVOLVED IN COLLISION
AND AIRBAG HAS NOT DEPLOYED)
(a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnosis System.
Page 9013
"Case1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (/\ Mark) and pull the terminal retainer
up to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Page 4136
Page 8987
(a) Connect the connector.
(b) Attach the 4 clips to install the panel.
3. INSTALL INSTRUMENT PANEL CUP HOLDER ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column
Shift Type)/Installation
4. INSTALL LOWER INSTRUMENT CLUSTER FINISH PANEL See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column
Shift Type)/Installation
5. INSTALL FRONT ASH RECEPTACLE BOX SUB-ASSEMBLY
6. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column
Shift Type)/Installation
7. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Installation
8. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
9. INSTALL CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service
and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
10. INSTALL COWL SIDE TRIM BOARD LH
(a) for Regular Cab:
Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular Cab)/Installation.
(b) for Double Cab:
Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Installation.
(c) for CrewMax:
Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for CrewMax)/Installation.
Page 1009
Parking Brake Warning Switch: Locations From 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Driver Side Squib Circuit
Air Bag: Diagrams Driver Side Squib Circuit
Components
Knock Sensor: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: COMPONENTS
Page 5578
Brake Fluid Pump Relay: Locations From 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 1330
* In the DTC check, it is very important to determine whether the problem indicated by the DTC is
either: 1) still occurring; or 2) occurred in the past but has since returned to normal. In addition, the
DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs
should be checked before and after confirmation of symptoms (i.e., whether or not problem
symptoms exist) to determine current system conditions, as shown in the flowchart below.
* Never skip the DTC check. Failing to check DTCs may, depending on the case, result in
unnecessary troubleshooting for systems operating normally or lead to repairs not related to the
problem. Follow the procedures listed in the flowchart in the correct order.
* The following flowchart shows how to proceed with troubleshooting using the DTC check.
Directions from the flowchart will indicate how to proceed either to DTC troubleshooting or to the
troubleshooting of each problem symptom.
1. DTC CHECK
NEXT -- Continue to next step.
2. MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR MEMORY
NEXT -- Continue to next step.
3. SYMPTOM CONFIRMATION
B -- Go to step 5 A -- Continue to next step.
4. SIMULATION TEST USING SYMPTOM SIMULATION METHODS
NEXT -- Continue to next step.
5. DTC CHECK
B -- TROUBLESHOOTING OF PROBLEM INDICATED BY DTC A -- Continue to next step.
6. SYMPTOM CONFIRMATION
Page 8783
(b) If the result is not as specified, replace the speaker assembly.
Front Door Courtesy Switch
Door Switch: Diagrams Front Door Courtesy Switch
Front Shock Absorber
Suspension Strut / Shock Absorber: Testing and Inspection Front Shock Absorber
SUSPENSION: FRONT SHOCK ABSORBER: INSPECTION
1. INSPECT FRONT SHOCK ABSORBER ASSEMBLY LH
(a) Compress and extend the shock absorber rod 4 times or more. Check that there is no abnormal
resistance or unusual sound during the
operation.
* If there is any abnormality, replace the shock absorber assembly with a new one.
NOTICE: When disposing of the shock absorber, see DISPOSAL See: Service and
Repair/Removal and Replacement/Front Shock Absorber/Disposal
Page 389
Page 2943
Knock Sensor: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: INSTALLATION
1. INSTALL KNOCK SENSOR
(a) Install the 4 sensors with the 4 bolts so that the sensors are angled as shown in the illustration.
Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)
NOTICE: The acceptable installation angle of the sensor is between 10° upward and downward
from the horizontal position.
(b) Connect the 4 sensor connectors.
2. INSTALL SEPARATOR CASE
(a) Install the separator case with the 4 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
3. INSTALL INTAKE MANIFOLD
(a) Install the intake manifold See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service
and Repair/Installation.
Page 2748
Parts Information
Calibration Information
Required Tools & Equipment
Repair Procedure
Page 9239
Disassembly
ENGINE HOOD / DOOR: REAR DOOR (for CrewMax): DISASSEMBLY
REAR DOOR TRIM BOARD SUB-ASSEMBLY LH
HINT *
Use the same procedures for the RH side and LH side.
* The procedures listed below are for the LH side.
1. REMOVE REAR DOOR INSIDE HANDLE BEZEL PLUG LH
(a) Using a screwdriver, detach the 4 claws and remove the inside handle bezel.
Emissions - MIL ON/Multiple Air Injection DTC's Set
Air Diverter Valve: Customer Interest Emissions - MIL ON/Multiple Air Injection DTC's Set
T-SB-0350-09
Rev1
October 1, 2009
Air Injection Pump With Water Intrusion: MIL "ON" DTC P04181P0419 and/or P244 #
Service Category Engine/Hybrid System
Section Engine Control
Market USA
Applicability
TSB REVISION NOTICE
May 21, 2010 Rev1:
^ DTCs P0418 and P0419 have been added to the TSB.
^ The Applicable Warranty has been updated in the Warranty Information section. Any previous
printed versions of this service bulletin should be discarded.
Introduction
Some 2010 model year Tundra vehicles built in the Texas plant may exhibit a MIL "ON" condition
with Diagnostic Trouble Code (DTC) P0418, P0419, P2440, P2441, P2442, P2443, P2446, and/or
P2447. This concern may be caused by water intrusion into the air injection pump assembly. Use
the following procedure to address this condition.
Parts Information
Production Change Information
Page 7480
Tire Pressure Module: Service and Repair Installation
TIRE AND WHEEL: TIRE PRESSURE WARNING ECU: INSTALLATION
1. INSTALL TIRE PRESSURE WARNING ECU
(a) Install the ECU with the 2 nuts.
Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
(b) Connect the ECU connector.
2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Installation
3. INSTALL INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
4. INSTALL COWL SIDE TRIM BOARD RH
(a) Install the cowl side trim board RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Installation.
HINT Use the same procedures described for the LH side.
5. INSTALL FRONT DOOR SCUFF PLATE RH (for Double Cab, for CrewMax)
(a) Install the front door scuff plate RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Installation.
HINT Use the same procedures described for the LH side.
6. INSTALL FRONT DOOR SCUFF PLATE RH (for Regular Cab)
(a) Install the front door scuff plate RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Installation.
HINT Use the same procedures described for the LH side.
7. REGISTRATION OF TRANSMITTER ID
(a) Register the transmitter ID See: Testing and Inspection/Programming and
Relearning/Registration.
8. PERFORM INITIALIZATION
(a) Perform initialization See: Testing and Inspection/Programming and Relearning/Initialization.
NOTICE: Be sure to inflate all tires to the proper inflation pressure before initialization.
9. CHECK TIRE PRESSURE AFTER REPAIRS
Diagram Information and Instructions
Multiple Junction Connector: Diagram Information and Instructions
Wiring Color Codes
Abbreviations Used Within Diagrams
Abbreviations Used Within Diagrams
Page 2036
J/B No.6 Assembly - Instrument Panel Center
Page 7073
Steering Column Control Module: Diagrams
Page 7205
Steering Control Module: Service and Repair Removal
POWER STEERING: POWER STEERING ECU (for 1UR-FE): REMOVAL
1. REMOVE FRONT DOOR SCUFF PLATE LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining
(For Double Cab)/Removal
2. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Removal
3. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal
4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Removal
5. REMOVE LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY See: Restraint
Systems/Air Bag Systems/Air Bag/Service and
Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Removal
6. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column
Shift Type)/Removal
7. REMOVE POWER STEERING ECU ASSEMBLY
(a) Disconnect the power steering ECU connector.
(b) Remove the nut and power steering ECU.
Page 710
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the switch.
Page 4014
HINT Make sure the direction of the hose clamp is as shown in the illustration.
(b) Connect the connector.
Page 9015
Push the terminal retainer down to the temporary lock position.
Page 3188
Body Control Module: Locations LIN Communication System
MULTIPLEX COMMUNICATION: LIN COMMUNICATION SYSTEM: PARTS LOCATION
Page 2558
Variable Valve Timing Actuator: Diagrams
Page 3384
4. SYMPTOM CONFIRMATION AND DTC (INCLUDING FREEZE FRAME DATA) CHECK
(a) Visually check the wire harnesses, connectors and fuses for open and short circuits.
(b) Warm up the engine to the normal operating temperature.
(c) Confirm the problem symptoms and conditions, and check for DTCs.
B -- Go to step 6 A -- Continue to next step.
5. DTC CHART
(a) Check the results obtained in the DTC check. Then find the output DTC in the DTC chart. Look
at the "Trouble Area" column for a list of
potentially malfunctioning circuits and / or parts.
NEXT -- Go to step 7
6. PROBLEM SYMPTOMS TABLE
(a) Check the results obtained in the symptom confirmation. Then find the problem symptoms in
the problem symptoms table. Look at the
"Suspected Area" column for a list of potentially malfunctioning circuits and / or parts.
NEXT -- Continue to next step.
7. CIRCUIT INSPECTION OR PARTS INSPECTION
(a) Confirm the malfunctioning circuit or part.
NEXT -- Continue to next step.
8. ADJUST, REPAIR OR REPLACE
(a) Adjust, repair or replace the malfunctioning circuit or parts.
NEXT -- Continue to next step.
9. CONFIRMATION TEST
(a) After the adjustment, repairs or replacement, confirm that the malfunction no longer exists. If the
malfunction does not reoccur, perform a
confirmation test under the same conditions and in the same environment as when the malfunction
occurred the first time.
NEXT -- END
2. CUSTOMER PROBLEM ANALYSIS
HINT *
In troubleshooting, confirm that the problem symptoms have been accurately identified.
Preconceptions should be discarded in order to make an accurate judgment. To clearly understand
what the problem symptoms are, it is extremely important to ask the customer about the problem
and the conditions at the time the malfunction occurred.
* Gather as much information as possible for reference. Past problems that seem unrelated may
also help in some cases.
* The following 5 questions are important points in the problem analysis:
Engine Control System - SFI System
Camshaft Position Sensor: Locations Engine Control System - SFI System
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Components
Four Wheel Drive Selector Switch: Service and Repair Components
JF1A TRANSFER: 4WD CONTROL SWITCH: COMPONENTS
Components
Alarm System Transmitter: Service and Repair Components
ENGINE IMMOBILISER: TRANSPONDER KEY ECU: COMPONENTS
Page 2381
Drive Belt: Service and Repair Removal
1UR-FE ENGINE MECHANICAL: DRIVE BELT: REMOVAL
1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Service and Repair/Removal and
Replacement/Engine Assembly/Removal
2. REMOVE NO. 1 ENGINE UNDER COVER See: Engine Lubrication/Engine Oil/Service and
Repair/Replacement
3. REMOVE FAN AND GENERATOR V BELT
(a) While turning the belt tensioner counterclockwise, align the service hole for the belt tensioner
and the belt tensioner fixing position, and then
insert a bar of dia 5 mm (0.197 in.) into the service hole to fix the belt tensioner in place.
HINT The pulley bolt for the belt tensioner has a left-hand thread.
(b) Remove the V belt.
Service and Repair
Maintenance Required Lamp/Indicator: Service and Repair
Oil Change Reset Procedure
1. Turn the engine switch off with the trip meter A reading shown.
2. While pressing the trip meter reset button, turn the engine switch on.
Without multi-information display
3. Continue to press and hold the button until the trip meter displays 000000.
With multi-information display
3. Continue to press and hold the button until "MAINT REQD RESET MODE COMPLETE" appears
in the display.
Navigation Maintenance Item Setting (If equipped)
When the navigation system is turned on, the "Information" screen displays when it is time to
replace a part or certain components.
1. Push the "INFO" button.
2. Touch "Maintenance"
3. Touch the desired button.
"Delete All": To cancel all conditions which have been input.
"Reset All" : To reset the item which has satisfied a condition.
If "ON" is selected, the system gives maintenance information with the "Information" screen when
the system is turned on.
If "OFF" is selected, the "Information" screen is disabled.
When the vehicle needs to be serviced, the touch screen button color will change to orange.
4. Input the conditions.
Notice of "Date": The next maintenance date can be input.
Notice of "Distance": The driving distance until the next maintenance check can be input.
"Delete": To cancel the date and distance conditions.
"Reset": To reset the date and distance conditions.
5. Touch "OK" The screen returns to the "Maintenance" screen.
Note:
- For scheduled maintenance information, please refer to the Scheduled maintenance guide or
Owners manual supplement.
- Depending on your driving or the road conditions, the system may have a time-lag between the
data which has been input and the actual date and driving distance.
Page 5075
SST : 09316-60011
09316-00041
34. INSTALL FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER
35. INSTALL FRONT DIFFERENTIAL CARRIER OIL SEAL
(a) Using SST and a hammer, tap in a new oil seal.
SST : 09502-12010
SST : 09316-60011
09316-00041
Standard oil seal depth:
5.6 to 6.6 mm (0.221 to 0.260 in.)
(b) Coat the lip of the oil seal with MP grease.
36. INSTALL FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY FRONT
(a) Using SST, install the companion flange.
SST : 09950-30012
09951-03010
09953-03010
09954-03010
09955-03030
Page 3984
Required Tools & Equipment
Repair Procedure
1. Using TIS Techstream check if DTC P0418, P0419, P2440, P2441, P2442, P2443, P2446
and/or P2447 are present.
2. Using Techstream perform the manual Air Injection Test (options 1 and 2) to verify if the signal
from the air injection control driver is reaching the
air pumps.
^ The pumps should be heard turning on at this point and there should be battery voltage on pin 2
of the pumps during this test.
^ If there is NO voltage refer to the Repair Manual for air injection control driver diagnosis.
Refer to the Technical Information System (TIS) 2010 model year Tundra Repair Manual:
3. If during the test voltage is present at the pump and the pump is NOT running or the Air
Pressure (gauge) value did NOT increase from 0 to 1 psi on
TIS Techstream with the pump running remove the air pump assemblies for inspection.
Refer to TIS 2010 model year Tundra Repair Manual:
4. With the pumps removed from the vehicle verify if there is liquid or evidence that liquid entered
the pumps.
^ YES - If there is liquid evidence go to step 5.
^ NO - If there is NO evidence of liquid go to step 7.
5. If liquid is present replace the affected pump assembly.
Refer to TIS 2010 model year Tundra Repair Manual:
Page 3205
Crankshaft Position Sensor: Locations Ignition System
1UR-FE IGNITION: IGNITION SYSTEM: PARTS LOCATION
Page 6725
General Information
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: GENERAL
INFORMATION
* A large number of ECU controlled systems are used in the TOYOTA TUNDRA. In general, ECU
controlled systems are considered to be very intricate, requiring a high level of technical knowledge
to troubleshoot. However, most problem checking procedures only involve inspecting the ECU
controlled system's circuits one by one. An adequate understanding of the system and a basic
knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and
necessary repairs.
1. TROUBLESHOOTING PROCEDURES
* The troubleshooting procedures consist of diagnosis procedures for when a DTC is stored and
diagnosis procedures for when no DTC is stored. The basic idea is explained in the following table.
* Vehicle systems are complex and use many ECUs that are difficult to inspect independently.
Therefore, a process of elimination is used, where components that can be inspected individually
are inspected, and if no problems are found in these components, the related ECU is identified as
the problem and replaced.
* It is extremely important to ask the customer about the environment and the conditions present
when the problem occurred (Customer Problem Analysis). This makes it possible to simulate the
conditions and confirm the symptom. If the symptom cannot be confirmed or the DTC does not
recur, the malfunctioning part may not be identified using the troubleshooting procedure, and the
ECU for the related system may be replaced even though it is not defective. If this happens, the
original problem will not be solved.
* In order to prevent endless expansion of troubleshooting procedures, the troubleshooting
procedures are written with the assumption that multiple malfunctions do not occur simultaneously
for a single problem symptom.
* To identify the malfunctioning part, troubleshooting procedures narrow down the target by
separating components, ECUs and wire harnesses during the inspection. If the wire harness is
identified as the cause of the problem, it is necessary to inspect not only the connections to
components and ECUs but also all of the wire harness connectors between the component and the
ECU.
DIAGNOSTIC TESTER
2. DESCRIPTION
System data and the Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector
3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the Techstream* to
check for a malfunction and perform repairs.
HINT *: Techstream is the name for the diagnostic tester in North America.
3. DATA LINK CONNECTOR 3 (DLC3)
(a) The vehicle's ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of
the DLC3 complies with SAE J1962 and
matches the ISO 15765-4 format.
Page 6962
Page 4838
* When you have replaced the transmission hose and/or output shaft oil seal, proceed to the "Fluid
Temperature Check" procedures.
3. TRANSMISSION FILL
(a) Remove the refill plug and overflow plug.
(b) Fill the transmission through the refill hole until fluid begins to trickle out of the overflow tube.
(c) Reinstall the overflow plug.
(d) Fill the transmission with the amount of fluid listed in the table below.
Reference Capacity:
(e) Install the refill plug.
HINT If you cannot fill the listed amount of fluid, perform the following:
(1) Start the engine and idle it.
NOTICE: Check that electrical systems such as the air conditioning system, audio system and
lighting system are off.
(2) Move the shift lever through the entire gear range to circulate the fluid.
(3) Wait for 30 seconds with the engine idling.
(4) Stop the engine.
(5) Remove the refill plug.
(6) Fill the transmission with the remaining fluid until the amount in the table has been filled.
(7) Install the refill plug.
4. FLUID TEMPERATURE CHECK
Page 9203
Page 7796
Refrigerant Pressure Sensor / Switch: Locations Air Conditioning System (for Manual Air
Conditioning System)
AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Manual Air Conditioning System):
PARTS LOCATION
Page 6337
Multiple Junction Connector: Diagnostic Aids
Continuity and Resistance Check
CONTINUITY AND RESISTANCE CHECK
Disconnect the battery terminal or wire so there is no voltage between the check points.
Contact the two leads of an ohmmeter to each of the check points.
Page 1211
without SST - Torque : 44 Nm (449 kgf-cm, 32 ft-lbf)
with SST - Torque : 40 Nm (408 kgf-cm, 30 ft-lbf)
HINT *
Use a torque wrench with a fulcrum length of 30 cm (11.8 in.). When using a torque wrench with a
fulcrum length that is not 30 cm (11.8 in.), calculate the torque specification for the torque wrench
and SST based on the "without SST" torque specification See: Service Precautions
* Make sure SST and the wrench are connected in a straight line.
(c) for 2WD:
Connect the air fuel ratio sensor connector.
2. INSTALL FRONT NO. 2 EXHAUST PIPE ASSEMBLY (for 4WD)
(a) Connect the front No. 2 exhaust pipe to the exhaust pipe support.
(b) Install a new gasket and the front No. 2 exhaust pipe to the exhaust manifold LH with 3 new
nuts.
Torque : 54 Nm (554 kgf-cm, 40 ft-lbf)
(c) Connect the air fuel ratio sensor connector.
(d) Connect the heated oxygen sensor connector.
3. INSTALL AIR FUEL RATIO SENSOR (for Bank 2 Sensor 1)
(a) Install the sensor to the exhaust pipe by hand.
(b) Using SST, tighten the sensor.
SST : 09224-00010
without SST - Torque : 44 Nm (449 kgf-cm, 32 ft-lbf)
Page 3612
Oxygen Sensor: Diagrams Heated Oxygen Sensor
Page 9339
Tires - Pressure Compensation And Adjustment
Tires: Technical Service Bulletins Tires - Pressure Compensation And Adjustment
T-SB-0345-08
Rev2
November 6, 2008
Tire Inflation Pressure Compensation and Adjustment
Service Category Suspension
Section Tire/Wheel
Market USA
Applicability
TSB REVISION NOTICE
^ December 22, 2009 Rev2:
^ Applicability has been updated to include 2010 model year Prius PHV model and 2011 vehicles.
Any previous printed versions of this service bulletin should be discarded.
TSB REVISION NOTICE
^ May 15, 2009 Rev1:
^ Applicability has been updated to include 2010 model year vehicles, and 2009 - 2010 model year
Venza.
^ Figure 1 has been updated, and Celsius temperatures have been removed from the bulletin.
Any previous printed versions of this service bulletin should be discarded.
Page 3658
^ Calibration ID(s) [Refer to the Calibration Identification Chart for the NEW CALIBRATION ID]
^ Dealer Code
^ Repair Date
^ Change Authority [This TSB number]
B. Affix the Authorized Modifications Label to the vehicle at the location shown in Figure 1. The
Authorized Modifications Label is available
through the MDC P/N 00451-00001-LBL.
Page 6420
Power Distribution Module: Service and Repair Removal
OTHER SYSTEM: VOLTAGE INVERTER (for CrewMax): REMOVAL
1. REMOVE BACK PANEL TRIM LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for
CrewMax)/Removal
2. REMOVE BACK PANEL TRIM RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for
CrewMax)/Removal
3. REMOVE REAR DOOR SCUFF PLATE LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining
(for CrewMax)/Removal
4. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH
5. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY LH See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (for CrewMax)/Removal
6. REMOVE VOLTAGE INVERTER ASSEMBLY
(a) Remove the 2 bolts.
(b) Disconnect the voltage inverter connector and removal the voltage inverter.
Page 5199
(f) Install the 6 balls.
HINT Apply grease onto the balls to keep them from falling out.
(g) Pack the inboard joint shaft and boot with grease in the boot kit.
Standard grease capacity:
380 to 400 g (13.3 to 14.1 oz.)
(h) Align the matchmarks placed before removal, and install the inboard joint shaft to the outboard
joint shaft.
(i) Install a new snap ring.
(j) Temporarily install the boot to the inboard joint shaft.
HINT Make sure that the boot is on the shaft groove.
(k) Check that the 2 boots are not stretched or contracted when the drive shaft is at standard
length.
Standard drive shaft length (A):
625.8 mm (2.05 ft.)
Page 5030
Replacement/Front Propeller Shaft Assembly/Removal.
5. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH
(a) Remove the front drive shaft See: Drive Axles, Bearings and Joints/Axle Shaft
Assembly/Service and Repair/Removal and
Replacement/Front Drive Shaft Assembly/Removal.
6. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH
HINT Use the same procedure as the LH side.
7. REMOVE FRONT DIFFERENTIAL CARRIER ASSEMBLY
(a) Remove the bolt and disconnect the front differential breather tube bracket.
(b) Disconnect the automatic disconnecting differential actuator hose.
(c) Disconnect the automatic disconnecting differential actuator connector.
(d) Support the front differential with a jack.
(e) Remove the A, B, C, D and E bolts.
(f) Slowly lower the jack, and remove the front differential carrier.
(g) Remove the F and G bolts, and differential support.
Installation
DIFFERENTIAL: FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD): INSTALLATION
1. INSTALL FRONT DIFFERENTIAL CARRIER ASSEMBLY
(a) Install the differential support with the F and G bolts.
Torque : 100 Nm (1019 kgf-cm, 74 ft-lbf)
(b) Using a jack, slowly raise the front differential carrier assembly to its installation position.
(c) Temporarily install the A, B, C, D and E bolts.
(d) Tighten the A bolt.
Torque : 120 Nm (1224 kgf-cm, 89 ft-lbf)
(e) Tighten the B and C bolts.
Page 7043
Standard vehicle height (unloaded vehicle):
for Double Cab of Long Deck
Standard vehicle height (unloaded vehicle):
for CrewMax of standard deck
Page 7042
Standard vehicle height (unloaded vehicle):
for Regular Cab of Long Deck
Standard vehicle height (unloaded vehicle):
for Double Cab of Standard Deck
Page 8541
Cellular Phone Microphone: Service and Repair Removal
AUDIO / VISUAL: MICROPHONE AMPLIFIER: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE ROOF CONSOLE BOX ASSEMBLY
(a) Remove the roof console box See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double
Cab)/Removal.
3. REMOVE MICROPHONE AMPLIFIER ASSEMBLY
(a) Disconnect the connector.
(b) Detach the 2 claws and clip, and remove the microphone.
Page 1241
Variable Valve Timing Actuator Position Sensor: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: VVT SENSOR: INSTALLATION
1. INSTALL VVT SENSOR
(a) Install the 4 sensors with the 4 bolts.
Page 5044
SST : 09330-00021
09330-00030
(d) Coat the threads of the nut with hypoid gear oil.
(e) Install the nut by tightening it until the standard preload is reached.
Torque : 441 Nm (4497 kgf-cm, 325 ft-lb for less)
NOTICE: As there is no spacer, tighten the nut a little at a time, being careful not to overtighten it.
(f) Using a torque wrench, measure the preload of the backlash between the drive pinion and ring
gear.
Standard preload (at starting):
HINT Measure the total preload after first turning the bearing clockwise and counterclockwise
several times to make the bearing smooth.
11. INSTALL REAR DIFFERENTIAL CASE ASSEMBLY
(a) Place the 2 bearing outer races on their respective bearings.
NOTICE: Do not interchange the right and left race.
12. INSTALL REAR DIFFERENTIAL BEARING ADJUSTING NUT
(a) Install the 2 adjusting nuts onto the carrier, making sure the nuts are threaded properly.
Page 218
Horn Relay: Testing and Inspection
HORN: INTEGRATION RELAY: ON-VEHICLE INSPECTION
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
NOTICE: *
Some systems need to be initialized after the cable is reconnected See: Testing and
Inspection/Programming and Relearning
* After the ignition switch is turned OFF, the navigation system requires approximately 90 seconds
to record various types of memory and settings. As a result, after turning the ignition switch OFF,
wait 90 seconds or more before disconnecting the cable from the negative (-) battery terminal.
2. REMOVE INTEGRATION RELAY (UNIT E)
(a) Remove the engine room relay block cover.
(b) Using a screwdriver, detach the 2 claws and disconnect the integration relay from the engine
room relay block.
HINT Tape the screwdriver tip before use.
(c) Disconnect the 3 connectors.
3. INSPECT INTEGRATION RELAY (HORN RELAY)
NOTICE: *
Some relays are built into the integration relay (unit E). The integration relay cannot be
disassembled. If there is a malfunction in the circuit of the integration relay, replace the integration
relay.
* The internal circuit of the integration relay is as shown in the illustration below. Inspect the
integration relay using the following procedures.
(a) Measure the resistance of the HORN fuse.
Page 8932
Integrated Accessory Switch Assembly: Service and Repair Removal
METER: DRIVE MONITOR SWITCH: REMOVAL
1. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Panel,
Gauges and Warning Indicators/Instrument Cluster
/ Carrier/Service and Repair/Combination Meter/Removal
2. REMOVE DRIVE MONITOR SWITCH
(a) Detach the 2 claws and remove the monitor switch.
Page 6996
Driver Side J/B - Cowl Side Left
Locations
Throttle Position Sensor: Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 6922
(a) For an open circuit in the wire harness in Fig. 1, check the resistance or voltage, as described
below.
(b) Check the resistance.
(1) Disconnect connectors A and C and measure the resistance between them.
Standard resistance (Fig. 2):
HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally.
If the results match the examples above, an open circuit exists between terminal 1 of connector A
and terminal 1 of connector C.
(2) Disconnect connector B and measure the resistance between the connectors.
Standard resistance (Fig. 3):
* If the results match the examples above, an open circuit exists between terminal 1 of connector
B2 and terminal 1 of connector C.
(c) Check the voltage.
Page 6527
"Case1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (/\ Mark) and pull the terminal retainer
up to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Page 5779
(c) Connect the parking brake switch connector.
2. CONNECT NO. 1 PARKING BRAKE CABLE ASSEMBLY
(a) Connect the parking brake cable to the control pedal.
(b) Using needle-nose pliers, slowly bend down the claw.
NOTICE: Be careful not to damage the parking brake cable or claw.
(c) Install the clip to the control pedal.
(d) Temporarily install the adjustment nut and lock nut.
HINT The nuts will be tightened to a torque specification in the "ADJUST PARKING BRAKE
PEDAL TRAVEL" procedure.
3. CHECK PARKING BRAKE PEDAL TRAVEL See: Adjustments
4. ADJUST PARKING BRAKE PEDAL TRAVEL See: Adjustments
5. INSTALL LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY See: Restraint
Systems/Air Bag Systems/Air Bag/Service and
Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Installation
6. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Installation
7. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
8. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Page 745
Seat Memory Switch: Testing and Inspection
SEAT: SEAT MEMORY SWITCH (w/ Seat Position Memory System): INSPECTION
1. INSPECT SEAT MEMORY SWITCH
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the switch.
Page 5190
4. DISCONNECT REAR BRAKE FLEXIBLE HOSE
(a) Disconnect the brake tube from the flexible hose with union nut wrench while holding the
flexible hose with a wrench.
NOTICE: *
Do not bend or damage the brake tube.
* Do not allow any foreign matter such as dirt and dust to enter the brake tube from the connecting
point.
(b) Remove the clip.
5. DISCONNECT REAR DISC BRAKE CYLINDER ASSEMBLY LH
(a) Remove the 2 bolts and disconnect rear disc brake cylinder.
NOTICE: *
Do not twist or bend the flexible hose.
* Do not disconnect the flexible hose from the disc brake cylinder.
6. REMOVE REAR DISC LH See: Brakes and Traction Control/Disc Brake System/Service and
Repair/Removal and Replacement/Rear
Brake/Removal
7. REMOVE PARKING BRAKE SHOE RETURN TENSION SPRING LH See: Brakes and Traction
Control/Parking Brake System/Service and
Repair/Disassembly
8. REMOVE NO. 1 PARKING BRAKE SHOE ASSEMBLY LH See: Brakes and Traction
Control/Parking Brake System/Service and
Repair/Disassembly
9. REMOVE NO. 2 PARKING BRAKE SHOE ASSEMBLY LH See: Brakes and Traction
Control/Parking Brake System/Service and
Repair/Disassembly
10. REMOVE PARKING BRAKE SHOE LEVER SUB-ASSEMBLY LH See: Brakes and Traction
Control/Parking Brake System/Service and
Repair/Disassembly
11. DISCONNECT NO. 3 PARKING BRAKE CABLE ASSEMBLY See: Brakes and Traction
Control/Parking Brake System/Service and
Repair/Disassembly
12. DISCONNECT REAR SPEED SENSOR LH See: Brakes and Traction Control/Antilock Brakes /
Traction Control Systems/Wheel Speed
Sensor/Service and Repair/Rear Speed Sensor/Removal
13. REMOVE REAR AXLE SHAFT
(a) Remove the 4 nuts and rear axle shaft together with the parking brake plate.
Center Airbag Sensor Assembly (for Column Shift Type)
Impact Sensor: Testing and Inspection Center Airbag Sensor Assembly (for Column Shift Type)
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Column
Shift Type): ON-VEHICLE INSPECTION
1. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION)
(a) Perform a diagnostic system check See: Air Bag Systems/Testing and Inspection/Initial
Inspection and Diagnostic Overview/Diagnosis
System.
2. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND
AIRBAG HAS NOT DEPLOYED)
(a) Perform a diagnostic system check See: Air Bag Systems/Testing and Inspection/Initial
Inspection and Diagnostic Overview/Diagnosis
System.
3. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND
AIRBAG IS DEPLOYED)
(a) Replace the center airbag sensor.
CAUTION: For removal and installation procedures of the center airbag sensor, be sure to follow
the correct procedure.
HINT The center airbag sensor should be replaced after any of the airbags has deployed, as it has
been subjected to the impact.
Page 5047
Standard drive pinion preload plus 0.24 to 0.46 N*m (3 to 4 kgf*cm, 3 to 4 in.*lbf)
15. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION
(a) Coat 3 or 4 teeth at 3 different positions on the ring gear with Prussian blue.
(b) Turn the companion flange in both directions to inspect the ring gear for proper tooth contact.
* If the teeth are not contacting properly, use the following table to select a proper washer for
correction.
Washer thickness:
Page 5646
Page 8125
Seat Occupant Classification Module - Air Bag: Locations Seat Belt Warning System
SEAT BELT: SEAT BELT WARNING SYSTEM: PARTS LOCATION
Page 7335
6. INSTALL FRONT AXLE HUB SUB-ASSEMBLY LH
(a) Install the front axle hub See: Wheel Hub/Service and Repair/Removal and
Replacement/Installation.
7. CONNECT FRONT SPEED SENSOR LH
(a) Connect the front speed sensor to the steering knuckle with the bolt.
Torque : 11 Nm (107 kgf-cm, 8 ft-lbf)
(b) Attach the clip to the steering knuckle.
8. INSTALL FRONT WHEEL
for Aluminum Wheel - Torque : 131 Nm (1336 kgf-cm, 97 ft-lbf)
for Steel Wheel - Torque : 209 Nm (2131 kgf-cm, 154 ft-lbf)
9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
10. CHECK SPEED SENSOR SIGNAL
(a) Check the speed sensor signal See: Brakes and Traction Control/Antilock Brakes / Traction
Control Systems/Testing and Inspection/Scan
Tool Testing and Procedures/Test Mode Procedure.
11. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
12. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
(a) Inspect and adjust the front wheel alignment See: Alignment/Service and Repair.
Page 8528
(a) Connect the connector.
(b) Attach the 4 clips to install the panel.
3. INSTALL CENTER LOWER INSTRUMENT PANEL FINISH PANEL See: Body and
Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
4. INSTALL REAR UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
5. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding
/ Trim/Dashboard / Instrument Panel/Service
and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
6. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation
7. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
8. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Floor Shift Type)/Installation
9. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation
10. INSTALL COWL SIDE TRIM BOARD LH
(a) for Regular Cab:
Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular Cab)/Installation.
(b) for Double Cab:
Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Installation.
(c) for CrewMax:
Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for CrewMax)/Installation.
Page 4993
(c) Install the valve body with the 19 bolts.
Torque : 11 Nm (112 kgf-cm, 8 ft-lbf)
HINT Each bolt length is indicated below.
36 mm (1.42 in.) for bolt A
25 mm (0.984 in.) for bolt B
45 mm (1.77 in.) for bolt C
50 mm (1.97 in.) for bolt D
(d) Install the detent spring and detent spring cover with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
2. CONNECT TRANSMISSION WIRE See: Wiring Harness/Service and Repair/Installation
3. INSTALL VALVE BODY OIL STRAINER ASSEMBLY See: Wiring Harness/Service and
Repair/Installation
4. INSTALL AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY See: Wiring
Harness/Service and Repair/Installation
5. ADD AUTOMATIC TRANSMISSION FLUID
(a) Add automatic transmission fluid See: Service and Repair/Procedures.
Locations
Tire Pressure Warning Reset Switch: Locations
TIRE AND WHEEL: TIRE PRESSURE WARNING SYSTEM: PARTS LOCATION
Page 4414
Main Relay (Computer/Fuel System): Testing and Inspection
1UR-FE ENGINE CONTROL SYSTEM: CIRCUIT OPENING RELAY: ON-VEHICLE INSPECTION
1. REMOVE CIRCUIT OPENING RELAY (C/OPN)
(a) Remove the circuit opening relay from the engine room relay block.
2. INSPECT CIRCUIT OPENING RELAY
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) If the result is not as specified, replace the circuit opening relay.
3. INSTALL CIRCUIT OPENING RELAY
(a) Install the circuit opening relay to the engine room relay block.
Page 8937
Page 2914
Camshaft Position Sensor: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT POSITION SENSOR: REMOVAL
1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Removal
2. REMOVE CAMSHAFT POSITION SENSOR
(a) Disconnect the sensor connector.
(b) Remove the bolt and sensor.
Page 6144
Use a volt/ohmmeter with high impedance (10 kohms/V minimum) for troubleshooting of the
electrical circuit.
Disconnection of Male and Female Connectors
DISCONNECTION OF MALE AND FEMALE CONNECTORS
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Finding A Short Circuit
FINDING A SHORT CIRCUIT
Page 1604
Standard voltage:
(3) If the voltage is not as specified, replace the 4WD control ECU See: Powertrain
Management/Transmission Control Systems/Relays and
Modules - Transmission and Drivetrain/Relays and Modules - Transfer Case/Control
Module/Service and Repair/Removal. If the voltage is normal, replace the 4WD control switch.
Page 6605
General Information
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: GENERAL
INFORMATION
* A large number of ECU controlled systems are used in the TOYOTA TUNDRA. In general, ECU
controlled systems are considered to be very intricate, requiring a high level of technical knowledge
to troubleshoot. However, most problem checking procedures only involve inspecting the ECU
controlled system's circuits one by one. An adequate understanding of the system and a basic
knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and
necessary repairs.
1. TROUBLESHOOTING PROCEDURES
* The troubleshooting procedures consist of diagnosis procedures for when a DTC is stored and
diagnosis procedures for when no DTC is stored. The basic idea is explained in the following table.
* Vehicle systems are complex and use many ECUs that are difficult to inspect independently.
Therefore, a process of elimination is used, where components that can be inspected individually
are inspected, and if no problems are found in these components, the related ECU is identified as
the problem and replaced.
* It is extremely important to ask the customer about the environment and the conditions present
when the problem occurred (Customer Problem Analysis). This makes it possible to simulate the
conditions and confirm the symptom. If the symptom cannot be confirmed or the DTC does not
recur, the malfunctioning part may not be identified using the troubleshooting procedure, and the
ECU for the related system may be replaced even though it is not defective. If this happens, the
original problem will not be solved.
* In order to prevent endless expansion of troubleshooting procedures, the troubleshooting
procedures are written with the assumption that multiple malfunctions do not occur simultaneously
for a single problem symptom.
* To identify the malfunctioning part, troubleshooting procedures narrow down the target by
separating components, ECUs and wire harnesses during the inspection. If the wire harness is
identified as the cause of the problem, it is necessary to inspect not only the connections to
components and ECUs but also all of the wire harness connectors between the component and the
ECU.
DIAGNOSTIC TESTER
2. DESCRIPTION
System data and the Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector
3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the Techstream* to
check for a malfunction and perform repairs.
HINT *: Techstream is the name for the diagnostic tester in North America.
3. DATA LINK CONNECTOR 3 (DLC3)
(a) The vehicle's ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of
the DLC3 complies with SAE J1962 and
matches the ISO 15765-4 format.
Page 6314
Multiple Junction Connector: Locations Wire and Wire In Instrument Panel [Column Shift]
AJ1-QK1
Door Control Receiver (for CrewMax)
Keyless Entry Module: Service and Repair Door Control Receiver (for CrewMax)
Components
DOOR LOCK: DOOR CONTROL RECEIVER (for CrewMax): COMPONENTS
Removal
DOOR LOCK: DOOR CONTROL RECEIVER (for CrewMax): REMOVAL
1. REMOVE BACK PANEL TRIM RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for
CrewMax)/Removal
Page 9074
Page 9008
Remove the blown fuse and disconnect all loads of the fuse.
Connect a test light in place of the fuse.
Establish conditions in which the test light comes on.
Example:
- [A] - Ignition SW on
- [B] - Ignition SW and SW1 on
- [C] - Ignition SW, SW1 and Relay on (Connect the Relay) and SW2 off (or Disconnect SW2)
Disconnect and reconnect the connectors while watching the test light.
Page 6757
Da1-RA3
Page 6810
Page 945
15. INSTALL NO. 3 AIR DUCT SUB-ASSEMBLY
(a) Attach the 4 claws to install the duct.
16. INSTALL LOWER DEFROSTER NOZZLE ASSEMBLY
(a) Attach the 4 claws to install the nozzle.
17. INSTALL AIR CONDITIONING UNIT
(a) Install the air conditioning unit See: Heating and Air Conditioning/Housing Assembly
HVAC/Service and Repair/Removal and
Replacement/Installation.
Page 9204
Disassembly
ENGINE HOOD / DOOR: FRONT DOOR (for CrewMax): DISASSEMBLY
FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH
HINT *
Use the same procedures for the RH side and LH side.
* The procedures listed below are for the LH side.
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
Page 6730
* In the DTC check, it is very important to determine whether the problem indicated by the DTC is
either: 1) still occurring; or 2) occurred in the past but has since returned to normal. In addition, the
DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs
should be checked before and after confirmation of symptoms (i.e., whether or not problem
symptoms exist) to determine current system conditions, as shown in the flowchart below.
* Never skip the DTC check. Failing to check DTCs may, depending on the case, result in
unnecessary troubleshooting for systems operating normally or lead to repairs not related to the
problem. Follow the procedures listed in the flowchart in the correct order.
* The following flowchart shows how to proceed with troubleshooting using the DTC check.
Directions from the flowchart will indicate how to proceed either to DTC troubleshooting or to the
troubleshooting of each problem symptom.
1. DTC CHECK
NEXT -- Continue to next step.
2. MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR MEMORY
NEXT -- Continue to next step.
3. SYMPTOM CONFIRMATION
B -- Go to step 5 A -- Continue to next step.
4. SIMULATION TEST USING SYMPTOM SIMULATION METHODS
NEXT -- Continue to next step.
5. DTC CHECK
B -- TROUBLESHOOTING OF PROBLEM INDICATED BY DTC A -- Continue to next step.
6. SYMPTOM CONFIRMATION
Engine Control System - SFI System
Crankshaft Position Sensor: Locations Engine Control System - SFI System
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 9250
Components
Air Flow Meter/Sensor: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: COMPONENTS
Page 690
(6) If the result is not as specified, replace the outer mirror switch.
(b) Inspect the retract switch.
(1) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(2) If the result is not as specified, replace the outer mirror switch.
Airbag Cut-OFF Switch
Air Bag Deactivation Switch: Service and Repair Airbag Cut-OFF Switch
Components
SUPPLEMENTAL RESTRAINT SYSTEM: AIRBAG CUT-OFF SWITCH: COMPONENTS
Removal
SUPPLEMENTAL RESTRAINT SYSTEM: AIRBAG CUT-OFF SWITCH: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY
(a) Remove the lower No. 2 instrument panel airbag assembly See: Air Bag/Service and
Repair/Removal and Replacement/Front Passenger Side
Knee Airbag Assembly/Removal.
3. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and
Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument
Panel Safety Pad (for Column Shift Type)/Removal
4. REMOVE AIRBAG CUT-OFF SWITCH
(a) Detach the 2 claws to remove the switch.
Installation
SUPPLEMENTAL RESTRAINT SYSTEM: AIRBAG CUT-OFF SWITCH: INSTALLATION
1. INSTALL AIRBAG CUT-OFF SWITCH
(a) Attach the 2 claws to install the switch.
2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY See: Body and
Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Column Shift Type)/Installation
3. INSTALL LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY
(a) Install the lower No. 2 instrument panel airbag assembly See: Air Bag/Service and
Repair/Removal and Replacement/Front Passenger Side
Knee Airbag Assembly/Installation.
4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Page 5666
Yaw Rate Sensor: Diagrams
Page 9099
Symbols Used Within Diagrams
Symbols Used Within Diagrams
Locations
Relay Box: Locations
Engine Compartment
Engine - Snow Ingestion Into Air Cleaner Box
Front Fender Liner: All Technical Service Bulletins Engine - Snow Ingestion Into Air Cleaner Box
T-SB-0396-09
December 8, 2009
Snow Entry Into Air Cleaner Box
Service Category Engine/Hybrid System
Section Intake/Exhaust
Market USA
Applicability
Introduction
Some Sequoia and Tundra vehicles operated in areas with significant snow volume may
experience snow accumulation in the air cleaner box which can cause the lid to fracture. The air
cleaner lid and fender liner have been revised to reduce accumulation.
Parts Information
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for
36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Production Change Information
CAN Communication System
Body Control Module: Locations CAN Communication System
CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: PARTS LOCATION
Page 7350
8. REMOVE REAR SPRING ASSEMBLY LH
(a) Remove the nut, washer and bolt from the front side.
(b) Remove the 2 nuts, 2 washers, shackle outer plate, No. 2 spring shackle plate and leaf spring
from the rear side.
9. REMOVE TUBE
(a) Using a brass bar and hammer, remove the tube from the frame.
10. REMOVE REAR SPRING SHACKLE BUSH
(a) Remove the 2 bushes from the frame.
Installation
SUSPENSION: REAR LEAF SPRING: INSTALLATION
HINT *
Use the same procedures for the RH side and LH side.
* The procedures listed below are for the LH side.
* A bolt without a torque specification is shown in the standard bolt chart See:
Specifications/Mechanical Specifications/Standard Bolt - Specified Torque For Standard Bolts
1. INSTALL REAR SPRING SHACKLE BUSH
(a) Install the 2 shackle bushes to the frame.
Page 4610
Ignition Switch: Testing and Inspection
1UR-FE STARTING: IGNITION SWITCH: INSPECTION
1. INSPECT IGNITION SWITCH ASSEMBLY
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) If the result is not as specified, replace the ignition switch assembly.
Page 1404
9. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH (for Rear Side)
10. INSTALL REAR DOOR SCUFF PLATE LH (for Rear Side) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and Repair/Roof
Headlining (For Double Cab)/Installation
11. INSTALL REAR SEAT ASSEMBLY (for Rear Side)
(a) Install the rear seat assembly See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Rear Seat Assembly (for Double
Cab)/Installation.
12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
13. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
Page 6735
Engine Room R/B, J/B - Engine Compartment Left
Ultrasonic Sensor (for Front Side)
Parking Assist Distance Sensor: Service and Repair Ultrasonic Sensor (for Front Side)
Components
PARK ASSIST / MONITORING: ULTRASONIC SENSOR (for Front Side): COMPONENTS
Components
Front Steering Knuckle: Service and Repair Components
AXLE: STEERING KNUCKLE: COMPONENTS
Page 3458
(c) Measure the voltage according to the value(s) in the table below.
Standard voltage:
NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- REPLACE CENTER AIRBAG SENSOR
Combination Meter ECU Communication Stop Mode
CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: Combination Meter ECU
Communication Stop Mode - Combination Meter ECU Communication Stop Mode
DESCRIPTION
WIRING DIAGRAM
INSPECTION PROCEDURE
PROCEDURE
1. CHECK HARNESS AND CONNECTOR (COMBINATION METER ECU - BATTERY AND BODY
GROUND)
Page 5507
Control Module: Service and Repair Installation
JF1A TRANSFER: 4WD CONTROL ECU: INSTALLATION
1. INSTALL 4WD CONTROL ECU
(a) Install the ECU with the bolt.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
(b) Connect the 2 ECU connectors.
2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Installation
3. INSTALL INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
4. INSTALL COWL SIDE TRIM BOARD RH
(a) Install the cowl side trim board RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Installation.
HINT Use the same procedures described for the LH side.
5. INSTALL FRONT DOOR SCUFF PLATE RH (for Regular Cab)
(a) Install the front door scuff plate RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Installation.
HINT Use the same procedures described for the LH side.
6. INSTALL FRONT DOOR SCUFF PLATE RH (for Double Cab, for CrewMax)
(a) Install the front door scuff plate RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Installation.
HINT Use the same procedures described for the LH side.
Page 4784
C. Choose desired ECU group(s) in the Health Check dialog box.
D. Click Next.
E. Click Continue to view Health Check results.
F. Available calibration updates are indicated by a link in the Cal. Update? column. Click the link to
access the appropriate service bulletin on TIS.
NOTE
^ Note any DTCs stored in Systems that will be flash reprogrammed.
^ Clicking the link will automatically launch TIS and perform a calibration search.
G. Log in to TIS. (If already logged in skip this step.)
H. To review the TSB and access the calibration file click the service bulletin link in the Document
Title column of the Calibration Search Result
portlet.
Page 1983
Page 1197
Page 8106
Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to
prevent airbag and seat belt pretensioner activation.
(c) Install the door airbag sensor with the screw.
Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)
NOTICE: *
If the door airbag sensor has been dropped, or there are any cracks, dents or other defects in the
case, bracket or connector, replace it with a new one.
* When installing the door airbag sensor, be careful that the SRS wiring does not interfere with
other parts and that it is not pinched between other parts.
(d) Check that there is no looseness in the installation parts of the door airbag sensor.
(e) Connect the connector.
2. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Reassembly
3. INSTALL COURTESY LIGHT ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood
and Trunk/Doors/Front Door/Service and
Repair/Front Door (for Double Cab)/Reassembly
4. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH LH (for Front Side) See: Body
and Frame/Doors, Hood and
Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly
5. INSTALL FRONT ARMREST BASE PANEL UPPER LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Reassembly
6. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Reassembly
7. INSTALL REAR SIDE AIRBAG SENSOR
(a) Check that the ignition switch is OFF.
(b) Check that the cable is disconnected from the battery negative (-) terminal.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
(c) Install the side airbag sensor with the bolt.
Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)
NOTICE: *
If the side airbag sensor has been dropped, or there are any cracks, dents or other defects in the
case, bracket or connector, replace it with a new one.
* When installing the side airbag sensor, be careful that the SRS wiring does not interfere with
other parts and that it is not pinched between other parts.
(d) Check that there is no looseness in the installation parts of the side airbag sensor.
(e) Connect the connector.
8. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY LH (for Rear Side) See: Body and
Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation
Components
Transmission Speed Sensor: Service and Repair Components
A760F AUTOMATIC TRANSMISSION: SPEED SENSOR: COMPONENTS
Page 5045
13. INSPECT AND ADJUST DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION
BACKLASH
(a) Align the matchmarks on the bearing cap and carrier.
(b) Install the right and left bearing caps with the 4 bolts.
Torque : 103 Nm (1050 kgf-cm, 76 ft-lbf)
* If the bearing cap does not fit tightly on the carrier, the adjusting nuts are not threaded properly.
Reinstall the adjusting nuts if necessary.
(c) Loosen the 4 bearing cap bolts to the point where the adjusting nuts can be turned using SST.
SST : 09504-00011
(d) Using SST, tighten the adjusting nut on the ring gear side until the ring has a backlash of about
0.2 mm (0.00788 in.).
(e) While turning the ring gear, use SST to tighten the adjusting nut on the drive pinion side. After
the bearings have settled, loosen the adjusting
nut on the drive pinion side.
Capacity Specifications
Engine Oil: Capacity Specifications
Engine Oil Capacity (drain and refill-Reference)
With filter ..............................................................................................................................................
............................................................. 7.9 qt (7.5L) Without filter ......................................................
................................................................................................................................................ 7.4 qt
(7.1L)
Page 8837
NOTICE: Do not touch the cone part of the speaker.
7. REMOVE FRONT NO. 2 SPEAKER ASSEMBLY RH
(a) Remove the 2 bolts.
(b) Remove the speaker and disconnect the connector.
NOTICE: Do not touch the cone part of the speaker.
8. REMOVE NO. 3 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY
(a) Using a screwdriver, detach the 6 clips and 2 claws.
HINT Tape the screwdriver tip before use.
(b) Remove the speaker panel.
9. REMOVE FRONT NO. 4 SPEAKER ASSEMBLY (for 10 Speakers)
(a) Remove the 2 bolts.
(b) Remove the speaker and disconnect the connector.
Recall 11V185000 - TPMS Non-Compliance
Tire Pressure Module: Recalls Recall 11V185000 - TPMS Non-Compliance
VEHICLE MAKE/MODEL: MODEL YEAR(S) Toyota/FJ Cruiser 2011
Toyota/Tundra 2009-2011
MANUFACTURER: Gulf States Toyota, Inc.
MFR'S REPORT DATE: March 16, 2011
NHTSA CAMPAIGN ID NUMBER: 11V185000
NHTSA ACTION NUMBER: N/A
COMPONENT: Tires: Pressure Monitoring and Regulating Systems
POTENTIAL NUMBER OF UNITS AFFECTED: 1,489
SUMMARY: Gulf States Toyota is recalling certain model year 2011 FJ Cruiser and model year
2009-2011 Tundra vehicles for failing to comply with the requirements of Federal Motor Vehicle
Safety Standard No. 138, "Tire Pressure Monitoring Systems." The TPMS on some vehicles may
not have been properly calibrated and as a result the low tire pressure warning lamp may not
illuminate should the inflation pressure in one or more of the vehicle's tires fall below the threshold
for when the low tire pressure warning lamp should illuminate.
CONSEQUENCE: Drivers will not receive a warning from the tire pressuring monitor that one or
more tires are underinflated increasing the risk that a vehicle will be driven with one or more
underinflated tires and increasing the risk of a tire failure that may lead to a crash.
REMEDY: Dealers will recalibrate the tire pressure monitoring system in accordance with the
regulation free of charge. The safety recall is expected to begin during April 2011. Owners may
contact Gulf State Toyota Customer Assistance Center toll free at 1-800-444-1074 Monday through
Thursday, 8:30 AM to 5:00 PM, or Friday 8:30 AM to 4:00 PM Central Standard Time.
NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle
Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov.
Page 1483
Push the secondary locking device or terminal retainer in to the full lock position.
CONNECT CONNECTOR
Voltage Check
VOLTAGE CHECK
Page 6084
Neutral Safety Switch: Component Tests and General Diagnostics
A760F AUTOMATIC TRANSMISSION: PARK / NEUTRAL POSITION SWITCH: INSPECTION
1. INSPECT PARK/NEUTRAL POSITION SWITCH ASSEMBLY
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) If the result is not as specified, replace the switch assembly.
Page 4475
Throttle Body: Testing and Inspection Inspection
1UR-FE ENGINE CONTROL SYSTEM: THROTTLE BODY: INSPECTION
1. INSPECT THROTTLE BODY ASSEMBLY
(a) Check the throttle valve.
(1) Check that the throttle valve opens and closes smoothly.
(2) Check that there is no sludge accumulating around the throttle body.
(b) Check the throttle control motor.
(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(2) If the result is not as specified, replace the throttle body assembly.
Page 3373
Push the terminal retainer down to the temporary lock position.
Page 8576
Parking Assist Distance Sensor: Service and Repair Ultrasonic Sensor (for Rear Side)
Components
PARK ASSIST / MONITORING: ULTRASONIC SENSOR (for Rear Side): COMPONENTS
Page 1393
Impact Sensor: Service and Repair Side Airbag Sensor (for CrewMax)
Components
SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for CrewMax):
COMPONENTS
Locations
Throttle Position Sensor: Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 4905
3. INSTALL TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY See:
Steering and Suspension/Steering/Steering
Column/Service and Repair/Removal and Replacement/Steering Column Assembly (for Power Tilt
and Power Telescopic Steering Column)/Installation
4. INSTALL UPPER STEERING COLUMN COVER See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Removal and
Replacement/Steering Column Assembly (for Power Tilt and Power Telescopic Steering
Column)/Installation
5. INSTALL LOWER STEERING COLUMN COVER See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Removal and
Replacement/Steering Column Assembly (for Power Tilt and Power Telescopic Steering
Column)/Installation
6. INSTALL STEERING WHEEL ASSEMBLY See: Steering and Suspension/Steering/Steering
Column/Service and Repair/Removal and
Replacement/Steering Column Assembly (for Power Tilt and Power Telescopic Steering
Column)/Installation
7. INSTALL STEERING PAD (w/ Steering Pad Switch) See: Restraint Systems/Air Bag
Systems/Air Bag/Service and Repair/Removal and
Replacement/Steering Pad/Installation
8. INSTALL STEERING PAD (w/o Steering Pad Switch) See: Restraint Systems/Air Bag
Systems/Air Bag/Service and Repair/Removal and
Replacement/Steering Pad/Installation
9. INSTALL LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY See: Restraint
Systems/Air Bag Systems/Air Bag/Service and
Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Installation
10. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Installation
11. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Installation
12. INSTALL FRONT DOOR SCUFF PLATE LH (for Double Cab, CrewMax) See: Body and
Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Installation
13. INSTALL FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Installation
14. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
15. INSPECT SHIFT LEVER POSITION See: Adjustments/SHIFT LEVER ASSEMBLY (for Column
Shift Type)
Components
A760F AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY (for Floor Shift Type):
COMPONENTS
Page 6583
Page 3623
(b) Using SST, remove the sensor.
SST : 09224-00010
Installation
1UR-FE ENGINE CONTROL SYSTEM: HEATED OXYGEN SENSOR: INSTALLATION
1. INSTALL HEATED OXYGEN SENSOR (for Bank 2 Sensor 2)
(a) Install the sensor to the exhaust pipe by hand.
(b) Using SST, tighten the sensor.
SST : 09224-00010
without SST - Torque : 44 Nm (449 kgf-cm, 32 ft-lbf)
with SST - Torque : 40 Nm (408 kgf-cm, 30 ft-lbf)
HINT *
Use a torque wrench with a fulcrum length of 30 cm (11.8 in.). When using a torque wrench with a
fulcrum length that is not 30 cm (11.8 in.), calculate the torque specification for the torque wrench
and SST based on the "without SST" torque specification See: Service Precautions
* Make sure SST and the wrench are connected in a straight line.
2. INSTALL HEATED OXYGEN SENSOR (for Bank 1 Sensor 2)
(a) Install the sensor to the exhaust pipe by hand.
(b) Using SST, tighten the sensor.
A760F Automatic Transmission System
Control Module: Locations A760F Automatic Transmission System
A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS
LOCATION
Page 4757
^ Figure 17 shows an example of the update procedure for a two-processor ECU.
G. Turn ignition OFF. Then click Next.
H. Confirm the following:
^ Ignition is ON and engine is OFF or "READY" OFF (hybrid vehicles).
^ Hood is open.
^ All accessories are OFF.
^ Battery voltage is above 11.4 volts.
NOTICE
Verify the vehicle is connected to a battery charger before continuing - If battery voltage falls below
11.4 volts, ECU damage may occur.
Page 61
Parking Assist Control Module: Service and Repair Installation
PARK ASSIST / MONITORING: CLEARANCE WARNING ECU: INSTALLATION
HINT A bolt without a torque specification is shown in the standard bolt chart See:
Specifications/Mechanical Specifications/Standard Bolt - Specified Torque For Standard Bolts
1. INSTALL CLEARANCE WARNING ECU ASSEMBLY
(a) Install the clearance warning ECU to the bracket with the 2 nuts.
NOTICE: *
Avoid any impact to the clearance warning ECU.
* Do not drop the ECU. If it is dropped, replace it with a new one.
2. INSTALL CLEARANCE WARNING ECU WITH BRACKET
(a) Install the ECU with bracket with the nut and bolt.
(b) Connect the ECU connectors and attach the harness clamp.
NOTICE: Do not apply excessive force to the wire harnesses.
3. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Installation
4. INSTALL LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY See: Restraint
Systems/Air Bag Systems/Air Bag/Service and
Repair/Removal and Replacement/Front Passenger Side Knee Airbag Assembly/Installation
5. INSTALL LOWER INSTRUMENT PANEL See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
6. INSTALL NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY See: Body and
Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Column Shift Type)/Installation
7. INSTALL INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
8. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
9. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Air Bag/Service and
Repair/Removal and Replacement/Driver Side
Knee Airbag Assembly/Installation.
Page 9237
Locations
Four Wheel Drive Selector Switch: Locations
JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION
Locations
Shift Solenoid: Locations
A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS
LOCATION
Page 3539
DESCRIPTION
WIRING DIAGRAM
INSPECTION PROCEDURE
HINT Operating the ignition switch, any switches or any doors triggers related ECU and sensor
communication with the CAN, which causes resistance variation.
PROCEDURE
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
(a) Disconnect the cable from the negative (-) battery terminal before measuring the resistances of
the main wire and the branch wire.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
NEXT -- Continue to next step.
Page 8702
Seat Memory Switch: Service and Repair Removal
SEAT: SEAT MEMORY SWITCH (w/ Seat Position Memory System): REMOVAL
1. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH See: Body and Frame/Doors,
Hood and Trunk/Doors/Front Door/Service and
Repair/Front Door (for Double Cab)/Disassembly
2. REMOVE FRONT ARMREST UPPER BASE PANEL LH See: Body and Frame/Doors, Hood
and Trunk/Doors/Front Door/Service and
Repair/Front Door (for Double Cab)/Disassembly
3. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Disassembly
4. REMOVE COURTESY LIGHT ASSEMBLY See: Body and Frame/Doors, Hood and
Trunk/Doors/Front Door/Service and Repair/Front Door
(for Double Cab)/Disassembly
5. REMOVE FRONT DOOR ARMREST COVER LH
6. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH See: Body and Frame/Doors,
Hood and Trunk/Doors/Front Door/Service and
Repair/Front Door (for Double Cab)/Disassembly
7. REMOVE SEAT MEMORY SWITCH
(a) Remove the 2 screws and seat memory switch.
Diagrams
Steering Angle Sensor: Diagrams
Page 9030
If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness
or connector in that circuit in the past. Check the wire harness and connectors.
B -- SYSTEM NORMAL
A -- TROUBLESHOOTING OF EACH PROBLEM SYMPTOM
The problem is still occurring in a place other than the diagnostic circuit (the DTC displayed first is
either for a past problem or a secondary problem).
4. SYMPTOM SIMULATION
HINT The most difficult case in troubleshooting is when no problem symptoms occur. In such a
case, a thorough problem analysis must be carried out. A simulation of the same or similar
conditions and environment in which the problem occurred in the customer's vehicle should be
carried out. No matter how much skill or experience a technician has, troubleshooting without
confirming the problem symptoms will lead to important repairs being overlooked and mistakes or
delays.
For example:
With a problem that only occurs when the engine is cold or as a result of vibration caused by the
road during driving, the problem can never be determined if the symptoms are being checked on a
stationary vehicle or on a vehicle with a warmed-up engine. Vibration, heat or water penetration
(moisture) is difficult to reproduce. The symptom simulation tests below are effective substitutes for
the conditions and can be applied on a stationary vehicle.
Important points in the symptom simulation test:
In the symptom simulation test, the problem symptoms as well as the problem area or parts must
be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then,
connect the tester and carry out the symptom simulation test, judging whether the circuit being
tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the
problem symptoms table for each system to narrow down the possible causes.
To reproduce DTCs, it is necessary to satisfy the respective DTC detection conditions.
(a) VIBRATION METHOD:
When a malfunction seems to occur as a result of vibration.
(1) PART AND SENSOR
Apply slight vibration with a finger to the part of the sensor suspected to be the cause of the
problem, and check whether or not the malfunction occurs.
NOTICE: Applying strong vibration to relays may open them.
Page 4954
(a) Disconnect the No. 2 transmission oil cooler inlet hose and No. 2 transmission oil cooler outlet
hose from the transmission oil thermostat.
(b) Disconnect the No. 2 transmission oil cooler inlet hose and No. 2 transmission oil cooler outlet
hose from the oil cooler tube, and remove
them.
NOTICE: When disconnecting the hoses from the tube, support the tube by hand and be careful to
prevent the tube from being deformed.
(c) Disconnect the 2 No. 1 transmission oil cooler hoses from the transmission.
(d) Remove the 3 bolts and transmission oil cooler with transmission oil thermostat.
(e) Remove the 2 No. 1 transmission oil cooler hoses from the transmission oil thermostat.
(f) Remove the 3 bolts and oil cooler from the transmission oil thermostat.
(g) Remove the 2 O-rings from the grooves of transmission oil cooler.
6. REMOVE OIL COOLER ACCESSORY ASSEMBLY (w/ Trailer Towing System)
(a) Disconnect the 2 hoses from the No. 2 oil cooler tube.
NOTICE: When disconnecting the hoses from the tube, support the tube by hand and be careful to
prevent the tube from being deformed.
(b) Detach the claw to open the No. 1 flexible hose clamp.
(c) Disconnect the 2 hoses from the oil cooler tube and remove the oil cooler accessory assembly.
NOTICE: When disconnecting the hoses from the tube, support the tube by hand and be careful to
prevent the tube from being deformed.
7. REMOVE COOLER CONDENSER ASSEMBLY (AIR COOLED OIL COOLER) (w/ Trailer
Towing System)
(a) Remove the cooler condenser See: Heating and Air Conditioning/Condenser HVAC/Service
and Repair/Removal.
8. REMOVE NO. 2 OIL COOLER TUBE
Page 6589
Remove the blown fuse and disconnect all loads of the fuse.
Connect a test light in place of the fuse.
Establish conditions in which the test light comes on.
Example:
- [A] - Ignition SW on
- [B] - Ignition SW and SW1 on
- [C] - Ignition SW, SW1 and Relay on (Connect the Relay) and SW2 off (or Disconnect SW2)
Disconnect and reconnect the connectors while watching the test light.
Page 7840
Cabin Temperature Sensor / Switch: Diagrams
Page 6421
Power Distribution Module: Service and Repair Installation
OTHER SYSTEM: VOLTAGE INVERTER (for CrewMax): INSTALLATION
1. INSTALL VOLTAGE INVERTER ASSEMBLY
(a) Connect the voltage inverter connector.
(b) Install the voltage inverter with the 2 bolts.
Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
2. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY LH See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (for CrewMax)/Installation
3. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH
4. INSTALL REAR DOOR SCUFF PLATE LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for
CrewMax)/Installation
5. INSTALL BACK PANEL TRIM LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for
CrewMax)/Installation
6. INSTALL BACK PANEL TRIM RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for
CrewMax)/Installation
Page 6070
Page 2343
Variable Valve Timing Actuator: Testing and Inspection On-Vehicle Inspection
1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT OIL CONTROL VALVE: ON-VEHICLE
INSPECTION
1. INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
(a) Connect the Techstream to the DLC3.
(b) Start the engine and turn the tester ON.
(c) Warm up the engine.
(d) Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the VVT Linear
(Bank 1) or Control the VVT Linear (Bank
2) or Control the VVT System (Bank 1) or Control the VVT System (Bank 2) or Control the VVT
Exhaust Linear (Bank 1) or Control the VVT Exhaust Linear (Bank 2).
(e) Check the engine speed while operating the Oil Control Valve (OCV) using the tester.
OK:
(f) If the result is not as specified, check the oil control valve, wiring and camshaft timing gear.
HINT *
Control the VVT Linear (Bank 1): Command to activate exhaust and intake side oil control valves of
bank 1 (Control range: Between -128 to 127%).
* Control the VVT Linear (Bank 2): Command to activate exhaust and intake side oil control valves
of bank 2 (Control range: Between -128 to 127%).
* Control VVT System (Bank 1): Command to activate oil control valve of bank 1 (Control range:
ON/OFF).
* Control VVT System (Bank 2): Command to activate oil control valve of bank 2 (Control range:
ON/OFF).
* Control the VVT Exhaust Linear (Bank 1): Command to activate exhaust side oil control valve of
bank 1 (Control range: Between -128 to 127%).
* Control the VVT Exhaust Linear (Bank 2): Command to activate exhaust side oil control valve of
bank 2 (Control range: Between -128 to 127%).
Page 951
Refrigerant Pressure Sensor / Switch: Diagrams
Page 5618
Page 4306
C. Choose desired ECU group(s) in the Health Check dialog box.
D. Click Next.
E. Click Continue to view Health Check results.
F. Available calibration updates are indicated by a link in the Cal. Update? column. Click the link to
access the appropriate service bulletin on TIS.
NOTE
^ Note any DTCs stored in Systems that will be flash reprogrammed.
^ Clicking the link will automatically launch TIS and perform a calibration search.
G. Log in to TIS. (If already logged in skip this step.)
H. To review the TSB and access the calibration file click the service bulletin link in the Document
Title column of the Calibration Search Result
portlet.
Page 7602
* In the DTC check, it is very important to determine whether the problem indicated by the DTC is
either: 1) still occurring; or 2) occurred in the past but has since returned to normal. In addition, the
DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs
should be checked before and after confirmation of symptoms (i.e., whether or not problem
symptoms exist) to determine current system conditions, as shown in the flowchart below.
* Never skip the DTC check. Failing to check DTCs may, depending on the case, result in
unnecessary troubleshooting for systems operating normally or lead to repairs not related to the
problem. Follow the procedures listed in the flowchart in the correct order.
* The following flowchart shows how to proceed with troubleshooting using the DTC check.
Directions from the flowchart will indicate how to proceed either to DTC troubleshooting or to the
troubleshooting of each problem symptom.
1. DTC CHECK
NEXT -- Continue to next step.
2. MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR MEMORY
NEXT -- Continue to next step.
3. SYMPTOM CONFIRMATION
B -- Go to step 5 A -- Continue to next step.
4. SIMULATION TEST USING SYMPTOM SIMULATION METHODS
NEXT -- Continue to next step.
5. DTC CHECK
B -- TROUBLESHOOTING OF PROBLEM INDICATED BY DTC A -- Continue to next step.
6. SYMPTOM CONFIRMATION
Page 1909
Required Tools & Equipment
Important Information
^ 100,000 Mile Maintenance Interval - Inspection only; ATF-WS does NOT require any flushing or
changing during the life of the vehicle.
^ The use of Genuine Toyota ATF-WS is recommended.
^ The use of additives or aftermarket fluids that are considered compatible or substitutes may result
in shift concerns and damage to the internal transmission components.
^ ATF-WS is NOT compatible with T-IV or Dexron ATF.
^ Containers storing Toyota ATF-WS should ALWAYS be sealed - If exposed to the atmosphere,
ATF-WS may absorb moisture and potentially cause shift concerns if used in operation.
^ One time use only.
^ When performing repairs on ATF-WS equipped transaxles, it is important to use only new, clean
ATF-WS when refilling the ATM.
^ ATF-WS equipped ATMs may use the overflow type procedure - Any fluid drained from the
overflow plug should be discarded following proper local regulations and never reused. Failure to
do so could result in shift concerns and damage to the internal transmission components.
Page 8346
Impact Sensor: Service and Repair Front Airbag Sensor
Components
SUPPLEMENTAL RESTRAINT SYSTEM: FRONT AIRBAG SENSOR: COMPONENTS
Removal
SUPPLEMENTAL RESTRAINT SYSTEM: FRONT AIRBAG SENSOR: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
Locations
Wiper Switch: Locations
WIPER AND WASHER: WIPER AND WASHER SYSTEM: PARTS LOCATION
Page 2787
Parts Information
Required Tools & Equipment
Repair Procedure
1. Confirm the condition matches the Introduction.
Components
Solar Sensor: Service and Repair Components
AIR CONDITIONING: SOLAR SENSOR (for Automatic Air Conditioning System): COMPONENTS
Component Tests and General Diagnostics
Steering Angle Sensor: Component Tests and General Diagnostics
BRAKE CONTROL: STEERING ANGLE SENSOR: INSPECTION
1. CHECK STEERING ANGLE SENSOR
(a) Check the steering angle sensor.
Under any of the following conditions, replace the sensor with a new one:
* The surface of the sensor is cracked, dented, or chipped.
* The connector is scratched, cracked, or damaged.
* The sensor has been dropped.
Page 6471
"Case2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 6854
Page 294
Engine Room R/B, J/B - Engine Compartment Left
Diagrams
Steering Angle Sensor: Diagrams
Page 3645
Body Control Module: Locations LIN Communication System
MULTIPLEX COMMUNICATION: LIN COMMUNICATION SYSTEM: PARTS LOCATION
Page 4789
Then click Next.
F. Verify correct current calibration and new calibration information. Then click Next.
NOTE
^ The total number of calibration IDs in the calibration file corresponds to the number of
reprogrammable processors in the ECU.
^ Each calibration file may contain up to three separate calibrations.
Page 679
(b) If replacing unlock warning switch assembly:
(1) While pushing the pin, slide the switch to install the warning switch.
(c) Connect the unlock warning switch connector.
2. INSTALL LOWER STEERING COLUMN COVER (for Power Tilt and Power Telescopic Steering
Column) See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering
Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Installation
3. INSTALL LOWER STEERING COLUMN COVER (for Manual Tilt and Manual Telescopic
Steering Column) See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering
Column Assembly (for Manual Tilt and Manual Telescopic Steering Column)/Installation
Specifications
Power Steering Fluid: Specifications
Power Steering Fluid Type
Type
.........................................................................................................................................................
Automatic Transmission Fluid DEXRON II or III
Page 4480
(f) Connect the 2 water by-pass hoses.
HINT When connecting the hoses, make sure the paint marks and clips are as shown in the
illustration.
2. INSTALL AIR CLEANER HOSE ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Installation
3. ADD ENGINE COOLANT See: Engine, Cooling and Exhaust/Cooling System/Coolant/Service
and Repair
4. INSPECT FOR COOLANT LEAK See: Engine, Cooling and Exhaust/Cooling System/Testing
and Inspection
5. INSTALL ENGINE UNDER COVER NO.1 See: Engine, Cooling and Exhaust/Engine/Engine
Lubrication/Engine Oil/Service and
Repair/Replacement
6. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Installation
7. PERFORM INITIALIZATION
NOTICE: *
Be sure to perform this procedure after reassembling the throttle body assembly or removing and
reinstalling any throttle body component.
* Perform the following procedure after replacing the ECM, throttle body assembly or any throttle
body components. The following procedure should also be performed if the throttle body is
cleaned.
* Be sure to perform this procedure after reconnecting the battery cable and replacing the ECM.
(a) Disconnect the EFI NO. 1 fuse at the same time. Wait at least 60 seconds and reconnect the
fuses.
(b) Turn the ignition switch to the ON position without operating the accelerator pedal.
NOTICE: If the accelerator pedal is operated, perform the above steps again.
(c) Connect the Techstream to the DLC3 and clear the DTCs See: Computers and Control
Systems/Testing and Inspection/Reading and Clearing
Diagnostic Trouble Codes/DTC Check / Clear.
(d) Start the engine and check that the MIL is not illuminated and that the idle speed is within the
specified range when the A/C is switched off
after the engine is warmed up.
Standard:
NOTICE: *
Be sure to perform this step with all accessories off.
* Make sure that the shift lever is in N or P.
(e) Enter the following menus: Powertrain / Engine and ETC / Data List / All Data / Throttle Sensor
Position. Sensor Output. Fully depress the
accelerator pedal and check that the value is 60% or more.
(f) Perform a road test and confirm that there are no abnormalities.
Page 3555
Scan Tool Testing and Procedures
MULTIPLEX COMMUNICATION: LIN COMMUNICATION SYSTEM: DATA LIST / ACTIVE TEST
1. READ DATA LIST
HINT Using the Techstream to read the Data List allows values or states of switches, sensors,
actuators and other items to be read without removing any parts. This non-intrusive inspection can
be very useful because intermittent conditions or signals may be discovered before parts or wiring
is disturbed. Reading the Data List information early in troubleshooting is one way to save
diagnostic time.
NOTICE: In the table below, the values listed under "Normal Condition" are reference values. Do
not depend solely on these reference values when deciding whether a part is faulty or not.
(a) Connect the Techstream to the DLC3.
(b) Turn the ignition switch to ON.
(c) Turn the Techstream on.
(d) Enter the following menus: Body Electrical / Main Body / Data List.
(e) According to the display on the Techstream, read the Data List.
LIN Communication System
MULTIPLEX COMMUNICATION: LIN COMMUNICATION SYSTEM: TERMINALS OF ECU
1. CHECK MAIN BODY ECU (DRIVER SIDE JUNCTION BLOCK)
Page 2803
^ Figure 17 shows an example of the update procedure for a two-processor ECU.
G. Turn ignition OFF. Then click Next.
H. Confirm the following:
^ Ignition is ON and engine is OFF or "READY" OFF (hybrid vehicles).
^ Hood is open.
^ All accessories are OFF.
^ Battery voltage is above 11.4 volts.
NOTICE
Verify the vehicle is connected to a battery charger before continuing - If battery voltage falls below
11.4 volts, ECU damage may occur.
Page 6313
Da1-RA3
Page 5522
Transmission Position Switch/Sensor: Diagrams
Page 5348
Transmission Speed Sensor: Diagrams
Page 8947
HINT The type of claw on the top and bottom of the sensor are different. Observe the claws
carefully before removing the sensor.
12. REMOVE NO. 1 ULTRASONIC SENSOR RETAINER
(a) Detach the 2 claws and remove the sensor retainer from the front bumper.
Installation
PARK ASSIST / MONITORING: ULTRASONIC SENSOR (for Front Side): INSTALLATION
1. INSTALL NO. 1 ULTRASONIC SENSOR RETAINER
(a) Align the keyhole and protrusion as shown in the illustration.
(b) Install the sensor retainer to the front bumper.
NOTICE: Do not damage the bumper with the protrusion when installing the retainer.
2. INSTALL NO. 1 ULTRASONIC SENSOR
(a) Attach the 2 claws to install the ultrasonic sensor.
Page 1844
4. Attach the Authorized Vehicle Modification Label.
Modifications to ECU calibrations MUST be recorded and properly displayed on the vehicle using
the Authorized Modification Label.
Techstream Preparation
Selecting the TIS Techstream VIM or the Mongoose MFC VIM.
Techstream software requires a VIM selection before you can use the Mongoose MFC VIM.
If using TIS Techstream no changes are needed.
Perform the following:
1. Select Setup from the Techstream Main Menu screen.
2. Select VIM Select from the Setup drop down menu.
3. Select the correct Interface Setup from the drop down list.
^ If using Techstream Lite select Mongoose MFC.
NOTE
Components
Seat Occupant Classification Module - Air Bag: Service and Repair Components
SUPPLEMENTAL RESTRAINT SYSTEM: OCCUPANT CLASSIFICATION ECU: COMPONENTS
Page 4620
Diagrams
Steering Mounted Controls Transmitter: Diagrams
Power Door Lock Control System
Power Door Lock Switch: Locations Power Door Lock Control System
DOOR LOCK: POWER DOOR LOCK CONTROL SYSTEM: PARTS LOCATION
Up to 11/2009
Braking Sensor/Switch: Locations Up to 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 4421
Fuel Pump Control Unit: Locations Crew Max
Body
Page 3685
Mongoose MFC Software and Driver MUST be installed before Mongoose MFC selection will be
available.
See TIS - Diagnostics - Scantool page for additional information.
^ If using TIS Techstream select TIS Techstream VIM (this is the default).
4. Click OK.
Operation Procedure
1. Verify the vehicle's applicability for recalibration and locate desired calibration file.
A. Connect Techstream and establish a vehicle connection.
B. Click the Health Check button on the System Select tab.
Page 1203
Oxygen Sensor: Diagrams Heated Oxygen Sensor
Page 5904
Wheel Speed Sensor: Locations From 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 4188
Capacity Specifications
Refrigerant Oil: Capacity Specifications
COMPRESSOR OIL
Standard
(Oil capacity inside the new compressor and magnetic clutch: 120 + 15 cc (4.1 + 0.51 fl.oz.)) (Remaining oil amount in the removed compressor and magnetic clutch) = (Oil amount to be
removed from the new compressor when replacing)
Page 6498
J/B No.5 - Instrument Panel Center
Page 7514
Introduction
The purpose of this bulletin is to provide a procedure to adjust tire pressure correctly when outside
temperature is significantly colder or warmer than shop temperature.
Seasonal temperature change can dramatically alter tire pressure, which can cause the tire
pressure warning lamp to illuminate.
NOTE
This bulletin applies to some 2004 - 2007 model year Toyota vehicles with direct TPWS and all
2008 and newer model year Toyota vehicles.
Warranty Information
Tire Pressure vs. Tire Temperature
Tire temperature is dependent on "cold" tire pressure, driving distance and speed, ambient
temperature and road surface temperature. As the temperature of the tire changes, air in the tire
expands and contracts, changing the tire's air pressure. The cold tire pressure for all Toyota
models will vary and will need to be adjusted accordingly.
"Cold" tire pressure, as shown on the tire pressure label on our vehicles, is generally considered to
be the pressure in a tire that has not been driven in the past 4 hours and has been parked
outdoors.
The TPWS MUST be initialized with the tire pressure marked on the vehicle placard. Tires are then
adjusted according to the information in this bulletin to ensure that the TPWS light does not
illuminate unnecessarily.
Page 4328
Air Flow Meter/Sensor: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: INSTALLATION
1. INSTALL MASS AIR FLOW METER
(a) Install the MAF meter with the 2 screws.
Torque : 1.7 Nm (17 kgf-cm, 15 in-lbf)
(b) Connect the MAF connector.
Page 7816
Control Module HVAC: Diagrams A/C Amplifier
Disassembly
Parking Brake Warning Switch: Service and Repair Disassembly
PARKING BRAKE: PARKING BRAKE PEDAL: DISASSEMBLY
1. REMOVE PARKING BRAKE SWITCH ASSEMBLY
(a) Remove the screw and switch.
Recall 11V185000 - TPMS Non-Compliance
Tire Pressure Module: All Technical Service Bulletins Recall 11V185000 - TPMS Non-Compliance
VEHICLE MAKE/MODEL: MODEL YEAR(S) Toyota/FJ Cruiser 2011
Toyota/Tundra 2009-2011
MANUFACTURER: Gulf States Toyota, Inc.
MFR'S REPORT DATE: March 16, 2011
NHTSA CAMPAIGN ID NUMBER: 11V185000
NHTSA ACTION NUMBER: N/A
COMPONENT: Tires: Pressure Monitoring and Regulating Systems
POTENTIAL NUMBER OF UNITS AFFECTED: 1,489
SUMMARY: Gulf States Toyota is recalling certain model year 2011 FJ Cruiser and model year
2009-2011 Tundra vehicles for failing to comply with the requirements of Federal Motor Vehicle
Safety Standard No. 138, "Tire Pressure Monitoring Systems." The TPMS on some vehicles may
not have been properly calibrated and as a result the low tire pressure warning lamp may not
illuminate should the inflation pressure in one or more of the vehicle's tires fall below the threshold
for when the low tire pressure warning lamp should illuminate.
CONSEQUENCE: Drivers will not receive a warning from the tire pressuring monitor that one or
more tires are underinflated increasing the risk that a vehicle will be driven with one or more
underinflated tires and increasing the risk of a tire failure that may lead to a crash.
REMEDY: Dealers will recalibrate the tire pressure monitoring system in accordance with the
regulation free of charge. The safety recall is expected to begin during April 2011. Owners may
contact Gulf State Toyota Customer Assistance Center toll free at 1-800-444-1074 Monday through
Thursday, 8:30 AM to 5:00 PM, or Friday 8:30 AM to 4:00 PM Central Standard Time.
NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle
Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov.
Page 6536
(1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be
checked by conducting a voltage check.
With each connector still connected, measure the voltage between the body ground and these
terminals (in this order): 1) terminal 1 of connector A; 2) terminal 1 of connector B; and 3) terminal
1 of connector C.
Standard voltage (Fig. 4):
* If the results match the examples above, an open circuit exists in the wire harness between
terminal 1 of connector B and terminal 1 of connector C.
3. CHECK FOR SHORT CIRCUIT
(a) If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance
check with the body ground (below).
(b) Check the resistance with the body ground.
(1) Disconnect connectors A and C and measure the resistance.
Standard resistance (Fig. 6):
HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally.
If your results match the examples above, a short circuit exists between terminal 1 of connector A
and terminal 1 of connector C.
Page 9258
From 11/2009
ENGINE HOOD / DOOR: REAR DOOR (for Double Cab): REASSEMBLY
REAR DOOR TRIM BOARD SUB-ASSEMBLY LH
HINT *
Use the same procedures for the RH side and LH side.
* The procedures listed below are for the LH side.
* A bolt without a torque specification is shown in the standard bolt chart See:
Specifications/Mechanical Specifications/Standard Bolt - Specified Torque For Standard Bolts
1. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY LH
(a) Connect the 2 cables to the inside handle.
(b) Attach the inside handle's knob to the door trim board.
(c) Attach the 9 clips to install the door trim board.
(d) Install the inside handle and door trim board to the door trim panel with the screw.
(e) Install the door trim board to the door panel with the screw
(f) Attach the clip.
2. INSTALL REAR DOOR ARMREST COVER LH
3. INSTALL REAR DOOR FRAME GARNISH LH
(a) Attach the 4 clips to install the rear door frame garnish.
Page 7944
* An airbag or pretensioner may be activated by static electricity. To prevent this, be sure to touch a
metal surface with bare hands to discharge static electricity before performing this procedure.
1. DISPOSE OF LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY (WHEN INSTALLED
IN VEHICLE)
HINT Prepare a battery as the power source to deploy the airbag.
(a) Check the function of SST See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
(b) Read the precaution See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
(c) Disconnect the cable from the negative (-) battery terminal.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to disable the SRS system.
(d) Remove the lower No. 1 instrument panel airbag See: Removal and Replacement/Driver Side
Knee Airbag Assembly/Removal.
(e) Install SST.
(1) Connect SST connector to the lower No. 1 instrument panel airbag.
SST : 09082-00700
SST : 09082-00780
NOTICE: To avoid damaging SST connector and wire harness, do not lock the secondary lock of
the twin lock.
(2) Install the lower No. 1 instrument panel airbag See: Removal and Replacement/Driver Side
Knee Airbag Assembly/Installation.
NOTICE: Take care not to damage SST wire harness.
(3) Move SST at least 10 m (32.8 ft.) away from the vehicle front side window.
(4) Maintaining enough clearance for SST wire harness in the front side window, close all doors
and windows of the vehicle.
NOTICE: Take care not to damage SST wire harness.
(5) Connect the red clip of SST to the positive (+) battery terminal and the black clip of SST to the
negative (-) battery terminal.
(f) Deploy the airbag.
Page 2197
Tire Pressure Monitor Receiver / Transponder: Service and Repair Removal
TIRE AND WHEEL: TIRE PRESSURE WARNING RECEIVER: REMOVAL
1. REMOVE ROOF HEADLINING ASSEMBLY
(a) for Regular Cab:
Remove the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Removal.
(b) for Double Cab:
Remove the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Double Cab)/Removal.
(c) for CrewMax:
Remove the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (for CrewMax)/Removal.
2. REMOVE TIRE PRESSURE WARNING ANTENNA AND RECEIVER
(a) Disconnect the receiver connector.
(b) Remove the bolt and receiver.
Components
Rear Fender Liner: Service and Repair Components
EXTERIOR: FENDER LINER (for Rear Side): COMPONENTS
Page 3140
(4) for Fuel Pipe Clamp Type:
Install the fuel pipe clamp to the connector.
(5) for Fuel Hose Connector Cover Type:
Attach the lock claw to the connector by pushing down on the cover, as shown in the illustration.
(6) Check that there is no fuel leakage.
3. CHECK FOR FUEL LEAK
(a) Check that there are no fuel leaks after performing maintenance anywhere on the fuel system
See: Fuel Delivery and Air Induction/Testing
and Inspection.
Page 3607
Engine Bank Identification
Page 292
Relay Box: Connector Views
Engine Room R/B, J/B - Engine Compartment Left
Page 7738
Evaporator Temperature Sensor / Switch: Service and Repair Reassembly
AIR CONDITIONING: FRONT EVAPORATOR TEMPERATURE SENSOR: REASSEMBLY
1. INSTALL NO. 1 COOLER THERMISTOR
NOTICE: If reusing the evaporator, do not insert the sensor into a location where the sensor was
previously inserted.
(a) Install the sensor to a location that is 1 fin to the right or left of its previous location.
2. INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY
(a) Install the evaporator to the blower case (front side).
(b) Install the blower case (back side).
Components
Variable Valve Timing Actuator: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT OIL CONTROL VALVE: COMPONENTS
Page 701
Page 8212
is over 45°, check that the belt locks. If the operation is not as specified, replace the seat belt
assembly.
(b) for Passenger's Seat only:
Check the fastening function of the child restraint system.
NOTICE: The check should be performed with the outer belt installed.
(1) When the belt is pulled out fully, the belt should automatically start to retract.
(2) After the belt has fully retracted, the belt should be able to be pulled out and retracted again.
If the operation is not as specified, replace the belt assembly.
Front Seat Outer Belt Assembly (for Regular Cab)
SEAT BELT: FRONT SEAT OUTER BELT ASSEMBLY (for Regular Cab): INSPECTION
1. INSPECT FRONT SEAT OUTER BELT ASSEMBLY
CAUTION: Do not disassemble the retractor.
(a) Before installing the seat belt, check the ELR.
(1) When the inclination of the retractor is 15° or less, check that the belt can be pulled from the
retractor. When the inclination of the retractor
is over 45°, check that the belt locks. If the operation is not as specified, replace the seat belt
assembly.
(b) for Passenger's Seat only:
Check the fastening function of the child restraint system.
NOTICE: The check should be performed with the outer belt installed.
(1) When the belt is pulled out fully, the belt should automatically start to retract.
(2) After the belt has fully retracted, the belt should be able to be pulled out and retracted again.
If the operation is not as specified, replace the belt assembly.
Rear Center Seat Outer Belt Assembly (for Double Cab)
SEAT BELT: REAR CENTER SEAT OUTER BELT ASSEMBLY (for Double Cab): INSPECTION
1. INSPECT CENTER REAR SEAT OUTER BELT ASSEMBLY
Page 2964
Oxygen Sensor: Diagrams Heated Oxygen Sensor
Locations
Temperature Sensor/Switch: Locations
JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION
Page 8169
Removal
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Column
Shift Type): REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service
and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Removal
3. REMOVE CENTER AIRBAG SENSOR ASSEMBLY
Page 5621
Steering Angle Sensor: Service and Repair Installation
BRAKE CONTROL: STEERING ANGLE SENSOR: INSTALLATION
1. INSTALL STEERING ANGLE SENSOR See: Restraint Systems/Air Bag Systems/Clockspring
Assembly / Spiral Cable/Service and
Repair/Installation
2. INSTALL SPIRAL CABLE SUB-ASSEMBLY See: Restraint Systems/Air Bag
Systems/Clockspring Assembly / Spiral Cable/Service and
Repair/Installation
3. INSTALL UPPER STEERING COLUMN COVER See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Removal and
Replacement/Steering Column Assembly (for Manual Tilt)/Installation
4. INSTALL LOWER STEERING COLUMN COVER See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Removal and
Replacement/Steering Column Assembly (for Manual Tilt)/Installation
5. ADJUST SPIRAL CABLE See: Restraint Systems/Air Bag Systems/Clockspring Assembly /
Spiral Cable/Service and Repair/Installation
6. INSTALL STEERING WHEEL ASSEMBLY See: Steering and Suspension/Steering/Steering
Column/Service and Repair/Removal and
Replacement/Steering Column Assembly (for Manual Tilt)/Installation
7. INSTALL STEERING PAD See: Restraint Systems/Air Bag Systems/Air Bag/Service and
Repair/Removal and Replacement/Steering
Pad/Installation
8. INSTALL LOWER NO. 3 STEERING WHEEL COVER See: Restraint Systems/Air Bag
Systems/Air Bag/Service and Repair/Removal and
Replacement/Steering Pad/Installation
9. INSTALL LOWER NO. 2 STEERING WHEEL COVER See: Restraint Systems/Air Bag
Systems/Air Bag/Service and Repair/Removal and
Replacement/Steering Pad/Installation
10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
11. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
Page 7050
Standard wheel angle (unloaded vehicle):
for Double Cab of Long Deck
Page 6970
"Case2" Open the secondary locking device.
[B] For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray
Gray or White : Black
Page 5941
Symbols Used Within Diagrams
Symbols Used Within Diagrams
Page 6788
"Case2" Open the secondary locking device.
[B] For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray
Gray or White : Black
Page 2737
Body Control Module: Locations LIN Communication System
MULTIPLEX COMMUNICATION: LIN COMMUNICATION SYSTEM: PARTS LOCATION
Page 4692
Transmission Position Switch/Sensor: Diagrams
Page 7504
Tire Pressure Warning Reset Switch: Diagrams
Page 7233
Power Steering Pressure Switch: Testing and Inspection
1UR-FE ENGINE CONTROL SYSTEM: POWER STEERING OIL PRESSURE SWITCH:
ON-VEHICLE INSPECTION
1. INSPECT POWER STEERING OIL PRESSURE SWITCH
(a) Check the oil pressure switch.
(1) Connect the Techstream to the DLC3.
(2) Turn the ignition switch to ON.
(3) Turn the Techstream main switch on.
(4) Enter the following menus: Powertrain / Engine and ECT / Data List / All Data / Power Steering
pressure.
(5) Start the engine.
(6) Operate the steering wheel while idling, and read the value on the Techstream.
Standard:
(7) If not as specified, check for DTCs See: Powertrain Management/Computers and Control
Systems/Testing and Inspection/Reading and
Clearing Diagnostic Trouble Codes/DTC Check / Clear. If the power steering system inspection
results are normal and a DTC is not output, replace the power steering oil pressure switch.
Inspect the power steering system See: Testing and Inspection/Component Tests and General
Diagnostics/Power Steering System/On-Vehicle Inspection. If the power steering system inspection
results are normal and a DTC is not output, replace the power steering oil pressure switch.
Page 9405
(b) Remove the 2 bolts.
(c) Remove the 10 bolts.
(d) Pull the radiator grille to detach the 5 clips and remove the radiator grille.
2. REMOVE LOWER RADIATOR GRILLE BRACKET LH
(a) Remove the bolt and nut.
(b) Detach the clip and remove the lower radiator grille bracket.
3. REMOVE LOWER RADIATOR GRILLE BRACKET RH
HINT Use the same procedures described for the LH side.
Page 6289
6. PROBLEM SYMPTOMS TABLE
When a "Normal" code is output during a DTC check but the problem is still occurring, use the
Problem Symptoms Table. The suspected areas (circuits or parts) for each problem symptom are
in the table. The suspected areas are listed in order of probability. A description of each of the
chart's columns is below.
HINT In some cases, the problem is not detected by the diagnostic system even though a problem
symptom is present. It is possible that the problem is occurring outside the detection range of the
diagnostic system, or that the problem is occurring in a completely different system.
7. CIRCUIT INSPECTION
A description of the main areas of each circuit inspection is below.
Locations
Fuse: Locations
Engine Room R/B, J/B - Engine Compartment Left
Page 7284
(b) for 3UR-FBE:
Install the engine assembly See: Engine, Cooling and Exhaust/Engine/Service and
Repair/Removal and Replacement/Engine Assembly/Installation.
(c) for 1UR-FE:
Install the engine assembly See: Engine, Cooling and Exhaust/Engine/Service and
Repair/Removal and Replacement/Engine Assembly/Installation.
(d) for 3UR-FE:
Install the engine assembly See: Engine, Cooling and Exhaust/Engine/Service and
Repair/Removal and Replacement/Engine Assembly/Installation.
7. INSTALL FRONT WHEEL
8. BLEED POWER STEERING FLUID (for 1GR-FE) See: Testing and Inspection/Component Tests
and General Diagnostics/Power Steering
System/On-Vehicle Inspection
9. BLEED POWER STEERING FLUID (for 1UR-FE) See: Testing and Inspection/Component Tests
and General Diagnostics/Power Steering
System/On-Vehicle Inspection
10. BLEED POWER STEERING FLUID (for 3UR-FE, 3UR-FBE) See: Testing and
Inspection/Component Tests and General Diagnostics/Power
Steering System/On-Vehicle Inspection
11. CHECK POWER STEERING FLUID LEVEL (for 1GR-FE) See: Testing and
Inspection/Component Tests and General Diagnostics/Power
Steering System/On-Vehicle Inspection
12. CHECK POWER STEERING FLUID LEVEL (for 1UR-FE) See: Testing and
Inspection/Component Tests and General Diagnostics/Power
Steering System/On-Vehicle Inspection
13. CHECK POWER STEERING FLUID LEVEL (for 3UR-FE, 3UR-FBE) See: Testing and
Inspection/Component Tests and General
Diagnostics/Power Steering System/On-Vehicle Inspection
14. INSPECT FOR POWER STEERING FLUID LEAK
15. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
HINT Perform this procedure with the front of the vehicle jacked up.
16. ADJUST FRONT WHEEL ALIGNMENT
(a) Adjust the front wheel alignment See: Alignment/Service and Repair.
Spiral Cable
Clockspring Assembly / Spiral Cable: Diagrams Spiral Cable
Page 5176
2. Install ChaSSiSEAR(TM) on the vehicle and attempt to isolate the source of the noise. Is the
noise loudest near the rear wheel bearing assembly?
^ YES - Go to step 3.
^ NO - This TSB does NOT apply. Continue diagnosis to isolate the source of the noise.
3. Replace the rear wheel bearing caliper bracket and related parts.
Refer to the Technical Information System (TIS) applicable model year Repair Manual:
4. Test drive the vehicle and confirm the noise is eliminated.
5. Re-check rear differential oil level and confirm NO leaks are present.
Page 3776
(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(2) If the result is not as specified, replace the MAF meter.
Page 9294
Page 6156
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: ELECTRONIC
CIRCUIT INSPECTION PROCEDURE
1. BASIC INSPECTION
(a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS
(1) Unless otherwise stated, all resistance measurements should be made at an ambient
temperature of 20°C (68°F). Resistance measurements
may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been
running. Measurements should be made after the engine has cooled down.
(b) HANDLING CONNECTORS
(1) When disconnecting a connector, first squeeze the mating halves tightly together to release the
lock, and then press the lock claw and
separate the connector.
(2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly
and separate it.
(3) Before connecting a connector, check that there are no deformed, damaged, loose or missing
terminals.
(4) When connecting a connector, press firmly until it locks with a "click" sound.
(5) If checking a connector with a TOYOTA electrical tester, check the connector from the backside
(harness side) using a mini test lead.
NOTICE: *
As a waterproof connector cannot be checked from the backside, check it by connecting a
sub-harness.
* Do not damage the terminals by moving the inserted tester needle.
(c) CHECKING CONNECTORS
(1) Checking when a connector is connected: Squeeze the connectors together to confirm that they
are fully connected and locked.
(2) Checking when a connector is disconnected: Check by pulling the wire harness lightly from the
backside of the connector. Look for
unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for
corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or
deformed terminals.
(3) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a
female terminal, and check for ample tension
Page 8209
Seat Belt: Testing and Inspection Front Seat Outer Belt Assembly (for Double Cab)
SEAT BELT: FRONT SEAT OUTER BELT ASSEMBLY (for Double Cab): INSPECTION
1. INSPECT FRONT SEAT OUTER BELT ASSEMBLY
CAUTION: Do not disassemble the retractor.
(a) Before installing the seat belt, check the ELR.
(1) When the inclination of the retractor is 15° or less, check that the belt can be pulled from the
retractor. When the inclination of the retractor
is over 45°, check that the belt locks. If the operation is not as specified, replace the seat belt
assembly.
(b) for Passenger's Seat only:
Check the fastening function of the child restraint system.
NOTICE: The check should be performed with the outer belt installed.
(1) When the belt is pulled out fully, the belt should automatically start to retract.
(2) After the belt has fully retracted, the belt should be able to be pulled out and retracted again.
If the operation is not as specified, replace the belt assembly.
Page 6203
Removal
OTHER SYSTEM: POWER OUTLET SOCKET (for Column Shift Type): REMOVAL
1. REMOVE FRONT DOOR SCUFF PLATE LH (for Double Cab)
2. REMOVE FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Removal
3. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Removal
4. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal
Front Brake Flexible Hose
Brake Hose/Line: Service and Repair Front Brake Flexible Hose
Components
BRAKE: FRONT BRAKE FLEXIBLE HOSE: COMPONENTS
Removal
BRAKE: FRONT BRAKE FLEXIBLE HOSE: REMOVAL
HINT *
Use the same procedures for the LH side and RH side.
* The procedures listed below are for the LH side.
1. REMOVE FRONT WHEEL
2. DRAIN BRAKE FLUID
NOTICE: Wash off brake fluid immediately if it comes in contact with any painted surface.
3. REMOVE FRONT FLEXIBLE HOSE
(a) Remove the brake tube and wheel cylinder tube from the flexible hose with a union nut wrench
while holding the flexible hose with a wrench.
NOTICE: *
Do not bend or damage the brake tube and wheel cylinder tube.
* Do not allow any foreign matter such as dirt and dust to enter the brake tube and wheel cylinder
tube from the connecting points.
(b) Remove the 2 clips (labeled A) and flexible hose.
Installation
BRAKE: FRONT BRAKE FLEXIBLE HOSE: INSTALLATION
HINT *
Use the same procedures for the LH side and RH side.
* The procedures listed below are for the LH side.
1. INSTALL FRONT FLEXIBLE HOSE
(a) Attach 2 new clips (labeled A) to the flexible hose.
Page 1295
Crankshaft Position Sensor: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: CRANKSHAFT POSITION SENSOR: INSTALLATION
1. INSTALL CRANKSHAFT POSITION SENSOR
(a) Install the sensor with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(b) Connect the sensor connector.
2. INSTALL CRANKSHAFT POSITION SENSOR PROTECTOR
(a) Install the sensor protector with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
Locations
Fuel Pump Relay: Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 6044
[A] For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
"Case1" Raise the terminal retainer up to the temporary lock position.
Components
Parking Assist Switch: Service and Repair Components
PARK ASSIST / MONITORING: CLEARANCE SONAR MAIN SWITCH: COMPONENTS
Page 8262
(b) Remove the seat belt as shown in the illustration.
17. REMOVE CENTER REAR SEAT OUTER BELT ASSEMBLY
(a) Remove the 3 nuts and belt sensor.
(b) Remove the nut and bolt, and then remove the outer belt.
Installation
SEAT BELT: REAR CENTER SEAT OUTER BELT ASSEMBLY (for CrewMax): INSTALLATION
1. INSTALL CENTER REAR SEAT OUTER BELT ASSEMBLY
(a) Install the outer belt with the bolt and nut.
HINT
Page 1991
Instrument Panel (Floor Shift)
Instrument Panel (Column Shift)
Page 1584
Transmission Speed Sensor: Diagrams
Page 4598
(1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be
checked by conducting a voltage check.
With each connector still connected, measure the voltage between the body ground and these
terminals (in this order): 1) terminal 1 of connector A; 2) terminal 1 of connector B; and 3) terminal
1 of connector C.
Standard voltage (Fig. 4):
* If the results match the examples above, an open circuit exists in the wire harness between
terminal 1 of connector B and terminal 1 of connector C.
3. CHECK FOR SHORT CIRCUIT
(a) If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance
check with the body ground (below).
(b) Check the resistance with the body ground.
(1) Disconnect connectors A and C and measure the resistance.
Standard resistance (Fig. 6):
HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally.
If your results match the examples above, a short circuit exists between terminal 1 of connector A
and terminal 1 of connector C.
Components
Engine Temperature Sensor: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: ENGINE COOLANT TEMPERATURE SENSOR:
COMPONENTS
Components
Power Steering Pressure Switch: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: POWER STEERING OIL PRESSURE SWITCH:
COMPONENTS
Locations
Overdrive Switch: Locations
A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS
LOCATION
Front Seat Side Airbag Assembly (except Fold Down Seat
Type)
Air Bag: Testing and Inspection Front Seat Side Airbag Assembly (except Fold Down Seat Type)
SUPPLEMENTAL RESTRAINT SYSTEM: FRONT SEAT SIDE AIRBAG ASSEMBLY (except Fold
Down Seat Type): ON-VEHICLE INSPECTION
1. CHECK FRONT SEAT SIDE AIRBAG ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION)
(a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnosis System.
(b) With the front seat side airbag installed on the vehicle, perform a visual check. If there are any
defects as mentioned below, replace the front
seat with a new one:
Cuts, minute cracks or marked discoloration on the front seatback around the front seat side
airbag.
2. CHECK FRONT SEAT SIDE AIRBAG ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND
AIRBAG HAS NOT DEPLOYED)
(a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnosis System.
(b) With the front seat side airbag removed from the vehicle, perform a visual check. If there are
any defects as mentioned below, replace the front
seat side airbag with a new one:
* Cuts, minute cracks or marked discoloration on the front seat side airbag.
* Cracks or other damage to the wire harness or connector.
CAUTION: For removal and installation procedures of the front seat side airbag, be sure to follow
the correct procedure.
Page 8298
^ Part Number Information
^ Owner Instructions
^ Seat Belt Extender Worksheet
Warranty Information
Ordering Procedure
1. Dealer verifies the need for a Seat Belt Extender and obtains a current copy of this TSIB and
copies the worksheet.
2. Dealer measures the customer and completes the worksheet. Dealer determines the correct part
number and places an order for the part through
Dealer Daily.
3. Dealer receives Seat Belt Extender and calls the customer to check the fit of the part.
4. If the Seat Belt Extender fit is good, dealership personnel complete the Customer Information
Label attached to the part, explains usage of the part,
and gives the customer a copy of the completed worksheet.
Page 2059
Remove the blown fuse and disconnect all loads of the fuse.
Connect a test light in place of the fuse.
Establish conditions in which the test light comes on.
Example:
- [A] - Ignition SW on
- [B] - Ignition SW and SW1 on
- [C] - Ignition SW, SW1 and Relay on (Connect the Relay) and SW2 off (or Disconnect SW2)
Disconnect and reconnect the connectors while watching the test light.
Page 3695
M. Turn ignition OFF for a minimum of 10 seconds. Then click Next.
N. Turn ignition to the ON position. Then click Next.
0. Confirm all calibrations were updated as specified in the service bulletin. Then click Finish.
Page 3874
Page 1322
(a) For an open circuit in the wire harness in Fig. 1, check the resistance or voltage, as described
below.
(b) Check the resistance.
(1) Disconnect connectors A and C and measure the resistance between them.
Standard resistance (Fig. 2):
HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally.
If the results match the examples above, an open circuit exists between terminal 1 of connector A
and terminal 1 of connector C.
(2) Disconnect connector B and measure the resistance between the connectors.
Standard resistance (Fig. 3):
* If the results match the examples above, an open circuit exists between terminal 1 of connector
B2 and terminal 1 of connector C.
(c) Check the voltage.
Page 5747
(a) Using a union nut wrench, disconnect the brake tube (labeled B) from the brake master
cylinder.
5. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY
(a) Remove the 2 nuts and brake master cylinder from the brake booster.
NOTICE: *
The master cylinder requires careful handling. Do not allow the master cylinder to receive any
impact, such as from being dropped. Do not reuse a master cylinder that has been dropped.
* Do not strike or pinch the master cylinder piston, and do not cause any damage to the master
cylinder piston by any other means.
* When installing the master cylinder to the brake booster, or when removing the master cylinder
from the brake booster, make sure that the master cylinder is kept horizontal or with its tip facing
downward (the piston faces upward) to prevent the master cylinder piston from falling out.
* Do not allow any foreign objects to contaminate the master cylinder piston. If a foreign object gets
on the piston, remove it by using a piece of cloth, and then apply an even layer of lithium soap
base glycol grease around the circumference (sliding part) of the piston.
* Do not use any other type of grease or fluid.
* Be careful not to damage the brake tubes.
(b) Remove the brake master cylinder seal from the brake master cylinder.
Installation
BRAKE: BRAKE MASTER CYLINDER: INSTALLATION
1. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY
(a) Install a new brake master cylinder seal onto the brake master cylinder.
(b) Install the brake master cylinder with 2 new nuts.
Torque : 25 Nm (255 kgf-cm, 18 ft-lbf)
2. CONNECT FRONT NO. 1 BRAKE TUBE
(a) Using a union nut wrench, connect the brake tube (labeled A) to the brake master cylinder.
without union nut wrench - Torque : 20 Nm (199 kgf-cm, 14 ft-lbf)
with union nut wrench - Torque : 18 Nm (186 kgf-cm, 13 ft-lbf)
Page 1692
*: for 5 leaf spring
Standard Steering Angle Inclination
for Regular Cab of Standard Deck
Page 3190
Page 8988
11. INSTALL FRONT DOOR SCUFF PLATE LH
(a) for Regular Cab:
Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular Cab)/Installation.
(b) for Double Cab:
Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Installation.
(c) for CrewMax:
Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for CrewMax)/Installation.
Page 933
Evaporator Temperature Sensor / Switch: Service and Repair Disassembly
AIR CONDITIONING: FRONT EVAPORATOR TEMPERATURE SENSOR: DISASSEMBLY
1. REMOVE AIR CONDITIONING UNIT
(a) Remove the air conditioning unit See: Heating and Air Conditioning/Housing Assembly
HVAC/Service and Repair/Removal and
Replacement/Removal.
2. REMOVE LOWER DEFROSTER NOZZLE ASSEMBLY
(a) Detach the 4 claws and remove the nozzle.
3. REMOVE NO. 3 AIR DUCT SUB-ASSEMBLY
(a) Detach the 4 claws and remove the duct.
4. REMOVE AIR FILTER COVER PLATE
(a) Detach the 2 clips and remove the plate.
5. REMOVE CLEAN AIR FILTER
Page 7836
Ambient Temperature Sensor / Switch HVAC: Service and Repair Installation
AIR CONDITIONING: AMBIENT TEMPERATURE SENSOR: INSTALLATION
1. INSTALL AMBIENT TEMPERATURE SENSOR
(a) Attach the clamp to install the ambient temperature sensor.
(b) Connect the connector.
Page 3418
(1) For Column Shift Type, refer to the following procedures See: Heating and Air
Conditioning/Control Assembly/Service and
Repair/Air Conditioning Panel (for Column Shift Type)/Removal.
(2) For Floor Shift Type, refer to the following procedures See: Heating and Air
Conditioning/Control Assembly/Service and Repair/Air
Conditioning Panel (for Floor Shift Type)/Removal.
(b) Check that the malfunction disappears.
OK:
Malfunction disappears.
NG -- REPLACE AIR CONDITIONING AMPLIFIER ASSEMBLY See: Heating and Air
Conditioning/Control Module HVAC/Service and Repair/Removal
OK -- END (INTEGRATION CONTROL AND PANEL ASSEMBLY IS DEFECTIVE)
Open In One Side of CAN Branch Line
CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: Open in One Side of CAN Branch
Line - Open in One Side of CAN Branch Line
DESCRIPTION
If 2 or more ECUs and/or sensors do not appear on the Techstream's "CAN Bus Check" screen,
one side of the CAN branch wire may be open. (One side of the CANH [branch wire]/CANL [branch
wire] of the ECU and/or sensor is open.)
HINT *
*1: w/ Bus Buffer ECU
* *2: w/ 4WD
* *3: w/ Power Steering ECU
WIRING DIAGRAM
Page 9174
Up to 11/2009
Brake Fluid Pressure Sensor/Switch: Locations Up to 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Air Fuel Ratio Sensor
Oxygen Sensor: Diagrams Air Fuel Ratio Sensor
Page 1486
when inserting and after full engagement.
NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal.
(d) REPAIR METHOD OF CONNECTOR TERMINAL
(1) If there is any foreign matter on the terminal, clean the contact point using an air gun or cloth.
Never rub the contact point using sandpaper
as the plating may come off.
(2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is
gold-plated (gold color), use a gold-plated female
terminal; if it is silver-plated (silver color), use a silver-plated female terminal.
(3) Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock
into the housing, the housing may have to be
replaced.
(e) HANDLING OF WIRE HARNESS
(1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be
restored in the same way.
(2) Never twist, pull or slacken the wire harness more than necessary.
(3) The wire harness should never come into contact with a high temperature part, or rotating,
moving, vibrating or sharp-edged parts. Avoid
contact with panel edges, screw tips and other sharp items.
(4) When installing parts, never pinch the wire harness.
(5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with
vinyl tape.
2. CHECK FOR OPEN CIRCUIT
Page 327
Parts Information
Calibration Information
Required Tools & Equipment
Repair Procedure
Page 5958
Push the secondary locking device or terminal retainer in to the full lock position.
CONNECT CONNECTOR
Voltage Check
VOLTAGE CHECK
Page 3450
NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO CENTER AIRBAG
SENSOR (CANH, CANL)
OK -- REPLACE CENTER AIRBAG SENSOR
19. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (NO. 2 JUNCTION CONNECTOR - AIR
CONDITIONING AMPLIFIER)
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- CHECK FOR SHORT TO B+ IN CAN BUS WIRE (AIR CONDITIONING AMPLIFIER) OK -Continue to next step.
20. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (NO. 2 JUNCTION CONNECTOR - BUS
BUFFER ECU)
NOTICE: For vehicles without a bus buffer ECU, go to "CHECK FOR SHORT TO B+ IN CAN BUS
WIRE (NO. 2 JUNCTION CONNECTOR - 4WD CONTROL ECU)".
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- CHECK FOR SHORT TO B+ IN CAN BUS WIRE (BUS BUFFER ECU) OK -- Continue to
next step.
21. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (NO. 2 JUNCTION CONNECTOR - 4WD
CONTROL ECU)
Page 8903
Removal
DOOR LOCK: DOOR CONTROL RECEIVER (for Regular Cab): REMOVAL
1. REMOVE UPPER BACK PANEL GARNISH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining
(For Regular Cab)/Removal
2. REMOVE LUGGAGE COMPARTMENT BOX LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof
Headlining (For Regular Cab)/Removal
3. REMOVE LUGGAGE COMPARTMENT BOX RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof
Headlining (For Regular Cab)/Removal
4. REMOVE FRONT DOOR SCUFF PLATE RH
Page 2982
Power Steering Pressure Switch: Testing and Inspection
1UR-FE ENGINE CONTROL SYSTEM: POWER STEERING OIL PRESSURE SWITCH:
ON-VEHICLE INSPECTION
1. INSPECT POWER STEERING OIL PRESSURE SWITCH
(a) Check the oil pressure switch.
(1) Connect the Techstream to the DLC3.
(2) Turn the ignition switch to ON.
(3) Turn the Techstream main switch on.
(4) Enter the following menus: Powertrain / Engine and ECT / Data List / All Data / Power Steering
pressure.
(5) Start the engine.
(6) Operate the steering wheel while idling, and read the value on the Techstream.
Standard:
(7) If not as specified, check for DTCs See: Computers and Control Systems/Testing and
Inspection/Reading and Clearing Diagnostic
Trouble Codes/DTC Check / Clear. If the power steering system inspection results are normal and
a DTC is not output, replace the power steering oil pressure switch.
Inspect the power steering system See: Steering and Suspension/Steering/Testing and
Inspection/Component Tests and General Diagnostics/Power Steering System/On-Vehicle
Inspection. If the power steering system inspection results are normal and a DTC is not output,
replace the power steering oil pressure switch.
Page 4532
Ignition Relay: Testing and Inspection
1UR-FE ENGINE CONTROL SYSTEM: IGNITION RELAY NO. 2: ON-VEHICLE INSPECTION
1. REMOVE INTEGRATION RELAY
(a) Remove the engine room relay block cover.
(b) Using a screwdriver, detach the 2 claws and remove the integration relay from the engine room
relay block.
HINT Tape the screwdriver tip before use.
(c) Disconnect the 3 connectors.
2. INSPECT INTEGRATION RELAY (IG2)
NOTICE: *
Some relays are built into the integration relay. The integration relay cannot be disassembled. If
there is a malfunction in the circuit of the integration relay, replace the integration relay.
* The internal circuit of the integration relay is as shown in the illustration below. Inspect the
integration relay using the following procedures.
(a) Measure the resistance of the IG2 MAIN fuse.
(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(2) If the result is not as specified, replace the IG2 MAIN fuse.
(b) Measure the resistance of the ignition relay No. 2 (IG2).
Page 1168
Engine Temperature Sensor: Testing and Inspection
1UR-FE ENGINE CONTROL SYSTEM: ENGINE COOLANT TEMPERATURE SENSOR:
INSPECTION
1. INSPECT ENGINE COOLANT TEMPERATURE SENSOR
(a) Partially immerse the sensor in water and warm up the water.
(b) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(c) If the result is not as specified, replace the engine coolant temperature sensor.
NOTICE: When checking the sensor in water, keep the terminals dry. After the check, wipe the
sensor dry.
HINT If the result is as specified, do not replace the engine coolant temperature sensor.
Page 5198
SST : 09240-00020
Standard clearance:
4. TEMPORARILY INSTALL INBOARD JOINT BOOT
(a) Temporarily install 2 new boot clamps and a boot to the outboard joint shaft.
5. INSTALL INBOARD JOINT SHAFT
(a) Install the cage to the outboard joint shaft.
NOTICE: Insert the cage with its smaller inner diameter side facing the outboard joint.
(b) Align the matchmarks placed before removal.
(c) Install the inner race.
(d) Using a snap ring expander, install a new snap ring.
(e) Align the matchmarks placed before removal, and install the cage to the inner race.
Airbag System
Air Bag Deactivation Switch: Locations Airbag System
SUPPLEMENTAL RESTRAINT SYSTEM: AIRBAG SYSTEM: PARTS LOCATION
Locations
Solar Sensor: Locations
AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Automatic Air Conditioning System):
PARTS LOCATION
Page 1459
2. INSTALL FRONT SEAT ASSEMBLY LH
(a) Install the front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Fold Down Seat
Type)/Installation.
3. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
Page 3870
Transmission Position Switch/Sensor: Diagrams
Page 2430
^ 1AR-FE (Highlander Venza)
^ 2AR-FE (RAV4 Camry)
Warranty Information
Required Tools & Equipment
Page 8775
Front Door Tweeter
Front Side Speaker
Page 7103
Tire Pressure Module: Locations
TIRE AND WHEEL: TIRE PRESSURE WARNING SYSTEM: PARTS LOCATION
Up to 11/2009
Steering Angle Sensor: Locations Up to 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 767
* The zero point calibration is performed only once after the system enters test mode.
* Calibration cannot be performed again until the stored data is cleared once.
(2) Check that the buzzer sounds for 3 seconds and DTC C1336 is erased.
(3) Turn the ignition switch OFF.
4. CLEAR ZERO POINT CALIBRATION DATA (WHEN USING SST CHECK WIRE)
(a) Turn the ignition switch to ON.
(b) Using SST, connect and disconnect terminals 12 (TS) and 4 (CG) of the DLC3 4 times or more
within 8 seconds.
SST : 09843-18040
(c) Check that the SLIP indicator light comes on.
(d) Using a check wire, perform the zero point calibration of the deceleration sensor.
5. PERFORM ZERO POINT CALIBRATION OF MASTER CYLINDER PRESSURE SENSOR AND
DECELERATION SENSOR (WHEN
USING SST CHECK WIRE)
NOTICE: *
While obtaining the zero point, do not vibrate the vehicle by tilting, moving or shaking it and keep it
stationary. (Do not start the engine.)
* While obtaining the zero point, do not depress the brake pedal.
* Obtain the zero point on a level surface (with an inclination of 1° or less).
(a) Enter Test Mode.
(1) Turn the ignition switch off.
(2) Check that the shift lever is in parking or neutral and apply the parking brake.
CAUTION: Application of the parking brake is not necessary for entering test mode. However,
apply the parking brake for safety.
(3) Using SST, connect terminals 12 (TS) and 4 (CG) of the DLC3.
SST : 09843-18040
(4) Turn the ignition switch to ON.
NOTICE: Do not start the engine.
(b) Obtain the zero points of the master cylinder pressure sensor and deceleration sensor.
Page 6978
when inserting and after full engagement.
NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal.
(d) REPAIR METHOD OF CONNECTOR TERMINAL
(1) If there is any foreign matter on the terminal, clean the contact point using an air gun or cloth.
Never rub the contact point using sandpaper
as the plating may come off.
(2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is
gold-plated (gold color), use a gold-plated female
terminal; if it is silver-plated (silver color), use a silver-plated female terminal.
(3) Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock
into the housing, the housing may have to be
replaced.
(e) HANDLING OF WIRE HARNESS
(1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be
restored in the same way.
(2) Never twist, pull or slacken the wire harness more than necessary.
(3) The wire harness should never come into contact with a high temperature part, or rotating,
moving, vibrating or sharp-edged parts. Avoid
contact with panel edges, screw tips and other sharp items.
(4) When installing parts, never pinch the wire harness.
(5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with
vinyl tape.
2. CHECK FOR OPEN CIRCUIT
Page 3367
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION: Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC
terminals are touched, the IC may be destroyed by static electricity.)
When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact with the terminals of leads from the IC, etc. of the
replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown on the left.
DISCONNECT CONNECTOR
Page 9215
Disassembly
ENGINE HOOD / DOOR: FRONT DOOR (for Double Cab): DISASSEMBLY
FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH
Page 6633
(a) Attach the 2 claws to install the power outlet socket cover.
2. INSTALL POWER OUTLET SOCKET ASSEMBLY
(a) Attach the claw to install the power outlet socket.
3. INSTALL LOWER INSTRUMENT CLUSTER FINISH PANEL See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column
Shift Type)/Installation
4. INSTALL FRONT ASH RECEPTACLE BOX SUB-ASSEMBLY
5. INSTALL CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service
and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
6. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Installation
7. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
8. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Installation
9. INSTALL FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Installation
10. INSTALL FRONT DOOR SCUFF PLATE LH (for Double Cab)
Page 9033
Trailer Connector: Connector Views
Page 5921
Torque : 11 Nm (107 kgf-cm, 8 ft-lbf)
(b) Connect the speed sensor connector (labeled C).
NOTICE: Securely connect the connector.
4. INSTALL REAR WHEEL See: Steering and Suspension/Suspension/Suspension Strut / Shock
Absorber/Service and Repair/Removal and
Replacement/Rear Shock Absorber/Installation
5. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
6. CHECK SPEED SENSOR SIGNAL
(a) Check the speed sensor signal See: Antilock Brakes / Traction Control Systems/Testing and
Inspection/Scan Tool Testing and
Procedures/Test Mode Procedure.
Page 6049
Release the locking lug from terminal and pull the terminal out from rear.
INSTALL TERMINAL TO CONNECTOR
Insert the terminal.
HINT: Make sure the terminal is positioned correctly.
Insert the terminal until the locking lug locks firmly.
Insert the terminal with terminal retainer in the temporary lock position.
Page 1398
Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)
NOTICE: *
If the side airbag sensor has been dropped, or there are any cracks, dents or other defects in the
case, bracket or connector, replace it with a new one.
* When installing the side airbag sensor, be careful that the SRS wiring does not interfere with
other parts and that it is not pinched between other parts.
(d) Check that there is no looseness in the installation parts of the side airbag sensor.
(e) Connect the connector.
8. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY LH (for Rear Side) See: Body and
Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation
9. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH (for Rear Side)
10. INSTALL REAR DOOR SCUFF PLATE LH (for Rear Side) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and Repair/Roof
Headlining (For Double Cab)/Installation
11. INSTALL REAR SEAT ASSEMBLY (for Rear Side)
(a) Install the rear seat assembly See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Rear Seat Assembly (for Double
Cab)/Installation.
12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
13. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
Page 6254
Instrument Panel (Floor Shift)
Instrument Panel (Column Shift)
Page 9126
3. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE
HINT The diagnostic system in the TOYOTA TUNDRA has various functions.
* The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU
memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a
previous malfunction's DTC can be checked by a technician during troubleshooting.
* Another function is the Input Signal Check, which checks if the signals from various switches are
sent to the ECU correctly.
* By using these functions, the problem areas can be narrowed down and troubleshooting is more
effective. Diagnostic functions are incorporated in the following systems in the TOYOTA TUNDRA.
Page 2168
Tire Pressure Warning Reset Switch: Service and Repair Removal
TIRE AND WHEEL: TIRE PRESSURE WARNING RESET SWITCH: REMOVAL
1. REMOVE FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Removal
2. REMOVE FRONT DOOR SCUFF PLATE LH (for Double Cab, for CrewMax) See: Body and
Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal
3. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Removal
4. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal
5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Removal
6. REMOVE TIRE PRESSURE WARNING RESET SWITCH
(a) Disconnect the switch connector.
(b) Detach the 2 claws and remove the reset switch.
Page 666
(b) If the result is not as specified, replace the control switch assembly.
Locations
Transmission Position Switch/Sensor: Locations
A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS
LOCATION
Page 4909
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Floor Shift Type)/Removal
5. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal
6. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding
/ Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
7. REMOVE REAR UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
8. REMOVE REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
9. REMOVE CONSOLE BOX CARPET
10. REMOVE REAR CONSOLE BOX ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal
11. REMOVE FRONT CONSOLE BOX See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal
and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal
12. REMOVE TRANSMISSION FLOOR SHIFT ASSEMBLY
(a) Move the shift lever to N.
(b) Disconnect the transmission control cable end from the shift lever.
(c) Remove the clip and disconnect the transmission control cable from the shift lever retainer.
(d) Disconnect the 2 connectors.
(e) Remove the 4 bolts and floor shift.
Installation
A760F AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY (for Floor Shift Type):
INSTALLATION
Page 8110
Door/Service and Repair/Front Door (for Regular Cab)/Disassembly
4. REMOVE FRONT DOOR WINDOW REGULATOR HANDLE ASSEMBLY (for Front Side) See:
Body and Frame/Doors, Hood and
Trunk/Doors/Front Door/Service and Repair/Front Door (for Regular Cab)/Disassembly
5. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH (for Front Side) See: Body
and Frame/Doors, Hood and
Trunk/Doors/Front Door/Service and Repair/Front Door (for Regular Cab)/Disassembly
6. REMOVE COURTESY LIGHT ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood
and Trunk/Doors/Front Door/Service and
Repair/Front Door (for Regular Cab)/Disassembly
7. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Regular Cab)/Disassembly
8. REMOVE FRONT SIDE AIRBAG SENSOR
(a) Disconnect the connector.
(b) Remove the screw and side airbag sensor.
9. REMOVE FRONT DOOR SCUFF PLATE LH (for Rear Side) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Removal
10. REMOVE REAR SIDE AIRBAG SENSOR
(a) Remove the bolt and side airbag sensor from the body.
(b) Disconnect the connector.
Installation
SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Regular Cab):
INSTALLATION
1. INSTALL FRONT SIDE AIRBAG SENSOR
(a) Check that the ignition switch is OFF.
Components
Fuel Injector: Service and Repair Components
1UR-FE FUEL: FUEL INJECTOR: COMPONENTS
Page 4064
(1) Remove the air hose between ports A and B.
(2) Connect the pressure gauge to the vent port of the canister.
(3) With port B, purge port and the air inlet port closed and port A open, apply 19.6 kPa (0.2
kgf/cm2, 2.81 psi) of pressurized air into the vent
port, and then confirm that pressure is retained for 1 minute.
If the result is not as specified, replace the canister assembly.
(e) Check the leak detection pump.
(1) Remove the detection pump from the canister.
(2) Check that air flows from port A to B and then to C.
If the result is not as specified, replace the canister assembly.
(3) Connect the positive (+) lead of the battery to terminal 7 and the negative (-) lead to terminal 6.
(4) Check that the valve is closed.
If the result is not as specified, replace the canister assembly.
(5) Install the detection pump.
Page 6538
General Information
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: GENERAL
INFORMATION
* A large number of ECU controlled systems are used in the TOYOTA TUNDRA. In general, ECU
controlled systems are considered to be very intricate, requiring a high level of technical knowledge
to troubleshoot. However, most problem checking procedures only involve inspecting the ECU
controlled system's circuits one by one. An adequate understanding of the system and a basic
knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and
necessary repairs.
1. TROUBLESHOOTING PROCEDURES
* The troubleshooting procedures consist of diagnosis procedures for when a DTC is stored and
diagnosis procedures for when no DTC is stored. The basic idea is explained in the following table.
* Vehicle systems are complex and use many ECUs that are difficult to inspect independently.
Therefore, a process of elimination is used, where components that can be inspected individually
are inspected, and if no problems are found in these components, the related ECU is identified as
the problem and replaced.
* It is extremely important to ask the customer about the environment and the conditions present
when the problem occurred (Customer Problem Analysis). This makes it possible to simulate the
conditions and confirm the symptom. If the symptom cannot be confirmed or the DTC does not
recur, the malfunctioning part may not be identified using the troubleshooting procedure, and the
ECU for the related system may be replaced even though it is not defective. If this happens, the
original problem will not be solved.
* In order to prevent endless expansion of troubleshooting procedures, the troubleshooting
procedures are written with the assumption that multiple malfunctions do not occur simultaneously
for a single problem symptom.
* To identify the malfunctioning part, troubleshooting procedures narrow down the target by
separating components, ECUs and wire harnesses during the inspection. If the wire harness is
identified as the cause of the problem, it is necessary to inspect not only the connections to
components and ECUs but also all of the wire harness connectors between the component and the
ECU.
DIAGNOSTIC TESTER
2. DESCRIPTION
System data and the Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector
3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the Techstream* to
check for a malfunction and perform repairs.
HINT *: Techstream is the name for the diagnostic tester in North America.
3. DATA LINK CONNECTOR 3 (DLC3)
(a) The vehicle's ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of
the DLC3 complies with SAE J1962 and
matches the ISO 15765-4 format.
Page 3878
Variable Valve Timing Actuator Position Sensor: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: VVT SENSOR: INSTALLATION
1. INSTALL VVT SENSOR
(a) Install the 4 sensors with the 4 bolts.
Page 5979
Ignition Switch: Service and Repair Removal
1UR-FE STARTING: IGNITION SWITCH: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE STEERING COLUMN ASSEMBLY
(a) for Manual Tilt:
Remove the steering column See: Steering and Suspension/Steering/Steering Column/Service and
Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Removal.
(b) for Manual Tilt and Manual Telescopic Steering Column:
Remove the steering column See: Steering and Suspension/Steering/Steering Column/Service and
Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt and Manual
Telescopic Steering Column)/Removal.
(c) for Power Tilt and Power Telescopic Steering Column:
Remove the steering column See: Steering and Suspension/Steering/Steering Column/Service and
Repair/Removal and Replacement/Steering Column Assembly (for Power Tilt and Power
Telescopic Steering Column)/Removal.
3. REMOVE UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Manual
Tilt) See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering Column Assembly
(for Manual Tilt)/Disassembly
4. REMOVE UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Manual Tilt
and Manual Telescopic Steering Column)
See: Steering and Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering
Column Assembly (for Manual Tilt and Manual Telescopic Steering Column)/Disassembly
5. REMOVE UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Power Tilt
and Power Telescopic Steering Column)
See: Steering and Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering
Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Disassembly
6. REMOVE IGNITION SWITCH ASSEMBLY
(a) Detach the 2 claws and remove the ignition switch from the steering lock.
Page 6347
Push the terminal retainer down to the temporary lock position.
Page 7596
(2) Disconnect connector B and measure the resistance.
Standard resistance (Fig. 7):
* If the results match the examples above, a short circuit exists between terminal 1 of connector B2
and terminal 1 of connector C.
4. CHECK AND REPLACE ECU
NOTICE: *
The connector should not be disconnected from the ECU. Perform the inspection from the backside
of the connector on the wire harness side.
* When no measuring condition is specified, perform the inspection with the engine stopped and
the ignition switch ON.
* Check that the connectors are fully seated. Check for loose, corroded or broken wires.
(a) First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be
faulty. Temporarily replace the ECU with a
normally functioning one and check if the symptoms occur. If the trouble symptoms disappear,
replace the original ECU.
(1) Measure the resistance between the ECU ground terminal and body ground.
Standard resistance:
Below 1 Ohms
(2) Disconnect the ECU connector. Check the ground terminal on the ECU side and wire harness
side for bending, corrosion or foreign matter.
Lastly, check the contact pressure of the female terminals.
Page 7371
Suspension Strut / Shock Absorber: Overhaul
Disassembly
SUSPENSION: FRONT SHOCK ABSORBER: DISASSEMBLY
1. REMOVE FRONT SUPPORT TO FRONT SHOCK ABSORBER NUT
(a) Using SST, compress the coil spring.
SST : 09727-30021
09727-00010
09727-00021
09727-00031
NOTICE: *
Make sure that the suspension support is free from the coil spring.
* Do not compress the coil spring more than necessary.
* Do not use an impact wrench. It will damage SST.
* Do not place yourself over the top of the shock absorber.
CAUTION: Be careful as the coil spring may spring upward and cause an injury.
(b) Remove the front support to front shock absorber nut.
2. REMOVE FRONT SUSPENSION SUPPORT SUB-ASSEMBLY LH
(a) Remove the suspension support, 2 retainers and 2 cushions from the shock absorber rod.
3. REMOVE FRONT COIL SPRING LH
(a) Remove the coil spring from the shock absorber.
Reassembly
SUSPENSION: FRONT SHOCK ABSORBER: REASSEMBLY
1. INSTALL FRONT COIL SPRING LH
Page 9109
DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector.
Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
Removal and Replacement
Hydraulic Control Assembly - Antilock Brakes: Removal and Replacement
Components
BRAKE CONTROL: BRAKE ACTUATOR: COMPONENTS
Removal
BRAKE CONTROL: BRAKE ACTUATOR: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to disable the SRS system.
2. DISCONNECT VSC ACTUATOR CONNECTOR
(a) Pull the release bar and disconnect the VSC actuator connector.
3. REMOVE BRAKE TUBE
(a) Use tags or make a note to identify the reconnection locations.
Page 6038
Ignition Switch: Diagnostic Aids
Continuity and Resistance Check
CONTINUITY AND RESISTANCE CHECK
Disconnect the battery terminal or wire so there is no voltage between the check points.
Contact the two leads of an ohmmeter to each of the check points.
Page 687
Power Mirror Switch: Testing and Inspection
MIRROR: OUTER MIRROR SWITCH: INSPECTION
1. INSPECT OUTER MIRROR SWITCH ASSEMBLY (w/o Retract Mirror)
(a) Check the resistance.
(1) Select "L" on the left/right adjustment switch.
(2) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(3) If the result is not as specified, replace the outer mirror switch.
(4) Select "R" on the left/right adjustment switch.
(5) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(6) If the result is not as specified, replace the outer mirror switch.
2. INSPECT OUTER MIRROR SWITCH ASSEMBLY (w/ Retract Mirror)
Components
Tire Pressure Sensor: Service and Repair Components
TIRE AND WHEEL: TIRE PRESSURE WARNING VALVE AND TRANSMITTER: COMPONENTS
Page 8667
"Case2" Open the secondary locking device.
[B] For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray
Gray or White : Black
Page 1333
6. PROBLEM SYMPTOMS TABLE
When a "Normal" code is output during a DTC check but the problem is still occurring, use the
Problem Symptoms Table. The suspected areas (circuits or parts) for each problem symptom are
in the table. The suspected areas are listed in order of probability. A description of each of the
chart's columns is below.
HINT In some cases, the problem is not detected by the diagnostic system even though a problem
symptom is present. It is possible that the problem is occurring outside the detection range of the
diagnostic system, or that the problem is occurring in a completely different system.
7. CIRCUIT INSPECTION
A description of the main areas of each circuit inspection is below.
Page 8153
Seat Position Sensor: Service and Repair Installation
SUPPLEMENTAL RESTRAINT SYSTEM: SEAT POSITION SENSOR: INSTALLATION
1. INSTALL SEAT POSITION SENSOR
(a) Check that the ignition switch is OFF.
(b) Check that the cable is disconnected from the battery negative (-) terminal.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
NOTICE: Some systems need to be initialized after the cable is reconnected See: Testing and
Inspection/Programming and Relearning
(c) Using a feeler gauge 1.0 mm (0.0393 in.), install the seat position sensor.
NOTICE: *
If the seat position sensor has been dropped, or there are any cracks, dents or other defects in the
case or connector, replace the seat position sensor with a new one.
* When installing the seat position sensor, be careful that the SRS wiring does not interfere with
other parts and that it is not pinched between other parts.
HINT Be sure that the clearance between the seat position sensor and the seat rail is within 0.6 to
1.4 mm (0.0236 to 0.0551 in.).
(d) Using a T30 "TORX" socket wrench, install the seat position sensor with the screw.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
(e) Make sure that the clearance between the seat position sensor and the seat rail is within 0.6 to
1.4 mm (0.0236 to 0.0551 in.).
(f) Check that there is no looseness in the installation parts of the seat position sensor.
(g) Connect the connector.
(h) Install the seat slide position sensor protector to the seat position sensor.
Page 3288
^ Engine Control Module (ECM)
^ Transmission Control Module (TCM)
^ Or any other Toyota specific control unit
Warranty Information
Parts Information
Required Tools & Equipment
NOTE
Additional SSTs may be ordered by calling 1-800-933-8335.
Process Overview
Techstream ECU flash reprogramming is a 4-step process:
1. Verify the vehicle's applicability for recalibration and locate desired calibration file by performing
the Techstream Health Check function.
NOTE
Techstream will automatically search TIS for the appropriate service bulletin using the current
Calibration ID from the vehicle. Calibration file links can be found embedded in the corresponding
service bulletin.
2. Connect the GR8 Battery Diagnostic Station using "Power Supply Mode" only.
The GR8 Battery Diagnostic Station includes a Power Supply Mode to help maintain battery
voltage at 13.5 volts during ECU reprogramming.
ECU damage may occur if the correct battery charger mode setting is NOT used.
3. Locate appropriate calibration ID and reprogram the vehicle ECU with Techstream.
Techstream uses the Calibration Update Wizard (CUW) application to open calibration files and
facilitate the ECU flash reprogramming process.
Page 2804
Then click Start.
I. Do NOT disturb the vehicle during flash reprogramming.
NOTE
^ ECU flash reprogramming may take anywhere from 3 - 30 minutes per calibration file.
^ Reprogramming time will vary depending on model and ECU communication protocol. Vehicles
using CAN communication protocol will reprogram much faster (2 - 7 minutes).
NOTE
^ If vehicle requires only ONE calibration update, then proceed to step N in this bulletin.
^ If vehicle requires a SECOND calibration update, then continue as follows:
^ For serial communication vehicles, go to step J.
^ For CAN communication vehicles, go to step L.
Page 1815
NOTE
Only Toyota Certified Technicians and above may access calibration files.
2. Connect the GR8 Battery Diagnostic Station.
A. Connect the GR8 Battery Diagnostic Station to the vehicle and turn it ON.
B. Select Power Supply Mode by following the screen flow below.
NOTICE
^ ECU damage may occur if the correct battery charger and mode setting are NOT used.
Page 2012
Establish conditions in which voltage is present at the check point.
Example:
- [A] - Ignition SW on
- [B] - Ignition SW and SW1 on
- [C] - Ignition SW, SW1 and Relay on (SW2 off)
Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or component terminal.
This check can be done with a test light instead of a voltmeter.
Electronic Circuit Inspection Procedure
Page 1240
Variable Valve Timing Actuator Position Sensor: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: VVT SENSOR: REMOVAL
1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Removal
2. REMOVE AIR CLEANER HOSE ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Removal
3. REMOVE VVT SENSOR
(a) Disconnect the 4 sensor connectors.
(b) Remove the 4 bolts and 4 sensors.
Air Fuel Ratio Sensor
Oxygen Sensor: Service and Repair Air Fuel Ratio Sensor
Components
1UR-FE ENGINE CONTROL SYSTEM: AIR FUEL RATIO SENSOR: COMPONENTS
Page 7785
Refrigerant: Service and Repair
AIR CONDITIONING: REFRIGERANT: REPLACEMENT
1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM
(a) Start up the engine.
(b) Turn the A/C switch ON.
(c) Operate the cooler compressor with an engine speed of approximately 1000 rpm for 5 to 6
minutes to circulate the refrigerant and collect the
compressor oil remaining in each component into the cooler compressor.
(d) Stop the engine.
(e) Recover the refrigerant from the A/C system using a refrigerant recovery unit.
2. CHARGE REFRIGERANT
SST : 09985-20010
09985-02010
09985-02050
09985-02060
09985-02070
09985-02090
09985-02110
09985-02130
09985-02150
(a) Perform vacuum purging using a vacuum pump.
(b) Charge refrigerant HFC-134a (R134a).
Standard:
600 +/-30 g (21.2 +/-1.1 oz.)
NOTICE:
Page 8773
Air Fuel Ratio Sensor
Oxygen Sensor: Service and Repair Air Fuel Ratio Sensor
Components
1UR-FE ENGINE CONTROL SYSTEM: AIR FUEL RATIO SENSOR: COMPONENTS
Page 771
Page 3360
Components
Air Flow Meter/Sensor: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: COMPONENTS
Page 4761
NOTE
On some models, DTCs may set as a result of reprogramming. If DTCs are present, clear codes
and run the Health Check again. Troubleshoot any remaining Current, Pending, or History codes.
Permanent codes will not be cleared using Techstream. Permanent codes do not illuminate the MIL
and do not require troubleshooting. They will clear during normal driving once the Universal Trip
Drive Pattern is performed.
4. Attach the Authorized Modifications Label.
A. Using a permanent marker or ball point pen complete the Authorized Modifications Label and
attach to the vehicle. The Authorized
Modifications Label is available through the MDC P/N 00451-00001-LBL.
B. Attach the label under the hood in the location determined by the specific TSB or Campaign.
NOTE
Wait 60 - 90 seconds for ink to set before handling.
Page 7759
Drain engine coolant See: Engine, Cooling and Exhaust/Cooling System/Coolant/Service and
Repair.
(b) for 1UR-FE:
Drain engine coolant See: Engine, Cooling and Exhaust/Cooling System/Coolant/Service and
Repair.
(c) for 3UR-FE:
Drain engine coolant See: Engine, Cooling and Exhaust/Cooling System/Coolant/Service and
Repair.
(d) for 3UR-FBE:
Drain engine coolant See: Engine, Cooling and Exhaust/Cooling System/Coolant/Service and
Repair.
3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
4. REMOVE NO. 2 COOLER COVER
(a) Remove the 2 nuts.
(b) Detach the 2 claws and remove the cover.
5. REMOVE SUCTION PIPE SUB-ASSEMBLY AND LIQUID TUBE
(a) Remove the bolt.
(b) Detach the plate as shown in the illustration.
(c) Disconnect the suction pipe sub-assembly and liquid tube.
Page 4946
^ Torque the bolts to the specification found in the applicable Repair Manual.
NOTE
In most applications there will be 1 black torque converter bolt, be sure to install this bolt first to aid
in aligning the torque converter to the flywheel assembly.
Page 3575
Knock Sensor: Diagrams
Page 8227
(5) Disconnect the pretensioner connector as shown in the illustration.
(d) Prepare SST for activation of the seat belt pretensioner.
(1) Install the floor anchor of the seat belt.
(2) Connect SST (A) to SST (B). Then connect SST (B)'s connector to the seat belt pretensioner.
SST : 09082-00700
SST : 09082-00770
NOTICE: To avoid damaging SST connector and wire harness, do not lock the secondary lock of
the twin lock.
(3) Move SST at least 10 m (32.8 ft.) away from the front of the vehicle.
(4) Close all the doors and windows of the vehicle.
HINT Leave a gap in one of the windows for inserting SST wire harness.
NOTICE: Take care not to damage SST wire harness.
(5) Connect SST's red clip to the battery's positive (+) terminal and the black clip to the negative (-)
terminal.
(e) Activate the seat belt pretensioner.
(1) Confirm that no one is inside the vehicle or within 10 m (32.8 ft.) of the vehicle.
(2) Press SST activation switch to activate the seat belt pretensioner.
HINT The seat belt pretensioner operates at the same time SST activation switch's LED
illuminates.
Page 2023
* In the DTC check, it is very important to determine whether the problem indicated by the DTC is
either: 1) still occurring; or 2) occurred in the past but has since returned to normal. In addition, the
DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs
should be checked before and after confirmation of symptoms (i.e., whether or not problem
symptoms exist) to determine current system conditions, as shown in the flowchart below.
* Never skip the DTC check. Failing to check DTCs may, depending on the case, result in
unnecessary troubleshooting for systems operating normally or lead to repairs not related to the
problem. Follow the procedures listed in the flowchart in the correct order.
* The following flowchart shows how to proceed with troubleshooting using the DTC check.
Directions from the flowchart will indicate how to proceed either to DTC troubleshooting or to the
troubleshooting of each problem symptom.
1. DTC CHECK
NEXT -- Continue to next step.
2. MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR MEMORY
NEXT -- Continue to next step.
3. SYMPTOM CONFIRMATION
B -- Go to step 5 A -- Continue to next step.
4. SIMULATION TEST USING SYMPTOM SIMULATION METHODS
NEXT -- Continue to next step.
5. DTC CHECK
B -- TROUBLESHOOTING OF PROBLEM INDICATED BY DTC A -- Continue to next step.
6. SYMPTOM CONFIRMATION
Page 6841
Page 3149
Spark Plug: Service and Repair Removal
1UR-FE IGNITION: IGNITION COIL AND SPARK PLUG: REMOVAL
1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Removal
2. REMOVE AIR CLEANER ASSEMBLY
(a) Disconnect the MAF meter connector and clamp.
(b) Disconnect the ventilation hose and vacuum hose.
(c) Loosen the hose clamp.
(d) Remove the 2 bolts and air cleaner.
3. REMOVE IGNITION COIL ASSEMBLY
(a) for Bank 1:
(1) Disconnect the 3 wire harness clamps.
(2) Disconnect the 4 ignition coil connectors.
(3) Remove the 4 bolts and 4 ignition coils.
(b) for Bank 2:
(1) Disconnect the 2 wire harness clamps.
(2) Disconnect the 4 ignition coil connectors.
(3) Disconnect the engine wire harness clamp.
Page 476
Seat Occupant Classification Module - Air Bag: Diagrams
Page 2710
Torque : 5.5 Nm (56 kgf-cm, 49 in-lbf)
8. INSTALL FRONT PROPELLER SHAFT ASSEMBLY (for 4WD) See: Transmission and
Drivetrain/Drive/Propeller Shafts, Bearings and
Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Front Propeller Shaft
Assembly/Installation
9. INSTALL EXHAUST PIPE ASSEMBLY
(a) for Regular Cab Standard Deck:
Install the exhaust pipe See: Exhaust Pipe/Service and Repair/Exhaust Pipe (for Regular Cab
Standard Deck)/Installation.
(b) except Regular Cab Standard Deck:
Install the exhaust pipe See: Exhaust Pipe/Service and Repair/Exhaust Pipe (Except Regular Cab
Standard Deck)/Installation.
10. CONNECT COOLER COMPRESSOR ASSEMBLY See: Heating and Air
Conditioning/Compressor HVAC/Service and Repair/Removal and
Replacement/Installation
11. INSTALL GENERATOR ASSEMBLY
(a) Install the generator See: Starting and Charging/Charging System/Alternator/Service and
Repair/Removal and Replacement/Installation.
12. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE
(a) Apply a light coat of engine oil to a new O-ring.
(b) Install the O-ring to the dipstick guide.
(c) Install the dipstick guide with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(d) Install the dipstick.
13. INSTALL INTAKE MANIFOLD ASSEMBLY
(a) Install the intake manifold See: Engine/Intake Manifold/Service and Repair/Installation.
14. INSPECT FOR EXHAUST GAS LEAK
If gas is leaking, tighten the areas necessary to stop the leak. Replace damaged parts as
necessary.
15. INSTALL FRONT FENDER APRON SEAL REAR LH
(a) Install the fender apron seal with the 5 clips.
16. INSTALL FRONT FENDER APRON SEAL LH
(a) Install the fender apron seal with the 6 clips.
17. INSTALL FRONT FENDER APRON SEAL REAR RH
(a) Install the fender apron seal with the 5 clips.
18. INSTALL FRONT FENDER APRON SEAL RH
(a) Install the fender apron seal with the 6 clips.
Components
EGR Cooler: Service and Repair Components
1UR-FE EMISSION CONTROL: EGR COOLER: COMPONENTS
Page 4601
NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do
not operate the ignition switch, any other switches, or the doors.
(a) If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the
harness and connector.
(b) Connect the cable of the Techstream to the DLC3, turn the ignition switch ON and attempt to
use the tester. If the display indicates that a
communication error has occurred, there is a problem either with the vehicle or with the tester.
HINT *
If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of
the original vehicle.
* If communication is still not possible when the tester is connected to another vehicle, the problem
may be in the tester itself. Consult the Service Department listed in the tester's instruction manual.
How To Proceed With Troubleshooting
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: HOW TO
PROCEED WITH TROUBLESHOOTING
1. OPERATION FLOW
HINT Perform troubleshooting in accordance with the procedures below. The following is an outline
of basic troubleshooting procedures. Confirm the troubleshooting procedures for the circuit you are
working on before beginning troubleshooting.
1. VEHICLE BROUGHT TO WORKSHOP
NEXT -- Continue to next step.
2. CUSTOMER PROBLEM ANALYSIS
(a) Ask the customer about the conditions and environment when the problem occurred.
NEXT -- Continue to next step.
3. INSPECT BATTERY VOLTAGE
Standard voltage:
11 to 14 V
If the voltage is below 11 V, recharge or replace the battery before proceeding.
NEXT -- Continue to next step.
Page 3975
This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown.
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60
months or 60,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Op Code EG9029 or EG9024: For California specification vehicles sold, registered, and operated
in California, Connecticut, Maine, Massachusetts, New Jersey, Oregon, Pennsylvania, Rhode
Island, Vermont, and Washington, this repair is covered under the California Emission Warranty.
This warranty is in effect for 84 months or 70,000 miles, whichever occurs first, from the vehicle's
in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Page 984
Door Switch: Testing and Inspection Rear Door Courtesy Switch
LIGHTING: REAR DOOR COURTESY SWITCH: INSPECTION
1. INSPECT REAR DOOR COURTESY SWITCH
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the switch.
Page 9068
(1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be
checked by conducting a voltage check.
With each connector still connected, measure the voltage between the body ground and these
terminals (in this order): 1) terminal 1 of connector A; 2) terminal 1 of connector B; and 3) terminal
1 of connector C.
Standard voltage (Fig. 4):
* If the results match the examples above, an open circuit exists in the wire harness between
terminal 1 of connector B and terminal 1 of connector C.
3. CHECK FOR SHORT CIRCUIT
(a) If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance
check with the body ground (below).
(b) Check the resistance with the body ground.
(1) Disconnect connectors A and C and measure the resistance.
Standard resistance (Fig. 6):
HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally.
If your results match the examples above, a short circuit exists between terminal 1 of connector A
and terminal 1 of connector C.
Page 6759
AJ1-AJ8
Page 8229
(c) Prepare SST for activation of the seat belt pretensioner.
(1) Connect SST (A) to SST (B). Then connect SST (B)'s connector to the seat belt pretensioner.
NOTICE: To avoid damaging SST connector and wire harness, do not lock the secondary lock of
the twin lock.
(2) Place the front seat outer belt on the ground and cover it with a tire (with wheel).
NOTICE: Set up the front seat outer belt as shown in the illustration.
(3) Move SST at least 10 m (32.8 ft.) away from the wheel.
NOTICE: Take care not to damage SST wire harness.
(d) Activate the seat belt pretensioner.
(1) Connect SST's red clip to the battery's positive (+) terminal and the black clip to the battery's
negative (-) terminal.
(2) Check that no one is within 10 m (32.8 ft.) of the wheel.
(3) Press SST activation switch to activate the seat belt pretensioner.
HINT The seat belt pretensioner operates at the same time SST activation switch's LED
illuminates.
(e) Dispose of the front seat outer belt (with the seat belt pretensioner).
CAUTION: *
Do not touch the front seat outer belt for at least 30 minutes after the seat belt pretensioner has
been activated. It is very hot.
* Use gloves and safety glasses when handling a front seat outer belt whose pretensioner has
been activated.
* Always wash your hands with water after completing the disposal.
* Do not apply water to a front seat outer belt that has an activated pretensioner.
(1) Remove the tire (with wheel) and SST.
Page 5690
(a) Install the stop light switch mounting adjuster See: Lighting and Horns/Brake Light
Switch/Service and Repair/Installation.
5. INSTALL STOP LIGHT SWITCH ASSEMBLY
(a) Attach the harness clip.
(b) Install the stop light switch See: Lighting and Horns/Brake Light Switch/Service and
Repair/Installation.
(c) Connect the stop light switch connector.
6. INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY
(a) Install the air duct with the bolt.
7. INSTALL LOWER NO. 1 INSTRUMENT PANEL AIR BAG ASSEMBLY See: Restraint
Systems/Air Bag Systems/Air Bag/Service and
Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Installation
8. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Installation
9. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Installation
10. INSTALL FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Installation
11. INSTALL FRONT DOOR SCUFF PLATE LH (for Double Cab, CrewMax) See: Body and
Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Installation
12. CHECK AND ADJUST BRAKE PEDAL
(a) Check and adjust brake pedal See: Adjustments.
13. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
14. CHECK MASTER CYLINDER PRESSURE SENSOR SIGNAL
(a) Check the sensor signal See: Antilock Brakes / Traction Control Systems/Testing and
Inspection/Scan Tool Testing and Procedures/Test
Mode Procedure.
Locations
Knock Sensor: Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 4462
Air Flow Meter/Sensor: Testing and Inspection On-Vehicle Inspection
1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: ON-VEHICLE INSPECTION
1. CHECK MASS AIR FLOW METER
(a) Check the mass air flow value.
(1) Connect the Techstream to the DLC3.
(2) Turn the ignition switch to ON.
(3) Turn the Techstream main switch ON.
(4) Enter the following menus: Powertrain / Engine / Data List / All Data / MAF.
(5) Blow air into the MAF meter, and check that the MAF value fluctuates.
(6) If the result is not as specified, check the MAF meter See: Inspection, or wiring and ECM See:
Computers and Control Systems/Testing
and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0102.
Page 3269
2. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in
Figure 1. Confirm if the ECM (PCM) calibration has
been updated. If the calibration ID listed is NOT the latest ECM (PCM) calibration - go to step 3.
3. Flash reprogram the ECM (PCM).
NOTE
^ The GR8 Battery Diagnostic Station MUST be used in Power Supply Mode to maintain battery
voltage at 13.5 volts while flash reprogramming the vehicle.
^ For details on how to use the GR8 Battery Diagnostic Station, refer to the located on the
Technical Information System (TIS), Diagnostics - Battery
Follow the procedures outlined in TSB No. T-SB-0064-10, "Techstream ECU Flash
Reprogramming Procedure1⁄4 and flash the ECM (PCM) with the NEW calibration file update.
4. Install the Authorized Modifications Label.
A. Using a permanent marker enter the following information on the label:
^ ECM part number [Refer to the Parts Information section for the CURRENT PART NUMBER]
^ Calibration ID(s) [Refer to the Calibration Identification Chart for the NEW CALIBRATION ID]
^ Dealer Code
^ Repair Date
^ Change Authority [This TSB number]
B. Affix the Authorized Modifications Label to the vehicle at the location shown in Figure 1. The
Authorized Modifications Label is available
through the MDC P/N 00451-00001-LBL.
5. Test drive the vehicle to confirm proper vehicle operation.
Page 6929
Page 8807
* The procedures listed below are for the LH side.
1. INSTALL FRONT NO. 3 SPEAKER ASSEMBLY (for 10 Speakers)
(a) Attach the 3 claws to install the speaker to the bracket.
NOTICE: Do not touch the cone part of the speaker.
(b) Install the speaker with bracket to the lower frame bracket garnish with the 3 screws.
2. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY
(a) Temporarily install the speaker by attaching the claws of the speaker to the door panel.
(b) Install the speaker with the 4 screws.
NOTICE: Do not touch the cone part of the speaker.
HINT Install the screws in the order shown in the illustration.
(c) Connect the connector.
3. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH See: Body and Frame/Doors,
Hood and Trunk/Doors/Front Door/Service and
Repair/Front Door (for Double Cab)/Reassembly
4. INSTALL FRONT DOOR ARMREST COVER LH
5. INSTALL COURTESY LIGHT ASSEMBLY See: Body and Frame/Doors, Hood and
Trunk/Doors/Front Door/Service and Repair/Front Door
(for Double Cab)/Reassembly
6. INSTALL FRONT UPPER ARMREST BASE PANEL LH See: Body and Frame/Doors, Hood and
Trunk/Doors/Front Door/Service and
Repair/Front Door (for Double Cab)/Reassembly
7. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH See: Body and Frame/Doors,
Hood and Trunk/Doors/Front Door/Service and
Page 2423
(f) Remove the oil filter element and O-ring from the oil filter cap.
NOTICE: Be sure to remove the O-ring for the cap by hand, without using any tools, to prevent
damage to the cap's O-ring groove.
4. INSTALL OIL FILTER ELEMENT
(a) Clean the inside of the oil filter cap, its threads and its O-ring groove.
(b) Apply a small amount of engine oil to a new O-ring and install it to the oil filter cap.
(c) Set a new oil filter element to the oil filter cap.
(d) Remove any dirt or foreign matter from the installation surface of the engine.
(e) Apply a small amount of engine oil to the O-ring again and temporarily install the oil filter cap.
(f) Using SST, tighten the oil filter cap.
SST : 09228-06501
Torque : 25 Nm (255 kgf-cm, 18 ft-lbf)
NOTICE: *
When tightening the oil filter cap, do not remove the oil filter bracket clip.
* Make sure that the oil filter is installed securely as shown in the illustration.
* Be careful that the O-ring does not get caught between any surrounding parts.
Page 1306
Ignition Switch: Diagnostic Aids
Continuity and Resistance Check
CONTINUITY AND RESISTANCE CHECK
Disconnect the battery terminal or wire so there is no voltage between the check points.
Contact the two leads of an ohmmeter to each of the check points.
Page 6363
(2) CONNECTORS
Slightly shake the connector vertically and horizontally.
(3) WIRE HARNESS
Slightly shake the wire harness vertically and horizontally.
HINT The connector joint and fulcrum of the vibration are the major areas that should be checked
thoroughly.
(b) HEAT METHOD:
When a malfunction seems to occur when the area in question is heated.
(1) Heat the component that is the possible cause of the malfunction with a hair dryer or similar
device. Check if the malfunction occurs.
NOTICE: *
Do not heat to more than 60°C (140°F). Exceeding this temperature may damage components.
* Do not apply heat directly to the parts in the ECU.
(c) WATER SPRINKLING METHOD:
When a malfunction seems to occur on a rainy day or in high-humidity.
(1) Sprinkle water onto the vehicle and check if the malfunction occurs.
NOTICE: *
Never sprinkle water directly into the engine compartment. Indirectly change the temperature and
humidity by spraying water onto the front of the radiator.
* Never apply water directly onto the electronic components.
HINT If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU
or connections. Look for evidence of corrosion or short circuits. Proceed with caution during water
tests.
(d) HIGH ELECTRICAL LOAD METHOD:
When a malfunction seems to occur when the electrical load is excessive.
(1) Turn on the heater blower, headlights, rear window defogger and all other electrical loads.
Check if the malfunction reoccurs.
5. DIAGNOSTIC TROUBLE CODE CHART
Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate
section's Diagnostic Trouble Code Chart. Use the chart to determine the trouble area and the
proper inspection procedure. A description of each of the chart's columns is below.
Page 1817
load while reprogramming.
^ Confirm the hood is open and ensure under hood temperature does NOT exceed 158°F (70°C).
^ Confirm cable connections between the vehicle and Techstream are secure.
^ Do NOT disconnect or turn off Techstream or vehicle ignition during reprogramming.
^ Set parking brake.
^ Complete ALL flash calibration updates provided for each ECU.
^ If the battery's state of charge or capacity are in question, test with SST. No. 00002-8150-KIT
"Digital Battery Analyze," and follow TSB No. PG001-06, "Battery Maintenance for In-Stock
Vehicles & Pre-Delivery" or the appropriate "Maintenance for HV & Auxiliary Batteries" service
bulletin.
^ The GR8 Battery Diagnostic Station MUST be used in Power Supply Mode to maintain battery
voltage at 13.5 volts while flash reprogramming the vehicle. For details on how to use the GR8
Battery Diagnostic Station, refer to the GR8 Instruction Manual located on TIS, Diagnostics - Tools
& Equipment - Battery Diagnostics.
3C. Click Next to start the calibration update process.
D. When using TIS Techstream select Techstream VIM as the desired programming device. Then
click Next.
Page 3562
(a) Disconnect the J2, DB and DD ECU connectors.
(b) Measure the resistance according to the value(s) in the table below.
HINT *
*1: for V bus
* *2: for MS bus
7. CHECK ECM
(a) Disconnect the A24 and D74 ECM connector.
Page 9038
Connectors Part 1
Page 5282
HINT *
Using the following chart, check if the calculated No. 3 joint angle is within the specified value.
* The tolerance is +/-0°60' (1.00°).
Standard No. 3 joint angle:
*1: for 5 leaf spring
*2: includes Off road package
* If the measured angle is not within the specification, adjust it with the bearing washer (See
"Adjust Propeller Shaft Angle").
6. ADJUST PROPELLER SHAFT ANGLE (for 3 Joint Type)
HINT If the propeller shaft angle is outside the specification or there is vibration and noise, perform
the propeller shaft adjustment using the
Page 3107
Knock Sensor: Testing and Inspection
1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: INSPECTION
1. INSPECT KNOCK SENSOR
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) If the result is not as specified, replace the knock sensor.
Page 6784
Remove the blown fuse and disconnect all loads of the fuse.
Connect a test light in place of the fuse.
Establish conditions in which the test light comes on.
Example:
- [A] - Ignition SW on
- [B] - Ignition SW and SW1 on
- [C] - Ignition SW, SW1 and Relay on (Connect the Relay) and SW2 off (or Disconnect SW2)
Disconnect and reconnect the connectors while watching the test light.
Page 4046
* Make sure the paint mark of the No. 2 air injection system hose is facing upward.
* Make sure the direction of the hose clamp is as shown in the illustration.
(d) Connect the black colored clamp to the No. 2 air injection system hose and wire harness shown
in the illustration below labeled H. Then insert
the clamp's clip into the body hole.
7. CONNECT FRONT FENDER APRON SEAL RH
(a) Connect the fender apron seal with the 2 clips.
8. CONNECT FRONT FENDER LINER RH
(a) Connect the fender liner with the 8 clips.
Page 8882
Central Control Module: Service and Repair Removal
AUDIO / VISUAL: MULTI-MEDIA INTERFACE ECU: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY
(a) for Column Shift Type:
Remove the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Column Shift Type)/Removal.
(b) for Floor Shift Type:
Remove the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Floor Shift Type)/Removal.
3. REMOVE MULTI-MEDIA INTERFACE ECU
(a) Remove the nut.
(b) Disconnect the connector and remove the multi-media interface ECU.
4. REMOVE MULTI-DISPLAY CONTROLLER BRACKET A
(a) Remove the 2 bolts and multi-display controller bracket A.
Page 7776
7. INSTALL BLOWER CASE SUB-ASSEMBLY
(a) Attach the 3 claws to install the case.
(b) Install the 3 screws.
8. INSTALL DAMPER SERVO SUB-ASSEMBLY
(a) Install the damper servo with the 3 screws.
(b) Connect the connector.
9. INSTALL DAMPER SERVO SUB-ASSEMBLY
(a) Install the servo motor.
(1) Set the plate so that the cutout part engages with the tooth of the gear, and attach the claw to
install the main plate.
(2) Install the 2 screws.
(b) Install the servo motor.
Testing and Inspection
Seat Heater Control Module: Testing and Inspection
SEAT: SEAT HEATER CONTROL (w/ Seat Heater System or Climate Control Seat System):
ON-VEHICLE INSPECTION
1. INSPECT SEAT HEATER CONTROL SUB-ASSEMBLY LH
(a) Disconnect the Z11 connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(c) If the result is not as specified, there may be a malfunction on the wire harness side.
(d) Measure the voltage according to the value(s) in the table below.
Standard voltage:
(e) If the result is not as specified, there may be a malfunction on the wire harness side.
(f) Connect the Z11 connector.
(g) Measure the voltage according to the value(s) in the table below.
Standard voltage:
Page 1717
Standard steering axis inclination (unloaded vehicle):
for Regular Cab of Long Deck
Standard steering axis inclination (unloaded vehicle):
for Double Cab of Standard Deck
Locations
Throttle Position Sensor: Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 6606
NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do
not operate the ignition switch, any other switches, or the doors.
(a) If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the
harness and connector.
(b) Connect the cable of the Techstream to the DLC3, turn the ignition switch ON and attempt to
use the tester. If the display indicates that a
communication error has occurred, there is a problem either with the vehicle or with the tester.
HINT *
If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of
the original vehicle.
* If communication is still not possible when the tester is connected to another vehicle, the problem
may be in the tester itself. Consult the Service Department listed in the tester's instruction manual.
How To Proceed With Troubleshooting
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: HOW TO
PROCEED WITH TROUBLESHOOTING
1. OPERATION FLOW
HINT Perform troubleshooting in accordance with the procedures below. The following is an outline
of basic troubleshooting procedures. Confirm the troubleshooting procedures for the circuit you are
working on before beginning troubleshooting.
1. VEHICLE BROUGHT TO WORKSHOP
NEXT -- Continue to next step.
2. CUSTOMER PROBLEM ANALYSIS
(a) Ask the customer about the conditions and environment when the problem occurred.
NEXT -- Continue to next step.
3. INSPECT BATTERY VOLTAGE
Standard voltage:
11 to 14 V
If the voltage is below 11 V, recharge or replace the battery before proceeding.
NEXT -- Continue to next step.
Page 592
Page 7591
Establish conditions in which voltage is present at the check point.
Example:
- [A] - Ignition SW on
- [B] - Ignition SW and SW1 on
- [C] - Ignition SW, SW1 and Relay on (SW2 off)
Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or component terminal.
This check can be done with a test light instead of a voltmeter.
Electronic Circuit Inspection Procedure
Page 3378
when inserting and after full engagement.
NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal.
(d) REPAIR METHOD OF CONNECTOR TERMINAL
(1) If there is any foreign matter on the terminal, clean the contact point using an air gun or cloth.
Never rub the contact point using sandpaper
as the plating may come off.
(2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is
gold-plated (gold color), use a gold-plated female
terminal; if it is silver-plated (silver color), use a silver-plated female terminal.
(3) Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock
into the housing, the housing may have to be
replaced.
(e) HANDLING OF WIRE HARNESS
(1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be
restored in the same way.
(2) Never twist, pull or slacken the wire harness more than necessary.
(3) The wire harness should never come into contact with a high temperature part, or rotating,
moving, vibrating or sharp-edged parts. Avoid
contact with panel edges, screw tips and other sharp items.
(4) When installing parts, never pinch the wire harness.
(5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with
vinyl tape.
2. CHECK FOR OPEN CIRCUIT
Page 9265
Locations
Transmission Temperature Sensor/Switch: Locations
A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS
LOCATION
Page 6386
Page 8152
Seat Position Sensor: Service and Repair Removal
SUPPLEMENTAL RESTRAINT SYSTEM: SEAT POSITION SENSOR: REMOVAL
1. REMOVE FRONT SEAT ASSEMBLY LH
(a) Remove the front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Fold Down Seat
Type)/Removal.
2. REMOVE SEAT POSITION SENSOR
(a) Using a T30 "TORX" socket wrench, remove the screw and seat position sensor with sensor
protector.
(b) Disconnect the connector.
(c) Remove the seat slide position sensor protector from the seat position sensor.
Page 1850
When using Techstream Lite, select Generic J2534 Interface. Then click Next.
E. Confirm the following:
^ PC is connected to VIM.
^ VIM is connected to DLC3 connector.
^ Ignition is ON and engine is OFF or "READY" OFF (hybrid vehicles).
Up to 11/2009
Wheel Speed Sensor: Locations Up to 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 3723
(e) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR OK -- Continue to next step.
6. INSPECT IGNITION SWITCH See: Testing and Inspection/Diagnostic Trouble Code Tests and
Associated Procedures/P Code
Charts/P0617
NG -- REPLACE IGNITION SWITCH See: Ignition System/Sensors and Switches - Ignition
System/Ignition Switch/Service and Repair/Removal OK -- Continue to next step.
7. CHECK HARNESS AND CONNECTOR (INTEGRATION RELAY - ECM, BATTERY AND BODY
GROUND)
(a) Disconnect the ECM connector.
(b) Disconnect the cable from the battery positive terminal.
(c) Remove the integration relay from the engine room relay block.
(d) Disconnect the integration relay connectors.
Locations
Fuse: Locations
Engine Room R/B, J/B - Engine Compartment Left
Skid Control Sensor Wire
Wheel Speed Sensor: Diagrams Skid Control Sensor Wire
Components
Cabin Temperature Sensor / Switch: Service and Repair Components
AIR CONDITIONING: ROOM TEMPERATURE SENSOR (for Automatic Air Conditioning System):
COMPONENTS
Page 7444
Tire Pressure Sensor: Diagrams
Front Speed Sensor
Wheel Speed Sensor: Service and Repair Front Speed Sensor
Components
BRAKE CONTROL: FRONT SPEED SENSOR: COMPONENTS
Removal
BRAKE CONTROL: FRONT SPEED SENSOR: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to disable the SRS system.
2. REMOVE FRONT WHEEL
3. REMOVE FRONT SKID CONTROL SENSOR WIRE LH
(a) Disconnect the connector (labeled A) from the front speed sensor.
(b) Detach the 3 clips (labeled B) and remove the clamp bolt (labeled C).
(c) Disconnect the connector (labeled D).
Page 6088
Neutral Safety Switch: Service and Repair Removal
A760F AUTOMATIC TRANSMISSION: PARK / NEUTRAL POSITION SWITCH: REMOVAL
1. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY
(a) Remove the nut and disconnect the cable.
2. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY
(a) Disconnect the switch connector.
(b) Remove the nut, spring washer and transmission control shaft lever RH.
(c) Using a screwdriver, bend the tabs of the lock washer.
(d) Remove the lock nut and lock washer.
(e) Remove the bolt and switch.
Air Conditioning System (for Automatic Air Conditioning
System)
Control Module HVAC: Locations Air Conditioning System (for Automatic Air Conditioning System)
AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Automatic Air Conditioning System):
PARTS LOCATION
Page 1092
(d) Check the fog light switch.
(1) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(2) If the result is not as specified, replace the headlight dimmer switch.
Page 4716
Standard voltage:
(3) If the voltage is not as specified, replace the 4WD control ECU See: Relays and Modules Transmission and Drivetrain/Relays and
Modules - Transfer Case/Control Module/Service and Repair/Removal. If the voltage is normal,
replace the 4WD control switch.
Components
Steering Column Control Module: Service and Repair Components
STEERING COLUMN: MULTIPLEX TILT AND TELESCOPIC ECU (for Power Tilt and Power
Telescopic Steering Column): COMPONENTS
Locations
Tire Pressure Sensor: Locations
TIRE AND WHEEL: TIRE PRESSURE WARNING SYSTEM: PARTS LOCATION
Page 6338
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Page 3421
A -- Continue to next step.
5. CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (SKID CONTROL ECU WITH
ACTUATOR BRANCH WIRE)
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE CAN BRANCH WIRE OR CONNECTOR (SKID CONTROL ECU
WITH ACTUATOR)
OK -- REPLACE SKID CONTROL ECU WITH ACTUATOR See: Brakes and Traction
Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock
Brakes/Service and Repair/Removal and Replacement/Removal
6. CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (STEERING ANGLE SENSOR)
(a) Disconnect the J6 steering angle sensor connector.
(b) Reconnect the cable to the negative (-) battery terminal.
(c) Select "CAN Bus Check" on the Techstream.
Result
B -- CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (BUS BUFFER ECU) A -Continue to next step.
7. CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (STEERING ANGLE SENSOR
BRANCH WIRE)
(a) Measure the resistance according to the value(s) in the table below.
Page 756
Sunroof / Moonroof Switch: Service and Repair Removal
SLIDING ROOF: SLIDING ROOF SWITCH ASSEMBLY (for CrewMax): REMOVAL
1. REMOVE ROOF CONSOLE BOX ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining
(for CrewMax)/Removal
2. REMOVE SLIDING ROOF SWITCH
(a) Disconnect the 2 connectors.
(b) Detach the clamp.
(c) Remove the 7 screws and lighting housing (upper side).
(d) Detach the 4 claws and remove the sliding roof switch.
Page 1699
Standard vehicle height (unloaded vehicle):
for Double Cab of Long Deck
Standard vehicle height (unloaded vehicle):
for CrewMax of standard deck
Page 5074
30. TEMPORARILY INSTALL DIFFERENTIAL DRIVE PINION
31. INSTALL FRONT DIFFERENTIAL CASE
32. INSTALL FRONT DIFFERENTIAL CROSS SHAFT BEARING RETAINER
(a) Remove any old FIPG material and be careful not to drop oil on the contact surfaces of the
differential carrier and side bearing retainer.
(b) Clean the contact surfaces with any residual FIPG material using gasoline or alcohol.
(c) Apply seal packing to the differential carrier as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
Standard Seal Diameter (A):
2.0 to 3.0 mm (0.0788 to 0.118 in.)
HINT Install the side bearing retainer within 10 minutes of applying seal packing.
(d) Install the front differential cross shaft bearing retainer and front differential front support
assembly LH with the 11 bolts (A), and 3 bolts (B).
for bolt A - Torque : 65 Nm (633 kgf-cm, 48 ft-lbf)
for bolt B - Torque : 155 Nm (1581 kgf-cm, 114 ft-lbf)
NOTICE: Do not add oil or drive the vehicle immediately after installing the cover, and leave it as is
for at least an hour. Also, for 12 hours or less, avoid rapid acceleration/deceleration.
33. INSTALL FRONT DRIVE PINION FRONT RADIAL BALL BEARING
(a) Using SST and a hammer, lightly tap in the bearing (inner race) to install it.
Page 7926
(b) With the front passenger airbag removed from the vehicle, perform a visual check. If there are
any defects as mentioned below, replace the
front passenger airbag, instrument panel or instrument panel reinforcement with a new one:
* Cuts, minute cracks or marked discoloration on the front passenger airbag.
* Cracks or other damage to the connectors.
* Deformation or cracks on the instrument panel or instrument panel reinforcement.
CAUTION: For removal and installation procedures of the front passenger airbag, be sure to follow
the correct procedure.
Steering Pad
SUPPLEMENTAL RESTRAINT SYSTEM: STEERING PAD: ON-VEHICLE INSPECTION
1. CHECK STEERING PAD (VEHICLE NOT INVOLVED IN COLLISION)
(a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnosis System.
(b) With the steering pad installed on the vehicle, perform a visual check. If there are any defects
as mentioned below, replace the steering pad
with a new one:
Cuts, minute cracks or marked discoloration on the steering pad top surface or in the grooved
portion.
2. CHECK STEERING PAD (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS NOT
DEPLOYED)
(a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnosis System.
Page 3396
Information Bus: Description and Operation CAN Communication System
CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: SYSTEM DIAGRAM
Locations
Telescoping Wheel Switch: Locations
STEERING COLUMN: POWER TILT AND POWER TELESCOPIC STEERING COLUMN
SYSTEM: PARTS LOCATION
Page 5392
Control Module: Locations JF1A Transfer Case
JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION
Page 7283
Torque : 29 Nm (296 kgf-cm, 21 ft-lbf)
NOTICE: Use the formula calculate special torque values for situations for situations where a union
nut wrench is combined with a torque wrench See: Service Precautions
(d) Using a union nut wrench, tighten the pressure feed tube (return tube side).
Torque : 25 Nm (255 kgf-cm, 18 ft-lbf)
NOTICE: Use the formula calculate special torque values for situations for situations where a union
nut wrench is combined with a torque wrench See: Service Precautions
3. CONNECT TIE ROD END SUB-ASSEMBLY LH
(a) Connect the tie rod end LH to the steering knuckle with the nut.
Torque : 69 Nm (704 kgf-cm, 51 ft-lbf)
(b) Install a new cotter pin.
HINT Further tighten the nut up to 60° if the holes for the cotter pin are not aligned.
4. CONNECT TIE ROD END SUB-ASSEMBLY RH
HINT Use the same procedures described for the LH side.
5. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY
(a) Align the matchmarks on the No. 2 steering intermediate shaft and power steering gear.
(b) Install the bolt.
Torque : 35 Nm (360 kgf-cm, 26 ft-lbf)
6. INSTALL ENGINE ASSEMBLY
(a) for 1GR-FE:
Install the engine assembly See: Engine, Cooling and Exhaust/Engine/Service and
Repair/Removal and Replacement/Engine Assembly/Installation.
Airbag Cutoff Switch
Air Bag Deactivation Switch: Diagrams Airbag Cutoff Switch
Page 386
(e) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- REPAIR OR REPLACE ENGINE ROOM RELAY BLOCK
Page 8014
(a) Disconnect the holder (with connectors).
(b) Remove the 3 bolts and airbag sensor.
Installation
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Column
Shift Type): INSTALLATION
1. INSTALL CENTER AIRBAG SENSOR ASSEMBLY
(a) Check that the ignition switch is OFF.
(b) Check that the cable is disconnected from the battery negative (-) terminal.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
(c) Install the airbag sensor with the 3 bolts.
Torque : 18 Nm (184 kgf-cm, 13 ft-lbf)
NOTICE: *
If the center airbag sensor has been dropped, or there are any cracks, dents or other defects in the
case, bracket or connector, replace it with a new one.
* When installing the center airbag sensor, be careful that the SRS wiring does not interfere with
other parts and that it is not pinched between other parts.
(d) Check that there is no looseness in the installation parts of the center airbag sensor.
(e) Connect the holder (with connectors).
(f) Check that the waterproof sheet is properly set.
2. INSTALL CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service
and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
NOTICE: Some systems need to be initialized after the cable is reconnected See: Testing and
Inspection/Programming and Relearning
4. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
Locations
Ignition Switch: Locations
1UR-FE STARTING: STARTING SYSTEM: PARTS LOCATION
Page 2026
6. PROBLEM SYMPTOMS TABLE
When a "Normal" code is output during a DTC check but the problem is still occurring, use the
Problem Symptoms Table. The suspected areas (circuits or parts) for each problem symptom are
in the table. The suspected areas are listed in order of probability. A description of each of the
chart's columns is below.
HINT In some cases, the problem is not detected by the diagnostic system even though a problem
symptom is present. It is possible that the problem is occurring outside the detection range of the
diagnostic system, or that the problem is occurring in a completely different system.
7. CIRCUIT INSPECTION
A description of the main areas of each circuit inspection is below.
Page 7065
(c) Read the adjustment chart (example).
(1) Find the wheel alignment standard value applicable for the particular model.
(2) Mark the selected standard value on the adjustment chart.
Standard value (reference):
(3) Mark the alignment value measured when the vehicle is unloaded on the adjustment chart.
Measured value (reference):
(4) As shown in the chart, read the distance from the marked point to 0, and adjust the front and/ or
rear adjusting cams accordingly.
Amount to turn adjusting cams (by gradation):
Up to 11/2009
Hydraulic Control Assembly - Antilock Brakes: Locations Up to 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 970
Standard resistance:
(b) If the result is not as specified, replace the rheostat.
Page 3904
This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown.
Page 4959
Install the front exhaust pipe See: Engine, Cooling and Exhaust/Exhaust System/Exhaust
Pipe/Service and Repair/Exhaust Pipe (Except Regular Cab Standard Deck)/Installation.
9. ADD ENGINE COOLANT See: Engine, Cooling and Exhaust/Cooling System/Coolant/Service
and Repair
10. ADJUST AUTOMATIC TRANSMISSION FLUID LEVEL
(a) Adjust the automatic transmission fluid level See: Service and Repair/Procedures.
11. INSPECT FOR COOLANT LEAK See: Engine, Cooling and Exhaust/Cooling System/Testing
and Inspection
12. INSPECT FOR EXHAUST GAS LEAK See: Engine, Cooling and Exhaust/Exhaust
System/Exhaust Manifold/Service and Repair/Installation
13. INSPECT FOR AUTOMATIC TRANSMISSION FLUID LEAK
Page 3780
Air Flow Meter/Sensor: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: MASS AIR FLOW METER: REMOVAL
1. REMOVE MASS AIR FLOW METER
(a) Disconnect the MAF connector.
(b) Remove the 2 screws and MAF meter.
Page 7621
Cabin Temperature Sensor / Switch: Service and Repair Installation
AIR CONDITIONING: ROOM TEMPERATURE SENSOR (for Automatic Air Conditioning System):
INSTALLATION
1. INSTALL ROOM TEMPERATURE SENSOR
(a) Attach the 2 claws to install the sensor.
2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH
(a) for Column Shift Type:
Remove the instrument panel finish panel See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument
Panel Safety Pad (for Column Shift Type)/Installation.
(b) for Floor Shift Type:
Remove the instrument panel finish panel See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument
Panel Safety Pad (for Floor Shift Type)/Installation.
3. INSTALL INSTRUMENT SIDE PANEL LH
(a) for Column Shift Type:
Remove the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Column Shift Type)/Installation.
(b) for Floor Shift Type:
Remove the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Floor Shift Type)/Installation.
4. INSTALL COWL SIDE TRIM BOARD LH
(a) for Regular Cab:
Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular Cab)/Installation.
(b) for Double Cab:
Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Installation.
(c) for CrewMax:
Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for CrewMax)/Installation.
5. INSTALL FRONT DOOR SCUFF PLATE LH
(a) for Regular Cab:
Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular
Page 6787
[A] For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
"Case1" Raise the terminal retainer up to the temporary lock position.
Page 7158
Tire Pressure Warning Reset Switch: Diagrams
Page 5677
* Low pedal or spongy pedal.
* Brake pedal is depressed firmly but braking is insufficient.
(c) Check and adjust brake fluid level in reservoir See: Hydraulic System/Brake Fluid/Testing and
Inspection.
2. BLEED BRAKE SYSTEM
(a) Bleed brake master cylinder
HINT If the master cylinder has been disassembled or if the reservoir becomes empty, bleed air
from the master cylinder.
(1) Remove the brake master cylinder reservoir filler cap assembly.
(2) Add brake fluid into the reservoir between MAX and MIN level on the brake fluid reservoir.
Brake fluid:
SAE J1703 or FMVSS No. 116 DOT3
(3) Using a union nut wrench, disconnect the 2 brake lines from the master cylinder.
(4) Slowly depress and hold the brake pedal.
(5) Block the outer holes with your fingers, and release the pedal.
(6) Repeat the 2 previous steps 3 or 4 times.
(7) Using a union nut wrench, connect the 2 brake lines to the master cylinder.
without union nut wrench - Torque : 20 Nm (199 kgf-cm, 14 ft-lbf)
with union nut wrench - Torque : 18 Nm (185 kgf-cm, 13 ft-lbf)
* Use a torque wrench with a fulcrum length of 300 mm (11.8 in.).
* This torque value is effective when union nut wrench is parallel to the torque wrench.
(b) Bleed brake line
(1) Connect a vinyl tube to the bleeder plug of the front disc brake cylinder RH.
(2) Depress the brake pedal several times, and then loosen the bleeder plug with the pedal
depressed.*1
(3) When fluid stops coming out, tighten the bleeder plug, and then release the brake pedal.*2
(4) Repeat *1 and *2 until all the air in the brake fluid is completely bled out and the new brake fluid
comes out.
(5) Tighten the bleeder plug completely.
Torque : 11 Nm (110 kgf-cm, 8 ft-lbf)
(6) Replace the brake fluid from the front disc brake cylinder LH using the same procedure as for
RH.
(7) Connect a vinyl tube to the bleeder plug of the rear disc brake cylinder RH.
Page 7382
Required Tools & Equipment
Repair Procedure Overview
^ Confirm noise is coming from the rear of the vehicle and changes with vehicle speed.
^ Install ChaSSiSEAR(TM) (or equivalent) and isolate the noise to the rear wheel bearing.
^ Remove the rear axle shaft assembly.
^ Install new rear wheel bearing brake caliper bracket and seals.
^ Reinstall rear axle shaft assembly and confirm the noise is no longer present.
Repair Procedure
1. Test drive the vehicle and confirm the customer complaint.
Does the noise increase and decrease with vehicle speed?
^ YES - Go to step 2.
^ NO - This TSB does NOT apply. Refer to the Repair Manual for further diagnosis.
Engine - MIL ON/DTC's P0012/P0022 Set
Variable Valve Timing Actuator: Customer Interest Engine - MIL ON/DTC's P0012/P0022 Set
T-SB-0019-10
January 20, 2010
MIL "ON" DTC P0012 and/or P0022
Service Category Engine/Hybrid System
Section Engine Control
Market USA
Applicability
Introduction
Some 2010 model year Sequoia and Tundra vehicles may exhibit a MIL "ON" condition for
Diagnostic Trouble Code (DTC) P0012 and/or P0022 ( Camshaft Position "A" - Timing
Over-Retarded Bank 1/2).
Please refer to the following repair procedure to address this condition.
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60
months or 60,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Production Change Information
Page 6516
Page 1554
Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf)
NOTICE: *
No further tightening is required once the nut is tightened with the specified torque.
* Check that there is no foreign matter on the washer and nut.
* Check that there is no oil, water or lubricant around the rim hole, tire pressure warning valve,
washer and nut. Failing to do so may result in improper installation.
(d) Set the wheel disc to a mounting machine and install the lower tire bead. Position the main
body of the tire pressure warning valve and
transmitter in the shaded area as shown in the illustration.
NOTICE: *
If the tire pressure warning valve and transmitter is positioned outside this area, the tire bead will
interfere with the tire pressure warning valve and transmitter, and may cause damage to it.
* If the use of lubricant is required when installing the bead, do not apply the lubricant directly to the
tire pressure warning valve and transmitter.
(e) Install the upper bead.
NOTICE: Make sure that the tire bead and tool do not interfere with the main body of the tire
pressure warning valve and transmitter and that the tire pressure warning valve and transmitter is
not clamped by the bead.
(f) Inflate the tire. Retighten the nut to the specified torque and then check for air leaks with soapy
water.
Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf)
NOTICE:
Page 5588
Braking Sensor/Switch: Locations From 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 6188
2. REMOVE FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Removal
3. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Removal
4. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal
5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Removal
6. REMOVE CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service
and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Removal
7. REMOVE FRONT ASH RECEPTACLE BOX SUB-ASSEMBLY
8. REMOVE LOWER INSTRUMENT CLUSTER FINISH PANEL See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column
Shift Type)/Removal
9. REMOVE POWER OUTLET SOCKET ASSEMBLY
(a) Using a screwdriver, detach the claw and remove the power outlet socket.
HINT Tape the screwdriver tip before use.
10. REMOVE POWER OUTLET SOCKET COVER
(a) Detach the 2 claws and remove the power outlet socket cover.
Installation
OTHER SYSTEM: POWER OUTLET SOCKET (for Column Shift Type): INSTALLATION
1. INSTALL POWER OUTLET SOCKET COVER
Page 9213
Page 7263
Steering Column Control Module: Service and Repair Installation
STEERING COLUMN: MULTIPLEX TILT AND TELESCOPIC ECU (for Power Tilt and Power
Telescopic Steering Column): INSTALLATION
1. INSTALL MULTIPLEX TILT AND TELESCOPIC ECU
(a) Install the ECU with the 2 screws.
Torque : 1.5 Nm (15 kgf-cm, 13 in-lbf)
(b) Connect the 2 ECU connectors.
2. INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY See: Service and Repair/Removal and
Replacement/Steering Column Assembly (for Power Tilt
and Power Telescopic Steering Column)/Removal
3. INSTALL LOWER NO. 1 INSTRUMENT PANEL AIR BAG ASSEMBLY See: Restraint
Systems/Air Bag Systems/Air Bag/Service and
Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Installation
4. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Floor Shift Type)/Removal
5. INSTALL HOOD LOCK CONTROL LEVER SUB-ASSEMBLY See: Body and Frame/Doors,
Hood and Trunk/Hood/Hood Latch Release
Cable/Service and Repair/Installation
6. INSTALL LOWER STEERING COLUMN COVER
(a) Attach the 2 claws to install the steering column lower cover.
7. INSTALL UPPER STEERING COLUMN COVER
Emissions - MIL ON/Multiple Air Injection DTC's Set
Air Injection Control Valve: Customer Interest Emissions - MIL ON/Multiple Air Injection DTC's Set
T-SB-0350-09
Rev1
October 1, 2009
Air Injection Pump With Water Intrusion: MIL "ON" DTC P04181P0419 and/or P244 #
Service Category Engine/Hybrid System
Section Engine Control
Market USA
Applicability
TSB REVISION NOTICE
May 21, 2010 Rev1:
^ DTCs P0418 and P0419 have been added to the TSB.
^ The Applicable Warranty has been updated in the Warranty Information section. Any previous
printed versions of this service bulletin should be discarded.
Introduction
Some 2010 model year Tundra vehicles built in the Texas plant may exhibit a MIL "ON" condition
with Diagnostic Trouble Code (DTC) P0418, P0419, P2440, P2441, P2442, P2443, P2446, and/or
P2447. This concern may be caused by water intrusion into the air injection pump assembly. Use
the following procedure to address this condition.
Parts Information
Production Change Information
Page 2900
(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(2) If the result is not as specified, replace the MAF meter.
Body - Tube Step Step Pad Lifting/Cracking
Auxiliary Step / Running Board: All Technical Service Bulletins Body - Tube Step Step Pad
Lifting/Cracking
T-SB-0164-10
June 28, 2010
Tube Step - Step Pad Lifting/Cracked
Service Category Vehicle Exterior
Section Exterior Panels/Trim
Market USA
Applicability
Introduction
Some 2007 - 2010 model year Tundra vehicles equipped with PPO/DIO tube steps may exhibit a
condition where the step pad has lifted or cracked. To improve the serviceability of the tube step
the step pad is now available as a separate service part. Follow the procedure in this bulletin to
replace the step pad. Removal of the tube step is not required to perform step pad replacement.
Parts Information
Warranty Information
APPLICABLE WARRANTY
^ Toyota accessories installed as original equipment are covered under the Toyota Comprehensive
Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the
vehicle's in-service date.
^ Toyota accessories installed after the new vehicle purchase are warranted for 12 months,
regardless of mileage, from the date of installation on the vehicle, or the remainder of the
applicable New Vehicle Limited Warranty, whichever provides the greater coverage.
^ Toyota accessories purchased over-the-counter are covered for 12 months from the date of
purchase.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Repair Procedure
Locations
Neutral Safety Switch: Locations
1UR-FE STARTING: STARTING SYSTEM: PARTS LOCATION
Page 3366
Remove the blown fuse and disconnect all loads of the fuse.
Connect a test light in place of the fuse.
Establish conditions in which the test light comes on.
Example:
- [A] - Ignition SW on
- [B] - Ignition SW and SW1 on
- [C] - Ignition SW, SW1 and Relay on (Connect the Relay) and SW2 off (or Disconnect SW2)
Disconnect and reconnect the connectors while watching the test light.
Page 992
(b) Disconnect the connector and remove the courtesy switch.
Installation
LIGHTING: REAR DOOR COURTESY SWITCH: INSTALLATION
HINT *
Use the same procedures for the RH and LH side.
* The procedures listed below are for the LH side.
* A bolt without a torque specification is shown in the standard bolt chart See:
Specifications/Mechanical Specifications/Standard Bolt - Specified Torque For Standard Bolts
1. INSTALL REAR DOOR COURTESY SWITCH
(a) Connect the connector.
(b) Install the courtesy switch with the bolt.
Page 6731
If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness
or connector in that circuit in the past. Check the wire harness and connectors.
B -- SYSTEM NORMAL
A -- TROUBLESHOOTING OF EACH PROBLEM SYMPTOM
The problem is still occurring in a place other than the diagnostic circuit (the DTC displayed first is
either for a past problem or a secondary problem).
4. SYMPTOM SIMULATION
HINT The most difficult case in troubleshooting is when no problem symptoms occur. In such a
case, a thorough problem analysis must be carried out. A simulation of the same or similar
conditions and environment in which the problem occurred in the customer's vehicle should be
carried out. No matter how much skill or experience a technician has, troubleshooting without
confirming the problem symptoms will lead to important repairs being overlooked and mistakes or
delays.
For example:
With a problem that only occurs when the engine is cold or as a result of vibration caused by the
road during driving, the problem can never be determined if the symptoms are being checked on a
stationary vehicle or on a vehicle with a warmed-up engine. Vibration, heat or water penetration
(moisture) is difficult to reproduce. The symptom simulation tests below are effective substitutes for
the conditions and can be applied on a stationary vehicle.
Important points in the symptom simulation test:
In the symptom simulation test, the problem symptoms as well as the problem area or parts must
be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then,
connect the tester and carry out the symptom simulation test, judging whether the circuit being
tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the
problem symptoms table for each system to narrow down the possible causes.
To reproduce DTCs, it is necessary to satisfy the respective DTC detection conditions.
(a) VIBRATION METHOD:
When a malfunction seems to occur as a result of vibration.
(1) PART AND SENSOR
Apply slight vibration with a finger to the part of the sensor suspected to be the cause of the
problem, and check whether or not the malfunction occurs.
NOTICE: Applying strong vibration to relays may open them.
Page 2316
NOTICE: *
Remove any oil from the contact surface.
* Install the camshaft housing within 3 minutes and tighten the bolts within 15 minutes after
applying seal packing.
(c) Install the camshaft housing, and install the 18 bolts in the order shown in the illustration.
for bolt A - Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
except bolt A - Torque : 30 Nm (306 kgf-cm, 22 ft-lbf)
NOTICE: *
Do not start the engine for at least 2 hours after the installation.
* Make sure that the knock pin of the camshaft is positioned as shown in the illustration before
installing the camshaft housing.
(d) Tighten the 10 bolts in the order shown in the illustration.
Torque : 16 Nm (163 kgf-cm, 12 ft-lbf)
NOTICE: Thoroughly wipe clean any seal packing.
3. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY
(a) Install the chain tensioner with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(b) While raising up the No. 2 chain tensioner, insert a pin of dia1.0 mm (0.0394 in.) into the hole to
fix it in place.
4. INSTALL NO. 1 CHAIN SUB-ASSEMBLY RH
Components
Alarm Module: Service and Repair Components
THEFT DETERRENT: THEFT WARNING ECU: COMPONENTS
Page 1326
NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do
not operate the ignition switch, any other switches, or the doors.
(a) If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the
harness and connector.
(b) Connect the cable of the Techstream to the DLC3, turn the ignition switch ON and attempt to
use the tester. If the display indicates that a
communication error has occurred, there is a problem either with the vehicle or with the tester.
HINT *
If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of
the original vehicle.
* If communication is still not possible when the tester is connected to another vehicle, the problem
may be in the tester itself. Consult the Service Department listed in the tester's instruction manual.
How To Proceed With Troubleshooting
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: HOW TO
PROCEED WITH TROUBLESHOOTING
1. OPERATION FLOW
HINT Perform troubleshooting in accordance with the procedures below. The following is an outline
of basic troubleshooting procedures. Confirm the troubleshooting procedures for the circuit you are
working on before beginning troubleshooting.
1. VEHICLE BROUGHT TO WORKSHOP
NEXT -- Continue to next step.
2. CUSTOMER PROBLEM ANALYSIS
(a) Ask the customer about the conditions and environment when the problem occurred.
NEXT -- Continue to next step.
3. INSPECT BATTERY VOLTAGE
Standard voltage:
11 to 14 V
If the voltage is below 11 V, recharge or replace the battery before proceeding.
NEXT -- Continue to next step.
Page 640
(a) for Regular Cab:
Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular Cab)/Removal.
(b) for Double Cab:
Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Removal.
(c) for CrewMax:
Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for CrewMax)/Removal.
2. REMOVE COWL SIDE TRIM BOARD LH
(a) for Regular Cab:
Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular Cab)/Removal.
(b) for Double Cab:
Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Removal.
(c) for CrewMax:
Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for CrewMax)/Removal.
3. REMOVE CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service
and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Removal
4. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal
5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Removal
6. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column
Shift Type)/Removal
7. REMOVE FRONT ASH RECEPTACLE BOX SUB-ASSEMBLY
8. REMOVE LOWER INSTRUMENT CLUSTER FINISH PANEL See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column
Shift Type)/Removal
9. REMOVE INSTRUMENT PANEL CUP HOLDER ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column
Shift Type)/Removal
10. REMOVE INTEGRATION CONTROL AND PANEL ASSEMBLY
Page 991
Removal
LIGHTING: REAR DOOR COURTESY SWITCH: REMOVAL
HINT *
Use the same procedures for the RH and LH side.
* The procedures listed below are for the LH side.
1. REMOVE REAR DOOR COURTESY SWITCH
(a) Remove the bolt.
Page 4018
4. INSTALL AIR CLEANER HOSE ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Installation
5. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Installation
Page 7995
Removal
SUPPLEMENTAL RESTRAINT SYSTEM: STEERING PAD: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE LOWER NO. 3 STEERING WHEEL COVER
(a) Using a screwdriver, remove the steering wheel cover.
Page 7737
(a) Remove the packing.
(b) Remove the 6 screws and detach the 4 claws.
(c) Remove the blower case (back side).
(d) Remove the evaporator from the blower case (front side).
17. REMOVE NO. 1 COOLER THERMISTOR
(a) Remove the No. 1 cooler thermistor.
Page 406
(b) Install the connector holder block cover.
4. INSTALL AIR CLEANER ASSEMBLY See: Powertrain Management/Ignition System/Ignition
Coil/Service and Repair/Installation
5. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Installation
Page 6843
Page 6109
(b) Inspect the load of the brush spring.
(1) Take a pull scale reading immediately after the brush spring separates from the brush.
Standard spring load:
22 to 28 N (2 to 3 kgf, 4.8 to 6.2 lbf)
Minimum spring load:
12 N (1 kgf, 2.8 lbf)
(2) If the load is less than the minimum, replace the starter brush holder assembly.
5. INSPECT STARTER YOKE ASSEMBLY
(a) Inspect the resistance of the field coil.
(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(2) If the result is not as specified, repair or replace the starter yoke assembly.
(3) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(4) If the result is not as specified, repair or replace the starter yoke assembly.
6. INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY
(a) Check the gear teeth of the planetary gears and starter center bearing clutch for wear or
damage.
If any planetary gear is damaged, replace the planetary gear assembly. If any teeth of the starter
center bearing clutch are damaged, replace the starter center bearing clutch sub-assembly.
Page 460
Removal
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Column
Shift Type): REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service
and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Removal
3. REMOVE CENTER AIRBAG SENSOR ASSEMBLY
Page 6166
* In the DTC check, it is very important to determine whether the problem indicated by the DTC is
either: 1) still occurring; or 2) occurred in the past but has since returned to normal. In addition, the
DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs
should be checked before and after confirmation of symptoms (i.e., whether or not problem
symptoms exist) to determine current system conditions, as shown in the flowchart below.
* Never skip the DTC check. Failing to check DTCs may, depending on the case, result in
unnecessary troubleshooting for systems operating normally or lead to repairs not related to the
problem. Follow the procedures listed in the flowchart in the correct order.
* The following flowchart shows how to proceed with troubleshooting using the DTC check.
Directions from the flowchart will indicate how to proceed either to DTC troubleshooting or to the
troubleshooting of each problem symptom.
1. DTC CHECK
NEXT -- Continue to next step.
2. MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR MEMORY
NEXT -- Continue to next step.
3. SYMPTOM CONFIRMATION
B -- Go to step 5 A -- Continue to next step.
4. SIMULATION TEST USING SYMPTOM SIMULATION METHODS
NEXT -- Continue to next step.
5. DTC CHECK
B -- TROUBLESHOOTING OF PROBLEM INDICATED BY DTC A -- Continue to next step.
6. SYMPTOM CONFIRMATION
Page 36
Collision Avoidance Module: Diagrams
Page 8084
Page 1875
Refer to the Technical Information System (TIS) when replacing the oil filter applicable model and
model year Repair Manual:
Components
Sunroof / Moonroof Switch: Service and Repair Components
SLIDING ROOF: SLIDING ROOF SWITCH ASSEMBLY (for CrewMax): COMPONENTS
Page 6324
JJ1-JL1
Page 2418
Refer to the Technical Information System (TIS) when replacing the oil filter applicable model and
model year Repair Manual:
Page 6636
Installation
OTHER SYSTEM: POWER OUTLET SOCKET (for CrewMax Column Shift Type): INSTALLATION
1. INSTALL REAR POWER POINT SOCKET (for AC Power Supply)
(a) Attach the 2 claws to install the power outlet socket.
2. INSTALL REAR POWER OUTLET SOCKET COVER (for Standard)
(a) Attach the 2 claws to install the power outlet socket cover.
3. INSTALL REAR POWER OUTLET SOCKET (for Standard)
(a) Attach the claw to install the power outlet socket.
4. INSTALL NO. 2 SEATBACK LOCK CONTROL BEZEL
Page 6933
6. PROBLEM SYMPTOMS TABLE
When a "Normal" code is output during a DTC check but the problem is still occurring, use the
Problem Symptoms Table. The suspected areas (circuits or parts) for each problem symptom are
in the table. The suspected areas are listed in order of probability. A description of each of the
chart's columns is below.
HINT In some cases, the problem is not detected by the diagnostic system even though a problem
symptom is present. It is possible that the problem is occurring outside the detection range of the
diagnostic system, or that the problem is occurring in a completely different system.
7. CIRCUIT INSPECTION
A description of the main areas of each circuit inspection is below.
Page 7559
Ambient Temperature Sensor / Switch HVAC: Locations Air Conditioning System (for Manual Air
Conditioning System)
AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Manual Air Conditioning System):
PARTS LOCATION
Page 2038
Fuse Block: Electrical Diagrams
Engine Room R/B And Engine Room J/B Inner Circuit
Center Speaker
Speaker: Diagrams Center Speaker
Page 4753
^ Power Supply Mode is used to maintain battery voltage at 13.5 volts while flash reprogramming
the vehicle.
^ For details on how to use the GR8 Battery Diagnostic Station, refer to the located on TIS,
Diagnostics - Tools & Equipment - Battery Diagnostics.
3. Click the appropriate calibration ID and reprogram the vehicle's ECU with Techstream.
A. After reviewing the procedures outlined in the selected TSB, click the appropriate calibration ID
link by matching the vehicle's current
calibration ID to the Previous Calibration ID in the Calibration Identification Chart.
NOTE
^ Calibration files are embedded as live links in the service bulletin.
^ Some vehicles require special preparation - please review the selected TSB carefully.
B. Click Open to load calibration file information.
Techstream pulls calibration files as needed to ensure the latest calibration file is used. Do NOT
save calibrations locally on the hard drive or other media.
NOTICE
Errors during the flash reprogramming process can permanently damage the vehicle ECU.
Minimize the risk by following the steps below.
^ Battery voltage MUST NOT FALL BELOW 11.4 volts during reprogramming. Confirm battery
voltage is higher than 11.4 volts, but be sure voltage DOES NOT RISE ABOVE 16.0 volts during
reprogramming.
^ Turn OFF all vehicle accessories (e.g. audio system, A/C, interior lights, DRL, etc.). Do NOT add
to or significantly change the vehicle's electrical
Diagrams
Steering Angle Sensor: Diagrams
Page 3511
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO POWER STEERING ECU
(CANH, CANL)
OK -- REPLACE POWER STEERING ECU See: Relays and Modules/Relays and Modules Steering and Suspension/Relays and Modules - Steering/Steering Control Module/Service and
Repair/Removal
18. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (CENTER AIRBAG SENSOR)
(a) Disconnect the J46 center airbag sensor connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
Components
Exhaust Manifold: Service and Repair Components
1UR-FE EXHAUST: EXHAUST MANIFOLD: COMPONENTS
Page 1445
Seat Occupant Sensor: Locations Occupant Classification System
SUPPLEMENTAL RESTRAINT SYSTEM: OCCUPANT CLASSIFICATION SYSTEM: PARTS
LOCATION
Page 4275
NOTE
Only Toyota Certified Technicians and above may access calibration files.
2. Connect the GR8 Battery Diagnostic Station.
A. Connect the GR8 Battery Diagnostic Station to the vehicle and turn it ON.
B. Select Power Supply Mode by following the screen flow below.
NOTICE
^ ECU damage may occur if the correct battery charger and mode setting are NOT used.
Page 8324
(b) Detach the 2 claws and remove the switch.
Installation
SUPPLEMENTAL RESTRAINT SYSTEM: CURTAIN SHIELD AIRBAG CUTOFF SWITCH:
INSTALLATION
1. INSTALL CURTAIN SHIELD AIRBAG CUTOFF SWITCH
(a) Attach the 2 claws to install the switch.
(b) Connect the connector.
2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Installation
3. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
4. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Installation
5. INSTALL FRONT DOOR SCUFF PLATE LH (for Double Cab, CrewMax) See: Body and
Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Installation
6. INSTALL FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Installation
7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
8. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Air Bag Systems/Testing and Inspection/Initial Inspection
and Diagnostic Overview/Diagnosis System.
Page 1552
Tire Pressure Sensor: Service and Repair Removal
TIRE AND WHEEL: TIRE PRESSURE WARNING VALVE AND TRANSMITTER: REMOVAL
1. REMOVE TIRE
2. REMOVE TIRE PRESSURE WARNING VALVE AND TRANSMITTER
(a) Remove the valve core and cap, and release the air from the tire.
(b) After ensuring that a sufficient amount of air has been released, remove the nut and washer
that is used to secure the tire pressure warning
valve and transmitter. Then drop the tire pressure warning valve and transmitter inside the tire.
HINT Keep the removed cap, valve core, nut and washer.
(c) Disengage the bead using the shoe of a tire remover.
NOTICE: Be careful as the tire pressure warning valve and transmitter may become damaged due
to interference between the sensor and tire bead.
(d) Remove the bead on the upper side.
(e) Take out the tire pressure warning valve and transmitter from the tire, then remove the bead on
the lower side.
HINT *
The grommet is a non-reusable part.
* Check that there are no cracks or damage on the grommet. If any damage is found, replace the
washer and nut.
Stereo Jack Adapter Assembly
Auxiliary Input / Output Jack: Diagrams Stereo Jack Adapter Assembly
Page 6259
Page 4337
(3) Check for dirt or mud on the pipe and around the connector before disconnection. Clean if
necessary.
(4) Pinch the connector and disconnect the connector and pipe.
(5) If the connector and the pipe are stuck together, pinch the connector, push and pull the pipe to
disconnect the pipe and pull it out.
NOTICE: Do not use any tools.
(6) Check for dirt or mud on the seal surface of the disconnected pipe. Clean if necessary.
(7) To protect the disconnected pipe and connector from damage and contamination, cover it with a
plastic bag.
(e) Observe these precautions when connecting the fuel tube connector (for Quick Type).
(1) Check that there is no damage or contamination in the connected part of the pipe.
(2) Align the axis of the connector with the axis of the pipe. Push the pipe into the connector until
the connector makes a "click" sound. If the
connection is tight, apply a small amount of fresh spindle oil or gasoline on the tip of the pipe.
(3) After having finished the connection, try to pull apart the pipe and the connector to confirm that
they are securely connected.
Page 3435
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO POWER STEERING ECU
(CANH, CANL)
OK -- REPLACE POWER STEERING ECU See: Relays and Modules/Relays and Modules Steering and Suspension/Relays and Modules - Steering/Steering Control Module/Service and
Repair/Removal
18. CHECK FOR SHORT IN CAN BUS WIRES (CENTER AIRBAG SENSOR)
(a) Disconnect the J46 center airbag sensor connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO CENTER AIRBAG
SENSOR (CANH, CANL)
OK -- REPLACE CENTER AIRBAG SENSOR
19. CHECK FOR SHORT IN CAN BUS WIRES (NO. 2 JUNCTION CONNECTOR - AIR
CONDITIONING AMPLIFIER)
(a) Measure the resistance according to the value(s) in the table below.
Page 8672
Push the secondary locking device or terminal retainer in to the full lock position.
CONNECT CONNECTOR
Voltage Check
VOLTAGE CHECK
Page 7497
Tire Pressure Sensor: Service and Repair Installation
TIRE AND WHEEL: TIRE PRESSURE WARNING VALVE AND TRANSMITTER: INSTALLATION
1. INSTALL TIRE PRESSURE WARNING VALVE AND TRANSMITTER
(a) Insert the tire pressure warning valve into the valve installation hole from the inside of the rim so
that the print surface can be seen.
NOTICE: *
Check that there is no visible deformation, damage or other abnormalities on the tire pressure
warning valve and transmitter.
* Check that there is no foreign matter on the inner grommet and around the rim hole.
* If the tire pressure warning valve and transmitter is installed in the reverse direction, it may be
damaged or fail to transmit signals when running at a high speed.
* If installing a new tire pressure warning valve and transmitter, write down the transmitter ID before
installation.
* The transmitter ID registration must be performed for all tire pressure warning valve and
transmitters, regardless of the number of tire pressure warning valve and transmitters replaced. If
all of the tire pressure warning valve and transmitters do not need to be replaced, check the DATA
LIST and write down the transmitter IDs of the tire pressure warning valve and transmitters that do
not need to be replaced before performing the transmitter ID registration See: Testing and
Inspection/Programming and Relearning/Registration
* It is necessary to perform initialization See: Testing and Inspection/Programming and
Relearning/Initialization after registration See: Testing and Inspection/Programming and
Relearning/Registration of the transmitter IDs into the tire pressure warning ECU after the tire
pressure warning valve and transmitter has been replaced.
(b) If reusing the tire pressure warning valve and transmitter:
Install a new grommet.
HINT A new tire pressure warning valve and transmitter is supplied with a grommet.
(c) Install the washer on the tire pressure warning valve from the rim side and tighten the nut.
Air Conditioning System (for Automatic Air Conditioning
System)
Compressor Clutch Relay: Locations Air Conditioning System (for Automatic Air Conditioning
System)
AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Automatic Air Conditioning System):
PARTS LOCATION
Page 423
Fuel Pump Control Unit: Locations Engine Control System - SFI System
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Locations
Horn Switch: Locations
HORN: HORN SYSTEM: PARTS LOCATION
Page 6620
Locations: The locations of components, connectors, ground points, and splices referred to within
these diagrams can be found at Vehicle Locations. See: Locations
Specifications
Compression Check: Specifications
COMPRESSION
Page 7937
(1) Place at least 2 tires under the tire which the front seat side airbag is tied to.
(2) Place at least 2 tires over the tire which the front seat side airbag is tied to. The top tire should
have the disc wheel installed.
NOTICE: *
Do not place SST connector under the tire because it could be damaged.
* As the disc wheel may be damaged by the airbag deployment, use a disc wheel that you are
planning to throw away.
* As the tires may be damaged by the airbag deployment, use a tire that you are planning to throw
away.
(3) Tie the tires together with 2 wire harnesses.
CAUTION: Make sure that the wire harnesses are tight. Looseness in the wire harnesses results in
the tires coming free due to the shock when the airbag is deployed.
(f) Install SST.
(1) Connect SST connector.
SST : 09082-00700
NOTICE: To avoid damaging SST connector and wire harness, do not lock the secondary lock of
the twin lock. Also, secure some slack for SST wire harness inside the tire.
(g) Deploy the airbag.
(1) Connect the red clip of SST to the battery positive (+) terminal and the black clip of SST to the
battery negative (-) terminal.
(2) Check that no one is within a 10 m (32.8 ft.) radius of the tire which the front seat side airbag is
tied to.
(3) Press SST activation switch and deploy the airbag.
Page 2064
"Case1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (/\ Mark) and pull the terminal retainer
up to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Page 3709
When using Techstream Lite, select Generic J2534 Interface. Then click Next.
E. Confirm the following:
^ PC is connected to VIM.
^ VIM is connected to DLC3 connector.
^ Ignition is ON and engine is OFF or "READY" OFF (hybrid vehicles).
Page 8213
(a) Check the ELR.
(1) When the inclination of the retractor is 15° or less, check that the belt can be pulled from the
retractor. When the inclination of the retractor
is over 45°, check that the belt locks.
If the operation is not as specified, replace the seat belt assembly.
(b) Check the fastening function of the child restraint system.
NOTICE: The check should be performed with the outer belt installed.
(1) When the belt is pulled out fully, the belt should automatically start to retract.
(2) After the belt has fully retracted, the belt should be able to be pulled out and retracted again.
If the operation is not as specified, replace the belt assembly.
Rear Seat Outer Belt Assembly (for CrewMax)
SEAT BELT: REAR SEAT OUTER BELT ASSEMBLY (for CrewMax): INSPECTION
1. INSPECT REAR SEAT OUTER BELT ASSEMBLY
(a) Check the ELR.
(1) When the inclination of the retractor is 15° or less, check that the belt can be pulled from the
retractor. When the inclination of the retractor
is over 45°, check that the belt locks.
If the operation is not as specified, replace the seat belt assembly.
(b) Check the fastening function of the child restraint system.
NOTICE: The check should be performed with the outer belt installed.
(1) When the belt is pulled out fully, the belt should automatically start to retract.
(2) After the belt has fully retracted, the belt should be able to be pulled out and retracted again.
If the operation is not as specified, replace the belt assembly.
Rear Seat Outer Belt Assembly (for Double Cab)
SEAT BELT: REAR SEAT OUTER BELT ASSEMBLY (for Double Cab): INSPECTION
1. INSPECT REAR SEAT OUTER BELT ASSEMBLY
Air Fuel Ratio Sensor
Oxygen Sensor: Diagrams Air Fuel Ratio Sensor
Page 1608
Four Wheel Drive Selector Switch: Service and Repair Installation
JF1A TRANSFER: 4WD CONTROL SWITCH: INSTALLATION
1. INSTALL 4WD CONTROL SWITCH
(a) Attach the 3 claws to install the switch.
2. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Panel,
Gauges and Warning Indicators/Instrument Cluster
/ Carrier/Service and Repair/Combination Meter/Installation
Page 8816
* The procedures listed below are for the LH side.
1. INSTALL FRONT NO. 3 SPEAKER ASSEMBLY (for 12 Speakers)
(a) Attach the 3 claws to install the speaker to the bracket.
NOTICE: Do not touch the cone part of the speaker.
(b) Install the speaker with bracket to the lower frame bracket garnish with the 3 screws.
2. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY
(a) Temporarily install the speaker by attaching the claws of the speaker to the door panel.
(b) Install the speaker with the 4 screws.
NOTICE: Do not touch the cone part of the speaker.
HINT Install the screws in the order shown in the illustration.
(c) Connect the connector.
3. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH See: Body and Frame/Doors,
Hood and Trunk/Doors/Front Door/Service and
Repair/Front Door (for CrewMax)/Reassembly
4. INSTALL FRONT DOOR ARMREST COVER LH
5. INSTALL COURTESY LIGHT ASSEMBLY See: Body and Frame/Doors, Hood and
Trunk/Doors/Front Door/Service and Repair/Front Door
(for CrewMax)/Reassembly
6. INSTALL FRONT UPPER ARMREST BASE PANEL LH See: Body and Frame/Doors, Hood and
Trunk/Doors/Front Door/Service and
Repair/Front Door (for CrewMax)/Reassembly
7. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH See: Body and Frame/Doors,
Hood and Trunk/Doors/Front Door/Service and
Page 8540
Page 1709
(b) Inspect the camber, caster and steering axis inclination.
Standard camber inclination (unloaded vehicle):
for Regular Cab of Standard Deck
Standard camber inclination (unloaded vehicle):
for Regular Cab of Long Deck
Standard camber inclination (unloaded vehicle):
for Double Cab of Standard Deck
Page 8276
Components
SEAT BELT: REAR SEAT OUTER BELT ASSEMBLY (for CrewMax): COMPONENTS
Page 2824
(c) WAVEFORM 2:
HINT The wavelength varies in accordance with the engine operating conditions.
(d) WAVEFORM 3:
HINT In the Data List, item O2S B1 S2 and O2S B2 S2 shows the ECM input values from the
heated oxygen sensor.
(e) WAVEFORM 4:
Air Conditioning Panel (for Column Shift Type)
Control Assembly: Service and Repair Air Conditioning Panel (for Column Shift Type)
Components
AIR CONDITIONING: AIR CONDITIONING PANEL (for Column Shift Type): COMPONENTS
Page 2028
Engine Room R/B, J/B - Engine Compartment Left
Page 1419
Page 8370
Removal
SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for CrewMax): REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Disassembly
3. REMOVE FRONT UPPER ARMREST BASE PANEL LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Page 8980
(a) for Regular Cab:
Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular Cab)/Removal.
(b) for Double Cab:
Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Removal.
(c) for CrewMax:
Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for CrewMax)/Removal.
2. REMOVE COWL SIDE TRIM BOARD LH
(a) for Regular Cab:
Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular Cab)/Removal.
(b) for Double Cab:
Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Removal.
(c) for CrewMax:
Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for CrewMax)/Removal.
3. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal
4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Floor Shift Type)/Removal
5. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
6. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal
7. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding
/ Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
8. REMOVE REAR UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
9. REMOVE CENTER LOWER INSTRUMENT PANEL FINISH PANEL See: Body and
Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
10. REMOVE INTEGRATION CONTROL AND PANEL ASSEMBLY
Page 8292
Seat Belt Buckle Switch: Diagrams
Page 335
2. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in
Figure 1. Confirm if the ECM (PCM) calibration has
been updated. If the calibration ID listed is NOT the latest ECM (PCM) calibration - go to step 3.
3. Flash reprogram the ECM (PCM).
NOTE
^ The GR8 Battery Diagnostic Station MUST be used in Power Supply Mode to maintain battery
voltage at 13.5 volts while flash reprogramming the vehicle.
^ For details on how to use the GR8 Battery Diagnostic Station, refer to the located on the
Technical Information System (TIS), Diagnostics - Battery
Follow the procedures outlined in TSB No. T-SB-0064-10, "Techstream ECU Flash
Reprogramming Procedure1⁄4 and flash the ECM (PCM) with the NEW calibration file update.
4. Install the Authorized Modifications Label.
A. Using a permanent marker enter the following information on the label:
^ ECM part number [Refer to the Parts Information section for the CURRENT PART NUMBER]
^ Calibration ID(s) [Refer to the Calibration Identification Chart for the NEW CALIBRATION ID]
^ Dealer Code
^ Repair Date
^ Change Authority [This TSB number]
B. Affix the Authorized Modifications Label to the vehicle at the location shown in Figure 1. The
Authorized Modifications Label is available
through the MDC P/N 00451-00001-LBL.
5. Test drive the vehicle to confirm proper vehicle operation.
Page 6173
Connectors
Locations: The locations of components, connectors, ground points, and splices referred to within
these diagrams can be found at Vehicle Locations. See: Locations
Power Outlet [12V]
Page 5411
Standard voltage:
(3) If the voltage is not as specified, replace the 4WD control ECU See: Control Module/Service
and Repair/Removal. If the voltage is
normal, replace the 4WD control switch.
Page 4315
M. Turn ignition OFF for a minimum of 10 seconds. Then click Next.
N. Turn ignition to the ON position. Then click Next.
0. Confirm all calibrations were updated as specified in the service bulletin. Then click Finish.
Page 5950
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION: Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC
terminals are touched, the IC may be destroyed by static electricity.)
When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact with the terminals of leads from the IC, etc. of the
replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown on the left.
DISCONNECT CONNECTOR
Page 9059
"Case1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (/\ Mark) and pull the terminal retainer
up to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Page 2382
Drive Belt: Service and Repair Installation
1UR-FE ENGINE MECHANICAL: DRIVE BELT: INSTALLATION
1. INSTALL FAN AND GENERATOR V BELT
(a) Set the V belt onto every part.
(b) While turning the belt tensioner counterclockwise, remove the pin.
NOTICE: Make sure that the V belt is properly set to each pulley.
(c) After installing the belt, check that it fits properly in the ribbed grooves.
HINT Make sure to check by hand that the belt has not slipped out of the grooves on the bottom of
the pulley.
2. INSTALL NO. 1 ENGINE UNDER COVER See: Engine Lubrication/Engine Oil/Service and
Repair/Replacement
3. INSTALL V-BANK COVER SUB-ASSEMBLY See: Service and Repair/Removal and
Replacement/Engine Assembly/Installation
Page 9053
Use a volt/ohmmeter with high impedance (10 kohms/V minimum) for troubleshooting of the
electrical circuit.
Disconnection of Male and Female Connectors
DISCONNECTION OF MALE AND FEMALE CONNECTORS
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Finding A Short Circuit
FINDING A SHORT CIRCUIT
Transmission Control Switch
Transmission Mode Switch: Diagrams Transmission Control Switch
Page 8387
(a) Disconnect the holder (with connectors).
(b) Remove the 3 bolts and airbag sensor.
Installation
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Column
Shift Type): INSTALLATION
1. INSTALL CENTER AIRBAG SENSOR ASSEMBLY
(a) Check that the ignition switch is OFF.
(b) Check that the cable is disconnected from the battery negative (-) terminal.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
(c) Install the airbag sensor with the 3 bolts.
Torque : 18 Nm (184 kgf-cm, 13 ft-lbf)
NOTICE: *
If the center airbag sensor has been dropped, or there are any cracks, dents or other defects in the
case, bracket or connector, replace it with a new one.
* When installing the center airbag sensor, be careful that the SRS wiring does not interfere with
other parts and that it is not pinched between other parts.
(d) Check that there is no looseness in the installation parts of the center airbag sensor.
(e) Connect the holder (with connectors).
(f) Check that the waterproof sheet is properly set.
2. INSTALL CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service
and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
NOTICE: Some systems need to be initialized after the cable is reconnected See: Testing and
Inspection/Programming and Relearning
4. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Air Bag Systems/Testing and Inspection/Initial Inspection
and Diagnostic Overview/Diagnosis System.
Page 2304
1UR-FE ENGINE MECHANICAL: CAMSHAFT (for Bank 1): REMOVAL
1. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY
(a) Remove the timing chain cover See: Engine Lubrication/Oil Pump/Service and Repair/Removal
and Replacement/Removal.
2. SET NO. 1 CYLINDER TO TDC / COMPRESSION See: Service and
Repair/Overhaul/Disassembly
3. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY LH
(a) Move the stopper plate upward to release the lock, and push the plunger deep into the
tensioner.
(b) Move the stopper plate downward to set the lock, and insert a hexagon wrench into the stopper
plate hole.
(c) Remove the 2 bolts, chain tensioner and gasket.
4. REMOVE NO. 1 CHAIN TENSIONER SLIPPER LH
5. REMOVE NO. 1 CHAIN VIBRATION DAMPER LH
(a) Remove the 2 bolts and chain vibration damper.
6. REMOVE NO. 1 CHAIN SUB-ASSEMBLY LH
(a) While pushing down the No. 3 chain tensioner, insert a pin of dia1.0 mm (0.0394 in.) into the
hole to fix it in place.
Page 649
Heated Mirror Switch: Locations Power Mirror Control System (w/o Memory)
MIRROR: POWER MIRROR CONTROL SYSTEM (w/o Memory): PARTS LOCATION
Page 1325
General Information
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: GENERAL
INFORMATION
* A large number of ECU controlled systems are used in the TOYOTA TUNDRA. In general, ECU
controlled systems are considered to be very intricate, requiring a high level of technical knowledge
to troubleshoot. However, most problem checking procedures only involve inspecting the ECU
controlled system's circuits one by one. An adequate understanding of the system and a basic
knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and
necessary repairs.
1. TROUBLESHOOTING PROCEDURES
* The troubleshooting procedures consist of diagnosis procedures for when a DTC is stored and
diagnosis procedures for when no DTC is stored. The basic idea is explained in the following table.
* Vehicle systems are complex and use many ECUs that are difficult to inspect independently.
Therefore, a process of elimination is used, where components that can be inspected individually
are inspected, and if no problems are found in these components, the related ECU is identified as
the problem and replaced.
* It is extremely important to ask the customer about the environment and the conditions present
when the problem occurred (Customer Problem Analysis). This makes it possible to simulate the
conditions and confirm the symptom. If the symptom cannot be confirmed or the DTC does not
recur, the malfunctioning part may not be identified using the troubleshooting procedure, and the
ECU for the related system may be replaced even though it is not defective. If this happens, the
original problem will not be solved.
* In order to prevent endless expansion of troubleshooting procedures, the troubleshooting
procedures are written with the assumption that multiple malfunctions do not occur simultaneously
for a single problem symptom.
* To identify the malfunctioning part, troubleshooting procedures narrow down the target by
separating components, ECUs and wire harnesses during the inspection. If the wire harness is
identified as the cause of the problem, it is necessary to inspect not only the connections to
components and ECUs but also all of the wire harness connectors between the component and the
ECU.
DIAGNOSTIC TESTER
2. DESCRIPTION
System data and the Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector
3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the Techstream* to
check for a malfunction and perform repairs.
HINT *: Techstream is the name for the diagnostic tester in North America.
3. DATA LINK CONNECTOR 3 (DLC3)
(a) The vehicle's ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of
the DLC3 complies with SAE J1962 and
matches the ISO 15765-4 format.
Page 817
Traction Control Switch: Diagrams
Page 3042
Camshaft Position Sensor: Diagrams
Page 8564
Parking Assist Control Module: Service and Repair Installation
PARK ASSIST / MONITORING: CLEARANCE WARNING ECU: INSTALLATION
HINT A bolt without a torque specification is shown in the standard bolt chart See:
Specifications/Mechanical Specifications/Standard Bolt - Specified Torque For Standard Bolts
1. INSTALL CLEARANCE WARNING ECU ASSEMBLY
(a) Install the clearance warning ECU to the bracket with the 2 nuts.
NOTICE: *
Avoid any impact to the clearance warning ECU.
* Do not drop the ECU. If it is dropped, replace it with a new one.
2. INSTALL CLEARANCE WARNING ECU WITH BRACKET
(a) Install the ECU with bracket with the nut and bolt.
(b) Connect the ECU connectors and attach the harness clamp.
NOTICE: Do not apply excessive force to the wire harnesses.
3. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Installation
4. INSTALL LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY See: Restraint
Systems/Air Bag Systems/Air Bag/Service and
Repair/Removal and Replacement/Front Passenger Side Knee Airbag Assembly/Installation
5. INSTALL LOWER INSTRUMENT PANEL See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
6. INSTALL NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY See: Body and
Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Column Shift Type)/Installation
7. INSTALL INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
8. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
9. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Air Bag/Service and
Repair/Removal and Replacement/Driver Side
Knee Airbag Assembly/Installation.
Locations
Tire Pressure Warning Reset Switch: Locations
TIRE AND WHEEL: TIRE PRESSURE WARNING SYSTEM: PARTS LOCATION
Page 5273
(a) Place matchmarks on the propeller shaft flange and differential flange.
(b) Remove the 4 bolts and 4 nuts.
(c) w/o Bearing Washer:
(1) Remove the 2 mounting bolts from the frame crossmember.
(d) w/ Bearing Washer:
(1) Remove the 2 mounting bolts and 2 bearing washers from the frame crossmember.
(e) Place matchmarks on the propeller shaft flange and transfer flange.
(f) Remove the 4 nuts and propeller shaft.
Installation
PROPELLER SHAFT: PROPELLER SHAFT ASSEMBLY (for 4WD): INSTALLATION
1. INSTALL PROPELLER SHAFT ASSEMBLY (for 2 Joint Type)
HINT When replacing the spider bearing, make sure that the grease fitting assembly hole is facing
in the direction shown in the illustration.
Page 6505
Driver Side J/B Inner Circuit
Page 8641
Television / Monitor: Service and Repair Video Terminal (for Separate Seat Type)
Components
AUDIO / VISUAL: VIDEO TERMINAL (for Separate Seat Type): COMPONENTS
Removal
AUDIO / VISUAL: VIDEO TERMINAL (for Separate Seat Type): REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
Page 2282
Refer to the Technical Information System (TIS) applicable model and model year Repair Manual:
2. Verify the vehicle has the proper coolant and oil levels.
3. Clear all DTCs and confirm the condition has been corrected.
Page 3491
(a) Reconnect the J86 No. 1 junction connector connector.
NEXT -- Continue to next step.
4. CHECK FOR SHORT IN CAN BUS WIRES (NO. 2 JUNCTION CONNECTOR)
(a) Disconnect the J113 No. 2 junction connector connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- CHECK FOR SHORT IN CAN BUS WIRES (NO. 2 JUNCTION CONNECTOR - AIR
CONDITIONING AMPLIFIER) OK -- Continue to next step.
5. CHECK FOR SHORT IN CAN BUS WIRES (NO. 1 JUNCTION CONNECTOR - NO. 2
JUNCTION CONNECTOR)
(a) Disconnect the J94 No. 1 junction connector connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE CAN MAIN WIRE OR CONNECTOR (NO. 1 JUNCTION
CONNECTOR - NO. 2 JUNCTION CONNECTOR) OK -- Continue to next step.
6. CONNECT CONNECTOR
(a) Reconnect the J94 No. 1 junction connector connector.
(b) Reconnect the J113 No. 2 junction connector connector.
Page 7573
Symbols Used Within Diagrams
Symbols Used Within Diagrams
Page 7129
Power Steering Pressure Switch: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: POWER STEERING OIL PRESSURE SWITCH:
INSTALLATION
1. INSTALL POWER STEERING OIL PRESSURE SWITCH
(a) Install a new O-ring to the power steering oil pressure switch.
(b) Apply a light coat of engine oil to the O-ring of the power steering oil pressure switch.
NOTICE: *
When reusing the power steering oil pressure switch, inspect the O-ring.
* If the O-ring has scratches or cuts, replace the power steering oil pressure switch.
(c) Using SST, install the power steering oil pressure switch.
SST : 09922-10010
without SST - Torque : 21 Nm (210 kgf-cm, 15 ft-lbf)
with SST - Torque : 15 Nm (148 kgf-cm, 11 ft-lbf)
HINT *
Use a torque wrench with a fulcrum length of 30 cm (11.8 in.). When using a torque wrench with a
fulcrum length that is not 30 cm (11.8 in.), calculate the torque specification for the torque wrench
and SST based on the "without SST" torque specification See: Service Precautions
* Make sure SST and the torque wrench are connected in a straight line.
(d) Connect the oil pressure switch connector.
2. INSTALL FAN AND GENERATOR V BELT
(a) Install the fan and generator V belt See: Engine, Cooling and Exhaust/Engine/Drive Belts,
Mounts, Brackets and Accessories/Drive
Belt/Service and Repair/Installation.
3. ADD POWER STEERING FLUID
4. BLEED POWER STEERING FLUID See: Steering/Testing and Inspection/Component Tests and
General Diagnostics/Power Steering
System/On-Vehicle Inspection
5. INSPECT FOR POWER STEERING FLUID LEAK
6. CHECK FLUID LEVEL See: Steering/Testing and Inspection/Component Tests and General
Diagnostics/Power Steering System/On-Vehicle
Inspection
7. INSTALL FRONT FENDER APRON SEAL RH See: Engine, Cooling and Exhaust/Exhaust
System/Exhaust Manifold/Service and
Repair/Installation
8. INSTALL FRONT WHEEL See: Suspension/Suspension Strut / Shock Absorber/Service and
Repair/Removal and Replacement/Front Shock
Absorber/Installation
Page 2492
10. INSTALL FAN SHROUD See: Cooling System/Radiator Cooling Fan/Service and
Repair/Installation
11. INSTALL FAN AND GENERATOR V BELT See: Drive Belts, Mounts, Brackets and
Accessories/Drive Belt/Service and Repair/Installation
12. INSTALL INLET RADIATOR HOSE See: Cooling System/Radiator Cooling Fan/Service and
Repair/Installation
13. ADD ENGINE COOLANT See: Cooling System/Coolant/Service and Repair
14. INSPECT FOR COOLANT LEAK See: Cooling System/Testing and Inspection
15. INSPECT FOR OIL LEAK See: Engine Lubrication/Engine Oil/Service and Repair/Replacement
16. CHECK ENGINE OIL LEVEL See: Engine Lubrication/Testing and Inspection
17. INSTALL NO. 1 ENGINE UNDER COVER See: Engine Lubrication/Engine Oil/Service and
Repair/Replacement
18. INSTALL V-BANK COVER SUB-ASSEMBLY See: Service and Repair/Removal and
Replacement/Engine Assembly/Installation
Page 1494
Page 359
^ Power Supply Mode is used to maintain battery voltage at 13.5 volts while flash reprogramming
the vehicle.
^ For details on how to use the GR8 Battery Diagnostic Station, refer to the located on TIS,
Diagnostics - Tools & Equipment - Battery Diagnostics.
3. Click the appropriate calibration ID and reprogram the vehicle's ECU with Techstream.
A. After reviewing the procedures outlined in the selected TSB, click the appropriate calibration ID
link by matching the vehicle's current
calibration ID to the Previous Calibration ID in the Calibration Identification Chart.
NOTE
^ Calibration files are embedded as live links in the service bulletin.
^ Some vehicles require special preparation - please review the selected TSB carefully.
B. Click Open to load calibration file information.
Techstream pulls calibration files as needed to ensure the latest calibration file is used. Do NOT
save calibrations locally on the hard drive or other media.
NOTICE
Errors during the flash reprogramming process can permanently damage the vehicle ECU.
Minimize the risk by following the steps below.
^ Battery voltage MUST NOT FALL BELOW 11.4 volts during reprogramming. Confirm battery
voltage is higher than 11.4 volts, but be sure voltage DOES NOT RISE ABOVE 16.0 volts during
reprogramming.
^ Turn OFF all vehicle accessories (e.g. audio system, A/C, interior lights, DRL, etc.). Do NOT add
to or significantly change the vehicle's electrical
Page 6056
(2) Disconnect connector B and measure the resistance.
Standard resistance (Fig. 7):
* If the results match the examples above, a short circuit exists between terminal 1 of connector B2
and terminal 1 of connector C.
4. CHECK AND REPLACE ECU
NOTICE: *
The connector should not be disconnected from the ECU. Perform the inspection from the backside
of the connector on the wire harness side.
* When no measuring condition is specified, perform the inspection with the engine stopped and
the ignition switch ON.
* Check that the connectors are fully seated. Check for loose, corroded or broken wires.
(a) First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be
faulty. Temporarily replace the ECU with a
normally functioning one and check if the symptoms occur. If the trouble symptoms disappear,
replace the original ECU.
(1) Measure the resistance between the ECU ground terminal and body ground.
Standard resistance:
Below 1 Ohms
(2) Disconnect the ECU connector. Check the ground terminal on the ECU side and wire harness
side for bending, corrosion or foreign matter.
Lastly, check the contact pressure of the female terminals.
Specifications
Engine Oil Pressure: Specifications
ENGINE OIL PRESSURE
Page 434
(2) If the result is not as specified, replace the integration relay.
3. INSTALL INTEGRATION RELAY See: Relays and Modules - Ignition System/Ignition
Relay/Testing and Inspection
Page 6989
(2) CONNECTORS
Slightly shake the connector vertically and horizontally.
(3) WIRE HARNESS
Slightly shake the wire harness vertically and horizontally.
HINT The connector joint and fulcrum of the vibration are the major areas that should be checked
thoroughly.
(b) HEAT METHOD:
When a malfunction seems to occur when the area in question is heated.
(1) Heat the component that is the possible cause of the malfunction with a hair dryer or similar
device. Check if the malfunction occurs.
NOTICE: *
Do not heat to more than 60°C (140°F). Exceeding this temperature may damage components.
* Do not apply heat directly to the parts in the ECU.
(c) WATER SPRINKLING METHOD:
When a malfunction seems to occur on a rainy day or in high-humidity.
(1) Sprinkle water onto the vehicle and check if the malfunction occurs.
NOTICE: *
Never sprinkle water directly into the engine compartment. Indirectly change the temperature and
humidity by spraying water onto the front of the radiator.
* Never apply water directly onto the electronic components.
HINT If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU
or connections. Look for evidence of corrosion or short circuits. Proceed with caution during water
tests.
(d) HIGH ELECTRICAL LOAD METHOD:
When a malfunction seems to occur when the electrical load is excessive.
(1) Turn on the heater blower, headlights, rear window defogger and all other electrical loads.
Check if the malfunction reoccurs.
5. DIAGNOSTIC TROUBLE CODE CHART
Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate
section's Diagnostic Trouble Code Chart. Use the chart to determine the trouble area and the
proper inspection procedure. A description of each of the chart's columns is below.
Page 8548
Central Control Module: Service and Repair Removal
AUDIO / VISUAL: MULTI-MEDIA INTERFACE ECU: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY
(a) for Column Shift Type:
Remove the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Column Shift Type)/Removal.
(b) for Floor Shift Type:
Remove the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Floor Shift Type)/Removal.
3. REMOVE MULTI-MEDIA INTERFACE ECU
(a) Remove the nut.
(b) Disconnect the connector and remove the multi-media interface ECU.
4. REMOVE MULTI-DISPLAY CONTROLLER BRACKET A
(a) Remove the 2 bolts and multi-display controller bracket A.
Page 6301
Fuse Block: Electrical Diagrams
Engine Room R/B And Engine Room J/B Inner Circuit
Page 604
Parking Assist Distance Sensor: Service and Repair Ultrasonic Sensor (for Rear Side)
Components
PARK ASSIST / MONITORING: ULTRASONIC SENSOR (for Rear Side): COMPONENTS
Page 9113
"Case2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 8236
Seat)/Removal.
2. REMOVE FRONT SEAT ASSEMBLY RH
(a) for Power Seat:
Remove the front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Power Seat)/Removal.
(b) for Manual Seat:
Remove the front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Manual Seat)/Removal.
3. REMOVE CENTER FRONT SEAT ASSEMBLY
(a) Remove the center front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Center
Seat)/Removal.
4. REMOVE CENTER SEATBACK PANEL See: Body and Frame/Seats/Service and
Repair/Overhaul/Front Seat Assembly (for Center
Seat)/Disassembly
5. REMOVE CENTER SEAT CUSHION SHIELD LH See: Body and Frame/Seats/Service and
Repair/Overhaul/Front Seat Assembly (for Center
Seat)/Disassembly
6. REMOVE CENTER FRONT SEAT INNER BELT ASSEMBLY
(a) Remove the bolt and the center front seat inner belt.
Installation
SEAT BELT: FRONT SEAT INNER BELT ASSEMBLY (for Center Seat): INSTALLATION
1. INSTALL CENTER FRONT SEAT INNER BELT ASSEMBLY
(a) Install the inner belt with the nut.
Torque : 42 Nm (428 kgf-cm, 31 ft-lbf)
NOTICE: Do not overlap the anchor part of the seat belt and protruding part of the seat adjuster.
2. INSTALL CENTER SEAT CUSHION SHIELD LH See: Body and Frame/Seats/Service and
Repair/Overhaul/Front Seat Assembly (for Center
Seat)/Reassembly
3. INSTALL CENTER SEAT BACK PANEL See: Body and Frame/Seats/Service and
Repair/Overhaul/Front Seat Assembly (for Center
Seat)/Reassembly
Locations
Ignition Switch: Locations
1UR-FE STARTING: STARTING SYSTEM: PARTS LOCATION
Page 8495
Double Cab)/Removal
5. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH
6. REMOVE REAR DOOR SCUFF PLATE RH
(a) Remove the front door scuff plate See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Removal.
HINT The procedures listed below are for the LH side.
7. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY RH See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Double Cab)/Removal
8. REMOVE DOOR CONTROL RECEIVER
(a) Disconnect the door control receiver connector.
(b) Remove the bolt and receiver.
Installation
DOOR LOCK: DOOR CONTROL RECEIVER (for Double Cab): INSTALLATION
1. INSTALL DOOR CONTROL RECEIVER
(a) Install the receiver with the bolt.
(b) Connect the door control receiver connector.
2. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY RH
3. INSTALL REAR DOOR SCUFF PLATE RH
(a) Install rear door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double
Cab)/Installation.
HINT The procedures listed below are for the LH side.
4. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH
5. INSTALL REAR SEAT ASSEMBLY See: Body and Frame/Seats/Service and Repair/Removal
and Replacement/Rear Seat Assembly (for
Double Cab)/Installation
6. INSTALL SEAT FLOOR BOX See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Rear Seat Assembly (for Double
Drivetrian - Rear End Howling/Growling Noises
Wheel Bearing: Customer Interest Drivetrian - Rear End Howling/Growling Noises
T-SB-0151-10
June11, 2010
Rear Axle Bearing Abnormal Noise
Service Category Drivetrain
Section Axle/Differential
Market USA
Applicability
Introduction
Some 2007 - 2010 model year Tundra vehicles may exhibit a howling or growling noise from the
rear of the vehicle that increases with vehicle speed. Changes have been made to the rear axle
bearing to correct this condition. Follow the procedure in the bulletin to address customer concerns.
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60
months or 60,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Parts Information
Page 8643
Television / Monitor: Service and Repair Video Terminal (for Bench Seat Type)
Components
AUDIO / VISUAL: VIDEO TERMINAL (for Bench Seat Type): COMPONENTS
Removal
AUDIO / VISUAL: VIDEO TERMINAL (for Bench Seat Type): REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
Page 8929
Integrated Accessory Switch Assembly: Testing and Inspection
METER: DRIVE MONITOR SWITCH: INSPECTION
1. INSPECT DRIVE MONITOR SWITCH
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(a) If the result is not as specified, replace the monitor switch.
(b) Inspect the switch illumination.
(1) Connect the battery's positive (+) lead to terminal 1 (ILL+) and the negative (-) lead to terminal 6
(ILL-).
(2) Check that the light comes on.
OK:
LED comes on.
(3) If the result is not as specified, replace the monitor switch.
Up to 11/2009
Traction Control Relay: Locations Up to 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Locations
Headlamp Alignment Switch: Locations
LIGHTING: LIGHTING SYSTEM: PARTS LOCATION
Locations
Knock Sensor: Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 1995
Page 18
Alarm Module: Diagrams Glass Breakage Sensor ECU
Page 8684
* Some transmitter's signals stop after 1 to 2 seconds. For these types of transmitters: 1) press and
hold one of the garage door opener switches, and 2) press and release (cycle) the transmitter
switch every 2 seconds. Check if the transmitter code was successfully registered.
* After entering the garage door opener registration mode, transmitter code registration must be
completed within 90 seconds. If 90 seconds elapse, the garage door opener will enter low power
mode (refer to "low power mode" below).
(b) Erase transmitter codes in the garage door opener clear mode.
HINT All 3 registered transmitter codes will be erased. No option exists for only erasing one
transmitter code.
(1) Press and hold the left and right switches of the garage door opener for 20 seconds. The LED
will begin to flash at a cycle of 5.6 Hz.
Releasing the switches will end clear mode.
HINT *
If the switches are released within 10 seconds after the transmitter codes have been erased, the
garage door opener will enter registration mode.
* If the switches are held for 10 seconds or more after the transmitter codes have been erased,
default codes will be set to the switches of the garage door opener. Using these default codes,
operation of the garage door opener can be checked using a tester.
Page 8439
(a) Install the antenna ornament as shown in the illustration.
4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Page 3615
Oxygen Sensor: Testing and Inspection Air Fuel Ratio Sensor
1UR-FE ENGINE CONTROL SYSTEM: AIR FUEL RATIO SENSOR: ON-VEHICLE INSPECTION
1. INSPECT AIR FUEL RATIO SENSOR
(a) Disconnect the 2 sensor connectors.
(b) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(c) If the result is not as specified, replace the air fuel ratio sensor.
(d) Connect the 2 sensor connectors.
Initial Inspection and Diagnostic Overview
Information Bus: Initial Inspection and Diagnostic Overview
LIN Communication System
MULTIPLEX COMMUNICATION: LIN COMMUNICATION SYSTEM: HOW TO PROCEED WITH
TROUBLESHOOTING
HINT *
Use these procedures to troubleshoot the LIN communication system.
* *: Use the Techstream.
1. VEHICLE BROUGHT TO WORKSHOP
NEXT -- Continue to next step.
2. INSPECT BATTERY VOLTAGE
Standard voltage:
11 to 14 V
If the voltage is below 11 V, recharge or replace the battery before proceeding.
NEXT -- Continue to next step.
3. CHECK COMMUNICATION FUNCTION OF CAN COMMUNICATION SYSTEM*
(a) Using the Techstream, inspect the CAN communication function to ensure there are no
malfunctions in the CAN communication system
See: CAN Communication System/How to Proceed With Troubleshooting.
B -- GO TO CAN COMMUNICATION SYSTEM See: CAN Communication System/How to Proceed
With Troubleshooting A -- Continue to next step.
4. PROBLEM SYMPTOMS TABLE
(a) Refer to the problem symptoms table See: Symptom Related Diagnostic Procedures/LIN
Communication System/Problem Symptoms
Table.
B -- Go to step 6 A -- Continue to next step.
5. OVERALL ANALYSIS AND TROUBLESHOOTING*
(a) Terminals of ECU See: Pinout Values and Diagnostic Parameters/LIN Communication System
(b) Data List / Active Test See: Scan Tool Testing and Procedures
NEXT -- Continue to next step.
6. REPAIR OR REPLACE
NEXT -- END
How to Proceed With Troubleshooting
Page 1630
Power Window Switch: Diagrams Power Window Regulator Master Switch
Page 8594
Rear Vision Camera: Service and Repair Removal
PARK ASSIST / MONITORING: TELEVISION CAMERA: REMOVAL
1. REMOVE TAIL GATE SERVICE HOLE COVER See: Body and Frame/Tailgate/Service and
Repair/Tail Gate/Removal
2. REMOVE TELEVISION CAMERA ASSEMBLY
(a) Disconnect the television camera connector.
(b) Detach the 3 clamps and remove the 2 bolts and television camera.
Page 5848
Disassembly
Parking Brake Warning Switch: Service and Repair Disassembly
PARKING BRAKE: PARKING BRAKE PEDAL: DISASSEMBLY
1. REMOVE PARKING BRAKE SWITCH ASSEMBLY
(a) Remove the screw and switch.
Page 6799
(2) Disconnect connector B and measure the resistance.
Standard resistance (Fig. 7):
* If the results match the examples above, a short circuit exists between terminal 1 of connector B2
and terminal 1 of connector C.
4. CHECK AND REPLACE ECU
NOTICE: *
The connector should not be disconnected from the ECU. Perform the inspection from the backside
of the connector on the wire harness side.
* When no measuring condition is specified, perform the inspection with the engine stopped and
the ignition switch ON.
* Check that the connectors are fully seated. Check for loose, corroded or broken wires.
(a) First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be
faulty. Temporarily replace the ECU with a
normally functioning one and check if the symptoms occur. If the trouble symptoms disappear,
replace the original ECU.
(1) Measure the resistance between the ECU ground terminal and body ground.
Standard resistance:
Below 1 Ohms
(2) Disconnect the ECU connector. Check the ground terminal on the ECU side and wire harness
side for bending, corrosion or foreign matter.
Lastly, check the contact pressure of the female terminals.
Page 6511
Instrument Panel (Floor Shift)
Instrument Panel (Column Shift)
Service and Repair
Fuel Pressure Release: Service and Repair
1UR-FE FUEL: FUEL SYSTEM: PRECAUTION
CAUTION: *
Before working on the fuel system, disconnect the cable from the negative (-) battery terminal.
* Do not smoke or be near an open flame when working on the fuel system.
* Keep gasoline away from rubber and leather parts.
1. DISCHARGE FUEL SYSTEM PRESSURE
CAUTION: *
Do not disconnect any part of the fuel system until you have discharged the fuel system pressure.
* After discharging the fuel pressure, place a cloth or equivalent over fittings as you separate them
to reduce the risk of fuel spray on yourself or in the engine compartment.
(a) Disconnect the cable from the negative (-) battery terminal.
(b) Disconnect the 2 fuel pump ECU connectors.
(c) Connect the cable to the negative (-) battery terminal.
(d) Start the engine. After the engine has stopped on its own, turn the ignition switch OFF.
HINT DTC P0171/0174 (system too lean) may be set.
(e) Crank the engine again, then check that the engine does not start.
(f) Loosen the fuel tank cap, then discharge the pressure in the fuel tank completely.
(g) Connect the 2 fuel pump ECU connectors.
2. FUEL SYSTEM
(a) When disconnecting the high fuel pressure line, a large amount of gasoline will spill out. Follow
these procedures.
(1) Perform the "DISCHARGE FUEL SYSTEM PRESSURE" procedures above.
(2) Put a container under the connecting part of the pressure line.
(3) Slowly loosen the connection.
(4) Disconnect the connection.
(5) Plug the connection with a rubber plug.
(b) Observe these precautions when removing and installing the injectors:
Page 6623
Removal
OTHER SYSTEM: CENTER POWER OUTLET SOCKET (for Column Shift Type): REMOVAL
1. REMOVE FRONT SEAT ASSEMBLY LH (for Manual Seat)
(a) Remove the front seat LH See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Manual
Seat)/Removal.
2. REMOVE FRONT SEAT ASSEMBLY RH (for Manual Seat)
HINT Use the same procedures described for the LH side.
Page 69
Keyless Entry Module: Service and Repair Door Control Receiver (for Double Cab)
Components
DOOR LOCK: DOOR CONTROL RECEIVER (for Double Cab): COMPONENTS
Page 8005
Page 9296
Page 1645
Power Window Switch: Service and Repair Front Passenger Side Power Window Switch
Components
WINDSHIELD / WINDOWGLASS: FRONT PASSENGER SIDE POWER WINDOW SWITCH:
COMPONENTS
Removal
WINDSHIELD / WINDOWGLASS: FRONT PASSENGER SIDE POWER WINDOW SWITCH:
REMOVAL
1. REMOVE FRONT UPPER ARMREST BASE PANEL RH
Page 1852
^ Figure 17 shows an example of the update procedure for a two-processor ECU.
G. Turn ignition OFF. Then click Next.
H. Confirm the following:
^ Ignition is ON and engine is OFF or "READY" OFF (hybrid vehicles).
^ Hood is open.
^ All accessories are OFF.
^ Battery voltage is above 11.4 volts.
NOTICE
Verify the vehicle is connected to a battery charger before continuing - If battery voltage falls below
11.4 volts, ECU damage may occur.
Page 6711
DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector.
Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
Page 1982
Components
Power Distribution Module: Service and Repair Components
OTHER SYSTEM: VOLTAGE INVERTER (for CrewMax): COMPONENTS
Page 3805
Engine Temperature Sensor: Testing and Inspection
1UR-FE ENGINE CONTROL SYSTEM: ENGINE COOLANT TEMPERATURE SENSOR:
INSPECTION
1. INSPECT ENGINE COOLANT TEMPERATURE SENSOR
(a) Partially immerse the sensor in water and warm up the water.
(b) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(c) If the result is not as specified, replace the engine coolant temperature sensor.
NOTICE: When checking the sensor in water, keep the terminals dry. After the check, wipe the
sensor dry.
HINT If the result is as specified, do not replace the engine coolant temperature sensor.
Page 1848
^ Power Supply Mode is used to maintain battery voltage at 13.5 volts while flash reprogramming
the vehicle.
^ For details on how to use the GR8 Battery Diagnostic Station, refer to the located on TIS,
Diagnostics - Tools & Equipment - Battery Diagnostics.
3. Click the appropriate calibration ID and reprogram the vehicle's ECU with Techstream.
A. After reviewing the procedures outlined in the selected TSB, click the appropriate calibration ID
link by matching the vehicle's current
calibration ID to the Previous Calibration ID in the Calibration Identification Chart.
NOTE
^ Calibration files are embedded as live links in the service bulletin.
^ Some vehicles require special preparation - please review the selected TSB carefully.
B. Click Open to load calibration file information.
Techstream pulls calibration files as needed to ensure the latest calibration file is used. Do NOT
save calibrations locally on the hard drive or other media.
NOTICE
Errors during the flash reprogramming process can permanently damage the vehicle ECU.
Minimize the risk by following the steps below.
^ Battery voltage MUST NOT FALL BELOW 11.4 volts during reprogramming. Confirm battery
voltage is higher than 11.4 volts, but be sure voltage DOES NOT RISE ABOVE 16.0 volts during
reprogramming.
^ Turn OFF all vehicle accessories (e.g. audio system, A/C, interior lights, DRL, etc.). Do NOT add
to or significantly change the vehicle's electrical
Page 1424
Page 5286
(a) Remove the 2 bolts and heat insulator from the heat insulator bracket.
2. REMOVE PROPELLER SHAFT HEAT INSULATOR BRACKET SUB-ASSEMBLY
(a) Remove the 2 bolts and heat insulator bracket from the crossmember.
3. REMOVE FRONT PROPELLER SHAFT ASSEMBLY
(a) for Front Differential Side:
(1) Place matchmarks on the differential and propeller shaft flange.
(2) Remove the 4 nuts, 4 washers and disconnect the propeller shaft from the differential.
NOTICE: Use a rope to suspend the front edge of the propeller shaft.
(b) for Transfer Side:
(1) Place matchmarks on the transfer and propeller shaft flanges.
(2) Remove the 4 nuts and 4 washers.
(c) Remove the propeller shaft from the transfer flange.
Installation
PROPELLER SHAFT: FRONT PROPELLER SHAFT ASSEMBLY: INSTALLATION
1. INSTALL FRONT PROPELLER SHAFT
Air Conditioning System (for Automatic Air Conditioning
System)
Evaporator Temperature Sensor / Switch: Locations Air Conditioning System (for Automatic Air
Conditioning System)
AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Automatic Air Conditioning System):
PARTS LOCATION
Page 9073
3. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE
HINT The diagnostic system in the TOYOTA TUNDRA has various functions.
* The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU
memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a
previous malfunction's DTC can be checked by a technician during troubleshooting.
* Another function is the Input Signal Check, which checks if the signals from various switches are
sent to the ECU correctly.
* By using these functions, the problem areas can be narrowed down and troubleshooting is more
effective. Diagnostic functions are incorporated in the following systems in the TOYOTA TUNDRA.
Page 8676
(a) For an open circuit in the wire harness in Fig. 1, check the resistance or voltage, as described
below.
(b) Check the resistance.
(1) Disconnect connectors A and C and measure the resistance between them.
Standard resistance (Fig. 2):
HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally.
If the results match the examples above, an open circuit exists between terminal 1 of connector A
and terminal 1 of connector C.
(2) Disconnect connector B and measure the resistance between the connectors.
Standard resistance (Fig. 3):
* If the results match the examples above, an open circuit exists between terminal 1 of connector
B2 and terminal 1 of connector C.
(c) Check the voltage.
Page 6921
when inserting and after full engagement.
NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal.
(d) REPAIR METHOD OF CONNECTOR TERMINAL
(1) If there is any foreign matter on the terminal, clean the contact point using an air gun or cloth.
Never rub the contact point using sandpaper
as the plating may come off.
(2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is
gold-plated (gold color), use a gold-plated female
terminal; if it is silver-plated (silver color), use a silver-plated female terminal.
(3) Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock
into the housing, the housing may have to be
replaced.
(e) HANDLING OF WIRE HARNESS
(1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be
restored in the same way.
(2) Never twist, pull or slacken the wire harness more than necessary.
(3) The wire harness should never come into contact with a high temperature part, or rotating,
moving, vibrating or sharp-edged parts. Avoid
contact with panel edges, screw tips and other sharp items.
(4) When installing parts, never pinch the wire harness.
(5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with
vinyl tape.
2. CHECK FOR OPEN CIRCUIT
Up to 11/2009
Acceleration/Deceleration Sensor: Locations Up to 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Components
Accelerator Pedal: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: ACCELERATOR PEDAL: COMPONENTS
Page 8851
(b) Remove the 3 screws and speaker.
NOTICE: Do not touch the cone part of the speaker.
From 11/2009
AUDIO / VISUAL: REAR DOOR SPEAKER (for Double Cab): REMOVAL
HINT *
Use the same procedures for the LH side and RH side.
* The procedures listed below are for the LH side.
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE REAR DOOR FRAME GARNISH LH See: Body and Frame/Doors, Hood and
Trunk/Doors/Rear Door/Service and Repair/Rear
Door (for Double Cab)/Disassembly
3. REMOVE REAR DOOR INSIDE HANDLE BEZEL PLUG LH See: Body and Frame/Doors, Hood
and Trunk/Doors/Rear Door/Service and
Repair/Rear Door (for Double Cab)/Disassembly
4. REMOVE REAR UPPER DOOR ARMREST BASE PANEL LH See: Body and Frame/Doors,
Hood and Trunk/Doors/Rear Door/Service and
Repair/Rear Door (for Double Cab)/Disassembly
5. REMOVE REAR DOOR ARMREST COVER LH
6. REMOVE REAR DOOR TRIM BOARD SUB-ASSEMBLY LH See: Body and Frame/Doors, Hood
and Trunk/Doors/Rear Door/Service and
Repair/Rear Door (for Double Cab)/Disassembly
7. REMOVE REAR NO. 1 SPEAKER ASSEMBLY
(a) Disconnect the speaker connector.
(b) Remove the 3 screws and speaker.
NOTICE: Do not touch the cone part of the speaker.
Up to 11/2009
AUDIO / VISUAL: REAR DOOR SPEAKER (for Double Cab): INSTALLATION
HINT *
Use the same procedures for the LH side and RH side.
* The procedures listed below are for the LH side.
1. INSTALL REAR NO. 1 SPEAKER ASSEMBLY
Page 4351
Fuel Injector: Service and Repair Removal
1UR-FE FUEL: FUEL INJECTOR: REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE
CAUTION: *
Do not disconnect any part of the fuel system until you have discharged the fuel system pressure.
* After discharging the fuel pressure, place a cloth or equivalent over fittings as you separate them
to reduce the risk of fuel spray on yourself or in the engine compartment.
(a) Disconnect the cable from the negative (-) battery terminal.
(b) Disconnect the 2 fuel pump ECU connectors.
(c) Connect the cable to the negative (-) battery terminal.
(d) Start the engine. After the engine has stopped on its own, turn the ignition switch OFF.
HINT DTC P0171/0174 (system too lean) may be set.
(e) Crank the engine again, then check that the engine does not start.
(f) Loosen the fuel tank cap, then discharge the pressure in the fuel tank completely.
(g) Connect the 2 fuel pump ECU connectors.
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
3. REMOVE EGR VALVE BRACKET
(a) Remove the EGR valve bracket See: Emission Control Systems/Exhaust Gas
Recirculation/EGR Valve/Service and Repair/Removal.
4. DISCONNECT NO. 2 FUEL TUBE SUB-ASSEMBLY
(a) Disconnect the No. 2 fuel tube from the fuel pressure regulator See: Service Precautions.
5. DISCONNECT FUEL TUBE SUB-ASSEMBLY
(a) Disconnect the fuel tube from the fuel delivery pipe RH See: Service Precautions.
(b) Disconnect the fuel tube from the fuel delivery pipe LH See: Service Precautions.
Engine Immobiliser System
Alarm Module: Locations Engine Immobiliser System
ENGINE IMMOBILISER: ENGINE IMMOBILISER SYSTEM: PARTS LOCATION
Page 4614
Ignition Switch: Service and Repair Removal
1UR-FE STARTING: IGNITION SWITCH: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE STEERING COLUMN ASSEMBLY
(a) for Manual Tilt:
Remove the steering column See: Steering and Suspension/Steering/Steering Column/Service and
Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Removal.
(b) for Manual Tilt and Manual Telescopic Steering Column:
Remove the steering column See: Steering and Suspension/Steering/Steering Column/Service and
Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt and Manual
Telescopic Steering Column)/Removal.
(c) for Power Tilt and Power Telescopic Steering Column:
Remove the steering column See: Steering and Suspension/Steering/Steering Column/Service and
Repair/Removal and Replacement/Steering Column Assembly (for Power Tilt and Power
Telescopic Steering Column)/Removal.
3. REMOVE UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Manual
Tilt) See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering Column Assembly
(for Manual Tilt)/Disassembly
4. REMOVE UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Manual Tilt
and Manual Telescopic Steering Column)
See: Steering and Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering
Column Assembly (for Manual Tilt and Manual Telescopic Steering Column)/Disassembly
5. REMOVE UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Power Tilt
and Power Telescopic Steering Column)
See: Steering and Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering
Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Disassembly
6. REMOVE IGNITION SWITCH ASSEMBLY
(a) Detach the 2 claws and remove the ignition switch from the steering lock.
Page 3465
CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: HOW TO PROCEED WITH
TROUBLESHOOTING
HINT *
DTCs for the CAN communication system are as follows: U0073, U0100, U0114, U0123, U0124,
U0126, U0129, U0199, U0208, U1002, U1115, B1499, and B2621
* Refer to the troubleshooting procedures of each system if DTCs regarding the CAN
communication system are not output.
* Before measuring the resistance, leave the vehicle for at least 1 minute and do not operate the
ignition switch, any switches or doors. If doors need to be opened in order to check connectors,
open the doors and leave them open.
HINT *
Operating the ignition switch, any switches or any doors triggers related ECU and sensor
communication with the CAN, which causes resistance variation.
* *: Use the Techstream.
1. VEHICLE BROUGHT TO WORKSHOP
NEXT -- Continue to next step.
2. INSPECT BATTERY VOLTAGE
Standard voltage:
11 to 14 V
If the voltage is below 11 V, recharge or replace the battery before proceeding.
NEXT -- Continue to next step.
3. CHECK AND CLEAR DTC*
(a) Using the Techstream, perform the ALL DTC check.
NOTICE: *
If a CAN communication malfunction code that informs that an ECU or sensor has a power
malfunction or interior malfunction is causing a communication stop, the problem may not be in the
communication line. There is a high possibility that the ECU or sensor has a signal transmission
failure. Therefore, first troubleshoot any DTCs related to the ECU or sensor.
* When CAN communication related connectors are disconnected with the ignition switch ON or
ACC, the ECU related to the connector and ECUs of related systems will store a CAN
communication DTC. NEXT -- Continue to next step.
4. CHECK INSTALLED SYSTEMS (ECU AND SENSOR) THAT USE CAN COMMUNICATION
(a) Based on the vehicle equipment and specifications, confirm the systems that use CAN
communication See: Initial Inspection and
Diagnostic Overview/CAN Communication System/Diagnosis System.
NEXT -- Continue to next step.
5. CHECK DLC3 BRANCH WIRE AND V BUS CIRCUIT MAIN WIRE (CANH - CANL)
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
Diagram Information and Instructions
Auxiliary Power Outlet: Diagram Information and Instructions
Wiring Color Codes
Abbreviations Used Within Diagrams
Abbreviations Used Within Diagrams
Page 1220
Power Steering Pressure Switch: Diagrams Power Steering Oil Pressure Switch
Page 4590
"Case2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Locations
Integrated Accessory Switch Assembly: Locations
METER: METER / GAUGE SYSTEM: PARTS LOCATION
Components
Auxiliary Power Outlet Switch: Service and Repair Components
OTHER SYSTEM: INVERTER MAIN SWITCH (for CrewMax): COMPONENTS
Front Power Seat Control ECU and Switch
Power Seat Switch: Diagrams Front Power Seat Control ECU and Switch
Page 198
4. SYMPTOM CONFIRMATION AND DTC (INCLUDING FREEZE FRAME DATA) CHECK
(a) Visually check the wire harnesses, connectors and fuses for open and short circuits.
(b) Warm up the engine to the normal operating temperature.
(c) Confirm the problem symptoms and conditions, and check for DTCs.
B -- Go to step 6 A -- Continue to next step.
5. DTC CHART
(a) Check the results obtained in the DTC check. Then find the output DTC in the DTC chart. Look
at the "Trouble Area" column for a list of
potentially malfunctioning circuits and / or parts.
NEXT -- Go to step 7
6. PROBLEM SYMPTOMS TABLE
(a) Check the results obtained in the symptom confirmation. Then find the problem symptoms in
the problem symptoms table. Look at the
"Suspected Area" column for a list of potentially malfunctioning circuits and / or parts.
NEXT -- Continue to next step.
7. CIRCUIT INSPECTION OR PARTS INSPECTION
(a) Confirm the malfunctioning circuit or part.
NEXT -- Continue to next step.
8. ADJUST, REPAIR OR REPLACE
(a) Adjust, repair or replace the malfunctioning circuit or parts.
NEXT -- Continue to next step.
9. CONFIRMATION TEST
(a) After the adjustment, repairs or replacement, confirm that the malfunction no longer exists. If the
malfunction does not reoccur, perform a
confirmation test under the same conditions and in the same environment as when the malfunction
occurred the first time.
NEXT -- END
2. CUSTOMER PROBLEM ANALYSIS
HINT *
In troubleshooting, confirm that the problem symptoms have been accurately identified.
Preconceptions should be discarded in order to make an accurate judgment. To clearly understand
what the problem symptoms are, it is extremely important to ask the customer about the problem
and the conditions at the time the malfunction occurred.
* Gather as much information as possible for reference. Past problems that seem unrelated may
also help in some cases.
* The following 5 questions are important points in the problem analysis:
Page 8899
Removal
DOOR LOCK: DOOR CONTROL RECEIVER (for Double Cab): REMOVAL
1. REMOVE LUGGAGE COMPARTMENT SIDE COVER SUB-ASSEMBLY LH See: Body and
Frame/Seats/Service and Repair/Removal and
Replacement/Rear Seat Assembly (for Double Cab)/Removal
2. REMOVE LUGGAGE COMPARTMENT SIDE COVER SUB-ASSEMBLY RH See: Body and
Frame/Seats/Service and Repair/Removal and
Replacement/Rear Seat Assembly (for Double Cab)/Removal
3. REMOVE SEAT FLOOR BOX See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Rear Seat Assembly (for Double
Cab)/Removal
4. REMOVE REAR SEAT ASSEMBLY See: Body and Frame/Seats/Service and Repair/Removal
and Replacement/Rear Seat Assembly (for
Page 1665
Wiper Switch: Testing and Inspection
WIPER AND WASHER: WIPER SWITCH: INSPECTION
1. INSPECT WIPER AND WASHER SWITCH ASSEMBLY
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the switch assembly.
(c) Check the intermittent operation.
(1) Connect the voltmeter's positive (+) lead to terminal B-3 (+1) and the negative (-) lead to
terminal A-2 (EW).
(2) Connect the battery's positive (+) lead to terminal B-2 (+B) and the negative (-) lead to terminals
A-2 (EW) and B-1 (+S).
(3) Turn the wiper switch to the INT position.
Page 1985
Rear Door (for CrewMax)
Rear Door Panel: Service and Repair Rear Door (for CrewMax)
Components
ENGINE HOOD / DOOR: REAR DOOR (for CrewMax): COMPONENTS
Page 6206
Removal
OTHER SYSTEM: POWER OUTLET SOCKET (for CrewMax Column Shift Type): REMOVAL
1. REMOVE CENTER SEATBACK PANEL See: Body and Frame/Seats/Service and
Repair/Overhaul/Front Seat Assembly (for Center
Seat)/Disassembly
2. REMOVE NO. 2 CONSOLE BOX REGISTER ASSEMBLY See: Body and Frame/Seats/Service
and Repair/Overhaul/Front Seat Assembly (for
Center Seat)/Disassembly
3. REMOVE NO. 1 CONSOLE BOX REGISTER ASSEMBLY See: Body and Frame/Seats/Service
and Repair/Overhaul/Front Seat Assembly (for
Center Seat)/Disassembly
4. REMOVE NO. 2 SEATBACK LOCK CONTROL BEZEL
Page 5250
2. Inspect the front driveshaft (propeller shaft assembly) for a loose parts label that may be
contacting other components (see Figure 1).
Is the label on the front driveshaft (propeller shaft assembly) loose and contacting other
components?
^ YES - Go to step 3.
^ NO - This TSB does NOT apply. Continue diagnosis to isolate the cause of this condition.
3. Completely remove the front driveshaft parts label.
4. Test drive and confirm there is no abnormal noise present when in 4WD.
Locations
Impact Sensor: Locations
SUPPLEMENTAL RESTRAINT SYSTEM: AIRBAG SYSTEM: PARTS LOCATION
Page 5130
Production Change Information
This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown
below.
Parts Information
Required Tools & Equipment
Inspection Procedure
1. Test drive the vehicle and confirm the noise is only present in 4WD.
2. Place the vehicle on the lift and remove the left front wheel.
Page 2646
Be careful not to damage the radiator core.
(g) Remove the fan pulley from the fan bracket.
7. REMOVE FAN
(a) Remove the 4 nuts and fan from the fluid coupling.
Page 2498
Oil Pressure Sender: Diagrams Oil Pressure Switch
Page 8573
Removal
PARK ASSIST / MONITORING: ULTRASONIC SENSOR (for Front Side): REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE FRONT END PANEL LH (for Resin Type Bumper) See: Body and
Frame/Bumper/Front Bumper/Service and Repair/Removal and
Replacement/Front Bumper (for Resin Type Bumper)/Removal
3. REMOVE FRONT END PANEL RH (for Resin Type Bumper) See: Body and
Frame/Bumper/Front Bumper/Service and Repair/Removal and
Replacement/Front Bumper (for Resin Type Bumper)/Removal
4. REMOVE FRONT BUMPER COVER (for Resin Type Bumper) See: Body and
Frame/Bumper/Front Bumper/Service and Repair/Removal and
Replacement/Front Bumper (for Resin Type Bumper)/Removal
5. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH (for Steel Type Bumper)
See: Body and Frame/Bumper/Front
Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Steel Type
Bumper)/Removal
6. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH (for Steel Type Bumper)
See: Body and Frame/Bumper/Front
Bumper/Service and Repair/Removal and Replacement/Front Bumper (for Steel Type
Bumper)/Removal
7. REMOVE FRONT END PANEL LH (for Steel Type Bumper) See: Body and
Frame/Bumper/Front Bumper/Service and Repair/Removal and
Replacement/Front Bumper (for Steel Type Bumper)/Removal
8. REMOVE FRONT END PANEL RH (for Steel Type Bumper) See: Body and
Frame/Bumper/Front Bumper/Service and Repair/Removal and
Replacement/Front Bumper (for Steel Type Bumper)/Removal
9. REMOVE FRONT LOWER BUMPER COVER (for Steel Type Bumper) See: Body and
Frame/Bumper/Front Bumper/Service and
Repair/Removal and Replacement/Front Bumper (for Steel Type Bumper)/Removal
10. REMOVE FRONT BUMPER BAR (for Steel Type Bumper) See: Body and
Frame/Bumper/Front Bumper/Service and Repair/Removal and
Replacement/Front Bumper (for Steel Type Bumper)/Removal
11. REMOVE NO. 1 ULTRASONIC SENSOR
(a) While pushing down on the lever with a finger to release the one claw, detach the claw on the
other side to remove the ultrasonic sensor.
Page 9230
(a) Connect the connectors.
(b) Attach the 2 clips to install the front upper armrest base panel.
8. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH
(a) Attach the 4 claws to install the bezel plug.
9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
10. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
Page 4352
6. DISCONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY
(a) Disconnect the No. 1 fuel pipe from the fuel delivery pipe LH See: Service Precautions.
7. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY RH
(a) Disconnect the No. 6 wire harness connector.
(b) Remove the 2 bolts and fuel delivery pipe RH.
NOTICE: When removing the delivery pipe, hold the pipe by both ends and pull it straight upward.
(c) Remove the 2 delivery pipe spacers and 4 insulators from the intake manifold.
8. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY LH
(a) Disconnect the No. 7 wire harness connector.
(b) Remove the 2 bolts and fuel delivery pipe LH.
NOTICE: When removing the delivery pipe, hold the pipe by both ends and pull it straight upward.
(c) Remove the 2 delivery pipe spacers and 4 insulators from the intake manifold.
9. REMOVE FUEL INJECTOR ASSEMBLY
(a) Remove the fuel injector from the fuel delivery pipe, and then disconnect the injector connector.
Page 7927
(b) With the steering pad removed from the vehicle, perform a visual check. If there are any defects
as mentioned below, replace the steering pad
or steering wheel assembly with a new one:
* Cuts, minute cracks or marked discoloration on the steering pad top surface or in the grooved
portion.
* Cracks or other damage to the connectors.
* Deformation of the steering pad contact plate of the steering pad.
* Deformation of the steering wheel.
* There should be no interference between the steering pad and steering wheel assembly, and the
clearance should be uniform all the way around when the new steering pad is installed on the
steering wheel assembly.
CAUTION: For removal and installation procedures of the steering pad, be sure to follow the
correct procedure.
Page 8494
Removal
DOOR LOCK: DOOR CONTROL RECEIVER (for Double Cab): REMOVAL
1. REMOVE LUGGAGE COMPARTMENT SIDE COVER SUB-ASSEMBLY LH See: Body and
Frame/Seats/Service and Repair/Removal and
Replacement/Rear Seat Assembly (for Double Cab)/Removal
2. REMOVE LUGGAGE COMPARTMENT SIDE COVER SUB-ASSEMBLY RH See: Body and
Frame/Seats/Service and Repair/Removal and
Replacement/Rear Seat Assembly (for Double Cab)/Removal
3. REMOVE SEAT FLOOR BOX See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Rear Seat Assembly (for Double
Cab)/Removal
4. REMOVE REAR SEAT ASSEMBLY See: Body and Frame/Seats/Service and Repair/Removal
and Replacement/Rear Seat Assembly (for
Page 163
Fog/Driving Lamp Relay: Testing and Inspection
LIGHTING: FOG LIGHT RELAY: ON-VEHICLE INSPECTION
1. REMOVE FOG LIGHT RELAY (FOG)
(a) Remove the fog light relay from the engine room relay box.
2. INSPECT FOG LIGHT RELAY
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the relay.
3. INSTALL FOG LIGHT RELAY
Page 9056
DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector.
Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
Page 4214
Regular Cab
Fuel Pump Control Unit: Locations Regular Cab
Body
Page 1383
(b) When the front bumper of the vehicle or its area is damaged, check if there is any damage to
the front airbag sensor. If the front airbag sensor
has defects as mentioned below, replace it with a new one:
* Cracks, dents or chips on the sensor housing.
* Cracks or other damage to the connector.
* Peeling off of the label or damage to the serial number.
CAUTION: For removal and installation procedures of the front airbag sensor, be sure to follow the
correct procedure.
3. CHECK FRONT AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS
DEPLOYED)
(a) Replace the front airbag sensor.
CAUTION: *
For removal and installation procedures of the front airbag sensor, be sure to follow the correct
procedure.
* If the airbags have deployed, replace the front airbag sensor on the side in which the collision
occurred. Replace both if necessary.
Side Airbag Sensor (for CrewMax)
SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for CrewMax): ON-VEHICLE
INSPECTION
1. CHECK REAR AIRBAG SENSOR (VEHICLE NOT INVOLVED IN COLLISION)
(a) Perform a diagnostic system check See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
2. CHECK REAR AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS
NOT DEPLOYED)
(a) Perform a diagnostic system check See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
(b) When the quarter panel of the vehicle or its area is damaged, check if there is any damage to
the rear airbag sensor. If there are any defects as
mentioned below, replace the side airbag sensor with a new one:
* Cracks, dents or chips on the sensor housing.
* Cracks or other damage to the connector.
* Peeling off of the label or damage to the serial number.
CAUTION: For removal and installation procedures of the side airbag sensor, be sure to follow the
correct procedure.
3. CHECK REAR AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS
DEPLOYED)
(a) Replace the side airbag sensor.
CAUTION: *
For removal and installation procedures of the side airbag sensor, be sure to follow the correct
procedure.
* If the airbags have deployed, replace the rear airbag sensor on the side in which the collision
occurred. Replace both if necessary.
Side Airbag Sensor (for Double Cab)
SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Double Cab):
ON-VEHICLE INSPECTION
1. CHECK REAR AIRBAG SENSOR (VEHICLE NOT INVOLVED IN COLLISION)
(a) Perform a diagnostic system check See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
2. CHECK REAR AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS
NOT DEPLOYED)
(a) Perform a diagnostic system check See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Initial Inspection and Diagnostic
Page 7373
HINT Release the coil spring while checking the position of the suspension support.
3. TIGHTEN FRONT SUPPORT TO FRONT SHOCK ABSORBER NUT
(a) Tighten the nut.
Torque : 25 Nm (255 kgf-cm, 18 ft-lbf)
Page 6450
Power Distribution Relay: Testing and Inspection ACC Relay
1UR-FE STARTING: ACC RELAY: ON-VEHICLE INSPECTION
1. INSPECT MAIN BODY ECU (ACC RELAY)
(a) Measure the resistance of the ACC relay circuit.
(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(2) If the result is not as specified, replace the main body ECU.
Page 6648
5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Removal
6. REMOVE CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service
and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Removal
7. REMOVE FRONT ASH RECEPTACLE BOX SUB-ASSEMBLY
8. REMOVE LOWER INSTRUMENT CLUSTER FINISH PANEL See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column
Shift Type)/Removal
9. REMOVE POWER OUTLET SOCKET ASSEMBLY
(a) Using a screwdriver, detach the claw and remove the power outlet socket.
HINT Tape the screwdriver tip before use.
10. REMOVE POWER OUTLET SOCKET COVER
(a) Detach the 2 claws and remove the power outlet socket cover.
Installation
OTHER SYSTEM: POWER OUTLET SOCKET (for Column Shift Type): INSTALLATION
1. INSTALL POWER OUTLET SOCKET COVER
(a) Attach the 2 claws to install the power outlet socket cover.
2. INSTALL POWER OUTLET SOCKET ASSEMBLY
Page 4134
Page 4902
Removal
A760F AUTOMATIC TRANSMISSION: SHIFT LEVER ASSEMBLY (for Column Shift Type):
REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to disable the SRS system.
2. REMOVE FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Removal
3. REMOVE FRONT DOOR SCUFF PLATE LH (for Double Cab, CrewMax) See: Body and
Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Removal
Page 5601
Hydraulic Control Assembly - Antilock Brakes: Testing and Inspection
BRAKE CONTROL: BRAKE ACTUATOR: ON-VEHICLE INSPECTION
1. CONNECT TECHSTREAM
(a) Connect the Techstream to the DLC3.
(b) Start the engine and run it at idle.
(c) Select the Active Test mode on the Techstream.
HINT Refer to the Techstream operator's manual for further details.
2. INSPECT ACTUATOR MOTOR OPERATION
(a) With the motor relay on, check the actuator motor operation noise.
(b) Turn the motor relay off.
(c) Depress the brake pedal and hold it for about 15 seconds. Check that the pedal does not go
down any further while holding it.
(d) With the motor relay on, check that the pedal could have pulsations.
NOTICE: Do not keep the motor relay on for more than 5 seconds continuously. When operating it
consecutively, wait more than 20 seconds between each operation.
(e) Turn the motor relay off and release the brake pedal.
3. INSPECT WHEEL OPERATION
NOTICE: Never turn on a solenoid that is not described below.
(a) With the brake pedal depressed, perform the following operations.
(b) Turn the ABS Solenoid (SFRH) and ABS Solenoid (SFRR) on simultaneously, and check that
the pedal cannot be depressed.
NOTICE: Do not keep the solenoid on for more than 10 seconds continuously. When operating it
consecutively, wait more than 20 seconds between each operation.
(c) Turn the ABS Solenoid (SFRH) and ABS Solenoid (SFRR) off simultaneously, and check that
the pedal can be depressed.
(d) Turn the motor relay on and check that the pedal returns.
NOTICE: Do not keep the motor relay on for more than 5 seconds continuously. When operating it
consecutively, wait more than 20 seconds between each operation.
(e) Turn the motor relay off and release the brake pedal.
(f) Using the procedure above, check the solenoids of the other wheels.
HINT LEFT Front wheel LH: ABS Solenoid (SFLH), ABS Solenoid (SFLR)
RIGHT Rear wheel RH: ABS Solenoid (SRRH), ABS Solenoid (SRRR)
LEFT Rear wheel LH: ABS Solenoid (SRLH), ABS Solenoid (SRLR)
(g) Clear the DTCs See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes.
Page 6815
Page 6197
HINT Tape the screwdriver tip before use.
10. REMOVE REAR POWER OUTLET SOCKET COVER (for Double Cab)
(a) Detach the 2 claws and remove the power outlet socket cover.
Installation
OTHER SYSTEM: CENTER POWER OUTLET SOCKET (for Column Shift Type): INSTALLATION
1. INSTALL REAR POWER OUTLET SOCKET COVER (for Double Cab)
(a) Attach the 2 claws to install the power outlet socket cover.
2. INSTALL REAR POWER OUTLET SOCKET ASSEMBLY (for Double Cab)
(a) Attach the claw to install the power outlet socket.
3. INSTALL CENTER SEATBACK PANEL (for Double Cab) See: Body and Frame/Seats/Service
and Repair/Overhaul/Front Seat Assembly (for
Center Seat)/Reassembly
4. INSTALL POWER OUTLET SOCKET COVER
(a) Attach the 2 claws to install the power outlet socket cover.
5. INSTALL POWER OUTLET SOCKET ASSEMBLY
Page 2725
(a) Remove the 4 bolts, 4 nuts, lower monolithic converter protector, upper monolithic converter
protector, 2 No. 1 converter protector stays and 2
No. 2 converter protector stays.
11. REMOVE NO. 1 MONOLITHIC CONVERTER PROTECTOR (for Bank 1)
(a) Remove the 4 bolts, 4 nuts, lower No. 1 monolithic converter protector, upper No. 1 monolithic
converter protector and 4 No. 1 converter
protector stays.
12. REMOVE MONOLITHIC CONVERTER PROTECTOR (for Bank 2)
(a) Remove the 4 bolts, 4 nuts, lower monolithic converter protector, upper monolithic converter
protector, 2 No. 1 converter protector stays and 2
No. 2 converter protector stays.
13. REMOVE NO. 1 MONOLITHIC CONVERTER PROTECTOR (for Bank 2)
(a) Remove the 4 bolts, 4 nuts, lower No. 1 monolithic converter protector, upper No. 1 monolithic
converter protector and 4 No. 1 converter
protector stays.
Installation
1UR-FE EXHAUST: EXHAUST PIPE (for Regular Cab Standard Deck): INSTALLATION
1. INSTALL MONOLITHIC CONVERTER PROTECTOR (for Bank 1)
(a) Install the 2 No. 1 converter protector stays and 2 No. 2 converter protector stays.
(b) Install the 2 monolithic converter protectors with the 4 bolts and 4 nuts.
Torque : 11 Nm (107 kgf-cm, 8 ft-lbf)
Page 8499
(a) Remove the front door scuff plate See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Removal.
HINT The procedures listed below are for the LH side.
5. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP RH
6. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY RH See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Removal
7. REMOVE FRONT QUARTER TRIM PANEL ASSEMBLY RH See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Removal
8. REMOVE DOOR CONTROL RECEIVER
(a) Disconnect the door control receiver connector.
(b) Remove the bolt and receiver.
Installation
DOOR LOCK: DOOR CONTROL RECEIVER (for Regular Cab): INSTALLATION
1. INSTALL DOOR CONTROL RECEIVER
(a) Install the receiver with the bolt.
(b) Connect the door control receiver connector.
2. INSTALL FRONT QUARTER TRIM PANEL ASSEMBLY RH See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Installation
3. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY RH See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Installation
4. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH
5. INSTALL FRONT DOOR SCUFF PLATE RH
(a) Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular
Cab)/Installation.
HINT The procedures listed below are for the LH side.
Diagram Information and Instructions
Fuse Block: Diagram Information and Instructions
Wiring Color Codes
Abbreviations Used Within Diagrams
Abbreviations Used Within Diagrams
Components
Dimmer Switch: Service and Repair Components
METER: LIGHT CONTROL RHEOSTAT: COMPONENTS
Page 8872
Page 716
Removal
SEAT: POWER SEAT SWITCH (w/o Seat Position Memory System): REMOVAL
HINT *
Use the same procedures for the LH side and RH side.
* The procedures listed below are for the LH side.
1. REMOVE FRONT SEAT ASSEMBLY LH
(a) Remove the front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Power
Seat)/Removal.
2. REMOVE SLIDE AND VERTICAL POWER SEAT SWITCH KNOB LH See: Body and
Frame/Seats/Service and Repair/Overhaul/Front Seat
Assembly (for Power Seat)/Disassembly
3. REMOVE RECLINING POWER SEAT SWITCH KNOB LH See: Body and Frame/Seats/Service
and Repair/Overhaul/Front Seat Assembly
(for Power Seat)/Disassembly
4. REMOVE FRONT SEAT CUSHION SHIELD LH See: Body and Frame/Seats/Service and
Repair/Overhaul/Front Seat Assembly (for Power
Seat)/Disassembly
5. REMOVE LEG SUPPORT ADJUSTMENT SWITCH (w/ Leg Support Adjustment Switch)
(a) Detach the 2 wire harness clamps and remove the 2 screws and switch.
(b) Disconnect the switch connector.
6. REMOVE FRONT POWER SEAT SWITCH LH
Page 2933
Engine Temperature Sensor: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: ENGINE COOLANT TEMPERATURE SENSOR:
INSTALLATION
1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR
(a) Install a new gasket to the sensor.
(b) Using a 19 mm ball joint lock nut wrench, install the sensor.
Torque : 20 Nm (200 kgf-cm, 14 ft-lbf)
NOTICE: Use the formula to calculate special torque values for situations where ball joint lock nut
wrench is combined with a torque wrench See: Service Precautions
(c) Connect the sensor connector.
2. ADD ENGINE COOLANT See: Engine, Cooling and Exhaust/Cooling System/Coolant/Service
and Repair
3. INSPECT FOR COOLANT LEAK See: Engine, Cooling and Exhaust/Cooling System/Testing
and Inspection
4. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Installation
5. INSTALL NO. 1 ENGINE UNDER COVER See: Engine, Cooling and Exhaust/Engine/Engine
Lubrication/Engine Oil/Service and
Repair/Replacement
Page 6283
4. SYMPTOM CONFIRMATION AND DTC (INCLUDING FREEZE FRAME DATA) CHECK
(a) Visually check the wire harnesses, connectors and fuses for open and short circuits.
(b) Warm up the engine to the normal operating temperature.
(c) Confirm the problem symptoms and conditions, and check for DTCs.
B -- Go to step 6 A -- Continue to next step.
5. DTC CHART
(a) Check the results obtained in the DTC check. Then find the output DTC in the DTC chart. Look
at the "Trouble Area" column for a list of
potentially malfunctioning circuits and / or parts.
NEXT -- Go to step 7
6. PROBLEM SYMPTOMS TABLE
(a) Check the results obtained in the symptom confirmation. Then find the problem symptoms in
the problem symptoms table. Look at the
"Suspected Area" column for a list of potentially malfunctioning circuits and / or parts.
NEXT -- Continue to next step.
7. CIRCUIT INSPECTION OR PARTS INSPECTION
(a) Confirm the malfunctioning circuit or part.
NEXT -- Continue to next step.
8. ADJUST, REPAIR OR REPLACE
(a) Adjust, repair or replace the malfunctioning circuit or parts.
NEXT -- Continue to next step.
9. CONFIRMATION TEST
(a) After the adjustment, repairs or replacement, confirm that the malfunction no longer exists. If the
malfunction does not reoccur, perform a
confirmation test under the same conditions and in the same environment as when the malfunction
occurred the first time.
NEXT -- END
2. CUSTOMER PROBLEM ANALYSIS
HINT *
In troubleshooting, confirm that the problem symptoms have been accurately identified.
Preconceptions should be discarded in order to make an accurate judgment. To clearly understand
what the problem symptoms are, it is extremely important to ask the customer about the problem
and the conditions at the time the malfunction occurred.
* Gather as much information as possible for reference. Past problems that seem unrelated may
also help in some cases.
* The following 5 questions are important points in the problem analysis:
Page 8587
Parking Assist Switch: Service and Repair Removal
PARK ASSIST / MONITORING: CLEARANCE SONAR MAIN SWITCH: REMOVAL
1. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Panel,
Gauges and Warning Indicators/Instrument Cluster
/ Carrier/Service and Repair/Combination Meter/Removal
2. REMOVE DRIVE MONITOR SWITCH
(a) Detach the 2 claws and remove the monitor switch.
Page 4005
Air Injection Control Valve: Diagrams
Page 2562
Variable Valve Timing Actuator: Testing and Inspection On-Vehicle Inspection
1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT OIL CONTROL VALVE: ON-VEHICLE
INSPECTION
1. INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
(a) Connect the Techstream to the DLC3.
(b) Start the engine and turn the tester ON.
(c) Warm up the engine.
(d) Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the VVT Linear
(Bank 1) or Control the VVT Linear (Bank
2) or Control the VVT System (Bank 1) or Control the VVT System (Bank 2) or Control the VVT
Exhaust Linear (Bank 1) or Control the VVT Exhaust Linear (Bank 2).
(e) Check the engine speed while operating the Oil Control Valve (OCV) using the tester.
OK:
(f) If the result is not as specified, check the oil control valve, wiring and camshaft timing gear.
HINT *
Control the VVT Linear (Bank 1): Command to activate exhaust and intake side oil control valves of
bank 1 (Control range: Between -128 to 127%).
* Control the VVT Linear (Bank 2): Command to activate exhaust and intake side oil control valves
of bank 2 (Control range: Between -128 to 127%).
* Control VVT System (Bank 1): Command to activate oil control valve of bank 1 (Control range:
ON/OFF).
* Control VVT System (Bank 2): Command to activate oil control valve of bank 2 (Control range:
ON/OFF).
* Control the VVT Exhaust Linear (Bank 1): Command to activate exhaust side oil control valve of
bank 1 (Control range: Between -128 to 127%).
* Control the VVT Exhaust Linear (Bank 2): Command to activate exhaust side oil control valve of
bank 2 (Control range: Between -128 to 127%).
Page 1979
Fuse: Application and ID
Fuse Layout and Amperage Ratings
Fuse Block Location - Engine Compartment
Fuse Location - Engine Compartment
Page 7052
(b) * for 5 leaf spring
6. INSPECT CAMBER, CASTER AND STEERING AXIS INCLINATION
(a) Install the camber-caster-kingpin gauge or place the front wheels on the center of the wheel
alignment tester.
Page 1497
(2) CONNECTORS
Slightly shake the connector vertically and horizontally.
(3) WIRE HARNESS
Slightly shake the wire harness vertically and horizontally.
HINT The connector joint and fulcrum of the vibration are the major areas that should be checked
thoroughly.
(b) HEAT METHOD:
When a malfunction seems to occur when the area in question is heated.
(1) Heat the component that is the possible cause of the malfunction with a hair dryer or similar
device. Check if the malfunction occurs.
NOTICE: *
Do not heat to more than 60°C (140°F). Exceeding this temperature may damage components.
* Do not apply heat directly to the parts in the ECU.
(c) WATER SPRINKLING METHOD:
When a malfunction seems to occur on a rainy day or in high-humidity.
(1) Sprinkle water onto the vehicle and check if the malfunction occurs.
NOTICE: *
Never sprinkle water directly into the engine compartment. Indirectly change the temperature and
humidity by spraying water onto the front of the radiator.
* Never apply water directly onto the electronic components.
HINT If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU
or connections. Look for evidence of corrosion or short circuits. Proceed with caution during water
tests.
(d) HIGH ELECTRICAL LOAD METHOD:
When a malfunction seems to occur when the electrical load is excessive.
(1) Turn on the heater blower, headlights, rear window defogger and all other electrical loads.
Check if the malfunction reoccurs.
5. DIAGNOSTIC TROUBLE CODE CHART
Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate
section's Diagnostic Trouble Code Chart. Use the chart to determine the trouble area and the
proper inspection procedure. A description of each of the chart's columns is below.
Locations
Turn Signal Relay: Locations
Instrument Panel (Floor Shift)
Instrument Panel (Column Shift)
Page 5656
(e) Attach the 3 clips (labeled F).
NOTICE: *
When installing the clips, do not twist the wire harness.
* When installing the clips, securely insert them as shown in the illustration.
(f) Connect the speed sensor connector (labeled G).
NOTICE: Securely connect the connector.
7. INSTALL FRONT WHEEL See: Steering and Suspension/Suspension/Suspension Strut / Shock
Absorber/Service and Repair/Removal and
Replacement/Front Shock Absorber/Installation
8. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
9. CHECK SPEED SENSOR SIGNAL
(a) Check the speed sensor signal See: Testing and Inspection/Scan Tool Testing and
Procedures/Test Mode Procedure.
Page 2831
Engine Control Module: Programming and Relearning
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: REGISTRATION
NOTICE: The Vehicle Identification Number (VIN) must be input into the replacement ECM.
HINT The VIN is in the form of a 17-digit alphanumeric vehicle identification number. The
Techstream is required to register the VIN.
1. DESCRIPTION
NOTICE: The Vehicle Identification Number (VIN) must be input into the replacement ECM.
HINT This registration section consists of two parts: Read VIN and Write VIN.
(a) Read VIN: Explains the VIN reading process in a flowchart. This process allows the VIN stored
in the ECM to be read in order to confirm that
the two VINs, the one provided with the vehicle and the one stored in the vehicle's ECM, are the
same.
(b) Write VIN: Explains the VIN writing process in a flowchart. This process allows the VIN to be
input into the ECM. If the ECM is changed, or
the ECM VIN and vehicle VIN do not match, the VIN can be registered or overwritten in the ECM
by following this procedure.
2. READ VIN
(a) Confirm the vehicle VIN.
(b) Connect the Techstream to the DLC3.
(c) Turn the ignition switch to ON.
(d) Turn the Techstream on.
(e) Enter the following menus: Powertrain / Engine and ECT / Utility / VIN / VIN Read.
3. WRITE VIN
(a) Confirm the vehicle VIN.
(b) Connect the Techstream to the DLC3.
(c) Turn the ignition switch to ON.
(d) Turn the Techstream on.
(e) Enter the following menus: Powertrain / Engine and ECT / Utility / VIN / VIN Write.
Page 1682
for Double Cab of Long Deck
Page 2696
HINT The direction of hose clamp is indicated in the illustration.
5. CONNECT NO. 8 WATER BY-PASS HOSE
(a) Connect the water by-pass hose.
HINT The direction of hose clamp is indicated in the illustration.
6. INSTALL NO. 1 WATER BY-PASS HOSE
(a) Install the water by-pass hose.
HINT The direction of hose clamp is indicated in the illustration.
7. INSTALL WATER BY-PASS PIPE (w/ Oil Cooler)
(a) Connect the 4 water hoses.
HINT Connect each hose so that the direction of each hose clamp is as indicated in the illustration.
(b) Install the water by-pass hose with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
Page 4303
^ Engine Control Module (ECM)
^ Transmission Control Module (TCM)
^ Or any other Toyota specific control unit
Warranty Information
Parts Information
Required Tools & Equipment
NOTE
Additional SSTs may be ordered by calling 1-800-933-8335.
Process Overview
Techstream ECU flash reprogramming is a 4-step process:
1. Verify the vehicle's applicability for recalibration and locate desired calibration file by performing
the Techstream Health Check function.
NOTE
Techstream will automatically search TIS for the appropriate service bulletin using the current
Calibration ID from the vehicle. Calibration file links can be found embedded in the corresponding
service bulletin.
2. Connect the GR8 Battery Diagnostic Station using "Power Supply Mode" only.
The GR8 Battery Diagnostic Station includes a Power Supply Mode to help maintain battery
voltage at 13.5 volts during ECU reprogramming.
ECU damage may occur if the correct battery charger mode setting is NOT used.
3. Locate appropriate calibration ID and reprogram the vehicle ECU with Techstream.
Techstream uses the Calibration Update Wizard (CUW) application to open calibration files and
facilitate the ECU flash reprogramming process.
Page 5269
Page 5415
Four Wheel Drive Selector Switch: Service and Repair Installation
JF1A TRANSFER: 4WD CONTROL SWITCH: INSTALLATION
1. INSTALL 4WD CONTROL SWITCH
(a) Attach the 3 claws to install the switch.
2. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Panel,
Gauges and Warning Indicators/Instrument Cluster
/ Carrier/Service and Repair/Combination Meter/Installation
Page 851
Yaw Rate Sensor: Testing and Inspection
BRAKE CONTROL: YAW RATE AND DECELERATION SENSOR: INSPECTION
1. CHECK YAW RATE SENSOR
(a) Check the yaw rate sensor.
Under any of the following conditions, replace the sensor with a new one:
* The surface of the sensor is cracked, dented, or chipped.
* The connector is scratched, cracked, or damaged.
* The sensor has been dropped.
Page 3717
Engine Control Module: Diagrams
Page 7359
Suspension Strut / Shock Absorber: Testing and Inspection Rear Shock Absorber
SUSPENSION: REAR SHOCK ABSORBER: INSPECTION
1. INSPECT REAR SHOCK ABSORBER ASSEMBLY LH
(a) Compress and extend the shock absorber rod 4 times or more. Check that there is no abnormal
resistance or unusual sound during the
operation.
If there is any abnormality, replace the shock absorber assembly with a new one.
NOTICE: *
When disposing of the shock absorber, see DISPOSAL See: Service and Repair/Removal and
Replacement/Rear Shock Absorber/Disposal
* Do not hold the rear shock absorber by the dust cover, as the dust cover will come off.
Page 1468
Page 9382
Parts Information
Repair Procedure
1. Test-drive the vehicle and confirm the condition.
NOTE
Repeat remaining steps for both No.3 cab mounts.
2. Loosen the No.2 cab mount nuts (at front of cab) down to the last thread on the long bolt. This is
necessary to allow the cab to be raised to remove
the No.3 mount.
The cab mounts in the front are only loosened to allow the technician to raise the cab to install the
rear cab mounts. Not necessary to change.
Components
Air Injection Pump: Service and Repair Components
1UR-FE EMISSION CONTROL: AIR PUMP: COMPONENTS
Page 7938
CAUTION: When deploying the airbag, make sure that no one is near the tire.
HINT The airbag is deployed as the LED of SST activation switch comes on.
(h) Dispose of the front seat side airbag.
CAUTION: *
The front seat side airbag becomes extremely hot when the airbag is deployed, so do not touch it
for at least 30 minutes after deployment.
* Use gloves and safety glasses when handling a front seat side airbag with a deployed airbag.
* Do not apply water to a front seat side airbag with a deployed airbag.
* Always wash your hands with water after completing the operation.
(1) Remove the front seat side airbag from the tire.
(2) Place the front seat side airbag in a plastic bag, tie it tightly and dispose of it in the same way as
other general parts.
Curtain Shield Airbag Assembly
SUPPLEMENTAL RESTRAINT SYSTEM: CURTAIN SHIELD AIRBAG ASSEMBLY: DISPOSAL
HINT When scrapping a vehicle equipped with the SRS or disposing of the curtain shield airbag
assembly, be sure to deploy the airbag first in accordance with the procedure described below. If
any abnormality occurs with the airbag deployment, contact the SERVICE DEPT. of TOYOTA
MOTOR SALES, U.S.A., INC.
CAUTION: *
Never dispose of a curtain shield airbag that has an unactivated airbag.
* The airbag produces an exploding sound when it is deployed, so perform the operation outdoors
and where it will not create a nuisance to nearby residents.
* When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool).
Perform the operation in a place away from electrical noise.
* When deploying the airbag, perform the operation at least 10 m (32.8 ft.) away from the curtain
shield airbag.
* The curtain shield airbag becomes extremely hot when the airbag is deployed, so do not touch it
for at least 30 minutes after deployment.
* Use gloves and safety glasses when handling a curtain shield airbag with a deployed airbag.
* Do not apply water to a curtain shield airbag with a deployed airbag.
* Always wash your hands with water after completing the operation.
* An airbag or pretensioner may be activated by static electricity. To prevent this, be sure to touch a
metal surface with bare hands to discharge static electricity before performing this procedure.
1. DISPOSE OF CURTAIN SHIELD AIRBAG ASSEMBLY (WHEN INSTALLED IN VEHICLE)
HINT Prepare a battery as the power source to deploy the airbag.
(a) Check the function of SST See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
Page 4624
Knock Sensor: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: REMOVAL
1. REMOVE INTAKE MANIFOLD
(a) Remove the intake manifold See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service
and Repair/Removal.
2. REMOVE SEPARATOR CASE
(a) Remove the 4 bolts and separator case.
3. REMOVE KNOCK SENSOR
(a) Disconnect the 4 knock sensor connectors.
(b) Remove the 4 bolts and 4 knock sensors.
Page 2256
12. INSTALL NO. 1 PARKING BRAKE SHOE ASSEMBLY LH See: Brakes and Traction
Control/Parking Brake System/Service and
Repair/Reassembly
13. INSTALL PARKING BRAKE SHOE RETURN TENSION SPRING LH See: Brakes and Traction
Control/Parking Brake System/Service and
Repair/Reassembly
14. CHECK PARKING BRAKE INSTALLATION See: Brakes and Traction Control/Parking Brake
System/Service and Repair/Reassembly
15. INSTALL REAR DISC LH See: Brakes and Traction Control/Disc Brake System/Service and
Repair/Removal and Replacement/Rear
Brake/Installation
16. ADJUST PARKING BRAKE SHOE CLEARANCE See: Brakes and Traction Control/Parking
Brake System/Adjustments
17. CONNECT REAR DISC BRAKE CYLINDER ASSEMBLY LH See: Brakes and Traction
Control/Parking Brake System/Service and
Repair/Reassembly
18. INSTALL REAR WHEEL LH
for Aluminum Wheel - Torque : 131 Nm (1336 kgf-cm, 97 ft-lbf)
for Steel Wheel - Torque : 209 Nm (2131 kgf-cm, 154 ft-lbf)
19. CHECK PARKING BRAKE TRAVEL See: Brakes and Traction Control/Parking Brake
System/Adjustments
20. ADJUST PARKING BRAKE TRAVEL See: Brakes and Traction Control/Parking Brake
System/Adjustments
A760F Automatic Transmission System
Control Module: Locations A760F Automatic Transmission System
A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS
LOCATION
Page 8065
Impact Sensor: Testing and Inspection Side Airbag Sensor (for CrewMax)
SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for CrewMax): ON-VEHICLE
INSPECTION
1. CHECK REAR AIRBAG SENSOR (VEHICLE NOT INVOLVED IN COLLISION)
(a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnosis System.
2. CHECK REAR AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS
NOT DEPLOYED)
(a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnosis System.
(b) When the quarter panel of the vehicle or its area is damaged, check if there is any damage to
the rear airbag sensor. If there are any defects as
mentioned below, replace the side airbag sensor with a new one:
* Cracks, dents or chips on the sensor housing.
* Cracks or other damage to the connector.
* Peeling off of the label or damage to the serial number.
CAUTION: For removal and installation procedures of the side airbag sensor, be sure to follow the
correct procedure.
3. CHECK REAR AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS
DEPLOYED)
(a) Replace the side airbag sensor.
CAUTION: *
For removal and installation procedures of the side airbag sensor, be sure to follow the correct
procedure.
* If the airbags have deployed, replace the rear airbag sensor on the side in which the collision
occurred. Replace both if necessary.
Page 1882
(a) Hook the engine under cover to the vehicle body as shown in the illustration.
(b) Install the 3 screws and 5 bolts.
for bolt - Torque : 29 Nm (296 kgf-cm, 21 ft-lbf)
for screw - Torque : 3.0 Nm (31 kgf-cm, 27 in-lbf)
Page 8368
Service and Repair
Fuel Pressure Release: Service and Repair
1UR-FE FUEL: FUEL SYSTEM: PRECAUTION
CAUTION: *
Before working on the fuel system, disconnect the cable from the negative (-) battery terminal.
* Do not smoke or be near an open flame when working on the fuel system.
* Keep gasoline away from rubber and leather parts.
1. DISCHARGE FUEL SYSTEM PRESSURE
CAUTION: *
Do not disconnect any part of the fuel system until you have discharged the fuel system pressure.
* After discharging the fuel pressure, place a cloth or equivalent over fittings as you separate them
to reduce the risk of fuel spray on yourself or in the engine compartment.
(a) Disconnect the cable from the negative (-) battery terminal.
(b) Disconnect the 2 fuel pump ECU connectors.
(c) Connect the cable to the negative (-) battery terminal.
(d) Start the engine. After the engine has stopped on its own, turn the ignition switch OFF.
HINT DTC P0171/0174 (system too lean) may be set.
(e) Crank the engine again, then check that the engine does not start.
(f) Loosen the fuel tank cap, then discharge the pressure in the fuel tank completely.
(g) Connect the 2 fuel pump ECU connectors.
2. FUEL SYSTEM
(a) When disconnecting the high fuel pressure line, a large amount of gasoline will spill out. Follow
these procedures.
(1) Perform the "DISCHARGE FUEL SYSTEM PRESSURE" procedures above.
(2) Put a container under the connecting part of the pressure line.
(3) Slowly loosen the connection.
(4) Disconnect the connection.
(5) Plug the connection with a rubber plug.
(b) Observe these precautions when removing and installing the injectors:
Diagram Information and Instructions
Compressor HVAC: Diagram Information and Instructions
Wiring Color Codes
Abbreviations Used Within Diagrams
Abbreviations Used Within Diagrams
Page 3002
Variable Valve Timing Actuator Position Sensor: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: VVT SENSOR: INSTALLATION
1. INSTALL VVT SENSOR
(a) Install the 4 sensors with the 4 bolts.
Testing and Inspection
Condenser HVAC: Testing and Inspection
AIR CONDITIONING: CONDENSER: ON-VEHICLE INSPECTION
1. INSPECT COOLER CONDENSER ASSEMBLY
(a) If the fins of the cooler condenser are dirty, clean them with water. Dry the fins with compressed
air.
NOTICE: Do not damage the fins of the condenser.
(b) If a fin of the cooler condenser is bent, straighten it using a screwdriver or pliers.
2. CHECK CONDENSER FOR LEAKAGE OF REFRIGERANT
(a) Using a halogen leak detector, check the pipe joints for gas leakage.
(b) If gas leakage is detected in a joint, check the torque of the joint.
Components
EGR Valve: Service and Repair Components
1UR-FE EMISSION CONTROL: EGR VALVE: COMPONENTS
Page 3581
Knock Sensor: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: INSTALLATION
1. INSTALL KNOCK SENSOR
(a) Install the 4 sensors with the 4 bolts so that the sensors are angled as shown in the illustration.
Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)
NOTICE: The acceptable installation angle of the sensor is between 10° upward and downward
from the horizontal position.
(b) Connect the 4 sensor connectors.
2. INSTALL SEPARATOR CASE
(a) Install the separator case with the 4 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
3. INSTALL INTAKE MANIFOLD
(a) Install the intake manifold See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service
and Repair/Installation.
Removal and Replacement
Compressor HVAC: Removal and Replacement
Components
AIR CONDITIONING: COMPRESSOR (for 1UR-FE): COMPONENTS
Page 5943
Components
Tire Pressure Module: Service and Repair Components
TIRE AND WHEEL: TIRE PRESSURE WARNING ECU: COMPONENTS
Airbag System
Seat Occupant Classification Module - Air Bag: Locations Airbag System
SUPPLEMENTAL RESTRAINT SYSTEM: AIRBAG SYSTEM: PARTS LOCATION
Page 2080
* In the DTC check, it is very important to determine whether the problem indicated by the DTC is
either: 1) still occurring; or 2) occurred in the past but has since returned to normal. In addition, the
DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs
should be checked before and after confirmation of symptoms (i.e., whether or not problem
symptoms exist) to determine current system conditions, as shown in the flowchart below.
* Never skip the DTC check. Failing to check DTCs may, depending on the case, result in
unnecessary troubleshooting for systems operating normally or lead to repairs not related to the
problem. Follow the procedures listed in the flowchart in the correct order.
* The following flowchart shows how to proceed with troubleshooting using the DTC check.
Directions from the flowchart will indicate how to proceed either to DTC troubleshooting or to the
troubleshooting of each problem symptom.
1. DTC CHECK
NEXT -- Continue to next step.
2. MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR MEMORY
NEXT -- Continue to next step.
3. SYMPTOM CONFIRMATION
B -- Go to step 5 A -- Continue to next step.
4. SIMULATION TEST USING SYMPTOM SIMULATION METHODS
NEXT -- Continue to next step.
5. DTC CHECK
B -- TROUBLESHOOTING OF PROBLEM INDICATED BY DTC A -- Continue to next step.
6. SYMPTOM CONFIRMATION
Page 7560
Ambient Temperature Sensor / Switch HVAC: Diagrams
Recall 10V017000: Accelerator Pedal Sticking
Accelerator Pedal Position Sensor: Recalls Recall 10V017000: Accelerator Pedal Sticking
VEHICLE MAKE/MODEL: MODEL YEAR(S): Toyota/Avalon 2005-2010 Toyota/Camry 2007-2010
Toyota/Corolla 2009-2010 Toyota/Corolla Matrix 2009-2010 Toyota/Highlander 2010 Toyota/ RAV4
2009-2010 Toyota/Sequoia 2008-2010 Toyota/Tundra 2007-2010 MANUFACTURER: Toyota
Motor North America, Inc.
MFR'S REPORT DATE: January 21, 2010
NHTSA CAMPAIGN ID NUMBER: 10V017000
NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Accelerator Assembly:
Pedal/Linkage
POTENTIAL NUMBER OF UNITS AFFECTED: ?
SUMMARY: Toyota is recalling certain model year 2005-2010 Avalon, model year 2007-2010
Camry, model year 2009-2010 Corolla, Corolla Matrix, RAV4, model year 2010 Highlander, model
year 2008-2010 Sequoia, and model year 2007-2010 Tundra. due to the manner in which the
friction lever interacts with the sliding surface of the accelerator pedal inside the pedal sensor
assembly, the sliding surface of the lever may become smooth during vehicle operation. In this
condition, if condensation occurs on the surface, as may occur from heater operation (without A/C)
when the pedal assembly is cold, the friction when the accelerator pedal is operated may increase,
which may result in the accelerator pedal becoming harder to depress, slower to return, or, in the
worst case, mechanically stuck in a partially depressed position.
CONSEQUENCE: The accelerator pedal may become hard to depress, slow to return to idle, or, in
the worst case, mechanically stuck in a partially depressed position, increasing the risk of a crash.
REMEDY: Toyota has not yet provided a remedy plan or an owner notification schedule. Owners
may contact Toyota at 1-800-331-4331.
NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle
Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov.
Specifications
Exhaust Manifold: Specifications
EXHAUST MANIFOLD SUB-ASSEMBLY RH
Temporarily install the exhaust manifold with 9 new nuts, and then uniformly tighten the 7 nuts that
are not labeled A. Then tighten the 2 nuts labeled A in the illustration.
For nut A - Torque................................................................................................................................
......................................10 Nm (102 kgf-cm, 7 ft-lbf)
Except nut A - Torque...........................................................................................................................
....................................21 Nm (214 kgf-cm, 15 ft-lbf)
EXHAUST MANIFOLD SUB-ASSEMBLY LH
Temporarily install the exhaust manifold with 9 new nuts, and then uniformly tighten the 7 nuts that
are not labeled A. Then tighten the 2 nuts labeled A in the illustration.
For nut A - Torque................................................................................................................................
......................................10 Nm (102 kgf-cm, 7 ft-lbf)
Except nut A - Torque...........................................................................................................................
....................................21 Nm (214 kgf-cm, 15 ft-lbf)
Page 5311
Flex Plate: Testing and Inspection
A760F AUTOMATIC TRANSMISSION: TORQUE CONVERTER CLUTCH AND DRIVE PLATE:
INSPECTION
1. INSPECT TORQUE CONVERTER CLUTCH ASSEMBLY
(a) Inspect the 1-way clutch.
(1) Install SST to the inner race of the 1-way clutch.
SST : 09350-32014
09351-32020
(2) Press on the serrations of the stator with a finger and rotate it.
Check that the stator rotates smoothly when turned clockwise and locks when turned
counterclockwise.
If the results are not as specified, clean the converter and recheck the 1-way clutch. If the results
still are not as specified, replace the torque converter clutch assembly.
(b) Determine the condition of the torque converter clutch.
(1) Check that the following conditions are met:
* During the stall test or when the shift lever is in N, metallic sounds are not emitted from the torque
converter clutch.
* The 1-way clutch turns in one direction and locks in the other direction.
* The amount of powder in the ATF is not more than the sample shown in the illustration.
(2) If the results are not as specified, replace the torque converter clutch assembly.
HINT The sample illustration shows approximately 0.25 liters (0.26 US qts, 0.22 Imp. qts) of ATF
taken from a removed torque converter clutch.
Page 2766
^ Power Supply Mode is used to maintain battery voltage at 13.5 volts while flash reprogramming
the vehicle.
^ For details on how to use the GR8 Battery Diagnostic Station, refer to the located on TIS,
Diagnostics - Tools & Equipment - Battery Diagnostics.
3. Click the appropriate calibration ID and reprogram the vehicle's ECU with Techstream.
A. After reviewing the procedures outlined in the selected TSB, click the appropriate calibration ID
link by matching the vehicle's current
calibration ID to the Previous Calibration ID in the Calibration Identification Chart.
NOTE
^ Calibration files are embedded as live links in the service bulletin.
^ Some vehicles require special preparation - please review the selected TSB carefully.
B. Click Open to load calibration file information.
Techstream pulls calibration files as needed to ensure the latest calibration file is used. Do NOT
save calibrations locally on the hard drive or other media.
NOTICE
Errors during the flash reprogramming process can permanently damage the vehicle ECU.
Minimize the risk by following the steps below.
^ Battery voltage MUST NOT FALL BELOW 11.4 volts during reprogramming. Confirm battery
voltage is higher than 11.4 volts, but be sure voltage DOES NOT RISE ABOVE 16.0 volts during
reprogramming.
^ Turn OFF all vehicle accessories (e.g. audio system, A/C, interior lights, DRL, etc.). Do NOT add
to or significantly change the vehicle's electrical
Page 7147
Tire Pressure Sensor: Diagrams
Page 6148
[A] For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
"Case1" Raise the terminal retainer up to the temporary lock position.
Page 7498
Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf)
NOTICE: *
No further tightening is required once the nut is tightened with the specified torque.
* Check that there is no foreign matter on the washer and nut.
* Check that there is no oil, water or lubricant around the rim hole, tire pressure warning valve,
washer and nut. Failing to do so may result in improper installation.
(d) Set the wheel disc to a mounting machine and install the lower tire bead. Position the main
body of the tire pressure warning valve and
transmitter in the shaded area as shown in the illustration.
NOTICE: *
If the tire pressure warning valve and transmitter is positioned outside this area, the tire bead will
interfere with the tire pressure warning valve and transmitter, and may cause damage to it.
* If the use of lubricant is required when installing the bead, do not apply the lubricant directly to the
tire pressure warning valve and transmitter.
(e) Install the upper bead.
NOTICE: Make sure that the tire bead and tool do not interfere with the main body of the tire
pressure warning valve and transmitter and that the tire pressure warning valve and transmitter is
not clamped by the bead.
(f) Inflate the tire. Retighten the nut to the specified torque and then check for air leaks with soapy
water.
Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf)
NOTICE:
Diagrams
Variable Valve Timing Actuator Position Sensor: Diagrams
Drivetrian - Rear End Howling/Growling Noises
Axle Bearing: Customer Interest Drivetrian - Rear End Howling/Growling Noises
T-SB-0151-10
June11, 2010
Rear Axle Bearing Abnormal Noise
Service Category Drivetrain
Section Axle/Differential
Market USA
Applicability
Introduction
Some 2007 - 2010 model year Tundra vehicles may exhibit a howling or growling noise from the
rear of the vehicle that increases with vehicle speed. Changes have been made to the rear axle
bearing to correct this condition. Follow the procedure in the bulletin to address customer concerns.
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60
months or 60,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Parts Information
Page 4672
Control Module: Locations JF1A Transfer Case
JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION
Locations
Transmission Position Switch/Sensor: Locations
A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS
LOCATION
Diagram Information and Instructions
Relay Box: Diagram Information and Instructions
Wiring Color Codes
Abbreviations Used Within Diagrams
Abbreviations Used Within Diagrams
Page 8819
4. REMOVE FRONT UPPER ARMREST BASE PANEL LH See: Body and Frame/Doors, Hood
and Trunk/Doors/Front Door/Service and
Repair/Front Door (for Double Cab)/Disassembly
5. REMOVE FRONT DOOR ARMREST COVER LH
6. REMOVE COURTESY LIGHT ASSEMBLY See: Body and Frame/Doors, Hood and
Trunk/Doors/Front Door/Service and Repair/Front Door
(for Double Cab)/Disassembly
7. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH See: Body and Frame/Doors,
Hood and Trunk/Doors/Front Door/Service and
Repair/Front Door (for Double Cab)/Disassembly
8. REMOVE FRONT NO. 1 SPEAKER ASSEMBLY
(a) Disconnect the speaker connector.
(b) Remove the 4 screws and speaker.
NOTICE: Do not touch the cone part of the speaker.
9. REMOVE FRONT NO. 3 SPEAKER ASSEMBLY (for 10 Speakers)
(a) Remove the 3 screws and speaker with bracket.
(b) Detach the 3 claws and remove the speaker from the bracket.
NOTICE: Do not touch the cone part of the speaker.
Installation
AUDIO / VISUAL: FRONT DOOR SPEAKER (for Double Cab): INSTALLATION
HINT *
Use the same procedures for the LH side and RH side.
Page 3729
Page 3462
Operating the ignition switch, any switches or any doors triggers related ECU and sensor
communication with the CAN, which causes resistance variation.
PROCEDURE
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
(a) Disconnect the cable from the negative (-) battery terminal before measuring the resistances of
the main wire and the branch wire.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
NEXT -- Continue to next step.
2. CHECK FOR OPEN IN CAN BUS WIRE (POWER STEERING ECU BRANCH WIRE)
(a) Disconnect the J101 power steering ECU connector.
Page 5353
Transmission Speed Sensor: Service and Repair Installation
A760F AUTOMATIC TRANSMISSION: SPEED SENSOR: INSTALLATION
1. INSTALL SPEED SENSOR SP2
(a) Coat a new O-ring with ATF and install it to the sensor.
(b) Install the sensor with the bolt.
Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)
(c) Connect the sensor connector.
2. INSTALL SPEED SENSOR NT
(a) Coat a new O-ring with ATF and install it to the sensor.
(b) Install the sensor with the bolt.
Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)
(c) Connect the sensor connector.
Page 3003
ERROR: undefined
OFFENDING COMMAND: f‘~
STACK:
Page 1585
Transmission Speed Sensor: Testing and Inspection
A760F AUTOMATIC TRANSMISSION: SPEED SENSOR: INSPECTION
1. INSPECT SPEED SENSOR NT
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) If the result is not as specified, replace the sensor.
2. INSPECT SPEED SENSOR SP2
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) If the result is not as specified, replace the sensor.
Page 1761
Spark Plug: Service and Repair Removal
1UR-FE IGNITION: IGNITION COIL AND SPARK PLUG: REMOVAL
1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Removal
2. REMOVE AIR CLEANER ASSEMBLY
(a) Disconnect the MAF meter connector and clamp.
(b) Disconnect the ventilation hose and vacuum hose.
(c) Loosen the hose clamp.
(d) Remove the 2 bolts and air cleaner.
3. REMOVE IGNITION COIL ASSEMBLY
(a) for Bank 1:
(1) Disconnect the 3 wire harness clamps.
(2) Disconnect the 4 ignition coil connectors.
(3) Remove the 4 bolts and 4 ignition coils.
(b) for Bank 2:
(1) Disconnect the 2 wire harness clamps.
(2) Disconnect the 4 ignition coil connectors.
(3) Disconnect the engine wire harness clamp.
Page 2407
(b) Disconnect the ground wire from the cylinder block.
11. REMOVE OIL FILTER BRACKET
(a) Remove the 2 bolts, 2 nuts and filter bracket.
(b) Remove the 2 O-rings.
12. REMOVE OIL COOLER ASSEMBLY
(a) Remove the 5 nuts and oil cooler from the oil filter bracket.
(b) Remove the 2 O-rings.
13. REMOVE OIL COOLER SPACER
(a) Remove the bolt and oil cooler spacer from the oil filter bracket.
Components
Camshaft Position Sensor: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT POSITION SENSOR: COMPONENTS
Page 4174
Page 2845
Oxygen Sensor Relay: Testing and Inspection
1UR-FE ENGINE CONTROL SYSTEM: A/F SENSOR HEATER RELAY: ON-VEHICLE
INSPECTION
1. REMOVE INTEGRATION RELAY See: Relays and Modules - Ignition System/Ignition
Relay/Testing and Inspection
2. INSPECT INTEGRATION RELAY (A/F)
NOTICE: *
Some relays are built into the integration relay. The integration relay cannot be disassembled. If
there is a malfunction in the circuit of the integration relay, replace the integration relay.
* The internal circuit of the integration relay is as shown in the illustration below. Inspect the
integration relay using the following procedures.
(a) Measure the resistance of the A/F fuse.
(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(2) If the result is not as specified, replace the A/F fuse.
(b) Measure the resistance of the A/F sensor heater relay.
(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
Page 4549
(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(2) If the result is not as specified, replace the integration relay.
3. INSTALL INTEGRATION RELAY
(a) Connect the 3 connectors.
(b) Install the integration relay to the engine room relay block.
(c) Install the engine room relay block cover.
Page 4090
EGR Valve: Service and Repair Removal
1UR-FE EMISSION CONTROL: EGR VALVE: REMOVAL
1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Removal
2. REMOVE AIR CLEANER HOSE ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Removal
3. DRAIN ENGINE COOLANT See: Engine, Cooling and Exhaust/Cooling System/Coolant/Service
and Repair
4. DISCONNECT NO. 12 WATER BY-PASS HOSE
(a) Disconnect the No. 12 water by-pass hose.
5. DISCONNECT NO. 13 WATER BY-PASS HOSE
(a) Disconnect the No. 13 water by-pass hose.
6. REMOVE EGR VALVE ASSEMBLY
(a) Disconnect the 3 clamps and connector.
(b) Remove the 4 nuts.
(c) Remove the 2 bolts and EGR valve.
Page 3743
Engine Control Module: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: ECM: INSTALLATION
1. INSTALL GASKET
(a) Clean the ECM seal's surface with non-residue solvent.
(b) Attach a new gasket to the ECM.
2. INSTALL ECM
(a) Install the ECM with the 4 bolts.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
NOTICE: *
Make sure the gasket is not folded or caught on any area on the surrounding part.
* Make sure there is no foreign matter caught between the gasket and surrounding part.
* Do not damage the gasket.
(b) Connect the 2 ECM connectors and push each lock lever down to lock the ECM connectors.
NOTICE: *
Make sure that the lock lever is raised 90° before connecting the ECM connectors. Failure to do
this may cause the lock lever and terminals to break.
* Do not twist the wire harness when connecting the ECM connectors.
(c) Connect the wire harness clamp.
3. CONNECT CONNECTOR HOLDER BLOCK
(a) Connect the connector holder block with the 3 bolts.
Torque : 7.3 Nm (74 kgf-cm, 65 in-lbf)
Page 8097
Page 9132
Trailer Connector: Connector Views
Page 2452
Engine - Snow Ingestion Into Air Cleaner Box
Air Cleaner Housing: Customer Interest Engine - Snow Ingestion Into Air Cleaner Box
T-SB-0396-09
December 8, 2009
Snow Entry Into Air Cleaner Box
Service Category Engine/Hybrid System
Section Intake/Exhaust
Market USA
Applicability
Introduction
Some Sequoia and Tundra vehicles operated in areas with significant snow volume may
experience snow accumulation in the air cleaner box which can cause the lid to fracture. The air
cleaner lid and fender liner have been revised to reduce accumulation.
Parts Information
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for
36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Production Change Information
Components
Drive Belt: Service and Repair Components
1UR-FE ENGINE MECHANICAL: DRIVE BELT: COMPONENTS
Components
Tire Pressure Sensor: Service and Repair Components
TIRE AND WHEEL: TIRE PRESSURE WARNING VALVE AND TRANSMITTER: COMPONENTS
Component Tests and General Diagnostics
Steering Angle Sensor: Component Tests and General Diagnostics
BRAKE CONTROL: STEERING ANGLE SENSOR: INSPECTION
1. CHECK STEERING ANGLE SENSOR
(a) Check the steering angle sensor.
Under any of the following conditions, replace the sensor with a new one:
* The surface of the sensor is cracked, dented, or chipped.
* The connector is scratched, cracked, or damaged.
* The sensor has been dropped.
Page 8656
Page 838
Torque : 13 Nm (127 kgf-cm, 9 ft-lbf)
NOTICE: *
When installing the clamp, do not twist the wire harness.
* Make sure the clamp's rotation stopper touches the installation position.
(d) Attach the 3 clips (labeled E).
NOTICE: *
When installing the clips, do not twist the wire harness.
* When installing the clips, securely insert them as shown in the illustration.
(e) Connect the speed sensor connector (labeled F).
NOTICE: Securely connect the connector.
4. INSTALL FRONT SKID CONTROL SENSOR CLAMP RH
(a) Install the skid control sensor clamp (labeled A) with the bolt (labeled B).
Torque : 13 Nm (127 kgf-cm, 9 ft-lbf)
NOTICE: Install the bracket so that the rotation stopper (labeled C) touches the knuckle.
5. INSTALL FRONT SPEED SENSOR RH
(a) Install the speed sensor (labeled D) with the hexagon socket head cap bolt (labeled E).
Page 8231
Seat Belt: Removal and Replacement
Components
SEAT BELT: FRONT SEAT INNER BELT ASSEMBLY: COMPONENTS
Page 1488
(1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be
checked by conducting a voltage check.
With each connector still connected, measure the voltage between the body ground and these
terminals (in this order): 1) terminal 1 of connector A; 2) terminal 1 of connector B; and 3) terminal
1 of connector C.
Standard voltage (Fig. 4):
* If the results match the examples above, an open circuit exists in the wire harness between
terminal 1 of connector B and terminal 1 of connector C.
3. CHECK FOR SHORT CIRCUIT
(a) If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance
check with the body ground (below).
(b) Check the resistance with the body ground.
(1) Disconnect connectors A and C and measure the resistance.
Standard resistance (Fig. 6):
HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally.
If your results match the examples above, a short circuit exists between terminal 1 of connector A
and terminal 1 of connector C.
Page 7668
Compressor HVAC: Overhaul
Disassembly
AIR CONDITIONING: COMPRESSOR (for 1UR-FE): DISASSEMBLY
1. REMOVE COOLER BRACKET
(a) Detach the clamp.
(b) Remove the screw and the cooler bracket.
2. REMOVE MAGNET CLUTCH ASSEMBLY
(a) Clamp the cooler compressor in a vise.
(b) Using SST, hold the magnet clutch hub.
SST : 09985-00270
(c) Remove the bolt, magnet clutch hub and magnet clutch washer(s).
HINT There is no set number of magnet clutch washers since they are used for adjusting.
(d) Using a snap ring expander, remove the snap ring and the magnet clutch rotor.
NOTICE: Do not damage the seal cover of the bearing when removing the snap ring.
(e) Disconnect the connector.
(f) Using a snap ring expander, remove the snap ring and magnet clutch stator.
Page 7222
Steering Control Module: Diagrams
Page 2721
Torque : 54 Nm (554 kgf-cm, 40 ft-lbf)
(c) Connect the air fuel ratio sensor connector.
10. INSTALL HEATED OXYGEN SENSOR (for Bank 1 Sensor 2) See: Powertrain
Management/Computers and Control Systems/Oxygen
Sensor/Service and Repair/Heated Oxygen Sensor/Installation
11. INSTALL PROPELLER SHAFT HEAT INSULATOR (for 4WD) See: Transmission and
Drivetrain/Drive/Propeller Shafts, Bearings and
Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Front Propeller Shaft
Assembly/Installation
12. INSTALL CENTER EXHAUST PIPE ASSEMBLY
(a) Connect the center exhaust pipe to the 3 exhaust pipe supports.
(b) Install 2 new gaskets to the front exhaust pipes.
(c) Install the center exhaust pipe with the 4 bolts.
Torque : 48 Nm (489 kgf-cm, 35 ft-lbf)
13. INSTALL TAILPIPE ASSEMBLY
(a) Connect the tailpipe to the exhaust pipe support.
(b) Install a new gasket to the center exhaust pipe.
(c) Connect the tailpipe to the center exhaust pipe.
(d) Attach a new clamp to the tailpipe and center exhaust pipe. Then install the bolt to the clamp.
Torque : 32 Nm (326 kgf-cm, 24 ft-lbf)
HINT Install the clamp within the angle range shown in the illustration.
14. INSPECT FOR EXHAUST GAS LEAK See: Exhaust Manifold/Service and Repair/Installation
Page 4989
(b) Apply 12 V battery voltage to the shift solenoid valve and check that the valve moves and
makes an operating noise.
OK:
(c) If the result is not as specified, replace the solenoid valve.
9. INSPECT SHIFT SOLENOID VALVE SLU
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) Apply 12 V battery voltage to the shift solenoid valve and check that the valve moves and
makes an operating noise.
OK:
(c) If the result is not as specified, replace the solenoid valve.
Locations
Transmission Mode Switch: Locations
A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS
LOCATION
Page 4173
Page 8413
Seat Position Sensor: Service and Repair Removal
SUPPLEMENTAL RESTRAINT SYSTEM: SEAT POSITION SENSOR: REMOVAL
1. REMOVE FRONT SEAT ASSEMBLY LH
(a) Remove the front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Fold Down Seat
Type)/Removal.
2. REMOVE SEAT POSITION SENSOR
(a) Using a T30 "TORX" socket wrench, remove the screw and seat position sensor with sensor
protector.
(b) Disconnect the connector.
(c) Remove the seat slide position sensor protector from the seat position sensor.
Engine - Controls - Non-Linear Acceleration From A Stop
Engine Control Module: All Technical Service Bulletins Engine - Controls - Non-Linear Acceleration
From A Stop
T-SB-0273-10
September 28, 2010
Non-Linear Acceleration from a Stop
Service Category Engine/Hybrid System
Section Engine Control
Market USA
Applicability
Introduction
Some 2010 model year Tundra vehicles with the 1UR-FE (4.6 L) engine may exhibit non-linear
acceleration from a stop under certain conditions of low engine rpm with high engine load. The
Engine Control Module/ECM (SAE term: Powertrain Control Module/PCM) logic has been revised
to address this condition. Use the following repair procedure to recalibrate the ECM (PCM).
Calibration Information
Warranty Information
Applicable Warranty
^ This repair is covered under the Toyota Federal Emission Warranty. This warranty is in effect for
96 months or 80,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Page 3370
"Case2" Open the secondary locking device.
[B] For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray
Gray or White : Black
Regular Cab
Fuel Pump Control Unit: Locations Regular Cab
Body
Specifications
Spark Plug: Specifications
SPARK PLUG
Using a 16 mm plug wrench, install the 8 spark plugs.
Torque..................................................................................................................................................
.....................................21 Nm (214 kgf-cm, 15 ft-lbf)
GAP
Page 1750
* Never reuse the O-ring.
* When placing a new O-ring on the injector, do not damage it.
* Coat a new O-ring with spindle oil or gasoline before installing it. Do not use engine oil, gear oil or
brake oil.
(c) Install the injector to the delivery pipe and intake manifold as shown in the illustration.
NOTICE: Before installing the injector, apply spindle oil or gasoline on the place where the delivery
pipe contacts the O-ring of the injector.
(d) Observe these precautions when disconnecting the fuel tube connector (for Quick Type).
(1) for Fuel Hose Connector Cover Type:
Detach the lock claw by lifting up the cover, as shown in the illustration.
(2) for Fuel Pipe Clamp Type:
Remove the fuel pipe clamp from the fuel tube connector.
Page 6729
Page 7435
Tire Pressure Monitor Receiver / Transponder: Diagrams
Page 8744
Required Tools & Equipment
Repair Procedure Overview
^ Confirm noise is coming from the rear of the vehicle and changes with vehicle speed.
^ Install ChaSSiSEAR(TM) (or equivalent) and isolate the noise to the rear wheel bearing.
^ Remove the rear axle shaft assembly.
^ Install new rear wheel bearing brake caliper bracket and seals.
^ Reinstall rear axle shaft assembly and confirm the noise is no longer present.
Repair Procedure
1. Test drive the vehicle and confirm the customer complaint.
Does the noise increase and decrease with vehicle speed?
^ YES - Go to step 2.
^ NO - This TSB does NOT apply. Refer to the Repair Manual for further diagnosis.
Page 8825
Page 6062
* In the DTC check, it is very important to determine whether the problem indicated by the DTC is
either: 1) still occurring; or 2) occurred in the past but has since returned to normal. In addition, the
DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs
should be checked before and after confirmation of symptoms (i.e., whether or not problem
symptoms exist) to determine current system conditions, as shown in the flowchart below.
* Never skip the DTC check. Failing to check DTCs may, depending on the case, result in
unnecessary troubleshooting for systems operating normally or lead to repairs not related to the
problem. Follow the procedures listed in the flowchart in the correct order.
* The following flowchart shows how to proceed with troubleshooting using the DTC check.
Directions from the flowchart will indicate how to proceed either to DTC troubleshooting or to the
troubleshooting of each problem symptom.
1. DTC CHECK
NEXT -- Continue to next step.
2. MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR MEMORY
NEXT -- Continue to next step.
3. SYMPTOM CONFIRMATION
B -- Go to step 5 A -- Continue to next step.
4. SIMULATION TEST USING SYMPTOM SIMULATION METHODS
NEXT -- Continue to next step.
5. DTC CHECK
B -- TROUBLESHOOTING OF PROBLEM INDICATED BY DTC A -- Continue to next step.
6. SYMPTOM CONFIRMATION
Diagrams
Accessory Control Display: Diagrams
Page 5845
(1) Keep the vehicle stationary on a level surface for 1 second or more.
HINT *
The zero point calibration is performed only once after the system enters test mode.
* Calibration cannot be performed again until the stored data is cleared once.
(2) Check that the buzzer sounds for 3 seconds and DTC C1336 is erased.
(3) Turn the ignition switch off.
6. PERFORM INITIALIZATION OF STEERING ANGLE SENSOR
NOTICE: Complete the adjustment of the steering wheel and wheel alignment, and then initialize
the steering angle sensor. If the order is reversed, the steering wheel and wheel alignment will
become misaligned.
(a) Check that the steering wheel is in the centered position.
(b) Disconnect the negative battery terminal for more than 2 seconds.
NOTICE: After the ignition switch is turned OFF, the navigation system requires approximately 90
seconds to record various types of memory and settings. As a result, after turning the ignition
switch OFF, wait 90 seconds or more before disconnecting the cable from the negative (-) battery
terminal.
(c) Reconnect the negative battery terminal.
Page 9127
Page 2424
(g) Apply a small amount of engine oil to a new drain plug O-ring, and install it to the oil filter cap.
NOTICE: Before installing the O-ring, remove any dirt or foreign matter from the installation surface
of the oil filter cap.
(h) Install the oil filter drain plug.
Torque : 13 Nm (127 kgf-cm, 9 ft-lbf)
NOTICE: Be careful that the O-ring does not get caught between any surrounding parts.
5. ADD ENGINE OIL
(a) Add fresh oil.
Standard Oil Grade (for USA):
Standard Oil Grade (for Canada):
Standard Oil Capacity:
(b) Install the oil filler cap.
6. INSPECT FOR OIL LEAK
(a) Start the engine. Make sure that there are no oil leaks from the area that was worked on.
7. CHECK ENGINE OIL LEVEL See: Testing and Inspection
8. INSTALL NO. 1 ENGINE UNDER COVER
Page 3744
(b) Install the connector holder block cover.
4. INSTALL AIR CLEANER ASSEMBLY See: Ignition System/Ignition Coil/Service and
Repair/Installation
5. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Installation
Page 3300
M. Turn ignition OFF for a minimum of 10 seconds. Then click Next.
N. Turn ignition to the ON position. Then click Next.
0. Confirm all calibrations were updated as specified in the service bulletin. Then click Finish.
Page 54
6. INSTALL LUGGAGE COMPARTMENT BOX RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof
Headlining (For Regular Cab)/Installation
7. INSTALL LUGGAGE COMPARTMENT BOX LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof
Headlining (For Regular Cab)/Installation
8. INSTALL UPPER BACK PANEL GARNISH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining
(For Regular Cab)/Installation
Page 245
Power Distribution Module: Service and Repair Installation
OTHER SYSTEM: VOLTAGE INVERTER (for CrewMax): INSTALLATION
1. INSTALL VOLTAGE INVERTER ASSEMBLY
(a) Connect the voltage inverter connector.
(b) Install the voltage inverter with the 2 bolts.
Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
2. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY LH See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (for CrewMax)/Installation
3. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH
4. INSTALL REAR DOOR SCUFF PLATE LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for
CrewMax)/Installation
5. INSTALL BACK PANEL TRIM LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for
CrewMax)/Installation
6. INSTALL BACK PANEL TRIM RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for
CrewMax)/Installation
Page 7960
(1) Connect the red clip of SST to the battery positive (+) terminal and the black clip of SST to the
battery negative (-) terminal.
(2) Check that no one is within a 10 m (32.8 ft.) radius of the disc wheel which the steering pad is
tied to.
(3) Press SST activation switch and deploy the airbag.
CAUTION: When deploying the airbag, make sure that no one is near the tire.
HINT The airbag is deployed as the LED of SST activation switch comes on.
(g) Dispose of the steering pad.
CAUTION: *
The steering pad becomes extremely hot when the airbag is deployed, so do not touch it for at
least 30 minutes after deployment.
* Use gloves and safety glasses when handling a steering pad with a deployed airbag.
* Do not apply water to a steering pad with a deployed airbag.
* Always wash your hands with water after completing the operation.
(1) Remove the steering pad from the disc wheel.
(2) Place the steering pad in a plastic bag, tie it tightly and dispose of it in the same way as other
general parts.
Curtain Shield Airbag Assembly (for CrewMax)
SUPPLEMENTAL RESTRAINT SYSTEM: CURTAIN SHIELD AIRBAG ASSEMBLY (for CrewMax):
DISPOSAL
Page 8270
(a) Remove the bolt and seat belt.
3. DISCONNECT REAR SEAT INNER BELT ASSEMBLY
(a) Remove the bolt and disconnect the inner belt.
4. REMOVE REAR SEAT ASSEMBLY LH
(a) Remove the 4 bolts and seat.
5. REMOVE SEPARATE TYPE REAR SEAT CUSHION COVER LH See: Body and
Frame/Seats/Service and Repair/Overhaul/Rear Seat
Assembly (for Crewmax LH Side)/Disassembly
Page 1963
* Low pedal or spongy pedal.
* Brake pedal is depressed firmly but braking is insufficient.
(c) Check and adjust brake fluid level in reservoir See: Fluids/Brake Fluid/Testing and Inspection.
2. BLEED BRAKE SYSTEM
(a) Bleed brake master cylinder
HINT If the master cylinder has been disassembled or if the reservoir becomes empty, bleed air
from the master cylinder.
(1) Remove the brake master cylinder reservoir filler cap assembly.
(2) Add brake fluid into the reservoir between MAX and MIN level on the brake fluid reservoir.
Brake fluid:
SAE J1703 or FMVSS No. 116 DOT3
(3) Using a union nut wrench, disconnect the 2 brake lines from the master cylinder.
(4) Slowly depress and hold the brake pedal.
(5) Block the outer holes with your fingers, and release the pedal.
(6) Repeat the 2 previous steps 3 or 4 times.
(7) Using a union nut wrench, connect the 2 brake lines to the master cylinder.
without union nut wrench - Torque : 20 Nm (199 kgf-cm, 14 ft-lbf)
with union nut wrench - Torque : 18 Nm (185 kgf-cm, 13 ft-lbf)
* Use a torque wrench with a fulcrum length of 300 mm (11.8 in.).
* This torque value is effective when union nut wrench is parallel to the torque wrench.
(b) Bleed brake line
(1) Connect a vinyl tube to the bleeder plug of the front disc brake cylinder RH.
(2) Depress the brake pedal several times, and then loosen the bleeder plug with the pedal
depressed.*1
(3) When fluid stops coming out, tighten the bleeder plug, and then release the brake pedal.*2
(4) Repeat *1 and *2 until all the air in the brake fluid is completely bled out and the new brake fluid
comes out.
(5) Tighten the bleeder plug completely.
Torque : 11 Nm (110 kgf-cm, 8 ft-lbf)
(6) Replace the brake fluid from the front disc brake cylinder LH using the same procedure as for
RH.
(7) Connect a vinyl tube to the bleeder plug of the rear disc brake cylinder RH.
Page 753
Sunroof / Moonroof Switch: Testing and Inspection
SLIDING ROOF: SLIDING ROOF SWITCH ASSEMBLY (for CrewMax): INSPECTION
1. INSPECT SLIDING ROOF SWITCH
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the switch.
Page 8030
Air Bag Deactivation Switch: Testing and Inspection Curtain Shield Airbag Cutoff Switch
SUPPLEMENTAL RESTRAINT SYSTEM: CURTAIN SHIELD AIRBAG CUTOFF SWITCH:
INSPECTION
1. INSPECT CURTAIN SHIELD AIRBAG CUTOFF SWITCH
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
Page 3534
Standard resistance:
NG -- REPAIR OR REPLACE CAN MAIN WIRE OR CONNECTOR (NO. 1 JUNCTION
CONNECTOR - NO. 2 JUNCTION CONNECTOR)
OK -- REPLACE NO. 2 JUNCTION CONNECTOR
8. CONNECT CONNECTOR
(a) Reconnect the J113 No. 2 junction connector connector.
NEXT -- Continue to next step.
9. CHECK FOR OPEN IN CAN BUS MAIN WIRE (ECM - NO. 2 JUNCTION CONNECTOR)
(a) Disconnect the A24 ECM connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
Result
E -- REPAIR OR REPLACE CAN MAIN WIRE CONNECTED TO ECM (ECM - NO. 2 JUNCTION
CONNECTOR)
Page 1427
(b) Check that the cable is disconnected from the battery negative (-) terminal.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation
(c) Install the door airbag sensor with the screw.
Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)
NOTICE: *
If the door airbag sensor has been dropped, or there are any cracks, dents or other defects in the
case, bracket or connector, replace it with a new one.
* When installing the door airbag sensor, be careful that the SRS wiring does not interfere with
other parts and that it is not pinched between other parts.
(d) Check that there is no looseness in the installation parts of the side airbag sensor.
(e) Connect the connector.
2. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Regular Cab)/Reassembly
3. INSTALL COURTESY LIGHT ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood
and Trunk/Doors/Front Door/Service and
Repair/Front Door (for Regular Cab)/Reassembly
4. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH LH (for Front Side) See: Body
and Frame/Doors, Hood and
Trunk/Doors/Front Door/Service and Repair/Front Door (for Regular Cab)/Reassembly
5. INSTALL FRONT DOOR WINDOW REGULATOR HANDLE ASSEMBLY (for Front Side) See:
Body and Frame/Doors, Hood and
Trunk/Doors/Front Door/Service and Repair/Front Door (for Regular Cab)/Reassembly
6. INSTALL FRONT ARMREST BASE PANEL UPPER LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Regular Cab)/Reassembly
7. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Regular Cab)/Reassembly
8. INSTALL REAR SIDE AIRBAG SENSOR
(a) Check that the ignition switch is OFF.
(b) Check that the cable is disconnected from the battery negative (-) terminal.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
(c) Install the side airbag sensor with the bolt.
Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)
NOTICE: *
If the side airbag sensor has been dropped, or there are any cracks, dents or other defects in the
case, bracket or connector, replace it with a new one.
* When installing the side airbag sensor, be careful that the SRS wiring does not interfere with
other parts and that it is not pinched
Page 7173
6. INSTALL FRONT AXLE HUB SUB-ASSEMBLY LH
(a) Install the front axle hub See: Suspension/Wheel Hub/Service and Repair/Removal and
Replacement/Installation.
7. CONNECT FRONT SPEED SENSOR LH
(a) Connect the front speed sensor to the steering knuckle with the bolt.
Torque : 11 Nm (107 kgf-cm, 8 ft-lbf)
(b) Attach the clip to the steering knuckle.
8. INSTALL FRONT WHEEL
for Aluminum Wheel - Torque : 131 Nm (1336 kgf-cm, 97 ft-lbf)
for Steel Wheel - Torque : 209 Nm (2131 kgf-cm, 154 ft-lbf)
9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
10. CHECK SPEED SENSOR SIGNAL
(a) Check the speed sensor signal See: Brakes and Traction Control/Antilock Brakes / Traction
Control Systems/Testing and Inspection/Scan
Tool Testing and Procedures/Test Mode Procedure.
11. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
12. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
(a) Inspect and adjust the front wheel alignment See: Alignment/Service and Repair.
Vehicle - Long Term Storage Guidelines
Battery: Technical Service Bulletins Vehicle - Long Term Storage Guidelines
T-SB-0079-09
Rev1
March 4, 2009
Long Term Vehicle Storage Guidelines
Service Category General
Section Maintenance
Market USA
Applicability
December 23, 2009 Rev1:
TSB REVISION NOTICE
^ Applicability has been updated to include 2010 Prius PHV model and 2011 vehicles.
Any previous printed versions of this service bulletin should be discarded.
Introduction
Long-term or off-site storage requires special care to keep vehicles factory fresh and ready for
delivery. The following guidelines should be performed to minimize vehicle component/part
degradation due to extended vehicle storage conditions. Long-term storage can affect a vehicle's
systems and components. Any problems that are found should be corrected immediately.
Required Tools & Equipment
Warranty Information
Procedure
Page 7586
"Case1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (/\ Mark) and pull the terminal retainer
up to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Page 3210
Crankshaft Position Sensor: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: CRANKSHAFT POSITION SENSOR: INSTALLATION
1. INSTALL CRANKSHAFT POSITION SENSOR
(a) Install the sensor with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(b) Connect the sensor connector.
2. INSTALL CRANKSHAFT POSITION SENSOR PROTECTOR
(a) Install the sensor protector with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
Page 4060
Canister Purge Solenoid: Diagrams
Page 856
Yaw Rate Sensor: Service and Repair Installation
BRAKE CONTROL: YAW RATE AND DECELERATION SENSOR: INSTALLATION
1. INSTALL YAW RATE SENSOR
(a) Connect the sensor connector (labeled A), and then attach the clamp (labeled B) to the hole of
the sensor bracket.
(b) Install the yaw rate sensor with the 2 nuts (labeled C).
Torque : 13 Nm (127 kgf-cm, 9 ft-lbf)
NOTICE: *
Make sure that the sensor is oriented correctly.
* If the sensor is dropped, replace it.
* Securely connect the connector.
* When installing the sensor, make sure to avoid impacts to the sensor.
2. INSTALL CENTER FRONT SEAT (for Center Seat) See: Body and Frame/Seats/Service and
Repair/Removal and Replacement/Front Seat
Assembly (for Center Seat)/Installation
3. INSTALL CONSOLE BOX ASSEMBLY (for Separate Seat Type)
(a) Install the console box See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and
Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation.
4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
5. PERFORM YAW RATE SENSOR ZERO POINT CALIBRATION
(a) Perform the yaw rate sensor zero point calibration See: Brakes and Traction Control/Antilock
Brakes / Traction Control Systems/Testing and
Inspection/Programming and Relearning.
6. CHECK YAW RATE SENSOR SIGNAL
(a) Check the yaw rate sensor signal See: Brakes and Traction Control/Antilock Brakes / Traction
Control Systems/Testing and Inspection/Scan
Tool Testing and Procedures/Test Mode Procedure.
Page 4059
Canister Purge Solenoid: Locations Engine Control System - SFI System
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 7878
Refrigerant Pressure Sensor / Switch: Locations Air Conditioning System (for Manual Air
Conditioning System)
AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Manual Air Conditioning System):
PARTS LOCATION
Page 6740
J/B No.3 - Instrument Panel Right
Page 2542
Parts Information
Required Tools & Equipment
Additional TIS Techstream units may be ordered by calling Approved Dealer Equipment (ADE).
TSB Overview
1. Confirm that DTC P0012 and/or P0022 is stored in the ECM.
2. Diagnose the Oil Control Valves (OCVs) for proper operation.
3. If the OCVs operate correctly replace both intake VVTi gear assemblies following the Repair
Manual.
Diagnostic Procedure
1. Using TIS Techstream confirm that DTC P0012 and/or P0022 is stored in the ECM.
2. Remove the affected Oil Control Valve (OCV) and inspect for debris in the valve or evidence that
the valve is stuck.
3. Check valve operation by applying positive (+) battery voltage to terminal 1 and negative (-)
battery voltage to terminal 2. Valve should move
quickly when voltage is applied. If NOT valve should be replaced.
4. Reinstall the OCVs warm up the engine to over 167°F (75°C) and perform an Active Test using
Tech stream.
Powertrain / Engine and ECT / Active Test / Control the WT System (Bank 1) or (Bank 2)
5. If there is NO debris and the OCV moves with battery voltage and Active Test functions Replace both intake VVTi gears following the repair
procedure below.
Repair Procedure
1. Replace both intake VVTi gears.
Page 21
Components
Refrigerant Pressure Sensor / Switch: Service and Repair Components
AIR CONDITIONING: PRESSURE SWITCH: COMPONENTS
Page 4676
Control Module: Service and Repair Removal
JF1A TRANSFER: 4WD CONTROL ECU: REMOVAL
1. REMOVE FRONT DOOR SCUFF PLATE RH (for Regular Cab)
(a) Remove the front door scuff plate RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Removal.
HINT Use the same procedures described for the LH side.
2. REMOVE FRONT DOOR SCUFF PLATE RH (for Double Cab, for CrewMax)
(a) Remove the front door scuff plate RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Removal.
HINT Use the same procedures described for the LH side.
3. REMOVE COWL SIDE TRIM BOARD RH
(a) Remove the cowl side trim board RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Removal.
HINT Use the same procedures described for the LH side.
4. REMOVE INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal
5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and
Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument
Panel Safety Pad (for Column Shift Type)/Removal
6. REMOVE 4WD CONTROL ECU
(a) Disconnect the 2 ECU connectors.
(b) Remove the bolt and ECU.
Page 4560
Camshaft Position Sensor: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT POSITION SENSOR: INSTALLATION
1. INSTALL CAMSHAFT POSITION SENSOR
(a) Install the sensor with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(b) Connect the sensor connector.
2. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Installation
Page 3481
INSPECTION PROCEDURE
HINT *
Perform the following inspection for the ECUs (sensors) which are not displayed on the
Techstream. If a malfunction cannot be identified, perform the following inspections for the ECUs
(sensors) connected to the CAN communication system.
* Do not remove the combination meter and ECM, as they are the end parts of the circuit. If
removed, CAN communication will not be possible.
* The open circuit confirmation of the combination meter, ECM and main wire is performed in the
CHECK CAN BUS LINE procedure of "HOW TO PROCEED WITH TROUBLESHOOTING". This
inspection only has procedures for checking for an open circuit on one side of the CAN branch
wire.
PROCEDURE
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
(a) Disconnect the cable from the negative (-) battery terminal before measuring the resistances of
the main wire and the branch wire.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
NEXT -- Continue to next step.
Locations
Fuel Pump Relay: Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Locations
Air Flow Meter/Sensor: Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 241
Power Distribution Module: Diagrams Voltage Inverter
Television Display
Television / Monitor: Service and Repair Television Display
Components
AUDIO / VISUAL: TELEVISION DISPLAY: COMPONENTS
Removal
AUDIO / VISUAL: TELEVISION DISPLAY: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
Page 3896
This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown.
Page 7237
Power Steering Pressure Switch: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: POWER STEERING OIL PRESSURE SWITCH:
INSTALLATION
1. INSTALL POWER STEERING OIL PRESSURE SWITCH
(a) Install a new O-ring to the power steering oil pressure switch.
(b) Apply a light coat of engine oil to the O-ring of the power steering oil pressure switch.
NOTICE: *
When reusing the power steering oil pressure switch, inspect the O-ring.
* If the O-ring has scratches or cuts, replace the power steering oil pressure switch.
(c) Using SST, install the power steering oil pressure switch.
SST : 09922-10010
without SST - Torque : 21 Nm (210 kgf-cm, 15 ft-lbf)
with SST - Torque : 15 Nm (148 kgf-cm, 11 ft-lbf)
HINT *
Use a torque wrench with a fulcrum length of 30 cm (11.8 in.). When using a torque wrench with a
fulcrum length that is not 30 cm (11.8 in.), calculate the torque specification for the torque wrench
and SST based on the "without SST" torque specification See: Service Precautions
* Make sure SST and the torque wrench are connected in a straight line.
(d) Connect the oil pressure switch connector.
2. INSTALL FAN AND GENERATOR V BELT
(a) Install the fan and generator V belt See: Engine, Cooling and Exhaust/Engine/Drive Belts,
Mounts, Brackets and Accessories/Drive
Belt/Service and Repair/Installation.
3. ADD POWER STEERING FLUID
4. BLEED POWER STEERING FLUID See: Testing and Inspection/Component Tests and General
Diagnostics/Power Steering
System/On-Vehicle Inspection
5. INSPECT FOR POWER STEERING FLUID LEAK
6. CHECK FLUID LEVEL See: Testing and Inspection/Component Tests and General
Diagnostics/Power Steering System/On-Vehicle Inspection
7. INSTALL FRONT FENDER APRON SEAL RH See: Engine, Cooling and Exhaust/Exhaust
System/Exhaust Manifold/Service and
Repair/Installation
8. INSTALL FRONT WHEEL See: Suspension/Suspension Strut / Shock Absorber/Service and
Repair/Removal and Replacement/Front Shock
Absorber/Installation
Page 8372
(b) Check that the cable is disconnected from the battery negative (-) terminal.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
(c) Install the door airbag sensor with the screw.
Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)
NOTICE: *
If the door airbag sensor has been dropped, or there are any cracks, dents or other defects in the
case, bracket or connector, replace it with a new one.
* When installing the door airbag sensor, be careful that the SRS wiring does not interfere with
other parts and that it is not pinched between other parts.
(d) Check that there is no looseness in the installation parts of the door airbag sensor.
(e) Connect the connector.
2. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Reassembly
3. INSTALL COURTESY LIGHT ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood
and Trunk/Doors/Front Door/Service and
Repair/Front Door (for Double Cab)/Reassembly
4. INSTALL FRONT LOWER DOOR FRAME BRACKET GARNISH LH (for Front Side) See: Body
and Frame/Doors, Hood and
Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly
5. INSTALL FRONT UPPER ARMREST BASE PANEL LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Reassembly
6. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Reassembly
7. INSTALL REAR SIDE AIRBAG SENSOR
(a) Check that the ignition switch is OFF.
(b) Check that the cable is disconnected from the battery negative (-) terminal.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
(c) Install the side airbag sensor with the bolt.
Locations
Headlamp Dimmer Relay: Locations
LIGHTING: LIGHTING SYSTEM: PARTS LOCATION
Page 836
(c) Disconnect the connector (labeled D).
(d) Remove the connector (labeled D) from the skid control sensor clamp (labeled H).
(e) Remove the 2 bolts (labeled E) and 2 harness clamps (labeled F).
(f) Remove the bolt (labeled G) and skid control sensor clamp (labeled H).
7. REMOVE FRONT SPEED SENSOR RH
(a) Remove the hexagon socket head cap bolt (labeled A) and speed sensor (labeled B) from the
knuckle.
8. REMOVE FRONT SKID CONTROL SENSOR CLAMP RH
(a) Remove the bolt (labeled C) and skid control sensor clamp (labeled D) from the knuckle.
Installation
BRAKE CONTROL: FRONT SPEED SENSOR: INSTALLATION
1. INSTALL FRONT SKID CONTROL SENSOR CLAMP LH
(a) Install the skid control sensor clamp (labeled A) with the bolt (labeled B).
Torque : 13 Nm (127 kgf-cm, 9 ft-lbf)
NOTICE: Install the bracket so that the rotation stopper (labeled C) touches the knuckle.
Page 3035
Throttle Position Sensor: Diagrams
Page 5678
(8) Depress the brake pedal several times, and then loosen the bleeder plug with the pedal
depressed.*1
(9) When fluid stops coming out, tighten the bleeder plug, and then release the brake pedal.*2
(10)Repeat *1 and *2 until all the air in the brake fluid is completely bled out and the new brake
fluid comes out.
(11)Tighten the bleeder plug completely.
Torque : 11 Nm (110 kgf-cm, 8 ft-lbf)
(12)Replace the brake fluid from the rear disc brake cylinder LH using the same procedure as for
RH.
(c) Bleed VSC actuator assembly
NOTICE: After bleeding the air from the brake system, if the height or feel of the brake pedal
cannot be obtained, perform air bleeding of the brake actuator with the Techstream by following the
procedure below.
(1) Depress the brake pedal more than 20 times with the engine off.
(2) Connect the Techstream to the DLC3, and turn the ignition switch on.
NOTICE: Do not start the engine.
(3) Select AIR BLEEDING on the Techstream.
HINT Refer to the Techstream operator's manual for further details.
(4) Bleed the air out of the suction line.
NOTICE: *
Perform the bleeding at the right front wheel and right rear wheel.
* Bleed the air by following the steps displayed on the Techstream.
(5) 1. Connect a vinyl tube to the bleeder plug at the right front wheel or the right rear wheel.
2. Loosen the bleeder plug.
3. Operate the brake actuator to bleed the air using the Techstream.
HINT This operation stops automatically after 4 seconds.
NOTICE: Release the brake pedal at this time.
(6) 4. Check if the operation has stopped by referring to the Techstream display.
5. Temporarily tighten the bleeder plug.
6. Repeat the 4 previous steps until all in the fluid is completely bled out.
7. Tighten the bleeder plug.
Torque : 11 Nm (110 kgf-cm, 8 ft-lbf)
(7) 8. Repeat all of the above procedures for the other wheel to bleed the air out of the suction line.
(8) Bleed the air out of the pressure reduction line.
NOTICE: *
Perform the bleeding at the 4 wheels.
* Bleed the air by following the steps displayed on the Techstream.
(9) 1. Connect a vinyl tube to one of the bleeder plugs.
Page 7733
(a) Remove the filter.
6. REMOVE NO. 2 AIR DUCT SUB-ASSEMBLY
(a) Remove the screw and duct.
7. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY
(a) Remove the 2 screws and amplifier.
8. REMOVE BLOWER WITH FAN MOTOR SUB-ASSEMBLY
(a) Remove the 3 screws and motor.
9. REMOVE AIR DUCT
(a) Remove the 2 screws and duct.
Page 9077
(2) CONNECTORS
Slightly shake the connector vertically and horizontally.
(3) WIRE HARNESS
Slightly shake the wire harness vertically and horizontally.
HINT The connector joint and fulcrum of the vibration are the major areas that should be checked
thoroughly.
(b) HEAT METHOD:
When a malfunction seems to occur when the area in question is heated.
(1) Heat the component that is the possible cause of the malfunction with a hair dryer or similar
device. Check if the malfunction occurs.
NOTICE: *
Do not heat to more than 60°C (140°F). Exceeding this temperature may damage components.
* Do not apply heat directly to the parts in the ECU.
(c) WATER SPRINKLING METHOD:
When a malfunction seems to occur on a rainy day or in high-humidity.
(1) Sprinkle water onto the vehicle and check if the malfunction occurs.
NOTICE: *
Never sprinkle water directly into the engine compartment. Indirectly change the temperature and
humidity by spraying water onto the front of the radiator.
* Never apply water directly onto the electronic components.
HINT If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU
or connections. Look for evidence of corrosion or short circuits. Proceed with caution during water
tests.
(d) HIGH ELECTRICAL LOAD METHOD:
When a malfunction seems to occur when the electrical load is excessive.
(1) Turn on the heater blower, headlights, rear window defogger and all other electrical loads.
Check if the malfunction reoccurs.
5. DIAGNOSTIC TROUBLE CODE CHART
Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate
section's Diagnostic Trouble Code Chart. Use the chart to determine the trouble area and the
proper inspection procedure. A description of each of the chart's columns is below.
Locations
Tire Pressure Monitor Receiver / Transponder: Locations
TIRE AND WHEEL: TIRE PRESSURE WARNING SYSTEM: PARTS LOCATION
Page 9176
Removal
EXTERIOR: SIDE STEP: REMOVAL
HINT *
Use the same procedures for the RH side and LH side.
* The procedures listed below are for the LH side.
1. REMOVE SIDE STEP ASSEMBLY
(a) Remove the 8 bolts and side step.
Restraints - OCS System Initialization
Seat Occupant Classification Module - Air Bag: Technical Service Bulletins Restraints - OCS
System Initialization
COLLISION REPAIR INFORMATION FOR THE COLLISION REPAIR PROFESSIONAL
TITLE: SRS OCCUPANT CLASSIFICATION SYSTEM INITIALIZATION
SECTION: ELECTRICAL BULLETIN # 177
MODELS: ALL EQUIPPED TOYOTA LEXUS and SCION MODELS
DATE: MARCH 2010
Models equipped with a Supplemental Restraint System (SRS) Occupant Classification System
(OCS) will enable or disable the passenger front and side airbags based on seat occupancy
passenger weight and seat belt latch engagement.
If an equipped vehicle sustains collision damage or if the front passenger seat or any of the OCS
components are serviced the SRS Malfunction Indicator Light (MIL) may illuminate setting a
Diagnostic Trouble Code (DTC).
NOTE:
It is necessary to diagnose and repair the root cause of a SRS or OCS DTC before initializing the
OCS system. If SRS and OCS DTC's are not cleared the system may not operate properly.
Be sure to check and clear DTC's and perform OCS initialization per repair manual instructions
with a Techstream Special Service Tool (SST) or capable diagnostic tester.
Any of the following conditions could set a DTC illuminate the SRS MIL or cause the PASSENGER
AIRBAG light to indicate incorrectly regardless of occupancy:
^ The OCS Electronic Control Unit (ECU) is replaced
^ Accessories such as a seatback tray are installed on the passenger seat
^ The passenger seat is removed and replaced or reinstalled
^ The vehicle is involved in an accident or collision
Model-specific repair manuals can be accessed through the Technical Information System (TIS)
www.techinfo.toyota.com
Page 214
Headlamp Relay: Testing and Inspection
LIGHTING: HEADLIGHT RELAY: ON-VEHICLE INSPECTION
1. REMOVE HEADLIGHT RELAY (HEAD)
(a) Remove the headlight relay from the engine room relay box.
2. INSPECT HEADLIGHT RELAY
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the relay.
3. INSTALL HEADLIGHT RELAY
Air Conditioning System (for Automatic Air Conditioning
System)
Compressor Clutch Relay: Locations Air Conditioning System (for Automatic Air Conditioning
System)
AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Automatic Air Conditioning System):
PARTS LOCATION
Page 8666
[A] For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
"Case1" Raise the terminal retainer up to the temporary lock position.
Diagrams
Trailer Brake Control Module: Diagrams
Page 3105
Knock Sensor: Diagrams
Page 2110
(a) Disconnect the ECM connector.
(b) Disconnect the combination meter connector.
(c) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- REPLACE COMBINATION METER ASSEMBLY See: Instrument Panel, Gauges and
Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Combination Meter/Removal
5. CHECK THAT MIL IS ILLUMINATED
(a) Check if the MIL is illuminated when the ignition switch is turned to ON.
OK:
MIL should be illuminated.
NG -- CHECK THAT ENGINE STARTS
OK -- END
6. CHECK THAT ENGINE STARTS
(a) Turn the ignition switch to ON.
(b) Start the engine.
Result
HINT *: The Techstream cannot communicate with the ECM.
Page 4259
1. Test drive the vehicle and confirm there is a harsh shift on acceleration below 20 mph and or
excessive lock-up operation at freeway speeds about 50
- 60 mph.
2. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in
Figure 1. Confirm if the ECM (PCM) calibration has
been updated. If the calibration ID listed is NOT the latest ECM (PCM) calibration - go to step 3.
3. Flash reprogram the ECM (PCM).
NOTE
^ The GR8 Battery Diagnostic Station MUST be used in Power Supply Mode to maintain battery
voltage at 13.5 volts while flash reprogramming the vehicle.
^ For details on how to use the GR8 Battery Diagnostic Station, refer to the GR8 Instruction Manual
located on the Technical Information System (TIS), Diagnostics - Battery.
Follow the procedures outlined in TSB No. T-SB-0064-10, "Techstream ECU Flash
Reprogramming Procedure", and flash the ECM (PCM) with the NEW calibration file update.
4. Start the engine and warm it up to normal operating temperature before test driving.
5. Test drive the vehicle to confirm proper vehicle operation and ECM (PCM) initial learning. Refer
to the Technical Information System (TIS) 2010
Tundra Repair Manual:
Drivetrain - Automatic Transmission/Transaxle - "A760E / A760F Automatic
Transmission/Transaxle: Automatic Transmission System: Initialization"
6. Install the Authorized Modifications Label.
A. Using a permanent marker enter the following information on the label:
^ ECM part number [Refer to the Parts Information section for the CURRENT PART NUMBER]
Page 8621
Auxiliary Input / Output Jack: Diagrams Video Terminal
Page 6121
6. REMOVE PLANETARY GEAR
(a) Remove the 3 planetary gears.
Reassembly
1UR-FE STARTING: STARTER (for 2.0 kW Type): REASSEMBLY
1. INSTALL PLANETARY GEAR
(a) Apply high temperature grease to the planetary gears and pins of the starter center bearing
clutch, as shown in the illustration.
(b) Install the 3 planetary gears.
2. INSTALL STARTER ARMATURE PLATE
(a) Install the plate to the starter center bearing clutch.
NOTICE: Check that the protrusion of the starter armature plate fits in the notch of the starter
center bearing clutch.
3. INSTALL STARTER ARMATURE ASSEMBLY
(a) Install the starter armature to the starter center bearing clutch.
4. INSTALL STARTER YOKE ASSEMBLY
(a) Align the protrusion of the starter center bearing clutch with the notch of the starter yoke, and
install the starter yoke.
Page 6935
Engine Room R/B, J/B - Engine Compartment Left
Capacity Specifications
Engine Oil: Capacity Specifications
Engine Oil Capacity (drain and refill-Reference)
With filter ..............................................................................................................................................
............................................................. 7.9 qt (7.5L) Without filter ......................................................
................................................................................................................................................ 7.4 qt
(7.1L)
Page 4852
Shift Interlock Control Module: Diagrams
Specifications
Timing Chain Tensioner: Specifications
NO. 1 CHAIN TENSIONER ASSEMBLY LH
Install a new gasket and the chain tensioner with the 2 bolts.
Torque..................................................................................................................................................
.......................................10 Nm (102 kgf-cm, 7 ft-lbf)
NO. 1 CHAIN TENSIONER ASSEMBLY RH
Install the chain tensioner with the 2 bolts.
Torque..................................................................................................................................................
.......................................10 Nm (102 kgf-cm, 7 ft-lbf)
NO. 2 CHAIN TENSIONER ASSEMBLY
Install the chain tensioner with the 2 bolts.
Torque..................................................................................................................................................
.......................................10 Nm (102 kgf-cm, 7 ft-lbf)
NO. 3 CHAIN TENSIONER ASSEMBLY
Install the chain tensioner with the 2 bolts.
Torque..................................................................................................................................................
.......................................10 Nm (102 kgf-cm, 7 ft-lbf)
Page 1691
for CrewMax of standard deck
Page 1372
Page 1891
Hose/Line HVAC: Tools and Equipment
A/C Clamp Remover
AST tool# TOY 200
Page 1549
Tire Pressure Sensor: Diagrams
Page 3716
Engine Control Module: Locations
Engine Compartment
Page 1867
(3) Check for dirt or mud on the pipe and around the connector before disconnection. Clean if
necessary.
(4) Pinch the connector and disconnect the connector and pipe.
(5) If the connector and the pipe are stuck together, pinch the connector, push and pull the pipe to
disconnect the pipe and pull it out.
NOTICE: Do not use any tools.
(6) Check for dirt or mud on the seal surface of the disconnected pipe. Clean if necessary.
(7) To protect the disconnected pipe and connector from damage and contamination, cover it with a
plastic bag.
(e) Observe these precautions when connecting the fuel tube connector (for Quick Type).
(1) Check that there is no damage or contamination in the connected part of the pipe.
(2) Align the axis of the connector with the axis of the pipe. Push the pipe into the connector until
the connector makes a "click" sound. If the
connection is tight, apply a small amount of fresh spindle oil or gasoline on the tip of the pipe.
(3) After having finished the connection, try to pull apart the pipe and the connector to confirm that
they are securely connected.
Page 8017
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
4. REMOVE UPPER CONSOLE REAR PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
5. REMOVE REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
6. REMOVE CONSOLE BOX CARPET
7. REMOVE REAR CONSOLE BOX ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal
8. REMOVE FRONT CONSOLE BOX See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal
and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal
9. REMOVE CENTER AIRBAG SENSOR ASSEMBLY
(a) Disconnect the holder (with connectors).
(b) Remove the 3 bolts and airbag sensor.
Installation
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift
Type): INSTALLATION
1. INSTALL CENTER AIRBAG SENSOR ASSEMBLY
(a) Check that the ignition switch is OFF.
(b) Check that the cable is disconnected from the battery negative (-) terminal.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
(c) Install the airbag sensor with the 3 bolts.
Torque : 18 Nm (184 kgf-cm, 13 ft-lbf)
NOTICE: *
If the center airbag sensor has been dropped, or there are any cracks, dents or other defects in the
case, bracket or connector, replace it with a new one.
* When installing the center airbag sensor, be careful that the SRS wiring does not interfere with
other parts and that it is not pinched between other parts.
(d) Check that there is no looseness in the installation parts of the center airbag sensor.
Page 3347
Engine Temperature Sensor: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: ENGINE COOLANT TEMPERATURE SENSOR:
REMOVAL
1. REMOVE NO. 1 ENGINE UNDER COVER See: Engine, Cooling and Exhaust/Engine/Engine
Lubrication/Engine Oil/Service and
Repair/Replacement
2. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Removal
3. DRAIN ENGINE COOLANT See: Engine, Cooling and Exhaust/Cooling System/Coolant/Service
and Repair
4. REMOVE ENGINE COOLANT TEMPERATURE SENSOR
(a) Disconnect the sensor connector.
(b) Using a 19 mm ball joint lock nut wrench, remove the sensor.
(c) Remove the gasket from the sensor.
Page 1632
Power Window Switch: Diagrams Rear Power Window Switch
Page 6714
"Case1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (/\ Mark) and pull the terminal retainer
up to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Page 3656
Parts Information
Calibration Information
Required Tools & Equipment
Repair Procedure
Page 8642
2. REMOVE REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
3. REMOVE VIDEO TERMINAL
(a) Detach the clamp from the end panel.
(b) Detach the 4 claws and remove the video terminal.
Installation
AUDIO / VISUAL: VIDEO TERMINAL (for Separate Seat Type): INSTALLATION
1. INSTALL VIDEO TERMINAL
(a) Attach the 4 claws to install the video terminal.
(b) Attach the clamp to the end panel.
2. INSTALL REAR CONSOLE END PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Page 6265
Remove the blown fuse and disconnect all loads of the fuse.
Connect a test light in place of the fuse.
Establish conditions in which the test light comes on.
Example:
- [A] - Ignition SW on
- [B] - Ignition SW and SW1 on
- [C] - Ignition SW, SW1 and Relay on (Connect the Relay) and SW2 off (or Disconnect SW2)
Disconnect and reconnect the connectors while watching the test light.
Page 2667
4. CONNECT OUTLET RADIATOR HOSE See: Thermostat/Service and Repair/Installation
5. INSTALL FAN SHROUD
(a) Install the fan shroud See: Radiator Cooling Fan/Service and Repair/Installation.
Page 4164
Page 6982
General Information
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: GENERAL
INFORMATION
* A large number of ECU controlled systems are used in the TOYOTA TUNDRA. In general, ECU
controlled systems are considered to be very intricate, requiring a high level of technical knowledge
to troubleshoot. However, most problem checking procedures only involve inspecting the ECU
controlled system's circuits one by one. An adequate understanding of the system and a basic
knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and
necessary repairs.
1. TROUBLESHOOTING PROCEDURES
* The troubleshooting procedures consist of diagnosis procedures for when a DTC is stored and
diagnosis procedures for when no DTC is stored. The basic idea is explained in the following table.
* Vehicle systems are complex and use many ECUs that are difficult to inspect independently.
Therefore, a process of elimination is used, where components that can be inspected individually
are inspected, and if no problems are found in these components, the related ECU is identified as
the problem and replaced.
* It is extremely important to ask the customer about the environment and the conditions present
when the problem occurred (Customer Problem Analysis). This makes it possible to simulate the
conditions and confirm the symptom. If the symptom cannot be confirmed or the DTC does not
recur, the malfunctioning part may not be identified using the troubleshooting procedure, and the
ECU for the related system may be replaced even though it is not defective. If this happens, the
original problem will not be solved.
* In order to prevent endless expansion of troubleshooting procedures, the troubleshooting
procedures are written with the assumption that multiple malfunctions do not occur simultaneously
for a single problem symptom.
* To identify the malfunctioning part, troubleshooting procedures narrow down the target by
separating components, ECUs and wire harnesses during the inspection. If the wire harness is
identified as the cause of the problem, it is necessary to inspect not only the connections to
components and ECUs but also all of the wire harness connectors between the component and the
ECU.
DIAGNOSTIC TESTER
2. DESCRIPTION
System data and the Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector
3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the Techstream* to
check for a malfunction and perform repairs.
HINT *: Techstream is the name for the diagnostic tester in North America.
3. DATA LINK CONNECTOR 3 (DLC3)
(a) The vehicle's ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of
the DLC3 complies with SAE J1962 and
matches the ISO 15765-4 format.
Components
Power Steering Pressure Switch: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: POWER STEERING OIL PRESSURE SWITCH:
COMPONENTS
Page 7368
3. REMOVE REAR SHOCK ABSORBER ASSEMBLY LH
(a) Support the rear axle housing with a jack using a wooden block to avoid damage.
(b) Remove the bolt and nut on the lower side of the shock absorber.
(c) While holding the piston rod, remove the nut, retainer, No. 1 cushion and shock absorber.
(d) Remove the 2 retainers and No. 3 cushion from the shock absorber.
Installation
SUSPENSION: REAR SHOCK ABSORBER: INSTALLATION
HINT *
Use the same procedures for the RH side and LH side.
* The procedures listed below are for the LH side.
* A bolt without a torque specification is shown in the standard bolt chart See:
Specifications/Mechanical Specifications/Standard Bolt - Specified Torque For Standard Bolts
1. TEMPORARILY INSTALL REAR SHOCK ABSORBER ASSEMBLY LH
(a) Install the 2 retainers and No. 3 cushion to the shock absorber.
Page 694
Power Mirror Switch: Service and Repair Installation
MIRROR: OUTER MIRROR SWITCH: INSTALLATION
1. INSTALL OUTER MIRROR SWITCH ASSEMBLY
(a) Attach the 2 claws to install the outer mirror switch.
2. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column
Shift Type)/Installation
Page 498
Steering Column Control Module: Service and Repair Installation
STEERING COLUMN: MULTIPLEX TILT AND TELESCOPIC ECU (for Power Tilt and Power
Telescopic Steering Column): INSTALLATION
1. INSTALL MULTIPLEX TILT AND TELESCOPIC ECU
(a) Install the ECU with the 2 screws.
Torque : 1.5 Nm (15 kgf-cm, 13 in-lbf)
(b) Connect the 2 ECU connectors.
2. INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY See: Steering and Suspension/Steering/Steering
Column/Service and Repair/Removal and
Replacement/Steering Column Assembly (for Power Tilt and Power Telescopic Steering
Column)/Removal
3. INSTALL LOWER NO. 1 INSTRUMENT PANEL AIR BAG ASSEMBLY See: Restraint
Systems/Air Bag Systems/Air Bag/Service and
Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Installation
4. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Floor Shift Type)/Removal
5. INSTALL HOOD LOCK CONTROL LEVER SUB-ASSEMBLY See: Body and Frame/Doors,
Hood and Trunk/Hood/Hood Latch Release
Cable/Service and Repair/Installation
6. INSTALL LOWER STEERING COLUMN COVER
(a) Attach the 2 claws to install the steering column lower cover.
7. INSTALL UPPER STEERING COLUMN COVER
Page 2148
Tire Pressure Monitor Receiver / Transponder: Service and Repair Installation
TIRE AND WHEEL: TIRE PRESSURE WARNING RECEIVER: INSTALLATION
1. INSTALL TIRE PRESSURE WARNING ANTENNA AND RECEIVER
(a) Install the receiver with the bolt.
Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
(b) Connect the receiver connector.
2. INSTALL ROOF HEADLINING ASSEMBLY
(a) for Regular Cab:
Install the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Installation.
(b) for Double Cab:
Install the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Double Cab)/Installation.
(c) for CrewMax:
Install the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (for CrewMax)/Installation.
Page 4165
Page 6326
MJ1-NP1
Page 6034
Page 7968
(a) Check the function of SST See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
(b) Remove the front seat side airbag See: Removal and Replacement/Front Seat Side Airbag
Assembly (for Fold Down Seat Type)/Removal.
(c) Using a service-purpose wire harness for the vehicle, tie down the front seat side airbag to the
tire.
Wire harness:
Stripped wire harness section
1.25 mm2 or more (0.00193 in.2 or more)
CAUTION: If the wire harness is too thin or an alternative object is used to tie down the curtain
shield airbag, it may be snapped by the shock when the airbag is deployed. Always use a wire
harness for vehicle use with an area of at least 1.25 mm2 (0.00193 in.2).
HINT To calculate the area of the stripped wire harness section:
Area = 3.14 x (Diameter)2 divided by 4
(1) Install the 2 nuts to the front seat side airbag.
(2) Wind the wire harness around the stud bolts of the front seat side airbag as shown in the
illustration.
(3) Position the front seat side airbag inside the tire.
Page 5067
10. INSTALL FRONT DIFFERENTIAL CASE BEARING
HINT When replacing the 2 differential case bearings, fit the thinnest washer to each bearing.
When reusing the bearings, fit a washer of the same thickness as the one removed to each
bearing.
(a) Install a new plate washer to the side bearing retainer.
(b) Using SST and a press, install the bearing (outer race) onto the differential case bearing
retainer.
SST : 09950-60020
09951-00890
SST : 09950-70010
09951-07150
(c) Install a new plate washer onto the differential carrier.
(d) Using SST and a press, press in the bearing (outer race) onto the differential carrier assembly.
SST : 09950-60020
09951-00890
SST : 09950-70010
09951-07150
11. INSTALL FRONT DRIVE PINION FRONT RADIAL BALL BEARING
(a) Using SST, install the bearing (outer race).
SST : 09950-60020
Locations
Manifold Pressure/Vacuum Sensor: Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 6742
J/B No.5 - Instrument Panel Center
Page 6201
7. REMOVE REAR POWER OUTLET SOCKET COVER (for Double Cab)
(a) Detach the 2 claws and remove the power outlet socket cover.
Installation
OTHER SYSTEM: CENTER POWER OUTLET SOCKET (for Floor Shift Type): INSTALLATION
1. INSTALL REAR POWER OUTLET SOCKET COVER (for Double Cab)
(a) Attach the 2 claws to install the power outlet socket cover.
2. INSTALL REAR POWER OUTLET SOCKET ASSEMBLY (for Double Cab)
(a) Attach the claw to install the power outlet socket.
3. INSTALL REAR CONSOLE END PANEL SUB-ASSEMBLY (for Double Cab) See: Body and
Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Floor Shift Type)/Installation
4. INSTALL POWER OUTLET SOCKET COVER
(a) Attach the 2 claws to install the power outlet socket cover.
5. INSTALL POWER OUTLET SOCKET ASSEMBLY
Door Control Receiver (for CrewMax)
Keyless Entry Module: Service and Repair Door Control Receiver (for CrewMax)
Components
DOOR LOCK: DOOR CONTROL RECEIVER (for CrewMax): COMPONENTS
Removal
DOOR LOCK: DOOR CONTROL RECEIVER (for CrewMax): REMOVAL
1. REMOVE BACK PANEL TRIM RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for
CrewMax)/Removal
Components
Parking Assist Switch: Service and Repair Components
PARK ASSIST / MONITORING: CLEARANCE SONAR MAIN SWITCH: COMPONENTS
Page 4570
Crankshaft Position Sensor: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: CRANKSHAFT POSITION SENSOR: INSTALLATION
1. INSTALL CRANKSHAFT POSITION SENSOR
(a) Install the sensor with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(b) Connect the sensor connector.
2. INSTALL CRANKSHAFT POSITION SENSOR PROTECTOR
(a) Install the sensor protector with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
Page 8049
Locations
Hood Sensor/Switch (For Alarm): Locations
THEFT DETERRENT: THEFT DETERRENT SYSTEM: PARTS LOCATION
Page 190
Establish conditions in which voltage is present at the check point.
Example:
- [A] - Ignition SW on
- [B] - Ignition SW and SW1 on
- [C] - Ignition SW, SW1 and Relay on (SW2 off)
Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or component terminal.
This check can be done with a test light instead of a voltmeter.
Electronic Circuit Inspection Procedure
Page 6132
Accessory Relay: Diagrams
Page 6907
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Page 7981
(a) Check the SRS warning light See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
Components
SUPPLEMENTAL RESTRAINT SYSTEM: FRONT PASSENGER AIRBAG ASSEMBLY:
COMPONENTS
Removal
SUPPLEMENTAL RESTRAINT SYSTEM: FRONT PASSENGER AIRBAG ASSEMBLY:
REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt
Components
Transmission Cooler: Service and Repair Components
A760F AUTOMATIC TRANSMISSION: OIL COOLER: COMPONENTS
Page 1505
Ignition Switch: Service and Repair Installation
1UR-FE STARTING: IGNITION SWITCH: INSTALLATION
1. INSTALL IGNITION SWITCH ASSEMBLY
(a) Attach the 2 claws to install the ignition switch to the steering lock.
2. INSTALL UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Manual Tilt)
See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering Column Assembly
(for Manual Tilt)/Reassembly
3. INSTALL UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Manual Tilt
and Manual Telescopic Steering Column)
See: Steering and Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering
Column Assembly (for Manual Tilt and Manual Telescopic Steering Column)/Reassembly
4. INSTALL UPPER STEERING COLUMN WITH SWITCH BRACKET ASSEMBLY (for Power Tilt
and Power Telescopic Steering Column)
See: Steering and Suspension/Steering/Steering Column/Service and Repair/Overhaul/Steering
Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Reassembly
5. INSTALL STEERING COLUMN ASSEMBLY
(a) for Manual Tilt:
Install the steering column See: Steering and Suspension/Steering/Steering Column/Service and
Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Installation.
(b) for Manual Tilt and Manual Telescopic Steering Column:
Install the steering column See: Steering and Suspension/Steering/Steering Column/Service and
Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt and Manual
Telescopic Steering Column)/Installation.
(c) for Power Tilt and Power Telescopic Steering Column:
Install the steering column See: Steering and Suspension/Steering/Steering Column/Service and
Repair/Removal and Replacement/Steering Column Assembly (for Power Tilt and Power
Telescopic Steering Column)/Installation.
6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Locations
Engine Temperature Sensor: Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 8549
Central Control Module: Service and Repair Installation
AUDIO / VISUAL: MULTI-MEDIA INTERFACE ECU: INSTALLATION
1. INSTALL MULTI-DISPLAY CONTROLLER BRACKET A
(a) Install the multi-display controller bracket A with the 2 bolts.
Torque : 2.0 Nm (20 kgf-cm, 17 in-lbf)
2. INSTALL MULTI-MEDIA INTERFACE ECU
(a) Connect the connector.
(b) Install the multi-media interface ECU with the nut.
Torque : 8.0 Nm (81 kgf-cm, 70 in-lbf)
3. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY
(a) for Column Shift Type:
Install the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column
Shift Type)/Installation.
(b) for Floor Shift Type:
Install the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation.
4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Air Conditioning System (for Automatic Air Conditioning
System)
Control Module HVAC: Locations Air Conditioning System (for Automatic Air Conditioning System)
AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Automatic Air Conditioning System):
PARTS LOCATION
Page 895
Variable Valve Timing Actuator Position Sensor: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: VVT SENSOR: INSTALLATION
1. INSTALL VVT SENSOR
(a) Install the 4 sensors with the 4 bolts.
Page 1324
(2) Disconnect connector B and measure the resistance.
Standard resistance (Fig. 7):
* If the results match the examples above, a short circuit exists between terminal 1 of connector B2
and terminal 1 of connector C.
4. CHECK AND REPLACE ECU
NOTICE: *
The connector should not be disconnected from the ECU. Perform the inspection from the backside
of the connector on the wire harness side.
* When no measuring condition is specified, perform the inspection with the engine stopped and
the ignition switch ON.
* Check that the connectors are fully seated. Check for loose, corroded or broken wires.
(a) First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be
faulty. Temporarily replace the ECU with a
normally functioning one and check if the symptoms occur. If the trouble symptoms disappear,
replace the original ECU.
(1) Measure the resistance between the ECU ground terminal and body ground.
Standard resistance:
Below 1 Ohms
(2) Disconnect the ECU connector. Check the ground terminal on the ECU side and wire harness
side for bending, corrosion or foreign matter.
Lastly, check the contact pressure of the female terminals.
Page 414
Oxygen Sensor Relay: Testing and Inspection
1UR-FE ENGINE CONTROL SYSTEM: A/F SENSOR HEATER RELAY: ON-VEHICLE
INSPECTION
1. REMOVE INTEGRATION RELAY See: Relays and Modules - Ignition System/Ignition
Relay/Testing and Inspection
2. INSPECT INTEGRATION RELAY (A/F)
NOTICE: *
Some relays are built into the integration relay. The integration relay cannot be disassembled. If
there is a malfunction in the circuit of the integration relay, replace the integration relay.
* The internal circuit of the integration relay is as shown in the illustration below. Inspect the
integration relay using the following procedures.
(a) Measure the resistance of the A/F fuse.
(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(2) If the result is not as specified, replace the A/F fuse.
(b) Measure the resistance of the A/F sensor heater relay.
(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
Page 9117
Establish conditions in which voltage is present at the check point.
Example:
- [A] - Ignition SW on
- [B] - Ignition SW and SW1 on
- [C] - Ignition SW, SW1 and Relay on (SW2 off)
Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or component terminal.
This check can be done with a test light instead of a voltmeter.
Electronic Circuit Inspection Procedure
Page 1380
Impact Sensor: Testing and Inspection Front Airbag Sensor
SUPPLEMENTAL RESTRAINT SYSTEM: FRONT AIRBAG SENSOR: ON-VEHICLE
INSPECTION
1. CHECK FRONT AIRBAG SENSOR (VEHICLE NOT INVOLVED IN COLLISION)
(a) Perform a diagnostic system check See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
2. CHECK FRONT AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS
NOT DEPLOYED)
(a) Perform a diagnostic system check See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
(b) When the front bumper of the vehicle or its area is damaged, check if there is any damage to
the front airbag sensor. If the front airbag sensor
has defects as mentioned below, replace it with a new one:
* Cracks, dents or chips on the sensor housing.
* Cracks or other damage to the connector.
* Peeling off of the label or damage to the serial number.
CAUTION: For removal and installation procedures of the front airbag sensor, be sure to follow the
correct procedure.
3. CHECK FRONT AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS
DEPLOYED)
(a) Replace the front airbag sensor.
CAUTION: *
For removal and installation procedures of the front airbag sensor, be sure to follow the correct
procedure.
* If the airbags have deployed, replace the front airbag sensor on the side in which the collision
occurred. Replace both if necessary.
Air Conditioning System (for Automatic Air Conditioning
System)
Blower Motor: Locations Air Conditioning System (for Automatic Air Conditioning System)
AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Automatic Air Conditioning System):
PARTS LOCATION
Page 172
Symbols Used Within Diagrams
Symbols Used Within Diagrams
Engine Controls - Techstream(R) ECU Re-Flash
Procedure
Engine Control Module: All Technical Service Bulletins Engine Controls - Techstream(R) ECU
Re-Flash Procedure
T-SB-0064-10
February 4, 2010
Techstream ECU Flash Reprogramming Procedure
Service Category Engine/Hybrid System
Section Engine Control
Market USA
Applicability
TSB SUPERSESSION NOTICE
The information contained in this TSB supersedes TSB No. SS002-07.
^ Applicability has been updated to include 2009 - 2011 model year Toyota vehicles.
^ A new section, Techstream Preparation, has been added.
^ Techstream Lite has been added as an option in Required Tools & Materials.
^ Process Overview and Operation Procedure sections have been updated.
TSB No. SS002-07 is Obsolete and any printed versions should be discarded. Be sure to review
the entire content of this service bulletin before proceeding.
Introduction
Flash reprogramming allows the ECU software to be updated without replacing the ECU. Flash
calibration updates for specific vehicle models/ECUs are released as field-fix procedures described
in individual service bulletins. This bulletin details the Techstream ECU flash reprogramming
process and outlines use of the Technical Information System (TIS) and the Calibration Update
Wizard (CUW). Flash calibration updates can only be applied to the vehicle/ECU combination for
which they are intended. ECUs have internal security that will not allow them to be programmed
with another ECU's information.
ECU
Electronic Control Unit (ECU) is a Toyota term used to describe integrated computerized devices
responsible for managing the operation of a system or subsystem. For the purposes of this bulletin,
the term "ECU" is used as a generic label for the following SAE J1930 standard references:
^ Powertrain Control Module (PCM)
Page 6671
Diode: Diagrams Diode (Ignition)
Page 3441
(a) Reconnect the J86 No. 1 junction connector connector.
NEXT -- Continue to next step.
4. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (NO. 2 JUNCTION CONNECTOR SIDE)
(a) Disconnect the J113 No. 2 junction connector connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- CHECK FOR SHORT TO B+ IN CAN BUS WIRE (NO. 2 JUNCTION CONNECTOR - AIR
CONDITIONING AMPLIFIER) OK -- Continue to next step.
5. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (NO. 1 JUNCTION CONNECTOR - NO. 2
JUNCTION CONNECTOR)
(a) Disconnect the J94 No. 1 junction connector connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
Page 9336
This TSB applies to all Sequoia and Tundra vehicles equipped with lUR-FE (4.6L) 2UZ-FE (4.7L)
and 3UR-FE/FBE (5.7L) engines produced BEFORE the Production Change Effective VINs shown.
Repair Procedure
1. Remove and replace the air cleaner lid.
2. Remove and replace the front right hand (RH) fender liner.
Page 5946
Ignition Switch: Diagnostic Aids
Continuity and Resistance Check
CONTINUITY AND RESISTANCE CHECK
Disconnect the battery terminal or wire so there is no voltage between the check points.
Contact the two leads of an ohmmeter to each of the check points.
Page 9212
Page 5571
Page 5425
Control Module: Diagrams
Page 5033
HINT Measure at 3 or more positions around the circumference of the ring gear.
(b) If the backlash is not within the specification, adjust or repair the side bearing preload as
necessary.
4. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH
(a) Using a dial indicator, measure the side gear backlash while holding one pinion gear toward the
case.
Standard backlash:
0.05 to 0.20 mm (0.00197 to 0.00788 in.)
(b) If the backlash is not within the specified value, replace the side gear thrust washer with one of
a different thickness.
5. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD
(a) Using a torque wrench, measure the preload of the backlash between the drive pinion and ring
gear.
Standard drive pinion preload (at starting):
0.85 to 1.37 N*m (9 to 13 kgf*cm, 8 to 12 in.*lbf)
(b) If necessary, disassemble and inspect the differential.
6. INSPECT TOTAL PRELOAD
(a) Using a torque wrench, measure the total preload with the teeth of the drive pinion and ring
gear in contact.
Standard total preload (at starting):
Standard drive pinion preload plus 0.24 to 0.46 N*m (3 to 4 kgf*cm, 3 to 4 in.*lbf)
(b) If necessary, disassemble and inspect the differential.
Page 3551
INSPECTION PROCEDURE
HINT Operating the ignition switch, any switches or any doors triggers related ECU and sensor
communication with the CAN, which causes resistance variation.
PROCEDURE
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
(a) Disconnect the cable from the negative (-) battery terminal before measuring the resistances of
the main wire and the branch wire.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
NEXT -- Continue to next step.
2. CHECK FOR OPEN IN CAN BUS WIRE (STEERING ANGLE SENSOR BRANCH WIRE)
(a) Disconnect the J6 steering angle sensor connector.
Page 7979
(a) Check the SRS warning light See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
Components
SUPPLEMENTAL RESTRAINT SYSTEM: DRIVER SIDE KNEE AIRBAG ASSEMBLY:
COMPONENTS
Removal
SUPPLEMENTAL RESTRAINT SYSTEM: DRIVER SIDE KNEE AIRBAG ASSEMBLY: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to disable the SRS system.
2. REMOVE FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Removal
3. REMOVE FRONT DOOR SCUFF PLATE LH (for Double Cab, CrewMax) See: Body and
Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Removal
4. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Removal
5. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal
6. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Removal
7. REMOVE LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY
(a) Remove the 4 bolts and remove the instrument panel airbag.
Page 486
Starter Relay: Testing and Inspection
1UR-FE STARTING: STARTER RELAY: ON-VEHICLE INSPECTION
1. REMOVE STARTER RELAY (ST)
(a) Remove the engine room relay box cover.
(b) Remove the starter relay from the engine room relay block.
2. INSPECT STARTER RELAY
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) If the result is not as specified, replace the relay.
3. INSTALL STARTER RELAY
Page 4774
Parts Information
Required Tools & Equipment
Repair Procedure
1. Confirm the condition matches the Introduction.
Page 4128
Page 2773
M. Turn ignition OFF for a minimum of 10 seconds. Then click Next.
N. Turn ignition to the ON position. Then click Next.
0. Confirm all calibrations were updated as specified in the service bulletin. Then click Finish.
Emissions - MIL ON/Multiple Air Injection DTC's Set
Air Injection Check Valve: Customer Interest Emissions - MIL ON/Multiple Air Injection DTC's Set
T-SB-0350-09
Rev1
October 1, 2009
Air Injection Pump With Water Intrusion: MIL "ON" DTC P04181P0419 and/or P244 #
Service Category Engine/Hybrid System
Section Engine Control
Market USA
Applicability
TSB REVISION NOTICE
May 21, 2010 Rev1:
^ DTCs P0418 and P0419 have been added to the TSB.
^ The Applicable Warranty has been updated in the Warranty Information section. Any previous
printed versions of this service bulletin should be discarded.
Introduction
Some 2010 model year Tundra vehicles built in the Texas plant may exhibit a MIL "ON" condition
with Diagnostic Trouble Code (DTC) P0418, P0419, P2440, P2441, P2442, P2443, P2446, and/or
P2447. This concern may be caused by water intrusion into the air injection pump assembly. Use
the following procedure to address this condition.
Parts Information
Production Change Information
Page 4162
Service and Repair
Air Bag(s) Arming and Disarming: Service and Repair
Air Bag(s) Arming and Disarming
Before starting work, wait at least 90 seconds after the ignition switch is turned OFF and after the
cable of the negative (-) battery terminal is disconnected. (SRS parts are equipped with a backup
power source. If work is started within 90 seconds of turning the ignition switch OFF and
disconnecting the cable from the negative (-) battery terminal, SRS parts may deploy.)
Components
Hood Latch Release Cable: Service and Repair Components
ENGINE HOOD / DOOR: HOOD LOCK CONTROL CABLE ASSEMBLY: COMPONENTS
Page 1038
Cargo Lamp Switch: Diagrams
Engine - Controls - Non-Linear Acceleration From A Stop
PROM - Programmable Read Only Memory: Customer Interest Engine - Controls - Non-Linear
Acceleration From A Stop
T-SB-0273-10
September 28, 2010
Non-Linear Acceleration from a Stop
Service Category Engine/Hybrid System
Section Engine Control
Market USA
Applicability
Introduction
Some 2010 model year Tundra vehicles with the 1UR-FE (4.6 L) engine may exhibit non-linear
acceleration from a stop under certain conditions of low engine rpm with high engine load. The
Engine Control Module/ECM (SAE term: Powertrain Control Module/PCM) logic has been revised
to address this condition. Use the following repair procedure to recalibrate the ECM (PCM).
Calibration Information
Warranty Information
Applicable Warranty
^ This repair is covered under the Toyota Federal Emission Warranty. This warranty is in effect for
96 months or 80,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Components
Fuel Pump Control Unit: Service and Repair Components
1UR-FE FUEL: FUEL PUMP ECU: COMPONENTS
Page 1473
Use a volt/ohmmeter with high impedance (10 kohms/V minimum) for troubleshooting of the
electrical circuit.
Disconnection of Male and Female Connectors
DISCONNECTION OF MALE AND FEMALE CONNECTORS
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Finding A Short Circuit
FINDING A SHORT CIRCUIT
Page 285
4. SYMPTOM CONFIRMATION AND DTC (INCLUDING FREEZE FRAME DATA) CHECK
(a) Visually check the wire harnesses, connectors and fuses for open and short circuits.
(b) Warm up the engine to the normal operating temperature.
(c) Confirm the problem symptoms and conditions, and check for DTCs.
B -- Go to step 6 A -- Continue to next step.
5. DTC CHART
(a) Check the results obtained in the DTC check. Then find the output DTC in the DTC chart. Look
at the "Trouble Area" column for a list of
potentially malfunctioning circuits and / or parts.
NEXT -- Go to step 7
6. PROBLEM SYMPTOMS TABLE
(a) Check the results obtained in the symptom confirmation. Then find the problem symptoms in
the problem symptoms table. Look at the
"Suspected Area" column for a list of potentially malfunctioning circuits and / or parts.
NEXT -- Continue to next step.
7. CIRCUIT INSPECTION OR PARTS INSPECTION
(a) Confirm the malfunctioning circuit or part.
NEXT -- Continue to next step.
8. ADJUST, REPAIR OR REPLACE
(a) Adjust, repair or replace the malfunctioning circuit or parts.
NEXT -- Continue to next step.
9. CONFIRMATION TEST
(a) After the adjustment, repairs or replacement, confirm that the malfunction no longer exists. If the
malfunction does not reoccur, perform a
confirmation test under the same conditions and in the same environment as when the malfunction
occurred the first time.
NEXT -- END
2. CUSTOMER PROBLEM ANALYSIS
HINT *
In troubleshooting, confirm that the problem symptoms have been accurately identified.
Preconceptions should be discarded in order to make an accurate judgment. To clearly understand
what the problem symptoms are, it is extremely important to ask the customer about the problem
and the conditions at the time the malfunction occurred.
* Gather as much information as possible for reference. Past problems that seem unrelated may
also help in some cases.
* The following 5 questions are important points in the problem analysis:
Page 8500
6. INSTALL LUGGAGE COMPARTMENT BOX RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof
Headlining (For Regular Cab)/Installation
7. INSTALL LUGGAGE COMPARTMENT BOX LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof
Headlining (For Regular Cab)/Installation
8. INSTALL UPPER BACK PANEL GARNISH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining
(For Regular Cab)/Installation
Page 2718
(a) Remove the 4 bolts, 4 nuts, lower monolithic converter protector, upper monolithic converter
protector, 2 No. 1 converter protector stays and 2
No. 2 converter protector stays.
11. REMOVE NO. 1 MONOLITHIC CONVERTER PROTECTOR (for Bank 1)
(a) Remove the 4 bolts, 4 nuts, lower No. 1 monolithic converter protector, upper No. 1 monolithic
converter protector and 4 No. 1 converter
protector stays.
12. REMOVE MONOLITHIC CONVERTER PROTECTOR (for Bank 2)
(a) Remove the 4 bolts, 4 nuts, lower monolithic converter protector, upper monolithic converter
protector, 2 No. 1 converter protector stays and 2
No. 2 converter protector stays.
13. REMOVE NO. 1 MONOLITHIC CONVERTER PROTECTOR (for Bank 2)
(a) Remove the 4 bolts, 4 nuts, lower No. 1 monolithic converter protector, upper No. 1 monolithic
converter protector and 4 No. 1 converter
protector stays.
Installation
1UR-FE EXHAUST: EXHAUST PIPE (except Regular Cab Standard Deck): INSTALLATION
1. INSTALL MONOLITHIC CONVERTER PROTECTOR (for Bank 1)
(a) Install the 2 No. 1 converter protector stays and 2 No. 2 converter protector stays.
(b) Install the 2 monolithic converter protectors with the 4 bolts and 4 nuts.
Torque : 11 Nm (107 kgf-cm, 8 ft-lbf)
HINT Install the monolithic converter protector within the angle range specified in the illustration.
2. INSTALL NO. 1 MONOLITHIC CONVERTER PROTECTOR (for Bank 1)
Page 7493
Tire Pressure Sensor: Diagrams
Page 1182
Knock Sensor: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: INSTALLATION
1. INSTALL KNOCK SENSOR
(a) Install the 4 sensors with the 4 bolts so that the sensors are angled as shown in the illustration.
Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)
NOTICE: The acceptable installation angle of the sensor is between 10° upward and downward
from the horizontal position.
(b) Connect the 4 sensor connectors.
2. INSTALL SEPARATOR CASE
(a) Install the separator case with the 4 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
3. INSTALL INTAKE MANIFOLD
(a) Install the intake manifold See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service
and Repair/Installation.
Page 6701
Symbols Used Within Diagrams
Symbols Used Within Diagrams
Page 9253
HINT Tape the screwdriver tip before use.
2. REMOVE REAR UPPER DOOR ARMREST BASE PANEL LH
(a) Using a screwdriver, detach the 2 clips and rear upper door armrest base panel. Then
disconnect the connector.
HINT Tape the screwdriver tip before use.
3. REMOVE REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY
(a) Detach the 4 claws and remove the power window regulator switch.
4. REMOVE REAR DOOR FRAME GARNISH LH
(a) Detach the 4 clips and remove the rear door frame garnish.
5. REMOVE COURTESY LIGHT ASSEMBLY
(a) Detach the claw and remove the courtesy light from the door trim.
Page 7761
(c) Remove the instrument panel reinforcement.
(1) for Driver Side:
Remove the 3 bolts and 3 caps.
(2) for Passenger Side:
Using a T40 "TORX" socket, remove the 2 "TORX" bolts.
HINT When removing the bolts, the collars may come off with the bolts.
(3) for Passenger Side:
Using a 12 mm hexagon wrench, remove the 2 collars.
Page 6534
when inserting and after full engagement.
NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal.
(d) REPAIR METHOD OF CONNECTOR TERMINAL
(1) If there is any foreign matter on the terminal, clean the contact point using an air gun or cloth.
Never rub the contact point using sandpaper
as the plating may come off.
(2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is
gold-plated (gold color), use a gold-plated female
terminal; if it is silver-plated (silver color), use a silver-plated female terminal.
(3) Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock
into the housing, the housing may have to be
replaced.
(e) HANDLING OF WIRE HARNESS
(1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be
restored in the same way.
(2) Never twist, pull or slacken the wire harness more than necessary.
(3) The wire harness should never come into contact with a high temperature part, or rotating,
moving, vibrating or sharp-edged parts. Avoid
contact with panel edges, screw tips and other sharp items.
(4) When installing parts, never pinch the wire harness.
(5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with
vinyl tape.
2. CHECK FOR OPEN CIRCUIT
Page 3488
NG -- REPAIR OR REPLACE CAN BRANCH WIRE OR CONNECTOR (AIR CONDITIONING
AMPLIFIER)
OK -- REPLACE AIR CONDITIONING AMPLIFIER ASSEMBLY
Problem Symptoms Table
CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: PROBLEM SYMPTOMS TABLE
HINT *
Use the table below to help determine the cause of problem symptoms. If multiple suspected areas
are listed, the potential causes of the symptoms are listed in order of probability in the "Suspected
Area" column of the table. Check each symptom by checking the suspected areas in the order they
are listed. Replace parts as necessary.
* Inspect the fuses and relays related to this system before inspecting the suspected areas below.
Components
Knock Sensor: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: COMPONENTS
Locations
Ignition Relay: Locations
MULTIPLEX COMMUNICATION: LIN COMMUNICATION SYSTEM: PARTS LOCATION
Page 6212
Installation
OTHER SYSTEM: POWER OUTLET SOCKET (for CrewMax Floor Shift Type): INSTALLATION
1. INSTALL REAR POWER POINT SOCKET (for AC Power Supply)
(a) Attach the 2 claws to install the power outlet socket.
2. INSTALL REAR POWER OUTLET SOCKET COVER (for Standard)
(a) Attach the 2 claws to install the power outlet socket cover.
3. INSTALL REAR POWER OUTLET SOCKET (for Standard)
(a) Attach the claw to install the power outlet socket.
4. INSTALL CONSOLE BOX BEZEL
Page 6052
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: ELECTRONIC
CIRCUIT INSPECTION PROCEDURE
1. BASIC INSPECTION
(a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS
(1) Unless otherwise stated, all resistance measurements should be made at an ambient
temperature of 20°C (68°F). Resistance measurements
may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been
running. Measurements should be made after the engine has cooled down.
(b) HANDLING CONNECTORS
(1) When disconnecting a connector, first squeeze the mating halves tightly together to release the
lock, and then press the lock claw and
separate the connector.
(2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly
and separate it.
(3) Before connecting a connector, check that there are no deformed, damaged, loose or missing
terminals.
(4) When connecting a connector, press firmly until it locks with a "click" sound.
(5) If checking a connector with a TOYOTA electrical tester, check the connector from the backside
(harness side) using a mini test lead.
NOTICE: *
As a waterproof connector cannot be checked from the backside, check it by connecting a
sub-harness.
* Do not damage the terminals by moving the inserted tester needle.
(c) CHECKING CONNECTORS
(1) Checking when a connector is connected: Squeeze the connectors together to confirm that they
are fully connected and locked.
(2) Checking when a connector is disconnected: Check by pulling the wire harness lightly from the
backside of the connector. Look for
unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for
corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or
deformed terminals.
(3) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a
female terminal, and check for ample tension
Page 7370
(a) Fully extend the rear shock absorber rod.
(b) Using a drill, make a hole in the cylinder between A and B shown in the illustration to discharge
the gas inside.
CAUTION: Be careful when drilling because shards of metal may fly about. Always use the proper
safety equipment.
NOTICE: The gas is colorless, odorless and nonpoisonous.
Page 5462
Transfer Case Actuator: Locations JF1A Transfer Case
JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION
Page 6995
Driver Side J/B - Cowl Side Left
Locations
Transmission Position Switch/Sensor: Locations
A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS
LOCATION
Locations
Seat Position Sensor: Locations
SUPPLEMENTAL RESTRAINT SYSTEM: AIRBAG SYSTEM: PARTS LOCATION
Page 3710
Then click Next.
F. Verify correct current calibration and new calibration information. Then click Next.
NOTE
^ The total number of calibration IDs in the calibration file corresponds to the number of
reprogrammable processors in the ECU.
^ Each calibration file may contain up to three separate calibrations.
Components
Yaw Rate Sensor: Service and Repair Components
BRAKE CONTROL: YAW RATE AND DECELERATION SENSOR: COMPONENTS
Components
Ambient Temperature Sensor / Switch HVAC: Service and Repair Components
AIR CONDITIONING: AMBIENT TEMPERATURE SENSOR: COMPONENTS
Page 6496
J/B No.3 - Instrument Panel Right
Page 4947
Torque Converter: Testing and Inspection
A760F AUTOMATIC TRANSMISSION: TORQUE CONVERTER CLUTCH AND DRIVE PLATE:
INSPECTION
1. INSPECT TORQUE CONVERTER CLUTCH ASSEMBLY
(a) Inspect the 1-way clutch.
(1) Install SST to the inner race of the 1-way clutch.
SST : 09350-32014
09351-32020
(2) Press on the serrations of the stator with a finger and rotate it.
Check that the stator rotates smoothly when turned clockwise and locks when turned
counterclockwise.
If the results are not as specified, clean the converter and recheck the 1-way clutch. If the results
still are not as specified, replace the torque converter clutch assembly.
(b) Determine the condition of the torque converter clutch.
(1) Check that the following conditions are met:
* During the stall test or when the shift lever is in N, metallic sounds are not emitted from the torque
converter clutch.
* The 1-way clutch turns in one direction and locks in the other direction.
* The amount of powder in the ATF is not more than the sample shown in the illustration.
(2) If the results are not as specified, replace the torque converter clutch assembly.
HINT The sample illustration shows approximately 0.25 liters (0.26 US qts, 0.22 Imp. qts) of ATF
taken from a removed torque converter clutch.
Page 3545
Operating the ignition switch, any switches or any doors triggers related ECU and sensor
communication with the CAN, which causes resistance variation.
PROCEDURE
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
(a) Disconnect the cable from the negative (-) battery terminal before measuring the resistances of
the main wire and the branch wire.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
NEXT -- Continue to next step.
2. CHECK FOR OPEN IN CAN BUS WIRE (POWER STEERING ECU BRANCH WIRE)
(a) Disconnect the J101 power steering ECU connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE POWER STEERING ECU BRANCH WIRE OR CONNECTOR
(CANH, CANL) OK -- Continue to next step.
3. CHECK HARNESS AND CONNECTOR (POWER STEERING ECU - BATTERY AND BODY
GROUND)
(a) Reconnect the cable to the negative (-) battery terminal before measuring the resistances of the
main wire and the branch wire.
(b) Disconnect the J101 power steering ECU connector.
(c) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(d) Measure the voltage according to the value(s) in the table below.
Standard voltage:
Page 6920
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: ELECTRONIC
CIRCUIT INSPECTION PROCEDURE
1. BASIC INSPECTION
(a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS
(1) Unless otherwise stated, all resistance measurements should be made at an ambient
temperature of 20°C (68°F). Resistance measurements
may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been
running. Measurements should be made after the engine has cooled down.
(b) HANDLING CONNECTORS
(1) When disconnecting a connector, first squeeze the mating halves tightly together to release the
lock, and then press the lock claw and
separate the connector.
(2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly
and separate it.
(3) Before connecting a connector, check that there are no deformed, damaged, loose or missing
terminals.
(4) When connecting a connector, press firmly until it locks with a "click" sound.
(5) If checking a connector with a TOYOTA electrical tester, check the connector from the backside
(harness side) using a mini test lead.
NOTICE: *
As a waterproof connector cannot be checked from the backside, check it by connecting a
sub-harness.
* Do not damage the terminals by moving the inserted tester needle.
(c) CHECKING CONNECTORS
(1) Checking when a connector is connected: Squeeze the connectors together to confirm that they
are fully connected and locked.
(2) Checking when a connector is disconnected: Check by pulling the wire harness lightly from the
backside of the connector. Look for
unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for
corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or
deformed terminals.
(3) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a
female terminal, and check for ample tension
Page 3983
This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown.
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60
months or 60,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Op Code EG9029 or EG9024: For California specification vehicles sold, registered, and operated
in California, Connecticut, Maine, Massachusetts, New Jersey, Oregon, Pennsylvania, Rhode
Island, Vermont, and Washington, this repair is covered under the California Emission Warranty.
This warranty is in effect for 84 months or 70,000 miles, whichever occurs first, from the vehicle's
in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Wire and Wire In Engine Compartment
Multiple Junction Connector: Locations Wire and Wire In Engine Compartment
AB1-RA3
Page 6809
Multiple Junction Connector: Connector Views
Frame Wire
Page 391
Components
Cabin Temperature Sensor / Switch: Service and Repair Components
AIR CONDITIONING: ROOM TEMPERATURE SENSOR (for Automatic Air Conditioning System):
COMPONENTS
Page 3469
* If CAN communication system DTCs are output, the trouble cannot be determined solely from the
DTCs. Perform troubleshooting according to "HOW TO PROCEED WITH TROUBLESHOOTING"
See: Initial Inspection and Diagnostic Overview/CAN Communication System/How to Proceed With
Troubleshooting
(a) MULTIPLEX TILT AND TELESCOPIC ECU
HINT DTC communication uses the CAN communication system.
(b) MAIN BODY ECU
HINT DTC communication uses the CAN communication system.
(c) ECM
HINT The ECM is connected to the CAN communication system but CAN communication DTCs
are not output.
(d) SKID CONTROL ECU WITH ACTUATOR
HINT DTC communication uses the CAN communication system.
(e) COMBINATION METER ECU
HINT DTC communication uses the CAN communication system.
(f) AIR CONDITIONING AMPLIFIER
HINT DTC communication uses the CAN communication system.
(g) STEERING ANGLE SENSOR
HINT
Page 4236
Accelerator Pedal Position Sensor: Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 615
Parking Assist Switch: Service and Repair Removal
PARK ASSIST / MONITORING: CLEARANCE SONAR MAIN SWITCH: REMOVAL
1. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Panel,
Gauges and Warning Indicators/Instrument Cluster
/ Carrier/Service and Repair/Combination Meter/Removal
2. REMOVE DRIVE MONITOR SWITCH
(a) Detach the 2 claws and remove the monitor switch.
Page 3229
"Case1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (/\ Mark) and pull the terminal retainer
up to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Page 1416
(b) Check that the cable is disconnected from the battery negative (-) terminal.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
(c) Install the door airbag sensor with the screw.
Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)
NOTICE: *
If the door airbag sensor has been dropped, or there are any cracks, dents or other defects in the
case, bracket or connector, replace it with a new one.
* When installing the door airbag sensor, be careful that the SRS wiring does not interfere with
other parts and that it is not pinched between other parts.
(d) Check that there is no looseness in the installation parts of the door airbag sensor.
(e) Connect the connector.
2. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Reassembly
3. INSTALL COURTESY LIGHT ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood
and Trunk/Doors/Front Door/Service and
Repair/Front Door (for Double Cab)/Reassembly
4. INSTALL FRONT LOWER DOOR FRAME BRACKET GARNISH LH (for Front Side) See: Body
and Frame/Doors, Hood and
Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly
5. INSTALL FRONT UPPER ARMREST BASE PANEL LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Reassembly
6. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Reassembly
7. INSTALL REAR SIDE AIRBAG SENSOR
(a) Check that the ignition switch is OFF.
(b) Check that the cable is disconnected from the battery negative (-) terminal.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
(c) Install the side airbag sensor with the bolt.
A760F Automatic Transmission System
Transfer Case Actuator: Locations A760F Automatic Transmission System
A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS
LOCATION
Components
Control Module: Service and Repair Components
JF1A TRANSFER: 4WD CONTROL ECU: COMPONENTS
Service and Repair
Fuel Pressure Release: Service and Repair
1UR-FE FUEL: FUEL SYSTEM: PRECAUTION
CAUTION: *
Before working on the fuel system, disconnect the cable from the negative (-) battery terminal.
* Do not smoke or be near an open flame when working on the fuel system.
* Keep gasoline away from rubber and leather parts.
1. DISCHARGE FUEL SYSTEM PRESSURE
CAUTION: *
Do not disconnect any part of the fuel system until you have discharged the fuel system pressure.
* After discharging the fuel pressure, place a cloth or equivalent over fittings as you separate them
to reduce the risk of fuel spray on yourself or in the engine compartment.
(a) Disconnect the cable from the negative (-) battery terminal.
(b) Disconnect the 2 fuel pump ECU connectors.
(c) Connect the cable to the negative (-) battery terminal.
(d) Start the engine. After the engine has stopped on its own, turn the ignition switch OFF.
HINT DTC P0171/0174 (system too lean) may be set.
(e) Crank the engine again, then check that the engine does not start.
(f) Loosen the fuel tank cap, then discharge the pressure in the fuel tank completely.
(g) Connect the 2 fuel pump ECU connectors.
2. FUEL SYSTEM
(a) When disconnecting the high fuel pressure line, a large amount of gasoline will spill out. Follow
these procedures.
(1) Perform the "DISCHARGE FUEL SYSTEM PRESSURE" procedures above.
(2) Put a container under the connecting part of the pressure line.
(3) Slowly loosen the connection.
(4) Disconnect the connection.
(5) Plug the connection with a rubber plug.
(b) Observe these precautions when removing and installing the injectors:
Page 5393
Control Module: Diagrams
Locations
Steering Column Control Module: Locations
Instrument Panel (Floor Shift)
Instrument Panel (Column Shift)
Recall 10V017000: Accelerator Pedal Sticking
Accelerator Pedal Position Sensor: All Technical Service Bulletins Recall 10V017000: Accelerator
Pedal Sticking
VEHICLE MAKE/MODEL: MODEL YEAR(S): Toyota/Avalon 2005-2010 Toyota/Camry 2007-2010
Toyota/Corolla 2009-2010 Toyota/Corolla Matrix 2009-2010 Toyota/Highlander 2010 Toyota/ RAV4
2009-2010 Toyota/Sequoia 2008-2010 Toyota/Tundra 2007-2010 MANUFACTURER: Toyota
Motor North America, Inc.
MFR'S REPORT DATE: January 21, 2010
NHTSA CAMPAIGN ID NUMBER: 10V017000
NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Accelerator Assembly:
Pedal/Linkage
POTENTIAL NUMBER OF UNITS AFFECTED: ?
SUMMARY: Toyota is recalling certain model year 2005-2010 Avalon, model year 2007-2010
Camry, model year 2009-2010 Corolla, Corolla Matrix, RAV4, model year 2010 Highlander, model
year 2008-2010 Sequoia, and model year 2007-2010 Tundra. due to the manner in which the
friction lever interacts with the sliding surface of the accelerator pedal inside the pedal sensor
assembly, the sliding surface of the lever may become smooth during vehicle operation. In this
condition, if condensation occurs on the surface, as may occur from heater operation (without A/C)
when the pedal assembly is cold, the friction when the accelerator pedal is operated may increase,
which may result in the accelerator pedal becoming harder to depress, slower to return, or, in the
worst case, mechanically stuck in a partially depressed position.
CONSEQUENCE: The accelerator pedal may become hard to depress, slow to return to idle, or, in
the worst case, mechanically stuck in a partially depressed position, increasing the risk of a crash.
REMEDY: Toyota has not yet provided a remedy plan or an owner notification schedule. Owners
may contact Toyota at 1-800-331-4331.
NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle
Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov.
Page 1095
Page 3887
Transmission Position Switch/Sensor: Diagrams
Page 4586
DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector.
Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
Page 1831
1. Test drive the vehicle and confirm there is a harsh shift on acceleration below 20 mph and or
excessive lock-up operation at freeway speeds about 50
- 60 mph.
2. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in
Figure 1. Confirm if the ECM (PCM) calibration has
been updated. If the calibration ID listed is NOT the latest ECM (PCM) calibration - go to step 3.
3. Flash reprogram the ECM (PCM).
NOTE
^ The GR8 Battery Diagnostic Station MUST be used in Power Supply Mode to maintain battery
voltage at 13.5 volts while flash reprogramming the vehicle.
^ For details on how to use the GR8 Battery Diagnostic Station, refer to the GR8 Instruction Manual
located on the Technical Information System (TIS), Diagnostics - Battery.
Follow the procedures outlined in TSB No. T-SB-0064-10, "Techstream ECU Flash
Reprogramming Procedure", and flash the ECM (PCM) with the NEW calibration file update.
4. Start the engine and warm it up to normal operating temperature before test driving.
5. Test drive the vehicle to confirm proper vehicle operation and ECM (PCM) initial learning. Refer
to the Technical Information System (TIS) 2010
Tundra Repair Manual:
Drivetrain - Automatic Transmission/Transaxle - "A760E / A760F Automatic
Transmission/Transaxle: Automatic Transmission System: Initialization"
6. Install the Authorized Modifications Label.
A. Using a permanent marker enter the following information on the label:
^ ECM part number [Refer to the Parts Information section for the CURRENT PART NUMBER]
Page 3084
(1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be
checked by conducting a voltage check.
With each connector still connected, measure the voltage between the body ground and these
terminals (in this order): 1) terminal 1 of connector A; 2) terminal 1 of connector B; and 3) terminal
1 of connector C.
Standard voltage (Fig. 4):
* If the results match the examples above, an open circuit exists in the wire harness between
terminal 1 of connector B and terminal 1 of connector C.
3. CHECK FOR SHORT CIRCUIT
(a) If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance
check with the body ground (below).
(b) Check the resistance with the body ground.
(1) Disconnect connectors A and C and measure the resistance.
Standard resistance (Fig. 6):
HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally.
If your results match the examples above, a short circuit exists between terminal 1 of connector A
and terminal 1 of connector C.
Page 8051
Clockspring Assembly / Spiral Cable: Service and Repair Installation
SUPPLEMENTAL RESTRAINT SYSTEM: SPIRAL CABLE: INSTALLATION
1. INSTALL SPIRAL CABLE
(a) Attach the 3 claws and install the spiral cable with steering sensor.
NOTICE: When replacing the spiral cable with a new one, remove the lock pin before installing the
steering wheel.
(b) Connect the connectors to the spiral cable with steering sensor.
NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness.
2. INSTALL UPPER STEERING COLUMN COVER See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Removal and
Replacement/Steering Column Assembly (for Manual Tilt)/Installation
3. INSTALL LOWER STEERING COLUMN COVER See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Removal and
Replacement/Steering Column Assembly (for Manual Tilt)/Installation
4. ADJUST SPIRAL CABLE
(a) Check that the ignition switch is OFF.
(b) Check that the battery negative (-) terminal is disconnected.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
(c) Rotate the spiral cable with steering sensor counterclockwise slowly by hand until it feels firm.
Power Mirror Control System (w/ Memory)
Heated Mirror Switch: Locations Power Mirror Control System (w/ Memory)
MIRROR: POWER MIRROR CONTROL SYSTEM (w/ Memory): PARTS LOCATION
Page 8631
Double Cab)/Installation.
(b) for Regular Cab:
Install the front door scuff plate LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For Regular Cab)/Installation.
(c) for CrewMax:
Install the front door scuff plate LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for CrewMax)/Installation.
17. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Page 5203
NOTICE: *
Install the washer with its tapered surface facing downward.
* Install the retainer with its chamfered surface facing downward.
(b) Using SST and a press, press in the rear axle shaft.
SST : 09631-12090
SST : 09726-40010
SST : 09951-01100
NOTICE: Make sure to securely fit the bearing to the rear axle shaft.
4. INSTALL REAR AXLE SHAFT SNAP RING
(a) Using a snap ring expander, install a new snap ring.
Components
Wiper Switch: Service and Repair Components
WIPER AND WASHER: WIPER SWITCH: COMPONENTS
Page 1242
ERROR: undefined
OFFENDING COMMAND: f‘~
STACK:
Page 3883
Throttle Position Sensor: Diagrams
Page 8423
Accessory Relay: Diagrams
Page 2312
1UR-FE ENGINE MECHANICAL: CAMSHAFT (for Bank 2): REMOVAL
1. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY
(a) Remove the timing chain cover See: Engine Lubrication/Oil Pump/Service and Repair/Removal
and Replacement/Removal.
2. SET NO. 1 CYLINDER TO TDC / COMPRESSION See: Service and
Repair/Overhaul/Disassembly
3. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY LH See: Camshaft (for Bank 1)/Removal
4. REMOVE NO. 1 CHAIN TENSIONER SLIPPER LH See: Camshaft (for Bank 1)/Removal
5. REMOVE NO. 1 CHAIN VIBRATION DAMPER LH See: Camshaft (for Bank 1)/Removal
6. REMOVE NO. 1 CHAIN SUB-ASSEMBLY LH See: Camshaft (for Bank 1)/Removal
7. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY RH
(a) Move the stopper plate upward to release the lock, and push the plunger deep into the
tensioner.
(b) Move the stopper plate downward to set the lock, and insert a hexagon wrench into the stopper
plate hole.
(c) Remove the 2 bolts and chain tensioner.
8. REMOVE NO. 1 CHAIN TENSIONER SLIPPER RH
9. REMOVE NO. 1 CHAIN VIBRATION DAMPER RH
(a) Remove the 2 bolts and vibration damper.
10. REMOVE NO. 1 CHAIN SUB-ASSEMBLY RH
Page 3670
Parts Information
Calibration Information
Required Tools & Equipment
Repair Procedure
Page 6191
2. REMOVE NO. 2 CONSOLE BOX REGISTER ASSEMBLY See: Body and Frame/Seats/Service
and Repair/Overhaul/Front Seat Assembly (for
Center Seat)/Disassembly
3. REMOVE NO. 1 CONSOLE BOX REGISTER ASSEMBLY See: Body and Frame/Seats/Service
and Repair/Overhaul/Front Seat Assembly (for
Center Seat)/Disassembly
4. REMOVE NO. 2 SEATBACK LOCK CONTROL BEZEL
(a) for AC Power Supply:
Disconnect the clamp.
(b) Remove the 4 screws and bezel.
5. REMOVE REAR POWER OUTLET SOCKET (for Standard)
(a) Detach the claw and remove the power outlet socket.
6. REMOVE REAR POWER OUTLET SOCKET COVER (for Standard)
(a) Detach the 2 claws and remove the power outlet socket cover.
7. REMOVE REAR POWER POINT SOCKET (for AC Power Supply)
(a) Detach the 2 claws and remove the power outlet socket.
Page 5099
Parts Information
Required Tools & Equipment
Repair Procedure Overview
^ Confirm noise is coming from the rear of the vehicle when driving.
^ Install ChassisEAR(TM) (or equivalent) and isolate noise to the rear differential area.
^ Remove the rear differential and axle shafts.
Page 2057
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Page 8161
Page 6407
Console Box Wire
Engine Wire
Page 1403
Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to
prevent airbag and seat belt pretensioner activation.
(c) Install the door airbag sensor with the screw.
Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)
NOTICE: *
If the door airbag sensor has been dropped, or there are any cracks, dents or other defects in the
case, bracket or connector, replace it with a new one.
* When installing the door airbag sensor, be careful that the SRS wiring does not interfere with
other parts and that it is not pinched between other parts.
(d) Check that there is no looseness in the installation parts of the door airbag sensor.
(e) Connect the connector.
2. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Reassembly
3. INSTALL COURTESY LIGHT ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood
and Trunk/Doors/Front Door/Service and
Repair/Front Door (for Double Cab)/Reassembly
4. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH LH (for Front Side) See: Body
and Frame/Doors, Hood and
Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Reassembly
5. INSTALL FRONT ARMREST BASE PANEL UPPER LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Reassembly
6. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Reassembly
7. INSTALL REAR SIDE AIRBAG SENSOR
(a) Check that the ignition switch is OFF.
(b) Check that the cable is disconnected from the battery negative (-) terminal.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
(c) Install the side airbag sensor with the bolt.
Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)
NOTICE: *
If the side airbag sensor has been dropped, or there are any cracks, dents or other defects in the
case, bracket or connector, replace it with a new one.
* When installing the side airbag sensor, be careful that the SRS wiring does not interfere with
other parts and that it is not pinched between other parts.
(d) Check that there is no looseness in the installation parts of the side airbag sensor.
(e) Connect the connector.
8. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY LH (for Rear Side) See: Body and
Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation
Components
Knock Sensor: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: COMPONENTS
Locations
Switch: Locations
JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION
Page 4378
Fuel Pump Control Unit: Locations Engine Control System - SFI System
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Locations
Transmission Position Switch/Sensor: Locations
A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS
LOCATION
Page 5968
3. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE
HINT The diagnostic system in the TOYOTA TUNDRA has various functions.
* The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU
memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a
previous malfunction's DTC can be checked by a technician during troubleshooting.
* Another function is the Input Signal Check, which checks if the signals from various switches are
sent to the ECU correctly.
* By using these functions, the problem areas can be narrowed down and troubleshooting is more
effective. Diagnostic functions are incorporated in the following systems in the TOYOTA TUNDRA.
Page 4210
Page 3879
ERROR: undefined
OFFENDING COMMAND: f‘~
STACK:
Page 5870
Parking Brake Warning Switch: Diagrams
Page 8217
(1) Connect SST's red clip to the battery's positive (+) terminal and the black clip to the battery's
negative (-) terminal.
HINT Do not connect the yellow connector. The yellow connector is used to connect to the seat belt
pretensioner.
(2) Press SST activation switch and check that the LED of SST activation switch illuminates.
CAUTION: If the LED illuminates when the activation switch is not being pressed, SST may be
malfunctioning. Replace SST with a new one.
(b) Disconnect SST from the battery.
(c) Disconnect the pretensioner connector.
(1) Disconnect the cable from the negative (-) battery terminal.
(2) Remove the front door scuff plate See: Removal and Replacement/Front Seat Outer Belt
Assembly (for CrewMax)/Removal.
(3) Remove the rear door scuff plate See: Removal and Replacement/Front Seat Outer Belt
Assembly (for CrewMax)/Removal.
(4) Remove the front door opening trim weatherstrip See: Removal and Replacement/Front Seat
Outer Belt Assembly (for
CrewMax)/Removal.
(5) Remove the rear door opening trim weatherstrip.
(6) Remove the lower center pillar garnish See: Removal and Replacement/Front Seat Outer Belt
Assembly (for CrewMax)/Removal.
(7) Disconnect the pretensioner connector as shown in the illustration.
(d) Prepare SST for activation of the seat belt pretensioner.
(1) Install the floor anchor of the seat belt.
(2) Connect SST (A) to SST (B). Then connect SST (B)'s connector to the seat belt pretensioner.
Up to 11/2009
Parking Brake Warning Switch: Locations Up to 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 8577
Removal
PARK ASSIST / MONITORING: ULTRASONIC SENSOR (for Rear Side): REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE LICENSE PLATE LIGHT ASSEMBLY LH (for Resin Type Bumper) See: Body and
Frame/Bumper/Rear Bumper/Service and
Repair/Removal and Replacement/Rear Bumper (for Resin Type Bumper)/Removal
3. REMOVE LICENSE PLATE LIGHT ASSEMBLY LH (for Steel Type Bumper) See: Body and
Frame/Bumper/Rear Bumper/Service and
Repair/Removal and Replacement/Rear Bumper (for Steel Type Bumper)/Removal
Floor Speaker (for CrewMax)
Speaker: Service and Repair Floor Speaker (for CrewMax)
Components
AUDIO / VISUAL: FLOOR SPEAKER (for CrewMax): COMPONENTS
Removal
AUDIO / VISUAL: FLOOR SPEAKER (for CrewMax): REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
Page 1530
Power Steering Pressure Switch: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: POWER STEERING OIL PRESSURE SWITCH:
REMOVAL
1. REMOVE FAN AND GENERATOR V BELT
(a) Remove the fan and generator V belt See: Engine, Cooling and Exhaust/Engine/Drive Belts,
Mounts, Brackets and Accessories/Drive
Belt/Service and Repair/Removal.
2. REMOVE FRONT WHEEL
3. REMOVE FRONT FENDER APRON SEAL RH See: Engine, Cooling and Exhaust/Exhaust
System/Exhaust Manifold/Service and
Repair/Removal
4. DRAIN POWER STEERING FLUID
5. REMOVE POWER STEERING OIL PRESSURE SWITCH
(a) Disconnect the power steering oil pressure switch connector.
(b) Remove the power steering oil pressure switch.
(c) Remove the O-ring.
Page 5080
Seal packing:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
HINT Install the actuator within 10 minutes of applying seal packing.
(d) Clean the threads of the 4 bolts and retainer bolt holes with toluene or trichloroethylene.
(e) Install the actuator onto the differential tube.
(f) Apply adhesive to 2 to 3 threads of each bolt end.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
(g) Install the 4 bolts.
Torque : 21 Nm (210 kgf-cm, 15 ft-lbf)
Page 4140
IV. Background
There is a possibility that certain accelerator pedal mechanisms may in rare instances
mechanically stick in a partially depressed position or return slowly to the idle position.
Over time some accelerator pedal mechanisms may become worn. As a result of this wear
combined with certain operating and environmental conditions friction in the mechanism may
increase and intermittently result in the accelerator pedal being hard to depress slow to return or in
the worst case stick in a partially open position.
Page 8183
Page 6341
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION: Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC
terminals are touched, the IC may be destroyed by static electricity.)
When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact with the terminals of leads from the IC, etc. of the
replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown on the left.
DISCONNECT CONNECTOR
Page 8436
Removal
AUDIO / VISUAL: RADIO ANTENNA: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE ANTENNA ORNAMENT
Page 9066
when inserting and after full engagement.
NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal.
(d) REPAIR METHOD OF CONNECTOR TERMINAL
(1) If there is any foreign matter on the terminal, clean the contact point using an air gun or cloth.
Never rub the contact point using sandpaper
as the plating may come off.
(2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is
gold-plated (gold color), use a gold-plated female
terminal; if it is silver-plated (silver color), use a silver-plated female terminal.
(3) Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock
into the housing, the housing may have to be
replaced.
(e) HANDLING OF WIRE HARNESS
(1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be
restored in the same way.
(2) Never twist, pull or slacken the wire harness more than necessary.
(3) The wire harness should never come into contact with a high temperature part, or rotating,
moving, vibrating or sharp-edged parts. Avoid
contact with panel edges, screw tips and other sharp items.
(4) When installing parts, never pinch the wire harness.
(5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with
vinyl tape.
2. CHECK FOR OPEN CIRCUIT
Page 9035
Trailer Towing Part 2
Air Conditioning System (for Automatic Air Conditioning
System)
Refrigerant Pressure Sensor / Switch: Locations Air Conditioning System (for Automatic Air
Conditioning System)
AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Automatic Air Conditioning System):
PARTS LOCATION
Page 5131
3. Inspect the front differential support bolt for separation.
Repair Procedure
1. If the differential support bolt is separated perform the five steps below.
NOTE
If there is NO damage to the differential support bolt, this TSB does NOT apply. Continue diagnosis
to isolate the cause of the condition.
A. Remove the differential support bolt.
Refer to the Technical Information System (TIS) applicable model and model year Repair Manual:
B. Clean the bracket and surrounding area.
C. Install the NEW differential support bolt.
Refer to TIS applicable model and model year Repair Manual:
Torque: 120 N*m (1224 kgf*cm, 89 ft*lbf)
Page 8498
Removal
DOOR LOCK: DOOR CONTROL RECEIVER (for Regular Cab): REMOVAL
1. REMOVE UPPER BACK PANEL GARNISH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining
(For Regular Cab)/Removal
2. REMOVE LUGGAGE COMPARTMENT BOX LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof
Headlining (For Regular Cab)/Removal
3. REMOVE LUGGAGE COMPARTMENT BOX RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof
Headlining (For Regular Cab)/Removal
4. REMOVE FRONT DOOR SCUFF PLATE RH
Page 7751
Page 6829
Page 8967
Remote Switch: Testing and Inspection
AUDIO / VISUAL: STEERING PAD SWITCH: INSPECTION
1. INSPECT STEERING PAD SWITCH ASSEMBLY
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the steering pad switch assembly.
Page 7610
Step 4. Remove the cover by sliding up while pulling toward you
Step 5. Remove the filter cover.
Page 2144
Tire Pressure Monitor Receiver / Transponder: Diagrams
Page 9149
Page 5318
Shift Interlock Control Module: Diagrams
Components
Engine Temperature Sensor: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: ENGINE COOLANT TEMPERATURE SENSOR:
COMPONENTS
Page 1099
Telescopic Steering Column)/Installation
8. INSTALL LOWER STEERING COLUMN COVER (for Manual Tilt) See: Steering and
Suspension/Steering/Steering Column/Service and
Repair/Removal and Replacement/Steering Column Assembly (for Manual Tilt)/Installation
9. INSTALL LOWER STEERING COLUMN COVER (for Manual Tilt and Manual Telescopic
Steering Column) See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering
Column Assembly (for Manual Tilt and Manual Telescopic Steering Column)/Installation
10. INSTALL LOWER STEERING COLUMN COVER (for Power Tilt and Power Telescopic
Steering Column) See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Removal and Replacement/Steering
Column Assembly (for Power Tilt and Power Telescopic Steering Column)/Installation
11. INSTALL STEERING WHEEL ASSEMBLY See: Steering and Suspension/Steering/Steering
Column/Service and Repair/Removal and
Replacement/Steering Column Assembly (for Power Tilt and Power Telescopic Steering
Column)/Installation
12. INSTALL STEERING PAD (w/ Steering Pad Switch) See: Restraint Systems/Air Bag
Systems/Air Bag/Service and Repair/Removal and
Replacement/Steering Pad/Installation
13. INSTALL STEERING PAD (w/o Steering Pad Switch) See: Restraint Systems/Air Bag
Systems/Air Bag/Service and Repair/Removal and
Replacement/Steering Pad/Installation
14. INSTALL LOWER NO. 3 STEERING WHEEL COVER See: Restraint Systems/Air Bag
Systems/Air Bag/Service and Repair/Removal and
Replacement/Steering Pad/Installation
15. INSTALL LOWER NO. 2 STEERING WHEEL COVER See: Restraint Systems/Air Bag
Systems/Air Bag/Service and Repair/Removal and
Replacement/Steering Pad/Installation
16. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
17. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
Page 4988
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) Apply 12 V battery voltage to the shift solenoid valve and check that the valve moves and
makes an operating noise.
OK:
(c) If the result is not as specified, replace the solenoid valve.
8. INSPECT SHIFT SOLENOID VALVE SLT
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
Page 7202
Steering Control Module: Diagrams
Locations
Tilt Wheel Switch: Locations
STEERING COLUMN: POWER TILT AND POWER TELESCOPIC STEERING COLUMN
SYSTEM: PARTS LOCATION
Specifications
Crankshaft Main Bearing: Specifications
CRANKSHAFT
Temporarily install the 10 main bearing cap bolts to the inside positions.
Insert the main bearing cap by hand until the clearance between the main bearing cap and cylinder
block is less than 6 mm (0.236 in.) by marking the 2 internal bearing cap bolts as a guide.
Bolt length.............................................................................................................................................
.........................................................91 mm (3.58 in.)
Temporarily install the 10 main bearing cap bolts to the outside positions.
Bolt length.............................................................................................................................................
......................................................79.5 mm (3.13 in.)
The main bearing cap bolts are tightened in 2 progressive steps.
Step 1:
Uniformly tighten the 20 main bearing cap bolts in the sequence shown in the illustration.
For inside position - Torque..................................................................................................................
....................................61 Nm (622 kgf-cm, 45 ft-lbf)
For outside position - Torque................................................................................................................
....................................27 Nm (275 kgf-cm, 20 ft-lbf)
If any of the main bearing cap bolts do not meet the specified torque, replace it.
Page 6772
Multiple Junction Connector: Locations Wire and Wire In Seat [Bench Seat]
JT1
JT1
Page 5727
Brake Hose/Line: Service and Repair Rear Brake Flexible Hose
Components
BRAKE: REAR BRAKE FLEXIBLE HOSE: COMPONENTS
Removal
BRAKE: REAR BRAKE FLEXIBLE HOSE: REMOVAL
HINT *
Use the same procedures for the LH side and RH side.
Page 6494
Driver Side J/B - Cowl Side Left
Page 193
(a) For an open circuit in the wire harness in Fig. 1, check the resistance or voltage, as described
below.
(b) Check the resistance.
(1) Disconnect connectors A and C and measure the resistance between them.
Standard resistance (Fig. 2):
HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally.
If the results match the examples above, an open circuit exists between terminal 1 of connector A
and terminal 1 of connector C.
(2) Disconnect connector B and measure the resistance between the connectors.
Standard resistance (Fig. 3):
* If the results match the examples above, an open circuit exists between terminal 1 of connector
B2 and terminal 1 of connector C.
(c) Check the voltage.
Page 3330
HINT The wavelength becomes shorter as engine rpm increases.
(i) WAVEFORM 8:
HINT If the waveform is not similar to the illustration, check the waveform again after idling for 10
minutes or more.
(j) WAVEFORM 9:
Page 8281
* Use the same procedures for the LH side and RH side.
* The procedures listed below are for the LH side.
1. INSTALL REAR SHOULDER BELT ANCHOR ADJUSTER ASSEMBLY
(a) Align the adjuster positioning hole with the claw, and install the adjuster with the 2 bolts.
HINT First install the upper bolt, and then install the lower bolt.
Torque : 42 Nm (428 kgf-cm, 31 ft-lbf)
2. INSTALL REAR SEAT OUTER BELT ASSEMBLY
(a) Align the vehicle's claws with the seat belt retractor positioning holes.
(b) Install the seat belt with the 2 bolts.
HINT First install bolt A, and then install bolt B.
for bolt A - Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
for bolt B - Torque : 42 Nm (428 kgf-cm, 31 ft-lbf)
(c) Install the shoulder anchor with the nut.
Torque : 42 Nm (428 kgf-cm, 31 ft-lbf)
3. INSTALL FRONT QUARTER TRIM PANEL ASSEMBLY See: Body and Frame/Interior Moulding
/ Trim/Headliner/Service and Repair/Roof
Headlining (For Double Cab)/Installation
4. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY
Page 802
Steering Angle Sensor: Locations From 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 6307
J/B No.6 Assembly Inner Circuit
Page 4010
(4) Check that air flows from port A to port B.
If the result is not as specified, replace the air switching valve.
Page 383
NG -- REPLACE RELAY OK -- Continue to next step.
3. CHECK HARNESS AND CONNECTOR (ECM - BODY GROUND)
(a) Disconnect the ECM connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR OK -- Continue to next step.
4. INSPECT ECM (IGSW VOLTAGE)
(a) Disconnect the ECM connectors.
(b) Turn the ignition switch to ON.
(c) Measure the voltage according to the value(s) in the table below.
Page 2073
(1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be
checked by conducting a voltage check.
With each connector still connected, measure the voltage between the body ground and these
terminals (in this order): 1) terminal 1 of connector A; 2) terminal 1 of connector B; and 3) terminal
1 of connector C.
Standard voltage (Fig. 4):
* If the results match the examples above, an open circuit exists in the wire harness between
terminal 1 of connector B and terminal 1 of connector C.
3. CHECK FOR SHORT CIRCUIT
(a) If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance
check with the body ground (below).
(b) Check the resistance with the body ground.
(1) Disconnect connectors A and C and measure the resistance.
Standard resistance (Fig. 6):
HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally.
If your results match the examples above, a short circuit exists between terminal 1 of connector A
and terminal 1 of connector C.
Page 5739
BRAKE CONTROL: BRAKE ACTUATOR: INSTALLATION
NOTICE: In case of replacing the skid control ECU, perform the zero point calibration of the
steering angle sensor, master cylinder pressure sensor, and yaw rate and deceleration sensor See:
Antilock Brakes / Traction Control Systems/Testing and Inspection/Programming and Relearning
1. INSTALL VSC ACTUATOR WITH ACTUATOR BRACKET ASSEMBLY
(a) Install the VSC actuator with actuator bracket with the 3 nuts.
NOTICE: Do not drop the actuator. If dropped, replace it.
(b) Tighten the 3 nuts uniformly in alphabetical order.
Torque : 22 Nm (224 kgf-cm, 16 ft-lbf)
2. CONNECT BRAKE TUBE
(a) Set each brake line to the correct position on the brake actuator as shown in the illustration.
HINT *
*1: FR RH
* *2: FR LH
* *3: RR RH
* *4: RR LH
* *5: FR Master Cylinder
* *6: RR Master Cylinder
(b) Install a new clamp onto the VSC actuator bracket.
(c) Using a union nut wrench, connect the 4 brake tubes.
Torque : 15 Nm (155 kgf-cm, 11 ft-lbf)
Locations
Power Distribution Module: Locations
Instrument Panel (Floor Shift)
Instrument Panel (Column Shift)
Page 6063
If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness
or connector in that circuit in the past. Check the wire harness and connectors.
B -- SYSTEM NORMAL
A -- TROUBLESHOOTING OF EACH PROBLEM SYMPTOM
The problem is still occurring in a place other than the diagnostic circuit (the DTC displayed first is
either for a past problem or a secondary problem).
4. SYMPTOM SIMULATION
HINT The most difficult case in troubleshooting is when no problem symptoms occur. In such a
case, a thorough problem analysis must be carried out. A simulation of the same or similar
conditions and environment in which the problem occurred in the customer's vehicle should be
carried out. No matter how much skill or experience a technician has, troubleshooting without
confirming the problem symptoms will lead to important repairs being overlooked and mistakes or
delays.
For example:
With a problem that only occurs when the engine is cold or as a result of vibration caused by the
road during driving, the problem can never be determined if the symptoms are being checked on a
stationary vehicle or on a vehicle with a warmed-up engine. Vibration, heat or water penetration
(moisture) is difficult to reproduce. The symptom simulation tests below are effective substitutes for
the conditions and can be applied on a stationary vehicle.
Important points in the symptom simulation test:
In the symptom simulation test, the problem symptoms as well as the problem area or parts must
be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then,
connect the tester and carry out the symptom simulation test, judging whether the circuit being
tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the
problem symptoms table for each system to narrow down the possible causes.
To reproduce DTCs, it is necessary to satisfy the respective DTC detection conditions.
(a) VIBRATION METHOD:
When a malfunction seems to occur as a result of vibration.
(1) PART AND SENSOR
Apply slight vibration with a finger to the part of the sensor suspected to be the cause of the
problem, and check whether or not the malfunction occurs.
NOTICE: Applying strong vibration to relays may open them.
Page 8444
(c) for Regular Cab:
Install the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Installation.
3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Locations
Air Flow Meter/Sensor: Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 4754
load while reprogramming.
^ Confirm the hood is open and ensure under hood temperature does NOT exceed 158°F (70°C).
^ Confirm cable connections between the vehicle and Techstream are secure.
^ Do NOT disconnect or turn off Techstream or vehicle ignition during reprogramming.
^ Set parking brake.
^ Complete ALL flash calibration updates provided for each ECU.
^ If the battery's state of charge or capacity are in question, test with SST. No. 00002-8150-KIT
"Digital Battery Analyze," and follow TSB No. PG001-06, "Battery Maintenance for In-Stock
Vehicles & Pre-Delivery" or the appropriate "Maintenance for HV & Auxiliary Batteries" service
bulletin.
^ The GR8 Battery Diagnostic Station MUST be used in Power Supply Mode to maintain battery
voltage at 13.5 volts while flash reprogramming the vehicle. For details on how to use the GR8
Battery Diagnostic Station, refer to the GR8 Instruction Manual located on TIS, Diagnostics - Tools
& Equipment - Battery Diagnostics.
3C. Click Next to start the calibration update process.
D. When using TIS Techstream select Techstream VIM as the desired programming device. Then
click Next.
Page 3664
2. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in
Figure 1. Confirm if the ECM (PCM) calibration has
been updated. If the calibration ID listed is NOT the latest ECM (PCM) calibration - go to step 3.
3. Flash reprogram the ECM (PCM).
NOTE
^ The GR8 Battery Diagnostic Station MUST be used in Power Supply Mode to maintain battery
voltage at 13.5 volts while flash reprogramming the vehicle.
^ For details on how to use the GR8 Battery Diagnostic Station, refer to the located on the
Technical Information System (TIS), Diagnostics - Battery
Follow the procedures outlined in TSB No. T-SB-0064-10, "Techstream ECU Flash
Reprogramming Procedure1⁄4 and flash the ECM (PCM) with the NEW calibration file update.
4. Install the Authorized Modifications Label.
A. Using a permanent marker enter the following information on the label:
^ ECM part number [Refer to the Parts Information section for the CURRENT PART NUMBER]
^ Calibration ID(s) [Refer to the Calibration Identification Chart for the NEW CALIBRATION ID]
^ Dealer Code
^ Repair Date
^ Change Authority [This TSB number]
B. Affix the Authorized Modifications Label to the vehicle at the location shown in Figure 1. The
Authorized Modifications Label is available
through the MDC P/N 00451-00001-LBL.
5. Test drive the vehicle to confirm proper vehicle operation.
Page 5076
09956-03020
37. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD
(a) Using SST to hold the companion flange.
SST : 09330-00021
09330-00030
(b) Coat the threads of a new nut with hypoid gear oil.
(c) Install the nut by tightening it until the standard preload is reached.
Torque : 451 Nm (4599 kgf-cm, 332 ft-lb for less)
(d) Using a torque wrench, measure the preload of the backlash between the drive pinion and ring
gear.
Standard preload (at starting):
(e) If the preload is greater than the specification, replace the bearing spacer.
If the preload is less than the specification, retighten the nut with 13 N*m (130 kgf*cm, 9 ft.*lbf) of
torque at a time until the specified preload is reached.
Torque : 451 Nm (4599 kgf-cm, 332 ft-lb for less)
(f) If the maximum torque is exceeded while retightening the nut, replace the bearing spacer and
repeat the preload procedure.
HINT Do not loosen the nut to reduce the preload.
38. INSPECT TOTAL PRELOAD
(a) With the drive pinion contacting the tooth side of the ring gear, use a torque wrench to measure
the total preload.
Page 3472
Page 6145
Remove the blown fuse and disconnect all loads of the fuse.
Connect a test light in place of the fuse.
Establish conditions in which the test light comes on.
Example:
- [A] - Ignition SW on
- [B] - Ignition SW and SW1 on
- [C] - Ignition SW, SW1 and Relay on (Connect the Relay) and SW2 off (or Disconnect SW2)
Disconnect and reconnect the connectors while watching the test light.
Locations
Power Distribution Relay: Locations
Instrument Panel (Floor Shift)
Instrument Panel (Column Shift)
Page 2798
NOTE
Only Toyota Certified Technicians and above may access calibration files.
2. Connect the GR8 Battery Diagnostic Station.
A. Connect the GR8 Battery Diagnostic Station to the vehicle and turn it ON.
B. Select Power Supply Mode by following the screen flow below.
NOTICE
^ ECU damage may occur if the correct battery charger and mode setting are NOT used.
Page 9270
(b) Connect the hood lock control cable.
(c) Install the hood lock.
(d) Install the 2 bolts and nut.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
(e) Install a new cap.
(f) w/ Theft Deterrent System:
Connect the connector.
4. INSTALL HOOD LOCK CONTROL CABLE COVER
(a) Attach the clamp to install the cable cover.
(b) Install the screw and nut.
Page 7669
Reassembly
AIR CONDITIONING: COMPRESSOR (for 1UR-FE): REASSEMBLY
1. INSTALL MAGNET CLUTCH ASSEMBLY
(a) Install the magnet clutch stator with the parts shown in the illustration matched.
(b) Using a snap ring expander, install a new snap ring with the chamfered side facing up.
(c) Connect the connector.
(d) Using a snap ring expander, install the magnet clutch rotor and a new snap ring with the
chamfered side facing up.
NOTICE: Do not damage the seal cover of the bearing when installing the snap ring.
(e) Install the compressor washer(s) and magnet clutch hub.
NOTICE: Do not change the combination of the compressor washer(s) used before disassembly.
(f) Using SST, hold the magnet clutch hub and install the bolt.
SST : 09985-00270
Page 24
Alarm Module: Service and Repair Installation
THEFT DETERRENT: THEFT WARNING ECU: INSTALLATION
1. INSTALL GLASS BREAKAGE SENSOR ECU
(a) Install the ECU with the nut.
(b) Install the junction block with the 2 nuts.
(c) Connect the connectors.
2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH
(a) for Column Shift Type:
Remove the instrument panel finish panel See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument
Panel Safety Pad (for Column Shift Type)/Installation.
(b) for Floor Shift Type:
Remove the instrument panel finish panel See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Replacement/Instrument
Panel Safety Pad (for Floor Shift Type)/Installation.
3. INSTALL INSTRUMENT SIDE PANEL LH
Page 6988
If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness
or connector in that circuit in the past. Check the wire harness and connectors.
B -- SYSTEM NORMAL
A -- TROUBLESHOOTING OF EACH PROBLEM SYMPTOM
The problem is still occurring in a place other than the diagnostic circuit (the DTC displayed first is
either for a past problem or a secondary problem).
4. SYMPTOM SIMULATION
HINT The most difficult case in troubleshooting is when no problem symptoms occur. In such a
case, a thorough problem analysis must be carried out. A simulation of the same or similar
conditions and environment in which the problem occurred in the customer's vehicle should be
carried out. No matter how much skill or experience a technician has, troubleshooting without
confirming the problem symptoms will lead to important repairs being overlooked and mistakes or
delays.
For example:
With a problem that only occurs when the engine is cold or as a result of vibration caused by the
road during driving, the problem can never be determined if the symptoms are being checked on a
stationary vehicle or on a vehicle with a warmed-up engine. Vibration, heat or water penetration
(moisture) is difficult to reproduce. The symptom simulation tests below are effective substitutes for
the conditions and can be applied on a stationary vehicle.
Important points in the symptom simulation test:
In the symptom simulation test, the problem symptoms as well as the problem area or parts must
be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then,
connect the tester and carry out the symptom simulation test, judging whether the circuit being
tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the
problem symptoms table for each system to narrow down the possible causes.
To reproduce DTCs, it is necessary to satisfy the respective DTC detection conditions.
(a) VIBRATION METHOD:
When a malfunction seems to occur as a result of vibration.
(1) PART AND SENSOR
Apply slight vibration with a finger to the part of the sensor suspected to be the cause of the
problem, and check whether or not the malfunction occurs.
NOTICE: Applying strong vibration to relays may open them.
Page 4533
(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(2) If the result is not as specified, replace the integration relay.
3. INSTALL INTEGRATION RELAY
(a) Connect the 3 connectors.
(b) Install the integration relay to the engine room relay block.
(c) Install the engine room relay block cover.
Engine - Snow Ingestion Into Air Cleaner Box
Air Cleaner Housing: All Technical Service Bulletins Engine - Snow Ingestion Into Air Cleaner Box
T-SB-0396-09
December 8, 2009
Snow Entry Into Air Cleaner Box
Service Category Engine/Hybrid System
Section Intake/Exhaust
Market USA
Applicability
Introduction
Some Sequoia and Tundra vehicles operated in areas with significant snow volume may
experience snow accumulation in the air cleaner box which can cause the lid to fracture. The air
cleaner lid and fender liner have been revised to reduce accumulation.
Parts Information
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for
36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Production Change Information
Inspection
Variable Valve Timing Actuator: Testing and Inspection Inspection
1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT OIL CONTROL VALVE: INSPECTION
1. INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) If the result is not as specified, replace the camshaft timing oil control valve assembly.
(c) Connect the battery's positive (+) lead to terminal 1 and the negative (-) lead to terminal 2, and
check the movement of the valve.
OK:
(d) If the result is not as specified, replace the camshaft timing oil control valve assembly. If the
valve cannot return properly because of foreign
matter, a small pressure leak in the advanced direction may occur and a DTC may be output.
Page 772
Acceleration/Deceleration Sensor: Service and Repair Removal
BRAKE CONTROL: YAW RATE AND DECELERATION SENSOR: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to disable the SRS system.
2. REMOVE CENTER FRONT SEAT ASSEMBLY (for Center Seat) See: Body and
Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Center Seat)/Removal
3. REMOVE CONSOLE BOX ASSEMBLY (for Separate Seat Type)
(a) Remove the console box See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and
Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal.
4. REMOVE YAW RATE SENSOR
(a) Remove the 2 nuts (labeled A) and sensor.
(b) Disconnect the sensor connector (labeled B), and then detach the clamp (labeled C) from the
sensor bracket.
Locations
Starter Relay: Locations
1UR-FE STARTING: STARTING SYSTEM: PARTS LOCATION
Specifications
Spark Plug: Specifications
SPARK PLUG
Using a 16 mm plug wrench, install the 8 spark plugs.
Torque..................................................................................................................................................
.....................................21 Nm (214 kgf-cm, 15 ft-lbf)
GAP
Engine - MIL ON/DTC's P0012/P0022 Set
Variable Valve Timing Actuator: Customer Interest Engine - MIL ON/DTC's P0012/P0022 Set
T-SB-0019-10
January 20, 2010
MIL "ON" DTC P0012 and/or P0022
Service Category Engine/Hybrid System
Section Engine Control
Market USA
Applicability
Introduction
Some 2010 model year Sequoia and Tundra vehicles may exhibit a MIL "ON" condition for
Diagnostic Trouble Code (DTC) P0012 and/or P0022 ( Camshaft Position "A" - Timing
Over-Retarded Bank 1/2).
Please refer to the following repair procedure to address this condition.
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60
months or 60,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Production Change Information
Page 6651
(a) for AC Power Supply:
Disconnect the clamp.
(b) Remove the 4 screws and bezel.
5. REMOVE REAR POWER OUTLET SOCKET (for Standard)
(a) Detach the claw and remove the power outlet socket.
6. REMOVE REAR POWER OUTLET SOCKET COVER (for Standard)
(a) Detach the 2 claws and remove the power outlet socket cover.
7. REMOVE REAR POWER POINT SOCKET (for AC Power Supply)
(a) Detach the 2 claws and remove the power outlet socket.
Components
Fuel Pump Control Unit: Service and Repair Components
1UR-FE FUEL: FUEL PUMP ECU: COMPONENTS
Page 7819
Control Module HVAC: Service and Repair Removal
AIR CONDITIONING: AIR CONDITIONING AMPLIFIER: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE FRONT DOOR SCUFF PLATE RH
(a) for Regular Cab:
Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular Cab)/Removal.
(b) for Double Cab:
Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Removal.
(c) for CrewMax:
Remove the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for CrewMax)/Removal.
3. REMOVE COWL SIDE TRIM BOARD RH
(a) for Regular Cab:
Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular Cab)/Removal.
(b) for Double Cab:
Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Removal.
(c) for CrewMax:
Remove the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for CrewMax)/Removal.
4. REMOVE NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY
(a) for Column Shift Type:
Remove the No. 2 instrument panel under cover sub-assembly See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and
Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal.
(b) for Floor Shift Type:
Remove the No. 2 instrument panel under cover sub-assembly See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and
Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal.
5. REMOVE INSTRUMENT SIDE PANEL RH
(a) for Column Shift Type:
Remove the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Column Shift Type)/Removal.
(b) for Floor Shift Type:
Body/Frame - Choppy Ride Under Various Conditions
Body / Frame Mount Bushing: Customer Interest Body/Frame - Choppy Ride Under Various
Conditions
T-SB-0270-10
September 13, 2010
Choppy Ride
Service Category Vehicle Exterior
Section Frame/Unibody
Market USA
Applicability
Introduction
Some 2007 - 2010 Tundra vehicles may exhibit a body vibration when driving under certain road
conditions. A newly designed cab mount has been developed to improve this condition.
NOTE
The Tundra performs similarly to other long wheelbase trucks on choppy, broken concrete
surfaces. The enhanced cab mounts of this TSB reduce the amplitude of body vibrations caused by
uneven road surfaces, but they do NOT eliminate the sensation entirely. Customers should be
counseled that they will experience an improvement in the condition and their truck will perform
better than competitors in identical conditions, but some body
Page 2453
Intake Manifold: Testing and Inspection
1UR-FE INTAKE: INTAKE SYSTEM: ON-VEHICLE INSPECTION
1. INSPECT INTAKE AIR CONTROL VALVE
(a) Remove the V-bank cover.
(b) Start the engine.
(c) While the engine is idling, check that the actuator rod moves as shown in the illustration.
(d) Disconnect the VSV connector, and check that the actuator rod returns.
If the operation is not as specified, inspect the intake air control valve, VSV and ECM.
(e) Connect the VSV connector.
(f) Install the V-bank cover.
2. INSPECT INTAKE AIR CONTROL VALVE
(a) Inspect the diaphragm.
(1) Using a vacuum pump, apply a vacuum of 60 kPa (450 mmHg, 17.7 in.Hg). Check that the lever
moves.
If the result is not as specified, replace the intake air surge tank.
3. CHECK AIR INDUCTION SYSTEM
HINT The illustration shows the areas that may draw in secondary air, which could lead to idling
problems.
(a) Check that the hoses are installed correctly.
(b) Check for cracks, etc. in the hoses.
Page 2111
B -- GO TO VC OUTPUT CIRCUIT See: Powertrain Management/Computers and Control
Systems/Testing and Inspection/Component Tests and General Diagnostics/VC Output Circuit A -Continue to next step.
7. CHECK HARNESS AND CONNECTOR (COMBINATION METER - ECM)
(a) Disconnect the ECM connector.
(b) Disconnect the combination meter connector.
(c) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- REPLACE COMBINATION METER ASSEMBLY See: Instrument Panel, Gauges and
Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Combination Meter/Removal
Page 3434
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO SKID CONTROL ECU
WITH ACTUATOR (CANH, CANL)
OK -- REPLACE SKID CONTROL ECU WITH ACTUATOR See: Brakes and Traction
Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock
Brakes/Service and Repair/Removal and Replacement/Removal
16. CHECK FOR SHORT IN CAN BUS WIRES (STEERING ANGLE SENSOR)
(a) Disconnect the J6 steering angle sensor connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO STEERING ANGLE
SENSOR (CANH, CANL)
OK -- REPLACE STEERING ANGLE SENSOR
17. CHECK FOR SHORT IN CAN BUS WIRES (POWER STEERING ECU)
(a) Disconnect the J101 power steering ECU connector.
Page 4389
(2) If the result is not as specified, replace the integration relay.
3. INSTALL INTEGRATION RELAY See: Ignition System/Ignition Relay/Testing and Inspection
Page 6666
Auxiliary Power Outlet Switch: Service and Repair Installation
OTHER SYSTEM: INVERTER MAIN SWITCH (for CrewMax): INSTALLATION
1. INSTALL INVERTER MAIN SWITCH
(a) Attach the 2 claws to install the main switch.
2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Floor Shift Type)/Installation
3. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation
4. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Installation
5. INSTALL FRONT DOOR SCUFF PLATE LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining
(For Double Cab)/Installation
Diagrams
Electronic Noise Suppressor: Diagrams
Components
Acceleration/Deceleration Sensor: Service and Repair Components
BRAKE CONTROL: YAW RATE AND DECELERATION SENSOR: COMPONENTS
Components
Transmission Speed Sensor: Service and Repair Components
A760F AUTOMATIC TRANSMISSION: SPEED SENSOR: COMPONENTS
Locations
Main Relay (Computer/Fuel System): Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 1716
(d) * for 5 leaf spring
Standard steering axis inclination (unloaded vehicle):
for Regular Cab of Standard Deck
Page 7741
7. INSTALL DAMPER SERVO SUB-ASSEMBLY
(a) Install the damper servo with the 3 screws.
(b) Connect the connector.
8. INSTALL DAMPER SERVO SUB-ASSEMBLY
(a) Install the servo motor.
(1) Set the plate so that the cutout part engages with the tooth of the gear, and attach the claw to
install the main plate.
(2) Install the 2 screws.
(b) Install the servo motor.
Page 1821
Then click Start.
I. Do NOT disturb the vehicle during flash reprogramming.
NOTE
^ ECU flash reprogramming may take anywhere from 3 - 30 minutes per calibration file.
^ Reprogramming time will vary depending on model and ECU communication protocol. Vehicles
using CAN communication protocol will reprogram much faster (2 - 7 minutes).
NOTE
^ If vehicle requires only ONE calibration update, then proceed to step N in this bulletin.
^ If vehicle requires a SECOND calibration update, then continue as follows:
^ For serial communication vehicles, go to step J.
^ For CAN communication vehicles, go to step L.
Page 2008
"Case2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 8243
Removal
SEAT BELT: FRONT SEAT OUTER BELT ASSEMBLY (for CrewMax): REMOVAL
HINT *
Use the same procedures for the LH side and RH side.
* The procedures listed below are for the LH side.
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
NOTICE:
Page 7282
POWER STEERING: STEERING GEAR: INSTALLATION
1. INSTALL POWER STEERING GEAR ASSEMBLY
(a) Install the power steering gear with the 2 bolts and 2 nuts.
Torque : 120 Nm (1224 kgf-cm, 89 ft-lbf)
2. INSTALL PRESSURE FEED TUBE ASSEMBLY
(a) Temporarily connect the pressure feed tube to the power steering gear.
(b) Install the pressure feed tube clamp with the 2 bolts.
Torque : 28 Nm (286 kgf-cm, 21 ft-lbf)
(c) Using a union nut wrench, tighten the pressure feed tube (pressure feed tube side).
Page 451
Air Bag Control Module: Locations Airbag System
SUPPLEMENTAL RESTRAINT SYSTEM: AIRBAG SYSTEM: PARTS LOCATION
Page 2353
Page 1477
[A] For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
"Case1" Raise the terminal retainer up to the temporary lock position.
Page 3678
2. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in
Figure 1. Confirm if the ECM (PCM) calibration has
been updated. If the calibration ID listed is NOT the latest ECM (PCM) calibration - go to step 3.
3. Flash reprogram the ECM (PCM).
NOTE
^ The GR8 Battery Diagnostic Station MUST be used in Power Supply Mode to maintain battery
voltage at 13.5 volts while flash reprogramming the vehicle.
^ For details on how to use the GR8 Battery Diagnostic Station, refer to the located on the
Technical Information System (TIS), Diagnostics - Battery
Follow the procedures outlined in TSB No. T-SB-0064-10, "Techstream ECU Flash
Reprogramming Procedure1⁄4 and flash the ECM (PCM) with the NEW calibration file update.
4. Install the Authorized Modifications Label.
A. Using a permanent marker enter the following information on the label:
^ ECM part number [Refer to the Parts Information section for the CURRENT PART NUMBER]
^ Calibration ID(s) [Refer to the Calibration Identification Chart for the NEW CALIBRATION ID]
^ Dealer Code
^ Repair Date
^ Change Authority [This TSB number]
B. Affix the Authorized Modifications Label to the vehicle at the location shown in Figure 1. The
Authorized Modifications Label is available
through the MDC P/N 00451-00001-LBL.
5. Test drive the vehicle to confirm proper vehicle operation.
Page 720
Removal
SEAT: FRONT POWER SEAT LUMBAR SWITCH (for Power Seat): REMOVAL
HINT *
Use the same procedures for the LH side and RH side.
* The procedures listed below are for the LH side.
1. REMOVE FRONT SEAT ASSEMBLY LH
(a) Remove the front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Power
Seat)/Removal.
2. REMOVE SLIDE AND VERTICAL POWER SEAT SWITCH KNOB LH See: Body and
Frame/Seats/Service and Repair/Overhaul/Front Seat
Assembly (for Power Seat)/Disassembly
3. REMOVE RECLINING POWER SEAT SWITCH KNOB LH See: Body and Frame/Seats/Service
and Repair/Overhaul/Front Seat Assembly
(for Power Seat)/Disassembly
4. REMOVE FRONT SEAT CUSHION SHIELD LH See: Body and Frame/Seats/Service and
Repair/Overhaul/Front Seat Assembly (for Power
Seat)/Disassembly
5. REMOVE FRONT POWER SEAT LUMBAR SWITCH LH
(a) Remove the 2 screws and switch.
Installation
SEAT: FRONT POWER SEAT LUMBAR SWITCH (for Power Seat): INSTALLATION
HINT *
Use the same procedures for the LH side and RH side.
* The procedures listed below are for the LH side.
1. INSTALL FRONT POWER SEAT LUMBAR SWITCH LH
Page 5310
Flex Plate: Specifications
DRIVE PLATE AND RING GEAR SUB-ASSEMBLY
Install and uniformly tighten 10 new bolts in the sequence shown in the illustration.
Torque..................................................................................................................................................
.....................................30 Nm (301 kgf-cm, 22 ft-lbf)
Mark the top of each drive plate installation bolt with paint.
Tighten the drive plate installation bolts 90° as shown in the illustration.
Check that the painted marks are now at a 90° angle to the top.
Page 7526
2. Install ChaSSiSEAR(TM) on the vehicle and attempt to isolate the source of the noise. Is the
noise loudest near the rear wheel bearing assembly?
^ YES - Go to step 3.
^ NO - This TSB does NOT apply. Continue diagnosis to isolate the source of the noise.
3. Replace the rear wheel bearing caliper bracket and related parts.
Refer to the Technical Information System (TIS) applicable model year Repair Manual:
4. Test drive the vehicle and confirm the noise is eliminated.
5. Re-check rear differential oil level and confirm NO leaks are present.
Removal and Replacement
Valve Body: Removal and Replacement
Components
A760F AUTOMATIC TRANSMISSION: VALVE BODY ASSEMBLY: COMPONENTS
Removal
Page 6971
"Case1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (/\ Mark) and pull the terminal retainer
up to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Page 3707
^ Power Supply Mode is used to maintain battery voltage at 13.5 volts while flash reprogramming
the vehicle.
^ For details on how to use the GR8 Battery Diagnostic Station, refer to the located on TIS,
Diagnostics - Tools & Equipment - Battery Diagnostics.
3. Click the appropriate calibration ID and reprogram the vehicle's ECU with Techstream.
A. After reviewing the procedures outlined in the selected TSB, click the appropriate calibration ID
link by matching the vehicle's current
calibration ID to the Previous Calibration ID in the Calibration Identification Chart.
NOTE
^ Calibration files are embedded as live links in the service bulletin.
^ Some vehicles require special preparation - please review the selected TSB carefully.
B. Click Open to load calibration file information.
Techstream pulls calibration files as needed to ensure the latest calibration file is used. Do NOT
save calibrations locally on the hard drive or other media.
NOTICE
Errors during the flash reprogramming process can permanently damage the vehicle ECU.
Minimize the risk by following the steps below.
^ Battery voltage MUST NOT FALL BELOW 11.4 volts during reprogramming. Confirm battery
voltage is higher than 11.4 volts, but be sure voltage DOES NOT RISE ABOVE 16.0 volts during
reprogramming.
^ Turn OFF all vehicle accessories (e.g. audio system, A/C, interior lights, DRL, etc.). Do NOT add
to or significantly change the vehicle's electrical
Page 7151
Tire Pressure Sensor: Service and Repair Installation
TIRE AND WHEEL: TIRE PRESSURE WARNING VALVE AND TRANSMITTER: INSTALLATION
1. INSTALL TIRE PRESSURE WARNING VALVE AND TRANSMITTER
(a) Insert the tire pressure warning valve into the valve installation hole from the inside of the rim so
that the print surface can be seen.
NOTICE: *
Check that there is no visible deformation, damage or other abnormalities on the tire pressure
warning valve and transmitter.
* Check that there is no foreign matter on the inner grommet and around the rim hole.
* If the tire pressure warning valve and transmitter is installed in the reverse direction, it may be
damaged or fail to transmit signals when running at a high speed.
* If installing a new tire pressure warning valve and transmitter, write down the transmitter ID before
installation.
* The transmitter ID registration must be performed for all tire pressure warning valve and
transmitters, regardless of the number of tire pressure warning valve and transmitters replaced. If
all of the tire pressure warning valve and transmitters do not need to be replaced, check the DATA
LIST and write down the transmitter IDs of the tire pressure warning valve and transmitters that do
not need to be replaced before performing the transmitter ID registration See: Wheels and
Tires/Tire Monitoring System/Testing and Inspection/Programming and Relearning/Registration
* It is necessary to perform initialization See: Wheels and Tires/Tire Monitoring System/Testing and
Inspection/Programming and Relearning/Initialization after registration See: Wheels and Tires/Tire
Monitoring System/Testing and Inspection/Programming and Relearning/Registration of the
transmitter IDs into the tire pressure warning ECU after the tire pressure warning valve and
transmitter has been replaced.
(b) If reusing the tire pressure warning valve and transmitter:
Install a new grommet.
HINT A new tire pressure warning valve and transmitter is supplied with a grommet.
(c) Install the washer on the tire pressure warning valve from the rim side and tighten the nut.
Page 259
Symbols Used Within Diagrams
Symbols Used Within Diagrams
Locations
Collision Avoidance System Switch: Locations
PARK ASSIST / MONITORING: INTUITIVE PARKING ASSIST SYSTEM: PARTS LOCATION
Page 7950
* When removing the front passenger airbag, work must be started 90 seconds after the ignition
switch is turned OFF and the negative (-) terminal cable is disconnected from the battery.
* When storing the front passenger airbag, keep the airbag deployment side facing upward.
(c) Install SST.
(1) After connecting SST each other, connect them to the front passenger airbag.
SST : 09082-00802
09082-10801
09082-30801
(d) Using a service-purpose wire harness for the vehicle, tie down the front passenger airbag to the
tire.
Wire harness:
Stripped wire harness section
1.25 mm2 or more (0.00193 in.2 or more)
CAUTION: If the wire harness is too thin or an alternative object is used to tie down the front
passenger airbag, it may be snapped by the shock when the airbag is deployed. Always use a wire
harness for vehicle use with an area of at least 1.25 mm2 (0.00193 in.2).
HINT To calculate the area of the stripped wire harness section:
Area = 3.14 x (Diameter)2 divided by 4
(1) Position the front passenger airbag inside the tire with the airbag deployment side facing inside.
Locations
Fuel Pump Relay: Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 274
Push the terminal retainer down to the temporary lock position.
Page 1176
Knock Sensor: Diagrams
Page 9001
Page 496
Steering Column Control Module: Service and Repair Removal
STEERING COLUMN: MULTIPLEX TILT AND TELESCOPIC ECU (for Power Tilt and Power
Telescopic Steering Column): REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE UPPER STEERING COLUMN COVER
(a) Remove the 2 screws.
HINT Turn the steering wheel to the right and left as necessary to remove the 2 screws.
(b) Detach the 4 clips.
(c) Detach the claw to remove the upper steering column cover.
3. REMOVE LOWER STEERING COLUMN COVER
(a) Detach the 2 claws to remove the lower steering column cover.
4. REMOVE HOOD LOCK CONTROL LEVER SUB-ASSEMBLY See: Body and Frame/Doors,
Hood and Trunk/Hood/Hood Latch Release
Cable/Service and Repair/Removal
5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Removal
Page 8376
Removal
SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Double Cab): REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Disassembly
3. REMOVE FRONT ARMREST BASE PANEL UPPER LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
CAN Communication System
Body Control Module: Locations CAN Communication System
CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: PARTS LOCATION
Tires - Pressure Compensation And Adjustment
Tires: Technical Service Bulletins Tires - Pressure Compensation And Adjustment
T-SB-0345-08
Rev2
November 6, 2008
Tire Inflation Pressure Compensation and Adjustment
Service Category Suspension
Section Tire/Wheel
Market USA
Applicability
TSB REVISION NOTICE
^ December 22, 2009 Rev2:
^ Applicability has been updated to include 2010 model year Prius PHV model and 2011 vehicles.
Any previous printed versions of this service bulletin should be discarded.
TSB REVISION NOTICE
^ May 15, 2009 Rev1:
^ Applicability has been updated to include 2010 model year vehicles, and 2009 - 2010 model year
Venza.
^ Figure 1 has been updated, and Celsius temperatures have been removed from the bulletin.
Any previous printed versions of this service bulletin should be discarded.
Page 2657
Engine Temperature Sensor: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: ENGINE COOLANT TEMPERATURE SENSOR:
INSTALLATION
1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR
(a) Install a new gasket to the sensor.
(b) Using a 19 mm ball joint lock nut wrench, install the sensor.
Torque : 20 Nm (200 kgf-cm, 14 ft-lbf)
NOTICE: Use the formula to calculate special torque values for situations where ball joint lock nut
wrench is combined with a torque wrench See: Service Precautions
(c) Connect the sensor connector.
2. ADD ENGINE COOLANT See: Coolant/Service and Repair
3. INSPECT FOR COOLANT LEAK See: Testing and Inspection
4. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine/Service and Repair/Removal and
Replacement/Engine Assembly/Installation
5. INSTALL NO. 1 ENGINE UNDER COVER See: Engine/Engine Lubrication/Engine Oil/Service
and Repair/Replacement
Page 4701
Transmission Speed Sensor: Service and Repair Installation
A760F AUTOMATIC TRANSMISSION: SPEED SENSOR: INSTALLATION
1. INSTALL SPEED SENSOR SP2
(a) Coat a new O-ring with ATF and install it to the sensor.
(b) Install the sensor with the bolt.
Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)
(c) Connect the sensor connector.
2. INSTALL SPEED SENSOR NT
(a) Coat a new O-ring with ATF and install it to the sensor.
(b) Install the sensor with the bolt.
Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)
(c) Connect the sensor connector.
Page 2816
(e) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- REPAIR OR REPLACE ENGINE ROOM RELAY BLOCK
Page 883
Oil Pressure Sender: Testing and Inspection
1UR-FE LUBRICATION: OIL PRESSURE SWITCH: ON-VEHICLE INSPECTION
1. INSPECT OIL PRESSURE SENDER GAUGE ASSEMBLY
(a) Disconnect the sender gauge connector.
(b) Apply battery positive (+) voltage to the sender gauge terminal through a test LED.
(c) Check that the LED does not illuminate when the engine is stopped.
(d) Check that the LED flashes when the engine is running. The number of flashes varies with
engine speed.
If the operation is not as specified, replace the oil pressure sender gauge assembly.
Page 9014
"Case2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 7113
Tire Pressure Monitor Receiver / Transponder: Diagrams
Page 2169
Tire Pressure Warning Reset Switch: Service and Repair Installation
TIRE AND WHEEL: TIRE PRESSURE WARNING RESET SWITCH: INSTALLATION
1. INSTALL TIRE PRESSURE WARNING RESET SWITCH
(a) Attach the 2 claws to install the reset switch.
(b) Connect the switch connector.
2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Installation
3. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
4. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Installation
5. INSTALL FRONT DOOR SCUFF PLATE LH (for Double Cab, for CrewMax) See: Body and
Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation
6. INSTALL FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Installation
Oil Pressure Sender
Oil Pressure Sender: Diagrams Oil Pressure Sender
Components
Alarm Module: Service and Repair Components
THEFT DETERRENT: THEFT WARNING ECU: COMPONENTS
Page 3487
(b) Reconnect the cable to the negative (-) battery terminal.
(c) Select "CAN Bus Check" on the Techstream.
Result
NG -- CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (AIR CONDITIONING
AMPLIFIER BRANCH WIRE) OK -- Continue to next step.
15. CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (POWER STEERING ECU
BRANCH WIRE)
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE CAN BRANCH WIRE OR CONNECTOR (POWER STEERING
ECU)
OK -- REPLACE POWER STEERING ECU See: Relays and Modules/Relays and Modules Steering and Suspension/Relays and Modules - Steering/Steering Control Module/Service and
Repair/Removal
16. CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (AIR CONDITIONING
AMPLIFIER BRANCH WIRE)
(a) Disconnect the J19 air conditioning amplifier connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
Locations
Transmission Mode Switch: Locations
A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS
LOCATION
Page 3696
NOTE
On some models, DTCs may set as a result of reprogramming. If DTCs are present, clear codes
and run the Health Check again. Troubleshoot any remaining Current, Pending, or History codes.
Permanent codes will not be cleared using Techstream. Permanent codes do not illuminate the MIL
and do not require troubleshooting. They will clear during normal driving once the Universal Trip
Drive Pattern is performed.
4. Attach the Authorized Modifications Label.
A. Using a permanent marker or ball point pen complete the Authorized Modifications Label and
attach to the vehicle. The Authorized
Modifications Label is available through the MDC P/N 00451-00001-LBL.
B. Attach the label under the hood in the location determined by the specific TSB or Campaign.
NOTE
Wait 60 - 90 seconds for ink to set before handling.
Page 6345
"Case1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (/\ Mark) and pull the terminal retainer
up to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Page 2724
(d) Remove the 2 gaskets from the front exhaust pipes.
3. REMOVE PROPELLER SHAFT HEAT INSULATOR (for 4WD) See: Transmission and
Drivetrain/Drive/Propeller Shafts, Bearings and
Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Front Propeller Shaft
Assembly/Removal
4. REMOVE HEATED OXYGEN SENSOR (for Bank 1 Sensor 2) See: Powertrain
Management/Computers and Control Systems/Oxygen
Sensor/Service and Repair/Heated Oxygen Sensor/Removal
5. REMOVE FRONT NO. 2 EXHAUST PIPE ASSEMBLY
(a) Remove the 2 bolts and 2 nuts.
(b) Disconnect the front No. 3 exhaust pipe from the exhaust pipe support.
(c) Remove the front No. 3 exhaust pipe from the front No. 2 exhaust pipe.
(d) Disconnect the air fuel ratio sensor connector.
(e) Remove the 3 nuts, front No. 2 exhaust pipe and 2 gaskets from the exhaust manifold LH.
6. REMOVE HEATED OXYGEN SENSOR (for Bank 2 Sensor 2) See: Powertrain
Management/Computers and Control Systems/Oxygen
Sensor/Service and Repair/Heated Oxygen Sensor/Removal
7. REMOVE FRONT EXHAUST PIPE ASSEMBLY
(a) Disconnect the air fuel ratio sensor connector.
(b) Remove the 3 nuts, front exhaust pipe and gasket from the exhaust manifold RH.
8. REMOVE AIR FUEL RATIO SENSOR (for Bank 2 Sensor 1) See: Powertrain
Management/Computers and Control Systems/Oxygen
Sensor/Service and Repair/Air Fuel Ratio Sensor/Removal
9. REMOVE AIR FUEL RATIO SENSOR (for Bank 1 Sensor 1)
(a) Using SST, remove the sensor.
SST : 09224-00010
10. REMOVE MONOLITHIC CONVERTER PROTECTOR (for Bank 1)
Page 2523
Torque..................................................................................................................................................
.....................................47 Nm (479 kgf-cm, 35 ft-lbf)
Tighten the 23 bolts and nut labeled 12 to 34 in several steps in the sequence shown in the
illustration.
Torque..................................................................................................................................................
.....................................23 Nm (235 kgf-cm, 17 ft-lbf)
Page 6739
Driver Side J/B - Cowl Side Left
Page 2543
Refer to the Technical Information System (TIS) applicable model and model year Repair Manual:
2. Verify the vehicle has the proper coolant and oil levels.
3. Clear all DTCs and confirm the condition has been corrected.
Page 7732
Evaporator Temperature Sensor / Switch: Service and Repair Disassembly
AIR CONDITIONING: FRONT EVAPORATOR TEMPERATURE SENSOR: DISASSEMBLY
1. REMOVE AIR CONDITIONING UNIT
(a) Remove the air conditioning unit See: Housing Assembly HVAC/Service and Repair/Removal
and Replacement/Removal.
2. REMOVE LOWER DEFROSTER NOZZLE ASSEMBLY
(a) Detach the 4 claws and remove the nozzle.
3. REMOVE NO. 3 AIR DUCT SUB-ASSEMBLY
(a) Detach the 4 claws and remove the duct.
4. REMOVE AIR FILTER COVER PLATE
(a) Detach the 2 clips and remove the plate.
5. REMOVE CLEAN AIR FILTER
Specifications
Brake Fluid: Specifications
Brake Fluid
Type .....................................................................................................................................................
.................... SAE J1703 or FMVSS No. 116 DOT 3
Page 5916
Torque : 11 Nm (107 kgf-cm, 8 ft-lbf)
NOTICE: *
Make sure there are no pieces of iron or other foreign matter attached to the sensor tip part.
* While inserting the speed sensor into the knuckle hole, do not strike or damage the sensor tip
part.
* After installing the speed sensor, make sure there is no clearance or foreign matter between the
sensor stay part and the knuckle.
* Make sure there is no foreign matter attached to the magnetic rotor.
6. INSTALL FRONT SKID CONTROL SENSOR WIRE RH
(a) Install the skid control sensor clamp (labeled A) with the bolt (labeled B).
for Bolt B - Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)
(b) Install the connector (labeled C) with connect the connector (labeled C).
(c) Install the 2 harness clamps (labeled D) with the 2 bolts (labeled E).
for Bolt E - Torque : 13 Nm (127 kgf-cm, 9 ft-lbf)
NOTICE: *
When installing the clamps, do not twist the wire harness.
* For clamps with rotation stoppers, make sure the rotation stopper touches the installation
position.
(d) Install the harness clamp with the bolt (labeled E).
Torque : 13 Nm (127 kgf-cm, 9 ft-lbf)
NOTICE: *
When installing the clamp, do not twist the wire harness.
* Make sure the clamp's rotation stopper touches the installation position.
Components
Four Wheel Drive Selector Switch: Service and Repair Components
JF1A TRANSFER: 4WD CONTROL SWITCH: COMPONENTS
Components
Remote Switch: Service and Repair Components
AUDIO / VISUAL: STEERING PAD SWITCH: COMPONENTS
Page 1721
(c) Read the adjustment chart (example).
(1) Find the wheel alignment standard value applicable for the particular model.
(2) Mark the selected standard value on the adjustment chart.
Standard value (reference):
(3) Mark the alignment value measured when the vehicle is unloaded on the adjustment chart.
Measured value (reference):
(4) As shown in the chart, read the distance from the marked point to 0, and adjust the front and/ or
rear adjusting cams accordingly.
Amount to turn adjusting cams (by gradation):
Page 8951
4. REMOVE LICENSE PLATE LIGHT ASSEMBLY RH (for Resin Type Bumper) See: Body and
Frame/Bumper/Rear Bumper/Service and
Repair/Removal and Replacement/Rear Bumper (for Resin Type Bumper)/Removal
5. REMOVE LICENSE PLATE LIGHT ASSEMBLY RH (for Steel Type Bumper) See: Body and
Frame/Bumper/Rear Bumper/Service and
Repair/Removal and Replacement/Rear Bumper (for Steel Type Bumper)/Removal
6. REMOVE REAR BUMPER PAD SUB-ASSEMBLY (for Steel Type Bumper) See: Body and
Frame/Bumper/Rear Bumper/Service and
Repair/Removal and Replacement/Rear Bumper (for Steel Type Bumper)/Removal
7. REMOVE REAR BUMPER PLATE LH (for Steel Type Bumper) See: Body and
Frame/Bumper/Rear Bumper/Service and Repair/Removal and
Replacement/Rear Bumper (for Steel Type Bumper)/Removal
8. REMOVE REAR BUMPER PLATE RH (for Steel Type Bumper) See: Body and
Frame/Bumper/Rear Bumper/Service and Repair/Removal and
Replacement/Rear Bumper (for Steel Type Bumper)/Removal
9. REMOVE REAR BUMPER COVER (for Resin Type Bumper) See: Body and
Frame/Bumper/Rear Bumper/Service and Repair/Removal and
Replacement/Rear Bumper (for Resin Type Bumper)/Removal
10. REMOVE REAR BUMPER BAR (for Steel Type Bumper) See: Body and Frame/Bumper/Rear
Bumper/Service and Repair/Removal and
Replacement/Rear Bumper (for Steel Type Bumper)/Removal
11. REMOVE NO. 1 ULTRASONIC SENSOR
(a) While pushing down on the lever with a finger to release the one claw, detach the claw on the
other side to remove the ultrasonic sensor.
HINT The type of claw on the top and bottom of the sensor are different. Observe the claws
carefully before removing the sensor.
12. REMOVE NO. 1 ULTRASONIC SENSOR RETAINER
(a) Detach the 2 claws and remove the sensor retainer from the rear bumper.
13. REMOVE NO. 2 ULTRASONIC SENSOR
(a) While pushing down on the lever with a finger to release the one claw, detach the claw on the
other side to remove the ultrasonic sensor.
Page 2328
This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown.
Diagram Information and Instructions
Trailer Connector: Diagram Information and Instructions
Wiring Color Codes
Abbreviations Used Within Diagrams
Abbreviations Used Within Diagrams
Page 7915
Air Bag: Diagrams Instrument Panel Airbag Assembly Lower
Page 4290
Parts Information
Calibration Information
Required Tools & Equipment
Repair Procedure
A/T - World Standard Automatic Transmission Fluid
Fluid - A/T: Technical Service Bulletins A/T - World Standard Automatic Transmission Fluid
T-SB-0006-11
January 6, 2011
World Standard Automatic Transmission Fluid
Service Category Drivetrain
Section Automatic Transmission/Transaxle
Market USA
Applicability
TSB SUPERSESSION NOTICE
The information contained in this TSB supersedes TSB No. TC010-07.
Applicability has been updated to include 2009 - 2011 model year Toyota vehicles.
TSB No. TC010-07 is Obsolete and any printed versions should be discarded. Be sure to review
the entire content of this service bulletin before proceeding.
Introduction
World Standard (WS) Automatic Transmission Fluid (ATF) was introduced to reduce maintenance
costs and increase the mileage between scheduled maintenance checks. Here are some important
tips when working with ATF-WS in Toyota vehicles requiring its use.
Warranty Information
Page 4555
Camshaft Position Sensor: Locations Ignition System
1UR-FE IGNITION: IGNITION SYSTEM: PARTS LOCATION
Page 7734
10. REMOVE DAMPER SERVO SUB-ASSEMBLY
(a) Disconnect the 2 connectors.
(b) Remove the 4 screws and damper servo.
(c) Remove the damper servo.
(1) Detach the claw and remove the main plate.
(2) Remove the 2 screws and damper servo.
(d) Remove the damper servo.
Page 3945
This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown.
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60
months or 60,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Op Code EG9029 or EG9024: For California specification vehicles sold, registered, and operated
in California, Connecticut, Maine, Massachusetts, New Jersey, Oregon, Pennsylvania, Rhode
Island, Vermont, and Washington, this repair is covered under the California Emission Warranty.
This warranty is in effect for 84 months or 70,000 miles, whichever occurs first, from the vehicle's
in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Page 8275
(a) Remove the bolt and belt.
3. REMOVE REAR SEAT INNER BELT ASSEMBLY
(a) Remove the bolt and belt.
Installation
SEAT BELT: REAR SEAT INNER BELT ASSEMBLY (for Double Cab): INSTALLATION
1. INSTALL REAR SEAT INNER BELT ASSEMBLY
(a) Install the belt with the bolt.
Torque : 42 Nm (428 kgf-cm, 31 ft-lbf)
NOTICE: Do not overlap the anchor part of the seat belt and protruding parts of the vehicle body.
2. INSTALL REAR NO. 1 SEAT INNER BELT ASSEMBLY RH
(a) Install the belt with the bolt.
Torque : 42 Nm (428 kgf-cm, 31 ft-lbf)
NOTICE: Do not overlap the anchor part of the seat belt and protruding parts of the vehicle body.
Page 7890
Solar Sensor: Service and Repair Removal
AIR CONDITIONING: SOLAR SENSOR (for Automatic Air Conditioning System): REMOVAL
1. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY
(a) for Column Shift Type:
Remove the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Column Shift Type)/Removal.
(b) for Floor Shift Type:
Remove the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Floor Shift Type)/Removal.
2. REMOVE AUTOMATIC LIGHT CONTROL SENSOR (SOLAR SENSOR)
(a) Detach the 2 claws.
(b) Disconnect the connector and remove the sensor.
Page 3468
C -- GO TO PROBLEM SYMPTOMS TABLE See: Symptom Related Diagnostic Procedures/CAN
Communication System/Problem Symptoms Table A -- Continue to next step.
10. CHECK DTC COMBINATION TABLE (V BUS CIRCUIT BRANCH WIRE OPEN PAST
MALFUNCTION)
(a) Based on the combination of stored CAN communication system DTCs, determine which ECUs
and sensors have a communication stop
malfunction See: Initial Inspection and Diagnostic Overview/CAN Communication
System/Diagnosis System.
NEXT -- Continue to next step.
11. PERFORM MALFUNCTION SIMULATION TEST (V BUS CIRCUIT MAIN WIRE PAST
MALFUNCTION)*
(a) Using the Techstream, clear all DTCs.
(b) Perform a malfunction simulation test on all harnesses and connectors related to the V bus
circuit main wire.
(c) Check the DTCs that were output as a result of the malfunction simulation test. Then determine
the malfunctioning area.
NEXT -- Continue to next step.
12. ADJUST, REPAIR AND REPLACE
NEXT -- Continue to next step.
13. CONFIRMATION TEST
NEXT -- END
Diagnosis System
CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: DIAGNOSIS SYSTEM
1. BUS CHECK
(a) Select "CAN Bus Check" from the "System Select".
2. CHECK INSTALLED SYSTEMS (ECUS AND SENSORS) THAT USE CAN COMMUNICATION
(a) Systems (ECUs and sensors) that use CAN communication vary depending on the vehicle's
optional settings. Check which systems (ECUs and
sensors) are installed on the vehicle.
3. DTC TABLE BY ECU
HINT *
In the CAN communication system, CAN communication system DTCs output by the ECU can be
displayed by using the Techstream.
Page 6794
Establish conditions in which voltage is present at the check point.
Example:
- [A] - Ignition SW on
- [B] - Ignition SW and SW1 on
- [C] - Ignition SW, SW1 and Relay on (SW2 off)
Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or component terminal.
This check can be done with a test light instead of a voltmeter.
Electronic Circuit Inspection Procedure
Page 480
Seat Occupant Classification Module - Air Bag: Service and Repair Removal
SUPPLEMENTAL RESTRAINT SYSTEM: OCCUPANT CLASSIFICATION ECU: REMOVAL
1. REMOVE FRONT SEAT ASSEMBLY RH
(a) Remove the front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Manual
Seat)/Removal.
2. REMOVE OCCUPANT CLASSIFICATION ECU
(a) Disconnect the connector.
(b) Detach the claw and remove the ECU from the seat.
Drivetrian - Rear End Howling/Growling Noises
Wheel Bearing: All Technical Service Bulletins Drivetrian - Rear End Howling/Growling Noises
T-SB-0151-10
June11, 2010
Rear Axle Bearing Abnormal Noise
Service Category Drivetrain
Section Axle/Differential
Market USA
Applicability
Introduction
Some 2007 - 2010 model year Tundra vehicles may exhibit a howling or growling noise from the
rear of the vehicle that increases with vehicle speed. Changes have been made to the rear axle
bearing to correct this condition. Follow the procedure in the bulletin to address customer concerns.
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60
months or 60,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Parts Information
Page 8234
Connect the connector and attach the clamp.
2. INSTALL FRONT SEAT INNER CUSHION SHIELD (for Manual Seat) See: Body and
Frame/Seats/Service and Repair/Overhaul/Front Seat
Assembly (for Manual Seat)/Reassembly
3. INSTALL FRONT SEAT ASSEMBLY (for Power Seat)
(a) Install the front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Power
Seat)/Installation.
4. INSTALL FRONT SEAT ASSEMBLY (for Manual Seat)
(a) Install the front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Manual
Seat)/Installation.
5. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Components
SEAT BELT: FRONT SEAT INNER BELT ASSEMBLY (for Center Seat): COMPONENTS
Page 3221
Data Link Connector: Diagnostic Aids
Continuity and Resistance Check
CONTINUITY AND RESISTANCE CHECK
Disconnect the battery terminal or wire so there is no voltage between the check points.
Contact the two leads of an ohmmeter to each of the check points.
Page 3628
Oxygen Sensor Relay: Testing and Inspection
1UR-FE ENGINE CONTROL SYSTEM: A/F SENSOR HEATER RELAY: ON-VEHICLE
INSPECTION
1. REMOVE INTEGRATION RELAY See: Ignition System/Ignition Relay/Testing and Inspection
2. INSPECT INTEGRATION RELAY (A/F)
NOTICE: *
Some relays are built into the integration relay. The integration relay cannot be disassembled. If
there is a malfunction in the circuit of the integration relay, replace the integration relay.
* The internal circuit of the integration relay is as shown in the illustration below. Inspect the
integration relay using the following procedures.
(a) Measure the resistance of the A/F fuse.
(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(2) If the result is not as specified, replace the A/F fuse.
(b) Measure the resistance of the A/F sensor heater relay.
(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
Diagrams
Radio Tuner: Diagrams
Page 7033
for Regular Cab of Long Deck
for Double Cab of Standard Deck
Page 1159
Crankshaft Position Sensor: Locations Ignition System
1UR-FE IGNITION: IGNITION SYSTEM: PARTS LOCATION
Page 2040
Driver Side J/B Inner Circuit
Page 794
Parking Brake Warning Switch: Testing and Inspection
PARKING BRAKE: PARKING BRAKE SWITCH: ON-VEHICLE INSPECTION
1. REMOVE PARKING BRAKE SWITCH ASSEMBLY See: Brakes and Traction Control/Parking
Brake System/Parking Brake Pedal/Service
and Repair/Overhaul/Disassembly
2. CHECK PARKING BRAKE SWITCH ASSEMBLY
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the parking brake switch assembly.
3. INSTALL PARKING BRAKE SWITCH ASSEMBLY See: Brakes and Traction Control/Parking
Brake System/Parking Brake Pedal/Service
and Repair/Overhaul/Reassembly
Page 2015
(a) For an open circuit in the wire harness in Fig. 1, check the resistance or voltage, as described
below.
(b) Check the resistance.
(1) Disconnect connectors A and C and measure the resistance between them.
Standard resistance (Fig. 2):
HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally.
If the results match the examples above, an open circuit exists between terminal 1 of connector A
and terminal 1 of connector C.
(2) Disconnect connector B and measure the resistance between the connectors.
Standard resistance (Fig. 3):
* If the results match the examples above, an open circuit exists between terminal 1 of connector
B2 and terminal 1 of connector C.
(c) Check the voltage.
Page 8661
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Page 8108
Page 7598
NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do
not operate the ignition switch, any other switches, or the doors.
(a) If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the
harness and connector.
(b) Connect the cable of the Techstream to the DLC3, turn the ignition switch ON and attempt to
use the tester. If the display indicates that a
communication error has occurred, there is a problem either with the vehicle or with the tester.
HINT *
If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of
the original vehicle.
* If communication is still not possible when the tester is connected to another vehicle, the problem
may be in the tester itself. Consult the Service Department listed in the tester's instruction manual.
How To Proceed With Troubleshooting
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: HOW TO
PROCEED WITH TROUBLESHOOTING
1. OPERATION FLOW
HINT Perform troubleshooting in accordance with the procedures below. The following is an outline
of basic troubleshooting procedures. Confirm the troubleshooting procedures for the circuit you are
working on before beginning troubleshooting.
1. VEHICLE BROUGHT TO WORKSHOP
NEXT -- Continue to next step.
2. CUSTOMER PROBLEM ANALYSIS
(a) Ask the customer about the conditions and environment when the problem occurred.
NEXT -- Continue to next step.
3. INSPECT BATTERY VOLTAGE
Standard voltage:
11 to 14 V
If the voltage is below 11 V, recharge or replace the battery before proceeding.
NEXT -- Continue to next step.
Page 4997
(a) Install the shift solenoid valve with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
6. INSTALL SHIFT SOLENOID VALVE SL1
7. INSTALL SHIFT SOLENOID VALVE SLT
(a) Install the shift solenoid valve.
(b) Install the 2 straight pins and lock plate with the bolt.
Torque : 6.4 Nm (65 kgf-cm, 57 in-lbf)
8. INSTALL SHIFT SOLENOID VALVE SLU
9. INSTALL SHIFT SOLENOID VALVE SL2
Page 2814
Standard Voltage:
NG -- CHECK HARNESS AND CONNECTOR (RELAY BLOCK - ECM, IGNITION SWITCH,
BATTERY AND BODY GROUND)
OK -- REPLACE ECM See: Service and Repair/Removal
5. CHECK HARNESS AND CONNECTOR (RELAY BLOCK - ECM, IGNITION SWITCH, BATTERY
AND BODY GROUND)
(a) Disconnect the ECM connector.
(b) Disconnect the ignition switch connector.
(c) Disconnect the cable from the battery positive (+) terminal.
(d) Remove the AM2 fuse and integration relay.
Page 2915
Camshaft Position Sensor: Service and Repair Installation
1UR-FE ENGINE CONTROL SYSTEM: CAMSHAFT POSITION SENSOR: INSTALLATION
1. INSTALL CAMSHAFT POSITION SENSOR
(a) Install the sensor with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(b) Connect the sensor connector.
2. INSTALL V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Installation
Diagrams
Brake Fluid Level Sensor/Switch: Diagrams
Page 6365
Multiple Junction Connector: Connector Views
Frame Wire
Oil Pressure Sender
Oil Pressure Sender: Diagrams Oil Pressure Sender
Page 8082
Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)
NOTICE: *
If the side airbag sensor has been dropped, or there are any cracks, dents or other defects in the
case, bracket or connector, replace it with a new one.
* When installing the side airbag sensor, be careful that the SRS wiring does not interfere with
other parts and that it is not pinched between other parts.
(d) Check that there is no looseness in the installation parts of the side airbag sensor.
(e) Connect the connector.
8. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY LH (for Rear Side) See: Body and
Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Installation
9. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH (for Rear Side)
10. INSTALL REAR DOOR SCUFF PLATE LH (for Rear Side) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and Repair/Roof
Headlining (For Double Cab)/Installation
11. INSTALL REAR SEAT ASSEMBLY (for Rear Side)
(a) Install the rear seat assembly See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Rear Seat Assembly (for Double
Cab)/Installation.
12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
13. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
Page 3516
C -- REPLACE ECM See: Engine Control Module/Service and Repair/Removal
B -- REPLACE ECM See: Engine Control Module/Service and Repair/Removal
A -- REPLACE ECM See: Engine Control Module/Service and Repair/Removal
Short to GND in CAN Bus Line
CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: Short to GND in CAN Bus Line Short to GND in CAN Bus Line
DESCRIPTION
There may be a short circuit between the CAN bus line and GND when there is resistance between
terminals 6 (CANH) and 4 (CG) or terminals 14 (CANL) and 4 (CG) of the DLC3.
HINT *
*1: w/ Bus Buffer ECU
* *2: w/ 4WD
* *3: w/ Power Steering ECU
WIRING DIAGRAM
Page 5022
Page 2243
Wheel Bearing: Tools and Equipment
Wheel Bearing Nut Socket
AST tool# TOY 185
For R and R of wheel bearing nut located on inboard side of wheel hub. Applicable: Newer Toyota
trucks and SUV's (2wd only).
- Made in USA
Contact AST for pricing.
Assenmacher Specialty Tools 1-800-525-2943
Page 230
Turn Signal Relay: Diagrams
Page 2305
(b) Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt.
NOTICE: *
Be careful not to damage the cylinder head with the wrench.
* Do not disassemble the camshaft timing gear.
(c) Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt.
NOTICE: Be careful not to damage the cylinder head with the wrench.
(d) Remove the 2 bolts. Then with the No. 1 and No. 2 chains still connected to the gears, remove
the camshaft timing gear, camshaft timing
exhaust gear and crankshaft timing sprocket LH.
(e) Remove the No. 1 and No. 2 chains from the gears.
7. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY
(a) Remove the 2 bolts and chain tensioner.
8. REMOVE CAMSHAFT BEARING CAP LH
(a) Make sure that the knock pin of the camshaft is positioned as shown in the illustration.
(b) Uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.
Page 2066
Push the terminal retainer down to the temporary lock position.
Components
Fuel Pressure Regulator: Service and Repair Components
1UR-FE FUEL: FUEL PRESSURE REGULATOR: COMPONENTS
Page 4273
Mongoose MFC Software and Driver MUST be installed before Mongoose MFC selection will be
available.
See TIS - Diagnostics - Scantool page for additional information.
^ If using TIS Techstream select TIS Techstream VIM (this is the default).
4. Click OK.
Operation Procedure
1. Verify the vehicle's applicability for recalibration and locate desired calibration file.
A. Connect Techstream and establish a vehicle connection.
B. Click the Health Check button on the System Select tab.
Page 6041
Remove the blown fuse and disconnect all loads of the fuse.
Connect a test light in place of the fuse.
Establish conditions in which the test light comes on.
Example:
- [A] - Ignition SW on
- [B] - Ignition SW and SW1 on
- [C] - Ignition SW, SW1 and Relay on (Connect the Relay) and SW2 off (or Disconnect SW2)
Disconnect and reconnect the connectors while watching the test light.
Page 5843
Acceleration/Deceleration Sensor: Programming and Relearning
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: CALIBRATION
1. DESCRIPTION
* After replacing components relating to the VSC or performing "Front wheel alignment
adjustment", clear and read the sensor calibration data.
* Follow the chart to perform calibration.
2. CLEAR ZERO POINT CALIBRATION DATA (WHEN USING TECHSTREAM)
(a) Connect the Techstream to the DLC3.
(b) Turn the ignition switch to ON.
(c) Operate the Techstream to erase the codes (select Reset Memory).
HINT Refer to the Techstream operator's manual for further details.
3. PERFORM ZERO POINT CALIBRATION OF MASTER CYLINDER PRESSURE SENSOR AND
DECELERATION SENSOR (WHEN
USING TECHSTREAM)
NOTICE: *
While obtaining the zero point, do not vibrate the vehicle by tilting, moving or shaking it and keep it
stationary. (Do not start the engine.)
* While obtaining the zero point, do not depress the brake and accelerator pedal.
* Obtain the zero point on a level surface (with an inclination of 1° or less).
(a) Enter Test Mode.
(1) Turn the ignition switch off.
(2) Check that the shift lever is in parking or neutral and apply the parking brake.
CAUTION: Application of the parking brake is not necessary for entering test mode. However,
apply the parking brake for safety.
(3) Connect the Techstream to the DLC3.
(4) Turn the ignition switch to ON.
NOTICE: Do not start the engine.
(5) Set the Techstream to test mode (select Test Mode).
HINT Refer to the Techstream operator's manual for further details.
(b) Obtain the zero points of the master cylinder pressure sensor and deceleration sensor.
(1) Keep the vehicle stationary on a level surface for 1 second or more.
HINT
Page 2484
ERROR: stackunderflow
OFFENDING COMMAND: ~
STACK:
Page 6658
Removal
OTHER SYSTEM: POWER OUTLET SOCKET (for Floor Shift Type): REMOVAL
1. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Removal
2. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding
/ Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
3. REMOVE REAR UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Removal
4. REMOVE CENTER LOWER INSTRUMENT PANEL FINISH PANEL See: Body and
Frame/Interior Moulding / Trim/Dashboard / Instrument
Page 1560
Tire Pressure Warning Reset Switch: Diagrams
Page 6968
DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector.
Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
Page 3209
Crankshaft Position Sensor: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: CRANKSHAFT POSITION SENSOR: REMOVAL
1. REMOVE CRANKSHAFT POSITION SENSOR PROTECTOR
(a) Remove the 2 bolts and sensor protector.
2. REMOVE CRANKSHAFT POSITION SENSOR
(a) Disconnect the sensor connector.
(b) Remove the bolt and sensor.
Page 3599
Manifold Pressure/Vacuum Sensor: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: MANIFOLD ABSOLUTE PRESSURE SENSOR:
REMOVAL
1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Removal
2. REMOVE MANIFOLD ABSOLUTE PRESSURE SENSOR
(a) Disconnect the manifold absolute pressure sensor connector.
(b) Remove the screw and manifold absolute pressure sensor.
(c) Remove the O-ring from the manifold absolute pressure sensor.
Page 1163
Crankshaft Position Sensor: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: CRANKSHAFT POSITION SENSOR: REMOVAL
1. REMOVE CRANKSHAFT POSITION SENSOR PROTECTOR
(a) Remove the 2 bolts and sensor protector.
2. REMOVE CRANKSHAFT POSITION SENSOR
(a) Disconnect the sensor connector.
(b) Remove the bolt and sensor.
Page 2048
Instrument Panel (Floor Shift)
Instrument Panel (Column Shift)
Page 9256
Up to 11/2009
ENGINE HOOD / DOOR: REAR DOOR (for Double Cab): REASSEMBLY
REAR DOOR TRIM BOARD SUB-ASSEMBLY LH
HINT *
Use the same procedures for the RH side and LH side.
* The procedures listed below are for the LH side.
* A bolt without a torque specification is shown in the standard bolt chart See:
Specifications/Mechanical Specifications/Standard Bolt - Specified Torque For Standard Bolts
1. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY LH
(a) Connect the 2 cables to the inside handle.
(b) Attach the inside handle's knob to the door trim board.
(c) Attach the 9 clips to install the door trim board.
(d) Install the inside handle and door trim board to the door trim panel with the screw.
(e) Install the door trim board to the door panel with the screw
(f) Attach the clip.
2. INSTALL REAR DOOR ARMREST COVER LH
3. INSTALL COURTESY LIGHT ASSEMBLY
(a) Connect the connector.
Locations
Transmission Position Switch/Sensor: Locations
A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS
LOCATION
Capacity Specifications
Fluid - Differential: Capacity Specifications
Differential Fluid Capacity
Front (4WD models) Capacity .............................................................................................................
.............................................................................................. 2.2 qt (2.05L)
Rear Regular Cab Models Standard Bed ............................................................................................
......................................................................................................... 4.3 qt (4.05L) Long Bed .............
..............................................................................................................................................................
................................ 4.9 qt (4.60L)
Double Cab and Crew Max Models Capacity ......................................................................................
.................................................................................................................... 4.9 qt (4.60L)
Page 7066
8. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
NOTICE: *
Some systems need to be initialized after the cable is reconnected ( See: Testing and
Inspection/Programming and Relearning).
* After the ignition switch is turned OFF, the navigation system requires approximately 90 seconds
to record various types of memory and settings. As a result, after turning the ignition switch OFF,
wait 90 seconds or more before disconnecting the cable from the negative (-) battery terminal.
9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
NOTICE: Some systems need to be initialized after the cable is reconnected See: Testing and
Inspection/Programming and Relearning
10. PERFORM YAW RATE AND DECELERATION SENSOR ZERO POINT CALIBRATION
(a) Perform the yaw rate and deceleration sensor zero point calibration See: Brakes and Traction
Control/Antilock Brakes / Traction Control
Systems/Testing and Inspection/Programming and Relearning.
11. CHECK STEERING ANGLE SENSOR ZERO POINT CALIBRATION
Page 1700
(b) : for 5 leaf spring
Measuring points:
A Ground clearance of the front drive shaft center
B Ground clearance of the front adjusting cam bolt center
C Ground clearance of the rear axle shaft center
D Ground clearance of the leaf spring front side bushing center
(c) If the vehicle height is not as specified, adjust the height by pressing down on the vehicle
several times to stabilize the suspension.
3. INSPECT TOE-IN
Page 5295
(b) Remove the grease fitting from the spider bearing.
(c) Using a brass bar and hammer, slightly tap in the 4 spider bearings.
(d) Using needle-nose pliers, remove the 4 snap rings from the grooves.
(e) Using a screwdriver, remove the 4 slingers of the spider bearing.
(f) Clamp the shaft in a vise between aluminum plates.
(g) Using SST, pull out the universal joint spider bearing from the shaft.
SST : 09331-60010
SST : 09950-40011
09951-04010
09952-04010
09953-04020
Page 6710
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION: Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC
terminals are touched, the IC may be destroyed by static electricity.)
When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact with the terminals of leads from the IC, etc. of the
replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown on the left.
DISCONNECT CONNECTOR
Page 5110
Actuator: Service and Repair Installation
DIFFERENTIAL: AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR (for 4WD):
INSTALLATION
1. INSTALL AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR
(a) Remove any old FIPG material and be careful not to drop oil on the contact surfaces of the
differential tube and actuator.
(b) Clean the contact surfaces with any residual FIPG material using gasoline or alcohol.
(c) Apply seal packing to the differential tube as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
HINT Install the actuator within 10 minutes of applying seal packing.
(d) Clean the threads of the 4 bolts and retainer bolt holes with toluene or trichloroethylene.
(e) Install the actuator onto the differential tube.
(f) Apply adhesive to 2 to 3 threads of each bolt end.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
(g) Install the 4 bolts.
Torque : 21 Nm (210 kgf-cm, 15 ft-lbf)
(h) Connect the actuator hose.
(i) Connect the actuator connector.
2. INSTALL NO. 1 ENGINE UNDER COVER See: Engine, Cooling and Exhaust/Engine/Drive
Belts, Mounts, Brackets and Accessories/Drive
Belt/Service and Repair/Installation
3. INSPECT AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR
(a) Inspect the automatic disconnecting differential actuator See: Transfer Case/Testing and
Inspection/Component Tests and General
Diagnostics/Touch Select 2-4 and High-Low System.
Components
Crankshaft Position Sensor: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: CRANKSHAFT POSITION SENSOR: COMPONENTS
Components
Power Steering Pressure Switch: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: POWER STEERING OIL PRESSURE SWITCH:
COMPONENTS
Page 3320
(e) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- REPAIR OR REPLACE ENGINE ROOM RELAY BLOCK
Page 2971
5. REMOVE PROPELLER SHAFT HEAT INSULATOR (for 4WD) See: Transmission and
Drivetrain/Drive/Propeller Shafts, Bearings and
Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Front Propeller Shaft
Assembly/Removal
6. REMOVE FRONT NO. 2 EXHAUST PIPE ASSEMBLY (for 4WD)
(a) Disconnect the heated oxygen sensor connector.
(b) Disconnect the air fuel ratio sensor connector.
(c) Disconnect the front No. 2 exhaust pipe from the exhaust pipe support.
(d) Remove the 3 nuts, front No. 2 exhaust pipe and gasket from the exhaust manifold LH.
7. REMOVE AIR FUEL RATIO SENSOR (for Bank 1 Sensor 1)
(a) for 2WD:
Disconnect the air fuel ratio sensor connector.
(b) Using SST, remove the sensor.
SST : 09224-00010
Installation
1UR-FE ENGINE CONTROL SYSTEM: AIR FUEL RATIO SENSOR: INSTALLATION
1. INSTALL AIR FUEL RATIO SENSOR (for Bank 1 Sensor 1)
(a) Install the sensor to the exhaust pipe by hand.
(b) Using SST, tighten the sensor.
SST : 09224-00010
Page 3657
1. Test drive the vehicle and confirm there is a harsh shift on acceleration below 20 mph and or
excessive lock-up operation at freeway speeds about 50
- 60 mph.
2. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in
Figure 1. Confirm if the ECM (PCM) calibration has
been updated. If the calibration ID listed is NOT the latest ECM (PCM) calibration - go to step 3.
3. Flash reprogram the ECM (PCM).
NOTE
^ The GR8 Battery Diagnostic Station MUST be used in Power Supply Mode to maintain battery
voltage at 13.5 volts while flash reprogramming the vehicle.
^ For details on how to use the GR8 Battery Diagnostic Station, refer to the GR8 Instruction Manual
located on the Technical Information System (TIS), Diagnostics - Battery.
Follow the procedures outlined in TSB No. T-SB-0064-10, "Techstream ECU Flash
Reprogramming Procedure", and flash the ECM (PCM) with the NEW calibration file update.
4. Start the engine and warm it up to normal operating temperature before test driving.
5. Test drive the vehicle to confirm proper vehicle operation and ECM (PCM) initial learning. Refer
to the Technical Information System (TIS) 2010
Tundra Repair Manual:
Drivetrain - Automatic Transmission/Transaxle - "A760E / A760F Automatic
Transmission/Transaxle: Automatic Transmission System: Initialization"
6. Install the Authorized Modifications Label.
A. Using a permanent marker enter the following information on the label:
^ ECM part number [Refer to the Parts Information section for the CURRENT PART NUMBER]
Transponder Key ECU
Alarm Module: Diagrams Transponder Key ECU
Page 5285
Removal
PROPELLER SHAFT: FRONT PROPELLER SHAFT ASSEMBLY: REMOVAL
1. REMOVE PROPELLER SHAFT HEAT INSULATOR
Page 3672
^ Calibration ID(s) [Refer to the Calibration Identification Chart for the NEW CALIBRATION ID]
^ Dealer Code
^ Repair Date
^ Change Authority [This TSB number]
B. Affix the Authorized Modifications Label to the vehicle at the location shown in Figure 1. The
Authorized Modifications Label is available
through the MDC P/N 00451-00001-LBL.
Testing and Inspection
Canister Purge Control Valve: Testing and Inspection
1UR-FE EMISSION CONTROL: PURGE VALVE: INSPECTION
1. INSPECT PURGE VSV
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) If the result is not as specified, replace the purge VSV.
(c) Inspect the purge VSV operation.
(1) Check that air does not flow from ports.
(2) Apply battery voltage across the terminals.
(3) Check that air flows from ports.
If the result is not as specified, replace the purge VSV.
Page 3216
Symbols Used Within Diagrams
Symbols Used Within Diagrams
Page 7594
(a) For an open circuit in the wire harness in Fig. 1, check the resistance or voltage, as described
below.
(b) Check the resistance.
(1) Disconnect connectors A and C and measure the resistance between them.
Standard resistance (Fig. 2):
HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally.
If the results match the examples above, an open circuit exists between terminal 1 of connector A
and terminal 1 of connector C.
(2) Disconnect connector B and measure the resistance between the connectors.
Standard resistance (Fig. 3):
* If the results match the examples above, an open circuit exists between terminal 1 of connector
B2 and terminal 1 of connector C.
(c) Check the voltage.
Page 5526
Transmission Speed Sensor: Diagrams
Page 6161
General Information
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: GENERAL
INFORMATION
* A large number of ECU controlled systems are used in the TOYOTA TUNDRA. In general, ECU
controlled systems are considered to be very intricate, requiring a high level of technical knowledge
to troubleshoot. However, most problem checking procedures only involve inspecting the ECU
controlled system's circuits one by one. An adequate understanding of the system and a basic
knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and
necessary repairs.
1. TROUBLESHOOTING PROCEDURES
* The troubleshooting procedures consist of diagnosis procedures for when a DTC is stored and
diagnosis procedures for when no DTC is stored. The basic idea is explained in the following table.
* Vehicle systems are complex and use many ECUs that are difficult to inspect independently.
Therefore, a process of elimination is used, where components that can be inspected individually
are inspected, and if no problems are found in these components, the related ECU is identified as
the problem and replaced.
* It is extremely important to ask the customer about the environment and the conditions present
when the problem occurred (Customer Problem Analysis). This makes it possible to simulate the
conditions and confirm the symptom. If the symptom cannot be confirmed or the DTC does not
recur, the malfunctioning part may not be identified using the troubleshooting procedure, and the
ECU for the related system may be replaced even though it is not defective. If this happens, the
original problem will not be solved.
* In order to prevent endless expansion of troubleshooting procedures, the troubleshooting
procedures are written with the assumption that multiple malfunctions do not occur simultaneously
for a single problem symptom.
* To identify the malfunctioning part, troubleshooting procedures narrow down the target by
separating components, ECUs and wire harnesses during the inspection. If the wire harness is
identified as the cause of the problem, it is necessary to inspect not only the connections to
components and ECUs but also all of the wire harness connectors between the component and the
ECU.
DIAGNOSTIC TESTER
2. DESCRIPTION
System data and the Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector
3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the Techstream* to
check for a malfunction and perform repairs.
HINT *: Techstream is the name for the diagnostic tester in North America.
3. DATA LINK CONNECTOR 3 (DLC3)
(a) The vehicle's ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of
the DLC3 complies with SAE J1962 and
matches the ISO 15765-4 format.
Page 4370
SST : 09268-31012
90467-13001
95336-08070
09268-41500
09268-41120
SST : 09268-45014
09268-41200
09268-41220
(g) Wipe off any gasoline.
(h) Reconnect the cable to the negative (-) battery terminal.
(i) Operate the fuel pump.
(1) Connect the Techstream to the DLC3.
(2) Turn the ignition switch to ON.
NOTICE: Do not start the engine.
(3) Turn the Techstream main switch ON.
(4) Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump /
Speed.
(j) Measure the fuel pressure.
Standard fuel pressure:
281 to 287 kPa (2.87 to 2.93 kgf/cm2, 41 to 42 psi)
(k) If the pressure is higher than the specification, replace the fuel pressure regulator.
If the pressure is lower than the specification, check the fuel hoses and connections, fuel pump,
fuel filter and fuel pressure regulator assembly.
(l) Start the engine.
Testing and Inspection
Drive Belt: Testing and Inspection
1UR-FE ENGINE MECHANICAL: DRIVE BELT: ON-VEHICLE INSPECTION
1. INSPECT FAN AND GENERATOR V BELT
(a) Check the belt for wear, cracks or other signs of damage.
(b) If any of the following defects is found, replace the fan and generator V belt.
* The belt is cracked.
* The belt is worn out to the extent that the cords are exposed.
* The belt has chunks missing from the ribs.
(c) Check that the belt fits properly in the ribbed grooves.
HINT Check with your hand to confirm that the belt has not slipped out of the grooves on the
bottom of the pulley. If it has slipped out, replace the fan and generator V belt. Install a new fan and
generator V belt correctly.
2. INSPECT V-RIBBED BELT TENSIONER ASSEMBLY
(a) Check that nothing gets caught in the tensioner by turning it clockwise and counterclockwise.
If the result is not as specified, replace the tensioner.
Page 8971
Remote Switch: Service and Repair Installation
AUDIO / VISUAL: STEERING PAD SWITCH: INSTALLATION
1. INSTALL STEERING PAD SWITCH ASSEMBLY
(a) Attach the 4 pins to install the switch with the 2 screws.
(b) Connect the connector.
2. INSTALL LOWER NO. 3 STEERING WHEEL COVER See: Restraint Systems/Air Bag
Systems/Air Bag/Service and Repair/Removal and
Replacement/Steering Pad/Installation
3. INSTALL LOWER NO. 2 STEERING WHEEL COVER See: Restraint Systems/Air Bag
Systems/Air Bag/Service and Repair/Removal and
Replacement/Steering Pad/Installation
4. INSTALL STEERING PAD See: Restraint Systems/Air Bag Systems/Air Bag/Service and
Repair/Removal and Replacement/Steering
Pad/Installation
5. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
6. INSPECT STEERING PAD See: Restraint Systems/Air Bag Systems/Air Bag/Service and
Repair/Removal and Replacement/Steering
Pad/Installation
7. CHECK SRS WARNING LIGHT See: Restraint Systems/Air Bag Systems/Air Bag/Service and
Repair/Removal and Replacement/Steering
Pad/Installation
Page 3453
Information Bus: Component Tests and General Diagnostics
Air Conditioning Amplifier Communication Stop Mode
CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: Air Conditioning Amplifier
Communication Stop Mode - Air Conditioning Amplifier Communication Stop Mode
DESCRIPTION
WIRING DIAGRAM
INSPECTION PROCEDURE
HINT Operating the ignition switch, any switches or any doors triggers related ECU and sensor
communication with the CAN, which causes resistance variation.
PROCEDURE
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
(a) Disconnect the cable from the negative (-) battery terminal before measuring the resistances of
the main wire and the branch wire.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
NEXT -- Continue to next step.
2. CHECK FOR OPEN IN CAN BUS WIRE (AIR CONDITIONING AMPLIFIER BRANCH WIRE)
(a) Disconnect the J19 air conditioning amplifier connector.
Page 7226
Steering Control Module: Service and Repair Installation
POWER STEERING: POWER STEERING ECU (for 1UR-FE): INSTALLATION
1. INSTALL POWER STEERING ECU ASSEMBLY
(a) Install the power steering ECU with the nut.
Torque : 8.5 Nm (87 kgf-cm, 75 in-lbf)
(b) Connect the power steering ECU connector.
2. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column
Shift Type)/Installation
3. INSTALL LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY See: Restraint
Systems/Air Bag Systems/Air Bag/Service and
Repair/Removal and Replacement/Driver Side Knee Airbag Assembly/Installation
4. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Installation
5. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
6. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Installation
7. INSTALL FRONT DOOR SCUFF PLATE LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining
(For Regular Cab)/Installation
Page 9228
(e) Remove the inside handle.
Reassembly
ENGINE HOOD / DOOR: FRONT DOOR (for Regular Cab): REASSEMBLY
FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH
HINT *
Use the same procedures for the RH side and LH side.
* The procedures listed below are for the LH side.
* A bolt without a torque specification is shown in the standard bolt chart See:
Specifications/Mechanical Specifications/Standard Bolt - Specified Torque For Standard Bolts
1. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH
(a) Connect the 2 cables to the inside handle.
(b) Attach the inside handle's knob to the door trim board.
(c) Attach the 10 clips to install the door trim board.
(d) Install the inside handle and door trim board to the door trim panel with the screw.
(e) Install the door trim board to the door panel with the screw.
Page 7022
for Regular Cab of Long Deck
for Double Cab of Standard Deck
Components
Seat Occupant Classification Module - Air Bag: Service and Repair Components
SUPPLEMENTAL RESTRAINT SYSTEM: OCCUPANT CLASSIFICATION ECU: COMPONENTS
Page 7291
(a) Install SST onto the power steering rack.
SST : 09631-20111
HINT If necessary, scrape the burrs off the power steering rack teeth end and burnish.
(b) Coat SST with power steering fluid.
(c) Install the power steering rack into the rack housing.
(d) Remove SST.
4. INSTALL POWER STEERING RACK BUSH
(a) Using SST and a press, install a new rack bush oil seal onto the rack bush.
SST : 09950-60010
09951-00440
SST : 09950-70010
09951-07100
NOTICE: Make sure that the rack bush oil seal is installed facing the correct direction.
(b) Coat a new O-ring with power steering fluid and install it onto the rack bush.
(c) To prevent the rack bush oil seal lip from being damaged, wind vinyl tape around the rack end
and apply power steering fluid.
Page 2202
Tire Pressure Sensor: Diagrams
Page 6353
(a) For an open circuit in the wire harness in Fig. 1, check the resistance or voltage, as described
below.
(b) Check the resistance.
(1) Disconnect connectors A and C and measure the resistance between them.
Standard resistance (Fig. 2):
HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally.
If the results match the examples above, an open circuit exists between terminal 1 of connector A
and terminal 1 of connector C.
(2) Disconnect connector B and measure the resistance between the connectors.
Standard resistance (Fig. 3):
* If the results match the examples above, an open circuit exists between terminal 1 of connector
B2 and terminal 1 of connector C.
(c) Check the voltage.
Door Control Switch (for Front LH)
Power Door Lock Switch: Testing and Inspection Door Control Switch (for Front LH)
DOOR LOCK: DOOR CONTROL SWITCH (for Front LH): INSPECTION
1. INSPECT DOOR CONTROL SWITCH ASSEMBLY (for Regular Cab)
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the control switch assembly.
2. INSPECT DOOR CONTROL SWITCH ASSEMBLY (for Double Cab)
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
Page 1666
(4) Connect the battery's positive (+) lead to terminal B-1 (+S) for 5 seconds.
(5) Connect the battery's negative (-) lead to terminal B-1 (+S). Operate the intermittent wiper relay
and check the voltage between terminals
B-3 (+1) and A-2 (EW).
OK:
Refer to illustration below.
(6) If the result is not as specified, replace the switch assembly.
(d) Check the washer operation.
(1) Turn the wiper switch OFF.
(2) Connect the battery's positive (+) lead to terminal B-2 (+B) and the negative (-) lead to terminals
B-1 (+S) and A-2 (EW).
(3) Connect the voltmeter's positive (+) lead to terminal B-3 (+1) and the negative (-) lead to
terminal A-2 (EW).
(4) Turn the washer switch ON and OFF, and check the voltage between terminals B-3 (+1) and
A-2 (EW).
OK:
Refer to illustration below.
(5) If the result is not as specified, replace the switch assembly.
Page 8066
Impact Sensor: Testing and Inspection
Center Airbag Sensor Assembly (for Column Shift Type)
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Column
Shift Type): ON-VEHICLE INSPECTION
1. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION)
(a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnosis System.
2. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND
AIRBAG HAS NOT DEPLOYED)
(a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnosis System.
3. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND
AIRBAG IS DEPLOYED)
(a) Replace the center airbag sensor.
CAUTION: For removal and installation procedures of the center airbag sensor, be sure to follow
the correct procedure.
HINT The center airbag sensor should be replaced after any of the airbags has deployed, as it has
been subjected to the impact.
Center Airbag Sensor Assembly (for Floor Shift Type)
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift
Type): ON-VEHICLE INSPECTION
1. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION)
(a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnosis System.
2. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND
AIRBAG HAS NOT DEPLOYED)
(a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnosis System.
3. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND
AIRBAG IS DEPLOYED)
(a) Replace the center airbag sensor.
CAUTION: For removal and installation procedures of the center airbag sensor, be sure to follow
the correct procedure.
HINT The center airbag sensor should be replaced after any of the airbags has deployed, as it has
been subjected to the impact.
Front Airbag Sensor
SUPPLEMENTAL RESTRAINT SYSTEM: FRONT AIRBAG SENSOR: ON-VEHICLE
INSPECTION
1. CHECK FRONT AIRBAG SENSOR (VEHICLE NOT INVOLVED IN COLLISION)
(a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnosis System.
2. CHECK FRONT AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS
NOT DEPLOYED)
(a) Perform a diagnostic system check See: Testing and Inspection/Initial Inspection and
Diagnostic Overview/Diagnosis System.
(b) When the front bumper of the vehicle or its area is damaged, check if there is any damage to
the front airbag sensor. If the front airbag sensor
has defects as mentioned below, replace it with a new one:
* Cracks, dents or chips on the sensor housing.
* Cracks or other damage to the connector.
Page 1262
Air Flow Meter/Sensor: Diagrams
Page 3866
Throttle Position Sensor: Diagrams
Page 7620
(a) Detach the 2 claws and remove the sensor.
Recall 11V185000 - TPMS Non-Compliance
Tire Pressure Module: Recalls Recall 11V185000 - TPMS Non-Compliance
VEHICLE MAKE/MODEL: MODEL YEAR(S) Toyota/FJ Cruiser 2011
Toyota/Tundra 2009-2011
MANUFACTURER: Gulf States Toyota, Inc.
MFR'S REPORT DATE: March 16, 2011
NHTSA CAMPAIGN ID NUMBER: 11V185000
NHTSA ACTION NUMBER: N/A
COMPONENT: Tires: Pressure Monitoring and Regulating Systems
POTENTIAL NUMBER OF UNITS AFFECTED: 1,489
SUMMARY: Gulf States Toyota is recalling certain model year 2011 FJ Cruiser and model year
2009-2011 Tundra vehicles for failing to comply with the requirements of Federal Motor Vehicle
Safety Standard No. 138, "Tire Pressure Monitoring Systems." The TPMS on some vehicles may
not have been properly calibrated and as a result the low tire pressure warning lamp may not
illuminate should the inflation pressure in one or more of the vehicle's tires fall below the threshold
for when the low tire pressure warning lamp should illuminate.
CONSEQUENCE: Drivers will not receive a warning from the tire pressuring monitor that one or
more tires are underinflated increasing the risk that a vehicle will be driven with one or more
underinflated tires and increasing the risk of a tire failure that may lead to a crash.
REMEDY: Dealers will recalibrate the tire pressure monitoring system in accordance with the
regulation free of charge. The safety recall is expected to begin during April 2011. Owners may
contact Gulf State Toyota Customer Assistance Center toll free at 1-800-444-1074 Monday through
Thursday, 8:30 AM to 5:00 PM, or Friday 8:30 AM to 4:00 PM Central Standard Time.
NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle
Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov.
Page 3496
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO SKID CONTROL ECU
WITH ACTUATOR (CANH, CANL)
OK -- REPLACE SKID CONTROL ECU WITH ACTUATOR See: Brakes and Traction
Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock
Brakes/Service and Repair/Removal and Replacement/Removal
16. CHECK FOR SHORT IN CAN BUS WIRES (STEERING ANGLE SENSOR)
(a) Disconnect the J6 steering angle sensor connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- REPAIR OR REPLACE CAN BRANCH WIRE CONNECTED TO STEERING ANGLE
SENSOR (CANH, CANL)
OK -- REPLACE STEERING ANGLE SENSOR
17. CHECK FOR SHORT IN CAN BUS WIRES (POWER STEERING ECU)
(a) Disconnect the J101 power steering ECU connector.
Page 7059
Standard caster inclination (unloaded vehicle):
for CrewMax of standard deck
Page 8405
Seat Occupant Sensor: Diagrams Rear Occupant Classification Sensor
Page 2704
Page 8171
Air Bag Control Module: Service and Repair Center Airbag Sensor Assembly (for Floor Shift Type)
Components
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift
Type): COMPONENTS
Page 7036
*: for 5 leaf spring
Standard Steering Angle Inclination
for Regular Cab of Standard Deck
Page 2959
Engine Bank Identification
Page 2616
Spark Plug: Service and Repair Installation
1UR-FE IGNITION: IGNITION COIL AND SPARK PLUG: INSTALLATION
1. INSTALL SPARK PLUG
(a) Using a 16 mm plug wrench, install the 8 spark plugs.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
2. INSTALL IGNITION COIL ASSEMBLY
(a) for Bank 1:
(1) Install the 4 ignition coils with the 4 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(2) Connect the 4 ignition coil connectors.
(3) Connect the 3 wire harness clamps.
(b) for Bank 2:
(1) Install the 4 ignition coils with the 4 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(2) Connect the 4 ignition coil connectors and 2 wire harness clamps.
(3) Connect the water by-pass pipe with the 2 bolts.
Torque : 18 Nm (184 kgf-cm, 13 ft-lbf)
Page 862
Engine Temperature Sensor: Testing and Inspection
1UR-FE ENGINE CONTROL SYSTEM: ENGINE COOLANT TEMPERATURE SENSOR:
INSPECTION
1. INSPECT ENGINE COOLANT TEMPERATURE SENSOR
(a) Partially immerse the sensor in water and warm up the water.
(b) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(c) If the result is not as specified, replace the engine coolant temperature sensor.
NOTICE: When checking the sensor in water, keep the terminals dry. After the check, wipe the
sensor dry.
HINT If the result is as specified, do not replace the engine coolant temperature sensor.
Page 404
(b) Spray gasket remover or equivalent on the remaining tape of the gasket.
NOTICE: When using gasket remover or equivalent, cover the ECM connector with a cloth.
(c) Remove the tape of the gasket without using bladed objects.
Page 9202
Page 7319
SST : 09950-40011
09951-04010
09953-04020
09954-04010
09955-04031
09958-04011
09952-04010
SST : 09955-04090
HINT Claw A 09955-04090
Claw B 09955-04031
Installation
SUSPENSION: FRONT LOWER SUSPENSION ARM: INSTALLATION
HINT *
Use the same procedures for the RH side and LH side.
* The procedures listed below are for the LH side.
* A bolt without a torque specification is shown in the standard bolt chart See:
Specifications/Mechanical Specifications/Standard Bolt - Specified Torque For Standard Bolts
1. TEMPORARILY INSTALL FRONT NO. 1 SUSPENSION ARM LOWER SUB-ASSEMBLY LH
Page 8802
* The procedures listed below are for the LH side.
1. INSTALL FRONT NO. 3 SPEAKER ASSEMBLY (for 12 Speakers)
(a) Attach the 3 claws to install the speaker to the bracket.
NOTICE: Do not touch the cone part of the speaker.
(b) Install the speaker with bracket to the lower frame bracket garnish with the 3 screws.
2. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY
(a) Temporarily install the speaker by attaching the claws of the speaker to the door panel.
(b) Install the speaker with the 4 screws.
NOTICE: Do not touch the cone part of the speaker.
HINT Install the screws in the order shown in the illustration.
(c) Connect the connector.
3. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH See: Body and Frame/Doors,
Hood and Trunk/Doors/Front Door/Service and
Repair/Front Door (for CrewMax)/Reassembly
4. INSTALL FRONT DOOR ARMREST COVER LH
5. INSTALL COURTESY LIGHT ASSEMBLY See: Body and Frame/Doors, Hood and
Trunk/Doors/Front Door/Service and Repair/Front Door
(for CrewMax)/Reassembly
6. INSTALL FRONT UPPER ARMREST BASE PANEL LH See: Body and Frame/Doors, Hood and
Trunk/Doors/Front Door/Service and
Repair/Front Door (for CrewMax)/Reassembly
7. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH See: Body and Frame/Doors,
Hood and Trunk/Doors/Front Door/Service and
Page 4178
Page 8569
Removal and Replacement
Suspension Spring ( Coil / Leaf ): Removal and Replacement
Components
SUSPENSION: REAR LEAF SPRING: COMPONENTS
Page 8222
(2) Press SST activation switch and check that the LED of SST activation switch illuminates.
CAUTION: If the LED illuminates when the activation switch is not being pressed, SST may be
malfunctioning. Replace SST with a new one.
(b) Disconnect SST from the battery.
(c) Disconnect the pretensioner connector.
(1) Disconnect the cable from the negative (-) battery terminal.
(2) Remove the front door scuff plate See: Removal and Replacement/Front Seat Outer Belt
Assembly (for Double Cab)/Removal.
(3) Remove the rear door scuff plate See: Removal and Replacement/Front Seat Outer Belt
Assembly (for Double Cab)/Removal.
(4) Remove the front door opening trim weatherstrip See: Removal and Replacement/Front Seat
Outer Belt Assembly (for Double
Cab)/Removal.
(5) Remove the rear door opening trim weatherstrip See: Removal and Replacement/Front Seat
Outer Belt Assembly (for Double
Cab)/Removal.
(6) Remove the lower center pillar garnish See: Removal and Replacement/Front Seat Outer Belt
Assembly (for Double Cab)/Removal.
(7) Disconnect the pretensioner connector as shown in the illustration.
(d) Prepare SST for activation of the seat belt pretensioner.
(1) Install the floor anchor of the seat belt.
(2) Connect SST (A) to SST (B). Then connect SST (B)'s connector to the seat belt pretensioner.
SST : 09082-00700
SST : 09082-00770
NOTICE: To avoid damaging SST connector and wire harness, do not lock the secondary lock of
the twin lock.
Components
Auxiliary Power Outlet Switch: Service and Repair Components
OTHER SYSTEM: INVERTER MAIN SWITCH (for CrewMax): COMPONENTS
Page 5148
Seals and Gaskets: Service and Repair Front Differential Carrier Oil Seal
Components
DIFFERENTIAL: FRONT DIFFERENTIAL CARRIER OIL SEAL (for 4WD): COMPONENTS
Page 7701
9. INSTALL LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY
10. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Installation
11. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
12. INSTALL CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service
and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
13. INSTALL FRONT PILLAR GARNISH LH
14. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH (Double cab, CrewMax)
15. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH (for Regular Cab)
16. INSTALL COWL SIDE TRIM BOARD LH
(a) for Regular Cab:
Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Column Shift Type)/Installation.
(b) for Double Cab:
Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Column Shift Type)/Installation.
(c) for CrewMax:
Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Column Shift Type)/Installation.
17. INSTALL FRONT DOOR SCUFF PLATE LH
(a) for Regular Cab:
Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Column Shift Type)/Installation.
(b) for Double Cab:
Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Column Shift Type)/Installation.
(c) for CrewMax:
Install the front door scuff plate See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Column Shift Type)/Installation.
18. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
19. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Reading and Clearing Diagnostic Trouble
Codes/Check Mode Procedure.
Page 1425
Removal
SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for Regular Cab): REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Regular Cab)/Disassembly
3. REMOVE FRONT ARMREST BASE PANEL UPPER LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Page 3937
This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown.
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60
months or 60,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Op Code EG9029 or EG9024: For California specification vehicles sold, registered, and operated
in California, Connecticut, Maine, Massachusetts, New Jersey, Oregon, Pennsylvania, Rhode
Island, Vermont, and Washington, this repair is covered under the California Emission Warranty.
This warranty is in effect for 84 months or 70,000 miles, whichever occurs first, from the vehicle's
in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Page 3635
Power Steering Pressure Switch: Testing and Inspection
1UR-FE ENGINE CONTROL SYSTEM: POWER STEERING OIL PRESSURE SWITCH:
ON-VEHICLE INSPECTION
1. INSPECT POWER STEERING OIL PRESSURE SWITCH
(a) Check the oil pressure switch.
(1) Connect the Techstream to the DLC3.
(2) Turn the ignition switch to ON.
(3) Turn the Techstream main switch on.
(4) Enter the following menus: Powertrain / Engine and ECT / Data List / All Data / Power Steering
pressure.
(5) Start the engine.
(6) Operate the steering wheel while idling, and read the value on the Techstream.
Standard:
(7) If not as specified, check for DTCs See: Testing and Inspection/Reading and Clearing
Diagnostic Trouble Codes/DTC Check / Clear. If
the power steering system inspection results are normal and a DTC is not output, replace the
power steering oil pressure switch.
Inspect the power steering system See: Steering and Suspension/Steering/Testing and
Inspection/Component Tests and General Diagnostics/Power Steering System/On-Vehicle
Inspection. If the power steering system inspection results are normal and a DTC is not output,
replace the power steering oil pressure switch.
Page 7845
(a) Detach the 2 claws and remove the sensor.
Page 281
(1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be
checked by conducting a voltage check.
With each connector still connected, measure the voltage between the body ground and these
terminals (in this order): 1) terminal 1 of connector A; 2) terminal 1 of connector B; and 3) terminal
1 of connector C.
Standard voltage (Fig. 4):
* If the results match the examples above, an open circuit exists in the wire harness between
terminal 1 of connector B and terminal 1 of connector C.
3. CHECK FOR SHORT CIRCUIT
(a) If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance
check with the body ground (below).
(b) Check the resistance with the body ground.
(1) Disconnect connectors A and C and measure the resistance.
Standard resistance (Fig. 6):
HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally.
If your results match the examples above, a short circuit exists between terminal 1 of connector A
and terminal 1 of connector C.
Engine - Oil Filter Cap Assembly Precaution
Oil Filter: Technical Service Bulletins Engine - Oil Filter Cap Assembly Precaution
T-SB-01 04-09
April 10, 2009
Oil Filter Cap Assembly Precautions
Service Category Engine/Hybrid System
Section Lubrication
Market USA
Applicability
TSB SUPERSESSION NOTICE
The information contained in this TSB supersedes TSB No. T-SB-0332-08.
^ Applicability has been updated to include 2009 - 2010 model year Highlander, 2010 model year
Camry, Corolla, Matrix, Sequoia, Tundra, and 2009 model year Venza vehicles.
^ The SST table has been updated with an illustration.
^ The Notice in the Repair Procedure has been updated with a Figure and torque specification
ranges to clarify SST usage.
TSB No. T-SB-0332-08 is Obsolete and any printed versions should be discarded. Be sure to
review the entire content of this service bulletin before proceeding.
Introduction
To prevent damage to the oil filter cap assembly this procedure must be closely followed during oil
filter replacement to avoid immediate and future oil filter serviceability concerns.
The following engines are equipped with a plastic oil filter cap assembly:
^ 1UR-FE (Tundra Sequoia)
^ 3UR-FE (Tundra Sequoia Land Cruiser)
^ 2ZR-FE (Corolla Matrix)
Page 1479
"Case1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (/\ Mark) and pull the terminal retainer
up to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Page 6287
If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness
or connector in that circuit in the past. Check the wire harness and connectors.
B -- SYSTEM NORMAL
A -- TROUBLESHOOTING OF EACH PROBLEM SYMPTOM
The problem is still occurring in a place other than the diagnostic circuit (the DTC displayed first is
either for a past problem or a secondary problem).
4. SYMPTOM SIMULATION
HINT The most difficult case in troubleshooting is when no problem symptoms occur. In such a
case, a thorough problem analysis must be carried out. A simulation of the same or similar
conditions and environment in which the problem occurred in the customer's vehicle should be
carried out. No matter how much skill or experience a technician has, troubleshooting without
confirming the problem symptoms will lead to important repairs being overlooked and mistakes or
delays.
For example:
With a problem that only occurs when the engine is cold or as a result of vibration caused by the
road during driving, the problem can never be determined if the symptoms are being checked on a
stationary vehicle or on a vehicle with a warmed-up engine. Vibration, heat or water penetration
(moisture) is difficult to reproduce. The symptom simulation tests below are effective substitutes for
the conditions and can be applied on a stationary vehicle.
Important points in the symptom simulation test:
In the symptom simulation test, the problem symptoms as well as the problem area or parts must
be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then,
connect the tester and carry out the symptom simulation test, judging whether the circuit being
tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the
problem symptoms table for each system to narrow down the possible causes.
To reproduce DTCs, it is necessary to satisfy the respective DTC detection conditions.
(a) VIBRATION METHOD:
When a malfunction seems to occur as a result of vibration.
(1) PART AND SENSOR
Apply slight vibration with a finger to the part of the sensor suspected to be the cause of the
problem, and check whether or not the malfunction occurs.
NOTICE: Applying strong vibration to relays may open them.
Page 8182
Seat Occupant Classification Module - Air Bag: Locations Occupant Classification System
SUPPLEMENTAL RESTRAINT SYSTEM: OCCUPANT CLASSIFICATION SYSTEM: PARTS
LOCATION
Page 2627
Water Pump: Service and Repair Removal
1UR-FE COOLING: WATER PUMP: REMOVAL
1. REMOVE FAN SHROUD
(a) Remove the fan shroud See: Cooling System/Radiator Cooling Fan/Service and
Repair/Removal.
2. REMOVE WATER INLET SUB-ASSEMBLY WITH THERMOSTAT
(a) Remove the water inlet with thermostat See: Cooling System/Thermostat/Service and
Repair/Removal.
3. REMOVE FRONT FENDER APRON SEAL LH See: Exhaust System/Exhaust Manifold/Service
and Repair/Removal
4. DISCONNECT COOLER COMPRESSOR ASSEMBLY (w/ Oil Cooler) See: Heating and Air
Conditioning/Compressor HVAC/Service and
Repair/Removal and Replacement/Removal
5. REMOVE WATER BY-PASS PIPE (w/ Oil Cooler)
(a) Remove the 2 bolts.
(b) Disconnect the 4 water hoses and remove the water by-pass pipe.
6. REMOVE NO. 1 WATER BY-PASS HOSE
(a) Remove the water by-pass hose.
7. DISCONNECT NO. 8 WATER BY-PASS HOSE
(a) Disconnect the water by-pass hose.
8. DISCONNECT NO. 5 WATER BY-PASS HOSE
(a) Disconnect the water by-pass hose.
9. REMOVE WATER INLET HOUSING
Page 4292
^ Calibration ID(s) [Refer to the Calibration Identification Chart for the NEW CALIBRATION ID]
^ Dealer Code
^ Repair Date
^ Change Authority [This TSB number]
B. Affix the Authorized Modifications Label to the vehicle at the location shown in Figure 1. The
Authorized Modifications Label is available
through the MDC P/N 00451-00001-LBL.
Page 672
(b) Disconnect the power window regulator master switch connector.
2. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY
(a) Remove the 3 screws and master switch.
Installation
DOOR LOCK: DOOR CONTROL SWITCH (for Front LH): INSTALLATION
1. INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY
(a) Install the master switch with the 3 screws.
Page 4343
Components
Power Steering Pressure Switch: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: POWER STEERING OIL PRESSURE SWITCH:
COMPONENTS
Adjustments
Parking Assist Control Module: Adjustments
PARK ASSIST / MONITORING: CLEARANCE WARNING ECU: ADJUSTMENT
1. ADJUST BUZZER VOLUME
(a) Turn the knob on the clearance warning ECU to adjust the volume.
Page 1400
Page 8822
Removal
AUDIO / VISUAL: FRONT DOOR SPEAKER (for Regular Cab): REMOVAL
HINT *
Use the same procedures for the LH side and RH side.
* The procedures listed below are for the LH side.
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE FRONT LOWER DOOR FRAME BRACKET GARNISH LH See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Regular Cab)/Disassembly
3. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH See: Body and Frame/Doors,
Hood and Trunk/Doors/Front Door/Service and
Repair/Front Door (for Regular Cab)/Disassembly
Page 8166
Air Bag Control Module: Testing and Inspection Center Airbag Sensor Assembly (for Floor Shift
Type)
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift
Type): ON-VEHICLE INSPECTION
1. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION)
(a) Perform a diagnostic system check See: Air Bag Systems/Testing and Inspection/Initial
Inspection and Diagnostic Overview/Diagnosis
System.
2. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND
AIRBAG HAS NOT DEPLOYED)
(a) Perform a diagnostic system check See: Air Bag Systems/Testing and Inspection/Initial
Inspection and Diagnostic Overview/Diagnosis
System.
3. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND
AIRBAG IS DEPLOYED)
(a) Replace the center airbag sensor.
CAUTION: For removal and installation procedures of the center airbag sensor, be sure to follow
the correct procedure.
HINT The center airbag sensor should be replaced after any of the airbags has deployed, as it has
been subjected to the impact.
Page 7005
Driver Side J/B Inner Circuit
Page 8365
Removal
SUPPLEMENTAL RESTRAINT SYSTEM: FRONT AIRBAG SENSOR: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE BATTERY
(a) Disconnect the cable from the positive (+) battery terminal.
Page 4790
^ Figure 17 shows an example of the update procedure for a two-processor ECU.
G. Turn ignition OFF. Then click Next.
H. Confirm the following:
^ Ignition is ON and engine is OFF or "READY" OFF (hybrid vehicles).
^ Hood is open.
^ All accessories are OFF.
^ Battery voltage is above 11.4 volts.
NOTICE
Verify the vehicle is connected to a battery charger before continuing - If battery voltage falls below
11.4 volts, ECU damage may occur.
Page 7192
Power Steering Pump: Overhaul
Disassembly
POWER STEERING: VANE PUMP (for 1UR-FE): DISASSEMBLY
1. FIX VANE PUMP ASSEMBLY
(a) Using SST, hold the vane pump in a vise.
SST : 09630-00014
09631-00132
2. REMOVE POWER STEERING SUCTION PORT UNION
(a) Remove the bolt and suction port union from the vane pump.
(b) Using a screwdriver, remove the O-ring from the suction port union.
3. REMOVE VANE PUMP REAR HOUSING
(a) Remove the 4 bolts and rear housing from the front housing.
(b) Using a screwdriver, remove the O-ring from the rear housing.
Page 6551
Driver Side J/B - Cowl Side Left
Locations
Knock Sensor: Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 6194
Auxiliary Power Outlet: Service and Repair
Components
OTHER SYSTEM: CENTER POWER OUTLET SOCKET (for Column Shift Type): COMPONENTS
Page 8751
Required Tools & Equipment
Repair Procedure Overview
^ Confirm noise is coming from the rear of the vehicle and changes with vehicle speed.
^ Install ChaSSiSEAR(TM) (or equivalent) and isolate the noise to the rear wheel bearing.
^ Remove the rear axle shaft assembly.
^ Install new rear wheel bearing brake caliper bracket and seals.
^ Reinstall rear axle shaft assembly and confirm the noise is no longer present.
Repair Procedure
1. Test drive the vehicle and confirm the customer complaint.
Does the noise increase and decrease with vehicle speed?
^ YES - Go to step 2.
^ NO - This TSB does NOT apply. Refer to the Repair Manual for further diagnosis.
Page 522
Tire Pressure Module: Locations
TIRE AND WHEEL: TIRE PRESSURE WARNING SYSTEM: PARTS LOCATION
Engine Control System - SFI System
Crankshaft Position Sensor: Locations Engine Control System - SFI System
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Locations
Throttle Position Sensor: Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 9312
Lower Side Moulding / Trim: Service and Repair Installation
EXTERIOR: SIDE MOULDING: INSTALLATION
HINT *
Use the same procedures for the RH side and LH side.
* The procedures listed below are for the LH side.
* When installing the moulding, heat the vehicle body and moulding using a heat light.
Standard heating temperature:
NOTICE: Do not heat the vehicle body and moulding excessively.
1. INSTALL LOWER NO. 1 SIDE PANEL MOULDING LH
(a) Clean the vehicle body surface.
(1) Using a heat light, heat the vehicle body surface.
(2) Remove the double-sided tape from the vehicle body.
(3) Wipe off any tape adhesive residue with cleaner.
(b) If reusing the moulding:
Clean the moulding.
(1) Using a heat light, heat the moulding.
(2) Remove the double-sided tape from the moulding.
(3) Wipe off any tape adhesive residue with cleaner.
(4) Apply new double-sided tape to the moulding, as shown in the illustration.
(c) Install the moulding.
(1) Using a heat light, heat the vehicle body and moulding.
(2) Remove the peeling paper from the face of the moulding.
HINT After removing the peeling paper, keep the exposed adhesive free from foreign matter.
Page 360
load while reprogramming.
^ Confirm the hood is open and ensure under hood temperature does NOT exceed 158°F (70°C).
^ Confirm cable connections between the vehicle and Techstream are secure.
^ Do NOT disconnect or turn off Techstream or vehicle ignition during reprogramming.
^ Set parking brake.
^ Complete ALL flash calibration updates provided for each ECU.
^ If the battery's state of charge or capacity are in question, test with SST. No. 00002-8150-KIT
"Digital Battery Analyze," and follow TSB No. PG001-06, "Battery Maintenance for In-Stock
Vehicles & Pre-Delivery" or the appropriate "Maintenance for HV & Auxiliary Batteries" service
bulletin.
^ The GR8 Battery Diagnostic Station MUST be used in Power Supply Mode to maintain battery
voltage at 13.5 volts while flash reprogramming the vehicle. For details on how to use the GR8
Battery Diagnostic Station, refer to the GR8 Instruction Manual located on TIS, Diagnostics - Tools
& Equipment - Battery Diagnostics.
3C. Click Next to start the calibration update process.
D. When using TIS Techstream select Techstream VIM as the desired programming device. Then
click Next.
Page 688
(a) Inspect the outer mirror switch.
(1) Select "L" on the left/right adjustment switch.
(2) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(3) If the result is not as specified, replace the outer mirror switch.
(4) Select "R" on the left/right adjustment switch.
(5) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(6) If the result is not as specified, replace the outer mirror switch.
(b) Inspect the retract switch.
(1) Measure the resistance according to the value(s) in the table below.
Standard resistance:
Page 2788
2. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in
Figure 1. Confirm if the ECM (PCM) calibration has
been updated. If the calibration ID listed is NOT the latest ECM (PCM) calibration - go to step 3.
3. Flash reprogram the ECM (PCM).
NOTE
^ The GR8 Battery Diagnostic Station MUST be used in Power Supply Mode to maintain battery
voltage at 13.5 volts while flash reprogramming the vehicle.
^ For details on how to use the GR8 Battery Diagnostic Station, refer to the located on the
Technical Information System (TIS), Diagnostics - Battery
Follow the procedures outlined in TSB No. T-SB-0064-10, "Techstream ECU Flash
Reprogramming Procedure1⁄4 and flash the ECM (PCM) with the NEW calibration file update.
4. Install the Authorized Modifications Label.
A. Using a permanent marker enter the following information on the label:
^ ECM part number [Refer to the Parts Information section for the CURRENT PART NUMBER]
^ Calibration ID(s) [Refer to the Calibration Identification Chart for the NEW CALIBRATION ID]
^ Dealer Code
^ Repair Date
^ Change Authority [This TSB number]
B. Affix the Authorized Modifications Label to the vehicle at the location shown in Figure 1. The
Authorized Modifications Label is available
through the MDC P/N 00451-00001-LBL.
5. Test drive the vehicle to confirm proper vehicle operation.
Components
Refrigerant Pressure Sensor / Switch: Service and Repair Components
AIR CONDITIONING: PRESSURE SWITCH: COMPONENTS
Page 6746
Engine Room R/B And Engine Room J/B Inner Circuit
Page 6704
Front Occupant Classification Sensor
Seat Occupant Sensor: Diagrams Front Occupant Classification Sensor
Page 8148
Page 7317
Removal
SUSPENSION: FRONT LOWER SUSPENSION ARM: REMOVAL
HINT *
Use the same procedures for the RH side and LH side.
* The procedures listed below are for the LH side.
1. REMOVE FRONT WHEEL
2. REMOVE FRONT STABILIZER LINK ASSEMBLY LH See: Stabilizer Bar/Service and
Repair/Removal
3. DISCONNECT FRONT SHOCK ABSORBER WITH COIL SPRING LH
Page 1646
(a) Using a screwdriver, detach the 2 clips and 5 claws, and remove the front upper armrest base
panel.
HINT Tape the screwdriver tip before use.
(b) Disconnect the 2 connectors.
2. REMOVE POWER WINDOW REGULATOR SWITCH ASSEMBLY
(a) Detach the 2 claws and remove the regulator switch.
Page 1363
Air Bag Deactivation Switch: Testing and Inspection Curtain Shield Airbag Cutoff Switch
SUPPLEMENTAL RESTRAINT SYSTEM: CURTAIN SHIELD AIRBAG CUTOFF SWITCH:
INSPECTION
1. INSPECT CURTAIN SHIELD AIRBAG CUTOFF SWITCH
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
Page 5963
(1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be
checked by conducting a voltage check.
With each connector still connected, measure the voltage between the body ground and these
terminals (in this order): 1) terminal 1 of connector A; 2) terminal 1 of connector B; and 3) terminal
1 of connector C.
Standard voltage (Fig. 4):
* If the results match the examples above, an open circuit exists in the wire harness between
terminal 1 of connector B and terminal 1 of connector C.
3. CHECK FOR SHORT CIRCUIT
(a) If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance
check with the body ground (below).
(b) Check the resistance with the body ground.
(1) Disconnect connectors A and C and measure the resistance.
Standard resistance (Fig. 6):
HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally.
If your results match the examples above, a short circuit exists between terminal 1 of connector A
and terminal 1 of connector C.
Page 1517
Neutral Safety Switch: Service and Repair Installation
A760F AUTOMATIC TRANSMISSION: PARK / NEUTRAL POSITION SWITCH: INSTALLATION
1. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY
(a) Install the switch to the manual valve shaft.
(b) Temporarily install the bolt.
(c) Install a new lock washer and the nut.
Torque : 6.9 Nm (70 kgf-cm, 61 in-lbf)
(d) Temporarily install the control shaft lever RH.
(e) Turn the control shaft lever RH counterclockwise until it stops, and then turn it clockwise 2
notches to set it to the N position.
(f) Align the groove with the neutral basic line.
Page 5016
Actuator: Service and Repair Removal
DIFFERENTIAL: AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR (for 4WD):
REMOVAL
1. REMOVE NO. 1 ENGINE UNDER COVER See: Engine, Cooling and Exhaust/Engine/Drive
Belts, Mounts, Brackets and Accessories/Drive
Belt/Service and Repair/Removal
2. REMOVE AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR
(a) Disconnect the actuator hose.
(b) Disconnect the actuator connector.
(c) Remove the 4 bolts and actuator.
Page 4461
(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(2) If the result is not as specified, replace the MAF meter.
Up to 11/2009
Yaw Rate Sensor: Locations Up to 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 5036
(a) Place matchmarks on the bearing cap and differential carrier.
(b) Remove the 4 bolts and 2 differential bearing caps.
(c) Remove the differential case from the differential carrier.
HINT Tag the 2 case bearing outer races to show the location for reassembly.
15. REMOVE REAR DIFFERENTIAL DRIVE PINION
(a) Remove the differential drive pinion and bearing spacer from the differential carrier.
16. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING
(a) Using SST and a press, press out the bearing (inner race).
SST : 09950-00020
(b) If either the drive pinion or ring gear is damaged, replace them as a set.
17. REMOVE REAR DIFFERENTIAL DRIVE PINION PLATE WASHER
18. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
(a) Using a brass bar and hammer, tap out the bearing (outer race).
Page 5197
HINT Before installing the boot, wrap vinyl tape around the spline of the shaft to prevent damaging
the boot.
(b) Temporarily install a new boot to the outboard joint shaft.
(c) Position the inside clamp onto the boot.
(d) Using SST, pinch the inside clamp.
SST : 09521-24010
NOTICE: Do not overtighten SST.
(e) Pack the outboard joint and boot with grease in the boot kit.
Standard grease capacity:
292 to 312 g (10.3 to 11.0 oz.)
(f) Position the outside clamp onto the boot.
(g) Using SST, pinch the outside clamp.
SST : 09521-24010
NOTICE: Do not overtighten SST.
(h) Using SST, adjust the clearance of the clamps.
Page 7000
J/B No.6 Assembly - Instrument Panel Center
Locations
Cabin Temperature Sensor / Switch: Locations
AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Automatic Air Conditioning System):
PARTS LOCATION
Locations
Tire Pressure Warning Reset Switch: Locations
TIRE AND WHEEL: TIRE PRESSURE WARNING SYSTEM: PARTS LOCATION
Page 3380
(1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be
checked by conducting a voltage check.
With each connector still connected, measure the voltage between the body ground and these
terminals (in this order): 1) terminal 1 of connector A; 2) terminal 1 of connector B; and 3) terminal
1 of connector C.
Standard voltage (Fig. 4):
* If the results match the examples above, an open circuit exists in the wire harness between
terminal 1 of connector B and terminal 1 of connector C.
3. CHECK FOR SHORT CIRCUIT
(a) If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance
check with the body ground (below).
(b) Check the resistance with the body ground.
(1) Disconnect connectors A and C and measure the resistance.
Standard resistance (Fig. 6):
HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally.
If your results match the examples above, a short circuit exists between terminal 1 of connector A
and terminal 1 of connector C.
Page 280
(a) For an open circuit in the wire harness in Fig. 1, check the resistance or voltage, as described
below.
(b) Check the resistance.
(1) Disconnect connectors A and C and measure the resistance between them.
Standard resistance (Fig. 2):
HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally.
If the results match the examples above, an open circuit exists between terminal 1 of connector A
and terminal 1 of connector C.
(2) Disconnect connector B and measure the resistance between the connectors.
Standard resistance (Fig. 3):
* If the results match the examples above, an open circuit exists between terminal 1 of connector
B2 and terminal 1 of connector C.
(c) Check the voltage.
Page 1964
(8) Depress the brake pedal several times, and then loosen the bleeder plug with the pedal
depressed.*1
(9) When fluid stops coming out, tighten the bleeder plug, and then release the brake pedal.*2
(10)Repeat *1 and *2 until all the air in the brake fluid is completely bled out and the new brake
fluid comes out.
(11)Tighten the bleeder plug completely.
Torque : 11 Nm (110 kgf-cm, 8 ft-lbf)
(12)Replace the brake fluid from the rear disc brake cylinder LH using the same procedure as for
RH.
(c) Bleed VSC actuator assembly
NOTICE: After bleeding the air from the brake system, if the height or feel of the brake pedal
cannot be obtained, perform air bleeding of the brake actuator with the Techstream by following the
procedure below.
(1) Depress the brake pedal more than 20 times with the engine off.
(2) Connect the Techstream to the DLC3, and turn the ignition switch on.
NOTICE: Do not start the engine.
(3) Select AIR BLEEDING on the Techstream.
HINT Refer to the Techstream operator's manual for further details.
(4) Bleed the air out of the suction line.
NOTICE: *
Perform the bleeding at the right front wheel and right rear wheel.
* Bleed the air by following the steps displayed on the Techstream.
(5) 1. Connect a vinyl tube to the bleeder plug at the right front wheel or the right rear wheel.
2. Loosen the bleeder plug.
3. Operate the brake actuator to bleed the air using the Techstream.
HINT This operation stops automatically after 4 seconds.
NOTICE: Release the brake pedal at this time.
(6) 4. Check if the operation has stopped by referring to the Techstream display.
5. Temporarily tighten the bleeder plug.
6. Repeat the 4 previous steps until all in the fluid is completely bled out.
7. Tighten the bleeder plug.
Torque : 11 Nm (110 kgf-cm, 8 ft-lbf)
(7) 8. Repeat all of the above procedures for the other wheel to bleed the air out of the suction line.
(8) Bleed the air out of the pressure reduction line.
NOTICE: *
Perform the bleeding at the 4 wheels.
* Bleed the air by following the steps displayed on the Techstream.
(9) 1. Connect a vinyl tube to one of the bleeder plugs.
Components
Water Pump: Service and Repair Components
1UR-FE COOLING: WATER PUMP: COMPONENTS
Page 4587
[A] For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
"Case1" Raise the terminal retainer up to the temporary lock position.
Page 9386
12. Torque the NEW nuts to the specified torque range on the No.2 mounts.
Torque: 54 N*m (551 kgf*cm, 40 ft*lbf)
13. Reinstall the body plugs for the cab mount bolt holes and then restore the carpet to its original
position.
14. Test drive vehicle to confirm the condition has been improved.
Page 2416
^ 1AR-FE (Highlander Venza)
^ 2AR-FE (RAV4 Camry)
Warranty Information
Required Tools & Equipment
Page 6590
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION: Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC
terminals are touched, the IC may be destroyed by static electricity.)
When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact with the terminals of leads from the IC, etc. of the
replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown on the left.
DISCONNECT CONNECTOR
Page 7990
Removal
SUPPLEMENTAL RESTRAINT SYSTEM: FRONT SEAT SIDE AIRBAG ASSEMBLY (for Fold
Down Seat Type): REMOVAL
CAUTION: *
Be sure to read Precaution thoroughly before servicing See: Service Precautions
* If the side airbag was deployed, replace the front seat assembly with a new one.
* Wear protective gloves. Sharp areas on the seat frame and adjuster may injure your hands.
1. REMOVE FRONT SEAT ASSEMBLY RH
(a) Remove the front seat assembly RH See: Body and Frame/Seats/Service and Repair/Removal
and Replacement/Front Seat Assembly (for
Fold Down Seat Type)/Removal.
2. REMOVE FRONT SEAT HEADREST ASSEMBLY RH
3. REMOVE RECLINING ADJUSTER RELEASE HANDLE RH See: Body and
Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly
(for Fold Down Seat Type)/Disassembly
4. REMOVE FRONT SEAT CUSHION SHIELD RH See: Body and Frame/Seats/Service and
Repair/Overhaul/Front Seat Assembly (for Fold
Down Seat Type)/Disassembly
5. REMOVE INNER FRONT SEAT CUSHION SHIELD RH See: Body and Frame/Seats/Service
and Repair/Overhaul/Front Seat Assembly (for
Fold Down Seat Type)/Disassembly
6. REMOVE FRONT SEATBACK LOCK HANDLE LH See: Body and Frame/Seats/Service and
Repair/Overhaul/Front Seat Assembly (for Fold
Down Seat Type)/Disassembly
7. REMOVE FRONT SEATBACK LOCK HANDLE RH See: Body and Frame/Seats/Service and
Repair/Overhaul/Front Seat Assembly (for Fold
Down Seat Type)/Disassembly
8. REMOVE FRONT SEATBACK SHIELD LH See: Body and Frame/Seats/Service and
Repair/Overhaul/Front Seat Assembly (for Fold Down
Seat Type)/Disassembly
9. REMOVE FRONT SEATBACK SHIELD RH See: Body and Frame/Seats/Service and
Repair/Overhaul/Front Seat Assembly (for Fold Down
Seat Type)/Disassembly
10. REMOVE FRONT SEATBACK ASSEMBLY RH
Page 741
Seat Heater Switch: Service and Repair Installation
SEAT: SEAT HEATER SWITCH (w/ Seat Heater System or Climate Control Seat System):
INSTALLATION
1. INSTALL SEAT HEATER SWITCH
(a) w/ Climate Control Seat System:
Attach the 8 claws to install the 2 seat heater switches.
(b) w/ Seat Heater System:
Attach the 4 claws to install the 2 seat heater switches.
2. INSTALL INTEGRATION CONTROL AND PANEL ASSEMBLY See: Heating and Air
Conditioning/Control Assembly/Service and
Repair/Air Conditioning Panel (for Floor Shift Type)/Installation
3. INSTALL CENTER LOWER INSTRUMENT PANEL FINISH PANEL See: Body and
Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
4. INSTALL REAR UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
5. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior Moulding
/ Trim/Dashboard / Instrument Panel/Service
and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
6. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation
7. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
8. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Floor Shift Type)/Installation
9. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation
10. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for
CrewMax)/Installation
11. INSTALL FRONT DOOR SCUFF PLATE LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining
(for CrewMax)/Installation
Page 2960
A/F and 02 Sensor Identification
A760F Automatic Transmission System
Control Module: Locations A760F Automatic Transmission System
A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS
LOCATION
Page 4932
(h) Remove the 2 bolts and then pull the transmission control cable into the vehicle to remove it.
Installation
A760F AUTOMATIC TRANSMISSION: TRANSMISSION CONTROL CABLE (for Column Shift
Type): INSTALLATION
1. INSTALL COLUMN SHIFT TRANSMISSION CONTROL CABLE ASSEMBLY
(a) Insert the transmission control cable from the vehicle interior, and install the cable retainer with
the 2 bolts.
Torque : 5.5 Nm (56 kgf-cm, 49 in-lbf)
(b) Connect the cable to the steering column shaft bracket so that the claws of the outer cable
socket are securely attached.
(c) Connect the column shift transmission control cable end to the column shift.
Page 5287
(a) for Front Differential Side:
(1) Align the matchmarks on the differential and propeller shaft flange.
(2) Install the propeller shaft with the 4 washers and 4 nuts.
Torque : 80 Nm (816 kgf-cm, 59 ft-lbf)
(b) for Transfer Side:
(1) Align the matchmarks on the transfer and propeller shaft flange.
(2) Connect the propeller shaft with the 4 washers and 4 nuts.
Torque : 80 Nm (816 kgf-cm, 59 ft-lbf)
2. INSTALL PROPELLER SHAFT HEAT INSULATOR BRACKET SUB-ASSEMBLY
(a) Install the heat insulator bracket to the crossmember with the 2 bolts.
Torque : 16 Nm (163 kgf-cm, 12 ft-lbf)
3. INSTALL PROPELLER SHAFT HEAT INSULATOR
(a) Install the heat insulator to the heat insulator bracket with the 2 bolts.
Torque : 16 Nm (163 kgf-cm, 12 ft-lbf)
Page 9169
Refer to the service kit instruction sheet for further detail.
Technical Service Bulletin # SB0164-10 Date: 100628
Body - Tube Step Step Pad Lifting/Cracking
T-SB-0164-10
June 28, 2010
Tube Step - Step Pad Lifting/Cracked
Service Category Vehicle Exterior
Section Exterior Panels/Trim
Market USA
Applicability
Introduction
Some 2007 - 2010 model year Tundra vehicles equipped with PPO/DIO tube steps may exhibit a
condition where the step pad has lifted or cracked. To improve the serviceability of the tube step
the step pad is now available as a separate service part. Follow the procedure in this bulletin to
replace the step pad. Removal of the tube step is not required to perform step pad replacement.
Parts Information
Warranty Information
APPLICABLE WARRANTY
^ Toyota accessories installed as original equipment are covered under the Toyota Comprehensive
Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the
vehicle's in-service date.
^ Toyota accessories installed after the new vehicle purchase are warranted for 12 months,
regardless of mileage, from the date of installation on the vehicle, or the remainder of the
applicable New Vehicle Limited Warranty, whichever provides the greater coverage.
^ Toyota accessories purchased over-the-counter are covered for 12 months from the date of
purchase.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Repair Procedure
Page 6864
Power Distribution Module: Service and Repair Removal
OTHER SYSTEM: VOLTAGE INVERTER (for CrewMax): REMOVAL
1. REMOVE BACK PANEL TRIM LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for
CrewMax)/Removal
2. REMOVE BACK PANEL TRIM RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for
CrewMax)/Removal
3. REMOVE REAR DOOR SCUFF PLATE LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining
(for CrewMax)/Removal
4. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH
5. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY LH See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (for CrewMax)/Removal
6. REMOVE VOLTAGE INVERTER ASSEMBLY
(a) Remove the 2 bolts.
(b) Disconnect the voltage inverter connector and removal the voltage inverter.
Page 7965
NOTICE: Make sure that the wire harnesses are tight. Looseness in the wire harnesses results in
the tires coming free due to the shock when the airbag is deployed.
(g) Install SST.
(1) Connect SST connector.
SST : 09082-00700
NOTICE: To avoid damaging SST connector and wire harness, do not lock the secondary lock of
the twin lock. Also, secure some slack for SST wire harness inside the tire.
(h) Deploy the airbag.
(1) Connect the red clip of SST to the battery positive (+) terminal and the black clip of SST to the
battery negative (-) terminal.
(2) Check that no one is within a 10 m (32.8 ft.) radius of the tire which the curtain shield airbag is
tied to.
(3) Press SST activation switch and deploy the airbag.
CAUTION: When deploying the airbag, make sure that no one is near the tire.
HINT The airbag is deployed as the LED of SST activation switch comes on.
(i) Dispose of the curtain shield airbag.
CAUTION: *
The curtain shield airbag becomes extremely hot when the airbag is deployed, so do not touch it for
at least 30 minutes after
Page 6861
Power Distribution Module: Diagrams Voltage Inverter
Page 7029
for Regular Cab of Long Deck
for Double Cab of Standard Deck
Page 45
2. REMOVE REAR DOOR SCUFF PLATE RH
(a) Detach the 8 claws and 2 clips, and remove the scuff plate.
3. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP RH
4. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY RH See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (for CrewMax)/Removal
5. REMOVE DOOR CONTROL RECEIVER
(a) Disconnect the door control receiver connector.
(b) Remove the bolt and receiver.
Installation
DOOR LOCK: DOOR CONTROL RECEIVER (for CrewMax): INSTALLATION
1. INSTALL DOOR CONTROL RECEIVER
(a) Install the receiver with the bolt.
(b) Connect the door control receiver connector.
2. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY RH See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (for CrewMax)/Installation
3. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP RH
4. INSTALL REAR DOOR SCUFF PLATE RH
Locations
Air Flow Meter/Sensor: Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 3559
doors need to be opened in order to check connectors, open the doors and leave them open.
2. JUNCTION CONNECTOR
(a) NO. 1 JUNCTION CONNECTOR
HINT *
*1: w/ Power Steering ECU
* *2: for V bus
* The connectors connected to the junction connector can be distinguished by the colors of the bus
lines and the connecting side of the connector.
* The connectors can be connected to any terminals on the same side.
(b) NO. 2 JUNCTION CONNECTOR
Engine - Snow Ingestion Into Air Cleaner Box
Air Cleaner Housing: Customer Interest Engine - Snow Ingestion Into Air Cleaner Box
T-SB-0396-09
December 8, 2009
Snow Entry Into Air Cleaner Box
Service Category Engine/Hybrid System
Section Intake/Exhaust
Market USA
Applicability
Introduction
Some Sequoia and Tundra vehicles operated in areas with significant snow volume may
experience snow accumulation in the air cleaner box which can cause the lid to fracture. The air
cleaner lid and fender liner have been revised to reduce accumulation.
Parts Information
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for
36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Production Change Information
Engine - Snow Ingestion Into Air Cleaner Box
Air Cleaner Housing: All Technical Service Bulletins Engine - Snow Ingestion Into Air Cleaner Box
T-SB-0396-09
December 8, 2009
Snow Entry Into Air Cleaner Box
Service Category Engine/Hybrid System
Section Intake/Exhaust
Market USA
Applicability
Introduction
Some Sequoia and Tundra vehicles operated in areas with significant snow volume may
experience snow accumulation in the air cleaner box which can cause the lid to fracture. The air
cleaner lid and fender liner have been revised to reduce accumulation.
Parts Information
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for
36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Production Change Information
Page 6290
Fuse Block: Connector Views
Engine Room R/B, J/B - Engine Compartment Left
Page 3726
Page 8630
AUDIO / VISUAL: STEREO JACK ADAPTER ASSEMBLY (for Floor Shift Type): INSTALLATION
1. INSTALL STEREO JACK ADAPTER ASSEMBLY
(a) Attach the 2 claws to install the adapter.
2. INSTALL INTEGRATION CONTROL AND PANEL ASSEMBLY (for Manual Air Conditioning
System) See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and
Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation
3. INSTALL INTEGRATION CONTROL AND PANEL ASSEMBLY (for Automatic Air Conditioning
System) See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and
Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation
4. INSTALL CENTER LOWER INSTRUMENT PANEL FINISH PANEL See: Body and
Frame/Interior Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
5. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
6. INSTALL FRONT CONSOLE BOX See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal
and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation
7. INSTALL REAR CONSOLE BOX ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation
8. INSTALL CONSOLE BOX CARPET See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation
9. INSTALL REAR CONSOLE END PANEL ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service
and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
10. INSTALL REAR UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
11. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument Panel/Service
and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift
Type)/Installation
12. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation
13. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Floor Shift Type)/Installation
14. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation
15. INSTALL COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Installation
16. INSTALL FRONT DOOR SCUFF PLATE LH
(a) for Double Cab:
Install the front door scuff plate LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Components
Amplifier: Service and Repair Components
AUDIO / VISUAL: STEREO COMPONENT AMPLIFIER: COMPONENTS
Page 8662
Use a volt/ohmmeter with high impedance (10 kohms/V minimum) for troubleshooting of the
electrical circuit.
Disconnection of Male and Female Connectors
DISCONNECTION OF MALE AND FEMALE CONNECTORS
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Finding A Short Circuit
FINDING A SHORT CIRCUIT
Page 7966
deployment.
* Use gloves and safety glasses when handling a curtain shield airbag with a deployed airbag.
* Do not apply water to a curtain shield airbag with a deployed airbag.
* Always wash your hands with water after completing the operation.
(1) Remove the curtain shield airbag from the tire.
(2) Place the curtain shield airbag in a plastic bag, tie it tightly and dispose of it in the same way as
other general parts.
Front Seat Side Airbag Assembly (for Fold Down Seat Type)
SUPPLEMENTAL RESTRAINT SYSTEM: FRONT SEAT SIDE AIRBAG ASSEMBLY (for Fold
Down Seat Type): DISPOSAL
HINT When scrapping a vehicle equipped with the SRS or disposing of the front seat side airbag,
be sure to deploy the airbag first in accordance with the procedure described below. If any
abnormality occurs with the airbag deployment, contact the SERVICE DEPT. of TOYOTA MOTOR
SALES, U.S.A., INC.
CAUTION: *
Never dispose of a front seat side airbag that has an unactivated airbag.
* The airbag produces an exploding sound when it is deployed, so perform the operation outdoors
and where it will not create a nuisance to nearby residents.
* When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool).
Perform the operation in a place away from electrical noise.
* When deploying the airbag, perform the operation at least 10 m (32.8 ft.) away from the airbag.
* The front seat side airbag becomes extremely hot when the airbag is deployed, so do not touch it
for at least 30 minutes after deployment.
* Use gloves and safety glasses when handling a front seat side airbag with a deployed airbag.
* Do not apply water to a front seat side airbag with a deployed airbag.
* Always wash your hands with water after completing the operation.
* An airbag or pretensioner may be activated by static electricity. To prevent this, be sure to touch a
metal surface with bare hands to discharge static electricity before performing this procedure.
1. DISPOSE OF FRONT SEAT SIDE AIRBAG ASSEMBLY (WHEN INSTALLED IN VEHICLE)
HINT Prepare a battery as the power source to deploy the airbag.
(a) Check the function of SST See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
(b) Read the precaution See: Testing and Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.
(c) Disconnect the cable from the negative (-) battery terminal.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
(d) Remove the front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Fold Down Seat
Type)/Removal.
HINT Keep the front seat in the cabin.
(e) Install SST.
Audio System - USB/iPod(R) Not Recognized
Auxiliary Input / Output Jack: All Technical Service Bulletins Audio System - USB/iPod(R) Not
Recognized
T-SB-0013-11
February 15, 2011
USB/Pod Not Recognized
Service Category Audio/Visual/Telematics
Section Audio/Video
Market USA
Applicability
Introduction
Some 2010 - 2011 Toyota vehicles may exhibit intermittent operation of USB/iPod(TM) devices
while in use. A newly designed Multi-Media Interface ECU has been developed to correct this
condition.
This bulletin applies to the models shown.
This bulletin does not apply to the following models: iPod(TM) mini iPod(TM) shuffle iPod(TM)
photo iPhone(TM) and 4th generation and earlier models. These versions of the iPod(TM) are NOT
compatible with this system.
* iPhone(TM) has limited compatibility with this system. Some functions may not operate properly.
Production Change Information
Page 5819
Brake Fluid Solenoid Valve Relay: Locations From 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 6174
Power Outlet [12V]
Page 5620
Steering Angle Sensor: Service and Repair Removal
BRAKE CONTROL: STEERING ANGLE SENSOR: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to disable the SRS system.
2. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
3. REMOVE LOWER NO. 3 STEERING WHEEL COVER See: Restraint Systems/Air Bag
Systems/Air Bag/Service and Repair/Removal and
Replacement/Steering Pad/Removal
4. REMOVE LOWER NO. 2 STEERING WHEEL COVER See: Restraint Systems/Air Bag
Systems/Air Bag/Service and Repair/Removal and
Replacement/Steering Pad/Removal
5. REMOVE STEERING PAD See: Restraint Systems/Air Bag Systems/Air Bag/Service and
Repair/Removal and Replacement/Steering
Pad/Removal
6. REMOVE STEERING WHEEL ASSEMBLY See: Steering and Suspension/Steering/Steering
Column/Service and Repair/Removal and
Replacement/Steering Column Assembly (for Manual Tilt)/Removal
7. REMOVE LOWER STEERING COLUMN COVER See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Removal and
Replacement/Steering Column Assembly (for Manual Tilt)/Removal
8. REMOVE UPPER STEERING COLUMN COVER See: Steering and
Suspension/Steering/Steering Column/Service and Repair/Removal and
Replacement/Steering Column Assembly (for Manual Tilt)/Removal
9. REMOVE SPIRAL CABLE SUB-ASSEMBLY See: Restraint Systems/Air Bag
Systems/Clockspring Assembly / Spiral Cable/Service and
Repair/Removal
10. REMOVE STEERING ANGLE SENSOR See: Restraint Systems/Air Bag Systems/Clockspring
Assembly / Spiral Cable/Service and
Repair/Removal
Page 8628
Removal
AUDIO / VISUAL: STEREO JACK ADAPTER ASSEMBLY (for Floor Shift Type): REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE FRONT DOOR SCUFF PLATE LH
(a) for Double Cab:
Remove the front door scuff plate LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal.
(b) for Regular Cab:
Page 8832
(a) Attach the 4 clips and claw to install the speaker panel.
7. INSTALL FRONT PILLAR GARNISH RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for
CrewMax)/Installation
8. INSTALL FRONT PILLAR GARNISH LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (for
CrewMax)/Installation
9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Components
AUDIO / VISUAL: INSTRUMENT PANEL SPEAKER (for Double Cab): COMPONENTS
Page 6966
Remove the blown fuse and disconnect all loads of the fuse.
Connect a test light in place of the fuse.
Establish conditions in which the test light comes on.
Example:
- [A] - Ignition SW on
- [B] - Ignition SW and SW1 on
- [C] - Ignition SW, SW1 and Relay on (Connect the Relay) and SW2 off (or Disconnect SW2)
Disconnect and reconnect the connectors while watching the test light.
Page 6013
Standard diameter:
14.2 to 14.4 mm (0.559 to 0.567 in.)
Minimum diameter:
14.0 mm (0.551 in.)
(e) If the diameter is less than the minimum, replace the generator rotor assembly.
2. INSPECT GENERATOR BRUSH HOLDER ASSEMBLY
(a) Using a vernier caliper, measure the exposed brush length.
Standard exposed length:
10.5 mm (0.413 in.)
Minimum exposed length:
4.5 mm (0.177 in.)
(b) If the exposed length is less than the minimum, replace the generator brush holder assembly.
3. INSPECT GENERATOR DRIVE END FRAME BEARING
(a) When rotating the bearing, check that there is no abnormal noise and that it rotates smoothly.
(b) If necessary, replace the generator drive end frame bearing.
4. INSPECT GENERATOR ROTOR BEARING
(a) When rotating the bearing, check that there is no abnormal noise and that it rotates smoothly.
Page 1020
Ambient Light Sensor: Testing and Inspection
LIGHTING: AUTOMATIC LIGHT CONTROL SENSOR: ON-VEHICLE INSPECTION
1. INSPECT AUTOMATIC LIGHT CONTROL SENSOR
(a) Connect the voltmeter's positive (+) lead to terminal K19-6 (CLTB) and the negative (-) lead to
terminal K19-3 (CLTE).
(b) Measure the voltage according to the value(s) in the table below.
Standard voltage:
(c) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(d) Reconnect the K19 sensor connector.
(e) Check the waveform according to the value(s) in the table below.
Waveform:
HINT If the ambient light becomes brighter, width A becomes narrower.
If the result is not as specified, replace the automatic light control sensor.
Page 3195
Camshaft Position Sensor: Locations Ignition System
1UR-FE IGNITION: IGNITION SYSTEM: PARTS LOCATION
Up to 11/2009
Brake Fluid Solenoid Valve Relay: Locations Up to 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Page 8247
(a) Attach the 7 clips and 2 claws to install the pillar garnish.
(b) Install the seat belt anchor with the bolt.
Torque : 42 Nm (428 kgf-cm, 31 ft-lbf)
(c) Attach the 2 claws to install the cover.
4. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP
5. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP
6. INSTALL FRONT DOOR SCUFF PLATE See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Installation
7. INSTALL REAR DOOR SCUFF PLATE See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Installation
8. INSTALL FRONT SEAT ASSEMBLY
(a) for Manual Seat:
Install the front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Manual Seat)/Installation.
(b) for Power Seat:
Install the front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Power Seat)/Installation.
9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Page 1952
Refrigerant: Service and Repair
AIR CONDITIONING: REFRIGERANT: REPLACEMENT
1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM
(a) Start up the engine.
(b) Turn the A/C switch ON.
(c) Operate the cooler compressor with an engine speed of approximately 1000 rpm for 5 to 6
minutes to circulate the refrigerant and collect the
compressor oil remaining in each component into the cooler compressor.
(d) Stop the engine.
(e) Recover the refrigerant from the A/C system using a refrigerant recovery unit.
2. CHARGE REFRIGERANT
SST : 09985-20010
09985-02010
09985-02050
09985-02060
09985-02070
09985-02090
09985-02110
09985-02130
09985-02150
(a) Perform vacuum purging using a vacuum pump.
(b) Charge refrigerant HFC-134a (R134a).
Standard:
600 +/-30 g (21.2 +/-1.1 oz.)
NOTICE:
Page 9351
Rear Fender Liner: Service and Repair Installation
EXTERIOR: FENDER LINER (for Rear Side): INSTALLATION
HINT *
Use the same procedures for the RH side and LH side.
* The procedures listed below are for the LH side.
1. INSTALL REAR WHEEL HOUSE LINER LH
(a) Install the rear wheel house liner (front).
(1) Install the wheel house liner with 4 new clips.
(2) Install the 2 screws.
(b) w/o Rear Fender Mudguard:
Install the rear wheel house liner (rear).
(1) Install the rear wheel house liner with 7 new clips.
(2) Install the 2 screws.
Components
Tire Pressure Warning Reset Switch: Service and Repair Components
TIRE AND WHEEL: TIRE PRESSURE WARNING RESET SWITCH: COMPONENTS
Page 7426
Tire Pressure Module: Diagrams
Page 6402
Page 1999
Fuse Block: Diagnostic Aids
Continuity and Resistance Check
CONTINUITY AND RESISTANCE CHECK
Disconnect the battery terminal or wire so there is no voltage between the check points.
Contact the two leads of an ohmmeter to each of the check points.
Components
Control Module HVAC: Service and Repair Components
AIR CONDITIONING: AIR CONDITIONING AMPLIFIER: COMPONENTS
Page 2756
2. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in
Figure 1. Confirm if the ECM (PCM) calibration has
been updated. If the calibration ID listed is NOT the latest ECM (PCM) calibration - go to step 3.
3. Flash reprogram the ECM (PCM).
NOTE
^ The GR8 Battery Diagnostic Station MUST be used in Power Supply Mode to maintain battery
voltage at 13.5 volts while flash reprogramming the vehicle.
^ For details on how to use the GR8 Battery Diagnostic Station, refer to the located on the
Technical Information System (TIS), Diagnostics - Battery
Follow the procedures outlined in TSB No. T-SB-0064-10, "Techstream ECU Flash
Reprogramming Procedure1⁄4 and flash the ECM (PCM) with the NEW calibration file update.
4. Install the Authorized Modifications Label.
A. Using a permanent marker enter the following information on the label:
^ ECM part number [Refer to the Parts Information section for the CURRENT PART NUMBER]
^ Calibration ID(s) [Refer to the Calibration Identification Chart for the NEW CALIBRATION ID]
^ Dealer Code
^ Repair Date
^ Change Authority [This TSB number]
B. Affix the Authorized Modifications Label to the vehicle at the location shown in Figure 1. The
Authorized Modifications Label is available
through the MDC P/N 00451-00001-LBL.
5. Test drive the vehicle to confirm proper vehicle operation.
Page 1723
(a) Check the steering angle sensor zero point calibration See: Powertrain
Management/Computers and Control Systems/Testing and
Inspection/Diagnostic Trouble Code Tests and Associated Procedures/C Code Charts/C1290.
Page 3915
(c) Remove the O-ring from the oil control valve.
Page 8099
Door/Service and Repair/Front Door (for Double Cab)/Disassembly
4. REMOVE FRONT LOWER DOOR FRAME BRACKET GARNISH LH (for Front Side) See: Body
and Frame/Doors, Hood and
Trunk/Doors/Front Door/Service and Repair/Front Door (for Double Cab)/Disassembly
5. REMOVE COURTESY LIGHT ASSEMBLY (for Front Side) See: Body and Frame/Doors, Hood
and Trunk/Doors/Front Door/Service and
Repair/Front Door (for Double Cab)/Disassembly
6. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Front Side) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Double Cab)/Disassembly
7. REMOVE FRONT SIDE AIRBAG SENSOR
(a) Disconnect the connector.
(b) Remove the screw and side airbag sensor.
8. REMOVE REAR SEAT ASSEMBLY (for Rear Side)
(a) Remove the rear seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Rear Seat Assembly (for Double
Cab)/Removal.
9. REMOVE REAR DOOR SCUFF PLATE LH (for Rear Side) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and Repair/Roof
Headlining (For Double Cab)/Removal
10. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH (for Rear Side)
11. REMOVE LOWER QUARTER TRIM PANEL ASSEMBLY LH (for Rear Side) See: Body and
Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal
12. REMOVE REAR SIDE AIRBAG SENSOR
(a) Remove the bolt and side airbag sensor.
(b) Disconnect the connector.
Installation
SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for CrewMax):
INSTALLATION
1. INSTALL FRONT SIDE AIRBAG SENSOR
(a) Check that the ignition switch is OFF.
Page 3475
HINT *
o: DTC is memorized.
* *1: Only during failure status.
Fail-Safe Chart
CAN COMMUNICATION: CAN COMMUNICATION SYSTEM: FAIL-SAFE CHART
1. FAIL-SAFE FUNCTION
(a) When communication fails in any of the main wires (communication lines) due to a short circuit
or other causes, the fail-safe function, which is
specified for each system, operates to prevent the system from malfunctioning.
(b) The table below shows the effects on each system when communication is impossible. For
further details, refer to each system.
Page 7628
Center Airbag Sensor Assembly (for Floor Shift Type)
Impact Sensor: Service and Repair Center Airbag Sensor Assembly (for Floor Shift Type)
Components
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift
Type): COMPONENTS
Page 3704
Mongoose MFC Software and Driver MUST be installed before Mongoose MFC selection will be
available.
See TIS - Diagnostics - Scantool page for additional information.
^ If using TIS Techstream select TIS Techstream VIM (this is the default).
4. Click OK.
Operation Procedure
1. Verify the vehicle's applicability for recalibration and locate desired calibration file.
A. Connect Techstream and establish a vehicle connection.
B. Click the Health Check button on the System Select tab.
Page 9067
(a) For an open circuit in the wire harness in Fig. 1, check the resistance or voltage, as described
below.
(b) Check the resistance.
(1) Disconnect connectors A and C and measure the resistance between them.
Standard resistance (Fig. 2):
HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally.
If the results match the examples above, an open circuit exists between terminal 1 of connector A
and terminal 1 of connector C.
(2) Disconnect connector B and measure the resistance between the connectors.
Standard resistance (Fig. 3):
* If the results match the examples above, an open circuit exists between terminal 1 of connector
B2 and terminal 1 of connector C.
(c) Check the voltage.
Restraints - OCS System Initialization
Seat Occupant Sensor: Technical Service Bulletins Restraints - OCS System Initialization
COLLISION REPAIR INFORMATION FOR THE COLLISION REPAIR PROFESSIONAL
TITLE: SRS OCCUPANT CLASSIFICATION SYSTEM INITIALIZATION
SECTION: ELECTRICAL BULLETIN # 177
MODELS: ALL EQUIPPED TOYOTA LEXUS and SCION MODELS
DATE: MARCH 2010
Models equipped with a Supplemental Restraint System (SRS) Occupant Classification System
(OCS) will enable or disable the passenger front and side airbags based on seat occupancy
passenger weight and seat belt latch engagement.
If an equipped vehicle sustains collision damage or if the front passenger seat or any of the OCS
components are serviced the SRS Malfunction Indicator Light (MIL) may illuminate setting a
Diagnostic Trouble Code (DTC).
NOTE:
It is necessary to diagnose and repair the root cause of a SRS or OCS DTC before initializing the
OCS system. If SRS and OCS DTC's are not cleared the system may not operate properly.
Be sure to check and clear DTC's and perform OCS initialization per repair manual instructions
with a Techstream Special Service Tool (SST) or capable diagnostic tester.
Any of the following conditions could set a DTC illuminate the SRS MIL or cause the PASSENGER
AIRBAG light to indicate incorrectly regardless of occupancy:
^ The OCS Electronic Control Unit (ECU) is replaced
^ Accessories such as a seatback tray are installed on the passenger seat
^ The passenger seat is removed and replaced or reinstalled
^ The vehicle is involved in an accident or collision
Model-specific repair manuals can be accessed through the Technical Information System (TIS)
www.techinfo.toyota.com
Page 1984
Fuse Block Location - Under The Instrument Panel
Fuse Location - Under The Instrument Panel
Page 1490
General Information
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: GENERAL
INFORMATION
* A large number of ECU controlled systems are used in the TOYOTA TUNDRA. In general, ECU
controlled systems are considered to be very intricate, requiring a high level of technical knowledge
to troubleshoot. However, most problem checking procedures only involve inspecting the ECU
controlled system's circuits one by one. An adequate understanding of the system and a basic
knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and
necessary repairs.
1. TROUBLESHOOTING PROCEDURES
* The troubleshooting procedures consist of diagnosis procedures for when a DTC is stored and
diagnosis procedures for when no DTC is stored. The basic idea is explained in the following table.
* Vehicle systems are complex and use many ECUs that are difficult to inspect independently.
Therefore, a process of elimination is used, where components that can be inspected individually
are inspected, and if no problems are found in these components, the related ECU is identified as
the problem and replaced.
* It is extremely important to ask the customer about the environment and the conditions present
when the problem occurred (Customer Problem Analysis). This makes it possible to simulate the
conditions and confirm the symptom. If the symptom cannot be confirmed or the DTC does not
recur, the malfunctioning part may not be identified using the troubleshooting procedure, and the
ECU for the related system may be replaced even though it is not defective. If this happens, the
original problem will not be solved.
* In order to prevent endless expansion of troubleshooting procedures, the troubleshooting
procedures are written with the assumption that multiple malfunctions do not occur simultaneously
for a single problem symptom.
* To identify the malfunctioning part, troubleshooting procedures narrow down the target by
separating components, ECUs and wire harnesses during the inspection. If the wire harness is
identified as the cause of the problem, it is necessary to inspect not only the connections to
components and ECUs but also all of the wire harness connectors between the component and the
ECU.
DIAGNOSTIC TESTER
2. DESCRIPTION
System data and the Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector
3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the Techstream* to
check for a malfunction and perform repairs.
HINT *: Techstream is the name for the diagnostic tester in North America.
3. DATA LINK CONNECTOR 3 (DLC3)
(a) The vehicle's ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of
the DLC3 complies with SAE J1962 and
matches the ISO 15765-4 format.
Components
Headlamp Dimmer Switch: Service and Repair Components
LIGHTING: HEADLIGHT DIMMER SWITCH: COMPONENTS
Page 4907
Page 3606
Page 7993
8. INSTALL FRONT SEATBACK SHIELD RH See: Body and Frame/Seats/Service and
Repair/Overhaul/Front Seat Assembly (for Fold Down
Seat Type)/Reassembly
9. INSTALL FRONT SEATBACK SHIELD LH See: Body and Frame/Seats/Service and
Repair/Overhaul/Front Seat Assembly (for Fold Down
Seat Type)/Reassembly
10. INSTALL FRONT SEATBACK LOCK HANDLE RH See: Body and Frame/Seats/Service and
Repair/Overhaul/Front Seat Assembly (for Fold
Down Seat Type)/Reassembly
11. INSTALL FRONT SEATBACK LOCK HANDLE LH
12. INSTALL FRONT SEAT HEADREST ASSEMBLY RH
13. INSTALL INNER FRONT SEAT CUSHION SHIELD RH See: Body and Frame/Seats/Service
and Repair/Overhaul/Front Seat Assembly (for
Fold Down Seat Type)/Reassembly
14. INSTALL FRONT SEAT CUSHION SHIELD RH See: Body and Frame/Seats/Service and
Repair/Overhaul/Front Seat Assembly (for Fold
Down Seat Type)/Reassembly
15. INSTALL RECLINING ADJUSTER RELEASE HANDLE RH See: Body and
Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly
(for Fold Down Seat Type)/Reassembly
16. INSTALL FRONT SEAT ASSEMBLY RH
(a) Install the front seat assembly RH See: Body and Frame/Seats/Service and Repair/Removal
and Replacement/Front Seat Assembly (for Fold
Down Seat Type)/Installation.
17. PERFORM INITIALIZATION
NOTICE: Some systems need initialization after reconnecting the cable to the negative battery
terminal See: Testing and Inspection/Programming and Relearning
Components
SUPPLEMENTAL RESTRAINT SYSTEM: STEERING PAD: COMPONENTS
Page 3503
(a) Reconnect the J86 No. 1 junction connector connector.
NEXT -- Continue to next step.
4. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (NO. 2 JUNCTION CONNECTOR SIDE)
(a) Disconnect the J113 No. 2 junction connector connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NG -- CHECK FOR SHORT TO B+ IN CAN BUS WIRE (NO. 2 JUNCTION CONNECTOR - AIR
CONDITIONING AMPLIFIER) OK -- Continue to next step.
5. CHECK FOR SHORT TO B+ IN CAN BUS WIRE (NO. 1 JUNCTION CONNECTOR - NO. 2
JUNCTION CONNECTOR)
(a) Disconnect the J94 No. 1 junction connector connector.
(b) Measure the resistance according to the value(s) in the table below.
Standard resistance:
Page 8232
Removal
SEAT BELT: FRONT SEAT INNER BELT ASSEMBLY: REMOVAL
HINT *
Use the same procedures for the LH side and RH side.
* The procedures listed below are for the LH side.
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag.
2. REMOVE FRONT SEAT ASSEMBLY (for Manual Seat)
Page 5658
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to disable the SRS system.
2. REMOVE REAR WHEEL
3. REMOVE REAR SPEED SENSOR LH
(a) Disconnect the speed sensor connector (labeled A).
(b) Remove the nut (labeled B) and speed sensor (labeled C).
4. REMOVE REAR SPEED SENSOR RH
(a) Disconnect the speed sensor connector (labeled A).
(b) Remove the nut (labeled B) and speed sensor (labeled C).
5. REMOVE SKID CONTROL SENSOR WIRE
(a) Disconnect the sensor connector (labeled A).
(b) Detach the 7 clips (labeled B).
(c) Remove the bolt (labeled C).
(d) Remove the nut (labeled D) and skid control sensor wire.
Installation
BRAKE CONTROL: REAR SPEED SENSOR: INSTALLATION
Page 3282
Parts Information
Required Tools & Equipment
Repair Procedure
1. Confirm the condition matches the Introduction.
Page 6765
Multiple Junction Connector: Locations Wire and Wire In Instrument Panel [Floor Shift]
AJ1-TJ1
Page 5566
Acceleration/Deceleration Sensor: Programming and Relearning
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: CALIBRATION
1. DESCRIPTION
* After replacing components relating to the VSC or performing "Front wheel alignment
adjustment", clear and read the sensor calibration data.
* Follow the chart to perform calibration.
2. CLEAR ZERO POINT CALIBRATION DATA (WHEN USING TECHSTREAM)
(a) Connect the Techstream to the DLC3.
(b) Turn the ignition switch to ON.
(c) Operate the Techstream to erase the codes (select Reset Memory).
HINT Refer to the Techstream operator's manual for further details.
3. PERFORM ZERO POINT CALIBRATION OF MASTER CYLINDER PRESSURE SENSOR AND
DECELERATION SENSOR (WHEN
USING TECHSTREAM)
NOTICE: *
While obtaining the zero point, do not vibrate the vehicle by tilting, moving or shaking it and keep it
stationary. (Do not start the engine.)
* While obtaining the zero point, do not depress the brake and accelerator pedal.
* Obtain the zero point on a level surface (with an inclination of 1° or less).
(a) Enter Test Mode.
(1) Turn the ignition switch off.
(2) Check that the shift lever is in parking or neutral and apply the parking brake.
CAUTION: Application of the parking brake is not necessary for entering test mode. However,
apply the parking brake for safety.
(3) Connect the Techstream to the DLC3.
(4) Turn the ignition switch to ON.
NOTICE: Do not start the engine.
(5) Set the Techstream to test mode (select Test Mode).
HINT Refer to the Techstream operator's manual for further details.
(b) Obtain the zero points of the master cylinder pressure sensor and deceleration sensor.
(1) Keep the vehicle stationary on a level surface for 1 second or more.
HINT
Page 3138
* Never reuse the O-ring.
* When placing a new O-ring on the injector, do not damage it.
* Coat a new O-ring with spindle oil or gasoline before installing it. Do not use engine oil, gear oil or
brake oil.
(c) Install the injector to the delivery pipe and intake manifold as shown in the illustration.
NOTICE: Before installing the injector, apply spindle oil or gasoline on the place where the delivery
pipe contacts the O-ring of the injector.
(d) Observe these precautions when disconnecting the fuel tube connector (for Quick Type).
(1) for Fuel Hose Connector Cover Type:
Detach the lock claw by lifting up the cover, as shown in the illustration.
(2) for Fuel Pipe Clamp Type:
Remove the fuel pipe clamp from the fuel tube connector.
Page 8823
4. REMOVE FRONT UPPER ARMREST BASE PANEL LH (w/ Power Window) See: Body and
Frame/Doors, Hood and Trunk/Doors/Front
Door/Service and Repair/Front Door (for Regular Cab)/Disassembly
5. REMOVE FRONT DOOR WINDOW REGULATOR HANDLE ASSEMBLY (w/o Power Window)
See: Body and Frame/Doors, Hood and
Trunk/Doors/Front Door/Service and Repair/Front Door (for Regular Cab)/Disassembly
6. REMOVE COURTESY LIGHT ASSEMBLY (w/ Power Window) See: Body and Frame/Doors,
Hood and Trunk/Doors/Front Door/Service and
Repair/Front Door (for Regular Cab)/Disassembly
7. REMOVE FRONT DOOR ARMREST COVER LH
8. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH See: Body and Frame/Doors,
Hood and Trunk/Doors/Front Door/Service and
Repair/Front Door (for Regular Cab)/Disassembly
9. REMOVE FRONT NO. 1 SPEAKER ASSEMBLY
(a) Disconnect the speaker connector.
(b) Remove the 4 screws and speaker.
NOTICE: Do not touch the cone part of the speaker.
Installation
AUDIO / VISUAL: FRONT DOOR SPEAKER (for Regular Cab): INSTALLATION
HINT *
Use the same procedures for the LH side and RH side.
* The procedures listed below are for the LH side.
1. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY
(a) Temporarily install the speaker by attaching the claws of the speaker to the door panel.
(b) Install the speaker with the 4 screws.
NOTICE: Do not touch the cone part of the speaker.
HINT Install the screws in the order shown in the illustration.
(c) Connect the connector.
2. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH See: Body and Frame/Doors,
Hood and Trunk/Doors/Front Door/Service and
Repair/Front Door (for Regular Cab)/Reassembly
Page 6033
Symbols Used Within Diagrams
Symbols Used Within Diagrams
Page 6123
(d) Using a T30 "TORX" socket wrench, install the starter drive housing with the 2 bolts.
Torque : 6.0 Nm (61 kgf-cm, 53 in-lbf)
6. INSTALL MAGNET STARTER SWITCH ASSEMBLY
(a) Temporarily install the magnet starter switch by hooking its tip to the upper side of the pinion
drive lever.
(b) Install the 2 nuts.
Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
(c) Connect the lead wire to the terminal with the nut.
Torque : 6.5 Nm (66 kgf-cm, 57 in-lbf)
Page 1412
Page 9104
Trailer Connector: Diagnostic Aids
Continuity and Resistance Check
CONTINUITY AND RESISTANCE CHECK
Disconnect the battery terminal or wire so there is no voltage between the check points.
Contact the two leads of an ohmmeter to each of the check points.
Page 7152
Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf)
NOTICE: *
No further tightening is required once the nut is tightened with the specified torque.
* Check that there is no foreign matter on the washer and nut.
* Check that there is no oil, water or lubricant around the rim hole, tire pressure warning valve,
washer and nut. Failing to do so may result in improper installation.
(d) Set the wheel disc to a mounting machine and install the lower tire bead. Position the main
body of the tire pressure warning valve and
transmitter in the shaded area as shown in the illustration.
NOTICE: *
If the tire pressure warning valve and transmitter is positioned outside this area, the tire bead will
interfere with the tire pressure warning valve and transmitter, and may cause damage to it.
* If the use of lubricant is required when installing the bead, do not apply the lubricant directly to the
tire pressure warning valve and transmitter.
(e) Install the upper bead.
NOTICE: Make sure that the tire bead and tool do not interfere with the main body of the tire
pressure warning valve and transmitter and that the tire pressure warning valve and transmitter is
not clamped by the bead.
(f) Inflate the tire. Retighten the nut to the specified torque and then check for air leaks with soapy
water.
Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf)
NOTICE:
Page 7438
Tire Pressure Monitor Receiver / Transponder: Service and Repair Removal
TIRE AND WHEEL: TIRE PRESSURE WARNING RECEIVER: REMOVAL
1. REMOVE ROOF HEADLINING ASSEMBLY
(a) for Regular Cab:
Remove the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Removal.
(b) for Double Cab:
Remove the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Double Cab)/Removal.
(c) for CrewMax:
Remove the roof headlining See: Body and Frame/Interior Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (for CrewMax)/Removal.
2. REMOVE TIRE PRESSURE WARNING ANTENNA AND RECEIVER
(a) Disconnect the receiver connector.
(b) Remove the bolt and receiver.
Page 9300
Page 5298
NOTICE: When measuring dimension B, fix the spider and spider bearings in a vise and hold them
firmly together.
(d) w/o Grease Fitting Spider Bearing:
(1) Select snap rings to make dimensions A and B the same.
Snap ring type for steel yoke:
Snap ring type for aluminum yoke:
NOTICE: *
Use new snap rings.
* If possible, use snap rings of the same thickness for both sides.
(e) w/ Grease Fitting Spider Bearing:
(1) Select snap rings to make dimensions A and B the same.
Snap ring type:
Power Steering Oil Pressure Sensor
Power Steering Pressure Switch: Diagrams Power Steering Oil Pressure Sensor
Page 642
(a) Connect the connector.
(b) Attach the 4 clips to install the panel.
3. INSTALL INSTRUMENT PANEL CUP HOLDER ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column
Shift Type)/Installation
4. INSTALL LOWER INSTRUMENT CLUSTER FINISH PANEL See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column
Shift Type)/Installation
5. INSTALL FRONT ASH RECEPTACLE BOX SUB-ASSEMBLY
6. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument
Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column
Shift Type)/Installation
7. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Installation
8. INSTALL INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
9. INSTALL CENTER LOWER INSTRUMENT COVER See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service
and Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
10. INSTALL COWL SIDE TRIM BOARD LH
(a) for Regular Cab:
Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular Cab)/Installation.
(b) for Double Cab:
Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Installation.
(c) for CrewMax:
Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for CrewMax)/Installation.
Page 9182
Page 6947
Driver Side J/B Inner Circuit
Page 7184
Power Steering Pump: Testing and Inspection
POWER STEERING: VANE PUMP (for 1UR-FE): INSPECTION
1. INSPECT VANE PUMP SHAFT AND BUSH IN VANE PUMP FRONT HOUSING
(a) Using a micrometer, measure the diameter (a) of the vane pump shaft with vane pump pulley.
(b) Using a caliper gauge, measure the inside diameter (b) of the vane pump front housing.
(c) Subtract (a) from (b) to calculate the oil clearance.
Maximum clearance:
0.07 mm (0.00276 in.)
(d) If it is greater than the maximum, replace the vane pump shaft with vane pump pulley.
2. INSPECT VANE PUMP ROTOR AND VANE PUMP PLATE
(a) Inspect the vane pump rotor groove and vane pump plate clearance.
(1) Using a feeler gauge, measure the clearance between the side face of the vane pump rotor
groove and the vane pump plates.
Maximum clearance:
0.03 mm (0.00118 in.)
(2) If the clearance is more than the maximum, replace the vane pump plates, vane pump rotor and
vane pump cam ring.
NOTICE: *
Check the marks on the vane pump rotor and vane pump cam ring.
* Refer to the following table to select an appropriate combination of vane pump rotor, vane pump
cam ring and vane pump plates.
Combination of vane pump rotor, vane pump cam ring and vane pump plates:
Page 2410
9. INSTALL FAN AND GENERATOR V BELT See: Drive Belts, Mounts, Brackets and
Accessories/Drive Belt/Service and Repair/Installation
10. ADD ENGINE OIL See: Engine Oil/Service and Repair/Replacement
11. ADD ENGINE COOLANT See: Cooling System/Coolant/Service and Repair
12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
13. INSPECT FOR OIL LEAK See: Engine Oil/Service and Repair/Replacement
14. CHECK ENGINE OIL LEVEL See: Testing and Inspection
15. INSPECT FOR COOLANT LEAK See: Cooling System/Testing and Inspection
16. INSTALL NO. 1 ENGINE UNDER COVER See: Engine Oil/Service and Repair/Replacement
Page 7857
Evaporator Temperature Sensor / Switch: Locations Air Conditioning System (for Manual Air
Conditioning System)
AIR CONDITIONING: AIR CONDITIONING SYSTEM (for Manual Air Conditioning System):
PARTS LOCATION
Page 5387
Transfer Case Actuator: Diagrams
Page 8059
Impact Sensor: Diagrams Door Side Airbag Sensor
Page 7729
Evaporator Temperature Sensor / Switch: Testing and Inspection
AIR CONDITIONING: FRONT EVAPORATOR TEMPERATURE SENSOR: INSPECTION
1. INSPECT NO. 1 COOLER THERMISTOR
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NOTICE: *
Even slightly touching the sensor may change the resistance value. Be sure to hold the connector
of the sensor.
* When measuring, the sensor temperature must be almost the same as the ambient temperature.
HINT As the temperature increases, the resistance decreases (see the graph).
(b) If the result is not as specified, replace the sensor.
Page 1892
A/C Clamp Remover for removing special air condition line clamps. Applicable: 1998 and newer
Toyota models with the new style A/C clamps. Comparable to Toyota Tool numbers 09870-00015
and 09870-00025.
- Made in USA
- Fits both Toyota AC Clamps, used on high and low pressure lines.
- Applicable to: 1998 and newer Toyota models
- Stainless Steel release pins
- Identification and Instructions are laser marked on the handle
Contact AST for pricing.
Assenmacher Specialty Tools 1-800-525-2943
Page 6045
"Case2" Open the secondary locking device.
[B] For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray
Gray or White : Black
Page 1394
Page 8835
Removal
AUDIO / VISUAL: INSTRUMENT PANEL SPEAKER (for Double Cab): REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE FRONT PILLAR GARNISH LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Removal
3. REMOVE FRONT PILLAR GARNISH RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Removal
4. REMOVE NO. 1 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY
Page 4357
7. INSTALL EGR VALVE BRACKET
(a) Install the EGR valve bracket See: Emission Control Systems/Exhaust Gas Recirculation/EGR
Valve/Service and Repair/Installation.
8. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
9. CHECK FOR FUEL LEAK
(a) Connect the Techstream to the DLC3.
(b) Turn the ignition switch to ON and Techstream main switch ON.
NOTICE: Do not start the engine.
(c) Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump /
Speed.
(d) Check that there are no fuel leaks after doing maintenance anywhere on the fuel system.
Components
Tire Pressure Sensor: Service and Repair Components
TIRE AND WHEEL: TIRE PRESSURE WARNING VALVE AND TRANSMITTER: COMPONENTS
Diagrams
Trailer Brake Control Module: Diagrams
Page 2067
Release the locking lug from terminal and pull the terminal out from rear.
INSTALL TERMINAL TO CONNECTOR
Insert the terminal.
HINT: Make sure the terminal is positioned correctly.
Insert the terminal until the locking lug locks firmly.
Insert the terminal with terminal retainer in the temporary lock position.
Page 264
Relay Box: Diagnostic Aids
Continuity and Resistance Check
CONTINUITY AND RESISTANCE CHECK
Disconnect the battery terminal or wire so there is no voltage between the check points.
Contact the two leads of an ohmmeter to each of the check points.
Page 7887
Solar Sensor: Testing and Inspection
AIR CONDITIONING: SOLAR SENSOR (for Automatic Air Conditioning System): INSPECTION
1. INSPECT AUTOMATIC LIGHT CONTROL SENSOR (SOLAR SENSOR)
(a) Connect the battery's positive (+) lead to terminal 6 and the negative (-) lead to terminal 3, then
measure the voltage according to the value(s)
in the table below.
Standard voltage:
NOTICE: The connection procedure for using a digital tester such as a TOYOTA electrical tester is
shown above.
HINT *
As the inspection light is moved away from the sensor, the voltage decreases.
* Use an incandescent light for inspection. Bring it within 30 cm (11.8 in.) of the solar sensor.
(b) If the result is not as specified, replace the solar sensor.
Page 8093
Removal
SUPPLEMENTAL RESTRAINT SYSTEM: FRONT AIRBAG SENSOR: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE BATTERY
(a) Disconnect the cable from the positive (+) battery terminal.
Page 146
Install the lower instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Column Shift Type)/Installation.
for Floor Shift Type:
Install the lower instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Floor Shift Type)/Installation.
5. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH
(a) for Column Shift Type:
Install the instrument panel finish panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Column Shift Type)/Installation.
(b) for Floor Shift Type:
Install the instrument panel finish panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Floor Shift Type)/Installation.
6. INSTALL NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY
(a) for Column Shift Type:
Install the No. 2 instrument panel under cover sub-assembly See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and
Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Installation.
(b) for Floor Shift Type:
Install the No. 2 instrument panel under cover sub-assembly See: Body and Frame/Interior
Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and
Replacement/Instrument Panel Safety Pad (for Floor Shift Type)/Installation.
7. INSTALL INSTRUMENT SIDE PANEL RH
(a) for Column Shift Type:
Install the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Column Shift Type)/Installation.
(b) for Floor Shift Type:
Install the instrument side panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Floor Shift Type)/Installation.
8. INSTALL COWL SIDE TRIM BOARD RH
(a) for Regular Cab:
Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Regular Cab)/Installation.
(b) for Double Cab:
Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (For Double Cab)/Installation.
(c) for CrewMax:
Install the cowl side trim board See: Body and Frame/Interior Moulding / Trim/Headliner/Service
and Repair/Roof Headlining (for CrewMax)/Installation.
9. INSTALL FRONT DOOR SCUFF PLATE RH
(a) for Regular Cab:
Locations
Overdrive Switch: Locations
A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS
LOCATION
Page 2011
Push the secondary locking device or terminal retainer in to the full lock position.
CONNECT CONNECTOR
Voltage Check
VOLTAGE CHECK
Page 1516
Page 3609
Oxygen Sensor: Locations
1UR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: PARTS LOCATION
Page 1489
(2) Disconnect connector B and measure the resistance.
Standard resistance (Fig. 7):
* If the results match the examples above, a short circuit exists between terminal 1 of connector B2
and terminal 1 of connector C.
4. CHECK AND REPLACE ECU
NOTICE: *
The connector should not be disconnected from the ECU. Perform the inspection from the backside
of the connector on the wire harness side.
* When no measuring condition is specified, perform the inspection with the engine stopped and
the ignition switch ON.
* Check that the connectors are fully seated. Check for loose, corroded or broken wires.
(a) First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be
faulty. Temporarily replace the ECU with a
normally functioning one and check if the symptoms occur. If the trouble symptoms disappear,
replace the original ECU.
(1) Measure the resistance between the ECU ground terminal and body ground.
Standard resistance:
Below 1 Ohms
(2) Disconnect the ECU connector. Check the ground terminal on the ECU side and wire harness
side for bending, corrosion or foreign matter.
Lastly, check the contact pressure of the female terminals.
Page 667
Power Door Lock Switch: Testing and Inspection Door Control Switch (for Front RH)
DOOR LOCK: DOOR CONTROL SWITCH (for Front RH): INSPECTION
1. INSPECT DOOR CONTROL SWITCH ASSEMBLY
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the control switch assembly.
Components
Control Module HVAC: Service and Repair Components
AIR CONDITIONING: AIR CONDITIONING AMPLIFIER: COMPONENTS
Page 8282
(a) for LH Side:
Attach the 4 clips to install the lower quarter trim panel lower.
(b) for RH Side:
Attach the 3 clips to install the lower quarter trim panel lower.
(c) Install the seat belt anchor with the bolt.
Torque : 42 Nm (428 kgf-cm, 31 ft-lbf)
(d) Attach the 2 claws to install the cover.
5. INSTALL REAR DOOR SCUFF PLATE See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Installation
Service and Repair
Vehicle Lifting: Service and Repair
INTRODUCTION: REPAIR INSTRUCTION: VEHICLE LIFT AND SUPPORT LOCATIONS
1. NOTICE ABOUT VEHICLE CONDITION WHEN JACKING UP VEHICLE
(a) The vehicle must be unloaded before jacking up / lifting up the vehicle. Never jack up / lift up a
heavily loaded vehicle.
(b) When removing heavy parts such as the engine and transmission, the center of gravity of the
vehicle may shift. To stabilize the vehicle, place a
balance weight in a location where it will not roll or shift, or use a mission jack to hold the jacking
support.
2. NOTICE FOR USING 4 POST LIFT
(a) Follow the safety procedures outlined in the lift's instruction manual.
(b) Use precautionary measures to prevent the free wheel beam from damaging tires or wheels.
(c) Use wheel chocks to secure the vehicle.
3. NOTICE FOR USING JACK AND SAFETY STAND
(a) Work on a level surface. Use wheel chocks at all times.
(b) Use safety stands with rubber attachments as shown in the illustration.
(c) Set the jack and safety stands to the specified locations of the vehicle accurately.
(d) When jacking up the vehicle, first release the parking brake and move the shift lever to N.
(e) When jacking up the entire vehicle:
(1) When jacking up the front wheels first, make sure wheel chocks are behind the rear wheels.
(2) When jacking up the rear wheels first, make sure wheel chocks are in front of the front wheels.
(f) When jacking up only the front or rear wheels of the vehicle:
(1) Before jacking up the front wheels, place wheel chocks on both sides of the rear wheels.
(2) Before jacking up the rear wheels, place wheel chocks on both sides of the front wheels.
(g) When lowering a vehicle that only has its front or rear wheels jacked up:
(1) Before lowering the front wheels, make sure wheel chocks are in front of the rear wheels.
(2) Before lowering the rear wheels, make sure wheel chocks are behind the front wheels.
Page 7430
Tire Pressure Module: Service and Repair Installation
TIRE AND WHEEL: TIRE PRESSURE WARNING ECU: INSTALLATION
1. INSTALL TIRE PRESSURE WARNING ECU
(a) Install the ECU with the 2 nuts.
Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
(b) Connect the ECU connector.
2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Installation
3. INSTALL INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
4. INSTALL COWL SIDE TRIM BOARD RH
(a) Install the cowl side trim board RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Installation.
HINT Use the same procedures described for the LH side.
5. INSTALL FRONT DOOR SCUFF PLATE RH (for Double Cab, for CrewMax)
(a) Install the front door scuff plate RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Installation.
HINT Use the same procedures described for the LH side.
6. INSTALL FRONT DOOR SCUFF PLATE RH (for Regular Cab)
(a) Install the front door scuff plate RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Installation.
HINT Use the same procedures described for the LH side.
7. REGISTRATION OF TRANSMITTER ID
(a) Register the transmitter ID See: Tire Monitoring System/Testing and Inspection/Programming
and Relearning/Registration.
8. PERFORM INITIALIZATION
(a) Perform initialization See: Tire Monitoring System/Testing and Inspection/Programming and
Relearning/Initialization.
NOTICE: Be sure to inflate all tires to the proper inflation pressure before initialization.
9. CHECK TIRE PRESSURE AFTER REPAIRS
Page 7959
Tire size:
Must exceed the following dimensions Tires
Width 185 mm (7.28 in.)
Inner diameter 360 mm (1.18 ft.)
CAUTION: Do not use tires with disc wheels except on the top and bottom.
NOTICE: *
As the tires may be damaged by the airbag deployment, use a tire that you are planning to throw
away.
* Do not place SST connector under the tire because it could be damaged.
(3) Tie the tires together with 2 wire harnesses.
CAUTION: Make sure that the wire harnesses are tight. Looseness in the wire harnesses results in
the tires coming free due to the shock when the airbag is deployed.
(f) Deploy the airbag.
Page 8337
Impact Sensor: Testing and Inspection Side Airbag Sensor (for CrewMax)
SUPPLEMENTAL RESTRAINT SYSTEM: SIDE AIRBAG SENSOR (for CrewMax): ON-VEHICLE
INSPECTION
1. CHECK REAR AIRBAG SENSOR (VEHICLE NOT INVOLVED IN COLLISION)
(a) Perform a diagnostic system check See: Air Bag Systems/Testing and Inspection/Initial
Inspection and Diagnostic Overview/Diagnosis
System.
2. CHECK REAR AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG HAS
NOT DEPLOYED)
(a) Perform a diagnostic system check See: Air Bag Systems/Testing and Inspection/Initial
Inspection and Diagnostic Overview/Diagnosis
System.
(b) When the quarter panel of the vehicle or its area is damaged, check if there is any damage to
the rear airbag sensor. If there are any defects as
mentioned below, replace the side airbag sensor with a new one:
* Cracks, dents or chips on the sensor housing.
* Cracks or other damage to the connector.
* Peeling off of the label or damage to the serial number.
CAUTION: For removal and installation procedures of the side airbag sensor, be sure to follow the
correct procedure.
3. CHECK REAR AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS
DEPLOYED)
(a) Replace the side airbag sensor.
CAUTION: *
For removal and installation procedures of the side airbag sensor, be sure to follow the correct
procedure.
* If the airbags have deployed, replace the rear airbag sensor on the side in which the collision
occurred. Replace both if necessary.
Page 361
When using Techstream Lite, select Generic J2534 Interface. Then click Next.
E. Confirm the following:
^ PC is connected to VIM.
^ VIM is connected to DLC3 connector.
^ Ignition is ON and engine is OFF or "READY" OFF (hybrid vehicles).
Page 6763
MJ1-NP1
Locations
Ignition Relay: Locations
MULTIPLEX COMMUNICATION: LIN COMMUNICATION SYSTEM: PARTS LOCATION
Locations
Tire Pressure Monitor Receiver / Transponder: Locations
TIRE AND WHEEL: TIRE PRESSURE WARNING SYSTEM: PARTS LOCATION
Page 1011
Parking Brake Warning Switch: Testing and Inspection
PARKING BRAKE: PARKING BRAKE SWITCH: ON-VEHICLE INSPECTION
1. REMOVE PARKING BRAKE SWITCH ASSEMBLY See: Brakes and Traction Control/Parking
Brake System/Parking Brake Pedal/Service
and Repair/Overhaul/Disassembly
2. CHECK PARKING BRAKE SWITCH ASSEMBLY
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
(b) If the result is not as specified, replace the parking brake switch assembly.
3. INSTALL PARKING BRAKE SWITCH ASSEMBLY See: Brakes and Traction Control/Parking
Brake System/Parking Brake Pedal/Service
and Repair/Overhaul/Reassembly
Center Airbag Sensor Assembly (for Floor Shift Type)
Impact Sensor: Service and Repair Center Airbag Sensor Assembly (for Floor Shift Type)
Components
SUPPLEMENTAL RESTRAINT SYSTEM: CENTER AIRBAG SENSOR ASSEMBLY (for Floor Shift
Type): COMPONENTS
Page 8429
Antenna, Navigation: Service and Repair Removal
NAVIGATION: NAVIGATION ANTENNA: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY
(a) for Column Shift Type:
Remove the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Column Shift Type)/Removal.
(b) for Floor Shift Type:
Remove the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Floor Shift Type)/Removal.
3. REMOVE NO. 1 HEATER TO REGISTER DUCT WITH NO. 2 HEATER TO REGISTER DUCT
See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and Repair/Overhaul/Instrument Panel Safety Pad (for
Column Shift Type)/Disassembly
4. REMOVE NO. 2 SIDE DEFROSTER NOZZLE DUCT See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service
and Repair/Overhaul/Instrument Panel Safety Pad (for Column Shift Type)/Disassembly
5. REMOVE NO. 1 SIDE DEFROSTER NOZZLE DUCT See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service
and Repair/Overhaul/Instrument Panel Safety Pad (for Column Shift Type)/Disassembly
6. REMOVE DEFROSTER NOZZLE ASSEMBLY See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Overhaul/Instrument Panel Safety Pad (for Column Shift Type)/Disassembly
7. REMOVE NAVIGATION ANTENNA ASSEMBLY
(a) Detach the clamp.
(b) Remove the 2 screws and antenna.
Page 303
Relay Box: Electrical Diagrams
Engine Room R/B And Engine Room J/B Inner Circuit
Page 9065
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: ELECTRONIC
CIRCUIT INSPECTION PROCEDURE
1. BASIC INSPECTION
(a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS
(1) Unless otherwise stated, all resistance measurements should be made at an ambient
temperature of 20°C (68°F). Resistance measurements
may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been
running. Measurements should be made after the engine has cooled down.
(b) HANDLING CONNECTORS
(1) When disconnecting a connector, first squeeze the mating halves tightly together to release the
lock, and then press the lock claw and
separate the connector.
(2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly
and separate it.
(3) Before connecting a connector, check that there are no deformed, damaged, loose or missing
terminals.
(4) When connecting a connector, press firmly until it locks with a "click" sound.
(5) If checking a connector with a TOYOTA electrical tester, check the connector from the backside
(harness side) using a mini test lead.
NOTICE: *
As a waterproof connector cannot be checked from the backside, check it by connecting a
sub-harness.
* Do not damage the terminals by moving the inserted tester needle.
(c) CHECKING CONNECTORS
(1) Checking when a connector is connected: Squeeze the connectors together to confirm that they
are fully connected and locked.
(2) Checking when a connector is disconnected: Check by pulling the wire harness lightly from the
backside of the connector. Look for
unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for
corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or
deformed terminals.
(3) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a
female terminal, and check for ample tension
Page 5385
Transfer Case Actuator: Locations JF1A Transfer Case
JF1A TRANSFER: TOUCH SELECT 2-4 AND HIGH-LOW SYSTEM: PARTS LOCATION
Center Power Outlet Socket (for Column Shift Type)
Auxiliary Power Outlet: Service and Repair Center Power Outlet Socket (for Column Shift Type)
Components
OTHER SYSTEM: CENTER POWER OUTLET SOCKET (for Column Shift Type): COMPONENTS
Page 6198
(a) Attach the claw to install the power outlet socket.
(b) Connect the power outlet socket connector.
6. INSTALL CENTER FRONT SEAT ASSEMBLY
(a) Install the center front seat See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Center
Seat)/Installation.
7. INSTALL FRONT SEAT ASSEMBLY LH (for Power Seat)
(a) Install the front seat LH See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Power
Seat)/Installation.
8. INSTALL FRONT SEAT ASSEMBLY RH (for Power Seat)
HINT Use the same procedures described for the LH side.
9. INSTALL FRONT SEAT ASSEMBLY LH (for Manual Seat)
(a) Install the front seat LH See: Body and Frame/Seats/Service and Repair/Removal and
Replacement/Front Seat Assembly (for Manual
Seat)/Installation.
10. INSTALL FRONT SEAT ASSEMBLY RH (for Manual Seat)
HINT Use the same procedures described for the LH side.
Components
OTHER SYSTEM: CENTER POWER OUTLET SOCKET (for Floor Shift Type): COMPONENTS
Page 2437
Oil Pressure Sender: Diagrams Oil Pressure Switch
Page 31
Central Control Module: Service and Repair Removal
AUDIO / VISUAL: MULTI-MEDIA INTERFACE ECU: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY
(a) for Column Shift Type:
Remove the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Column Shift Type)/Removal.
(b) for Floor Shift Type:
Remove the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad (for
Floor Shift Type)/Removal.
3. REMOVE MULTI-MEDIA INTERFACE ECU
(a) Remove the nut.
(b) Disconnect the connector and remove the multi-media interface ECU.
4. REMOVE MULTI-DISPLAY CONTROLLER BRACKET A
(a) Remove the 2 bolts and multi-display controller bracket A.
Page 974
Dimmer Switch: Service and Repair Installation
METER: LIGHT CONTROL RHEOSTAT: INSTALLATION
1. INSTALL LIGHT CONTROL RHEOSTAT
(a) Attach the 2 claws to install the rheostat.
2. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Panel,
Gauges and Warning Indicators/Instrument Cluster
/ Carrier/Service and Repair/Combination Meter/Installation
Page 8094
(b) Loosen the nut, move the stay off the battery, and remove the battery.
3. REMOVE FRONT AIRBAG SENSOR
(a) Remove the nut and front airbag sensor from the body.
(b) Disconnect the connector.
Installation
SUPPLEMENTAL RESTRAINT SYSTEM: FRONT AIRBAG SENSOR: INSTALLATION
1. INSTALL FRONT AIRBAG SENSOR
(a) Check that the ignition switch is OFF.
(b) Check that the cable is disconnected from the battery negative (-) terminal.
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to prevent airbag and seat belt pretensioner activation.
(c) Connect the connector.
(d) Install the front airbag sensor with the nut.
Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)
NOTICE: *
If the front airbag sensor has been dropped, or there are any cracks, dents or other defects in the
case, bracket or connector, replace it with a new one.
* When installing the front airbag sensor, be careful that the SRS wiring does not interfere with
other parts and that it is not pinched between other parts.
(e) Check that there is no looseness in the installation parts of the front airbag sensor.
2. INSTALL BATTERY
Page 3753
(2) If the result is not as specified, replace the integration relay.
3. INSTALL INTEGRATION RELAY See: Ignition System/Ignition Relay/Testing and Inspection
Glass Breakage Sensor (for Floor Shift Type)
Ultrasonic Sensor: Service and Repair Glass Breakage Sensor (for Floor Shift Type)
Components
THEFT DETERRENT: GLASS BREAKAGE SENSOR (for Floor Shift Type): COMPONENTS
Removal
THEFT DETERRENT: GLASS BREAKAGE SENSOR (for Floor Shift Type): REMOVAL
1. REMOVE FRONT DOOR SCUFF PLATE LH
Front Axle Hub Bolt
Wheel Fastener: Service and Repair Front Axle Hub Bolt
Components
AXLE: FRONT AXLE HUB BOLT: COMPONENTS
Replacement
AXLE: FRONT AXLE HUB BOLT: REPLACEMENT
HINT *
Use the same procedures for the LH side and RH side.
Page 301
J/B No.6 Assembly - Instrument Panel Center
Locations
Shock Sensor: Locations
THEFT DETERRENT: THEFT DETERRENT SYSTEM: PARTS LOCATION
Page 82
Power Mirror Control Module: Diagrams
Page 6771
PJ1-TJ1
Locations
Fog/Driving Lamp Switch: Locations
LIGHTING: LIGHTING SYSTEM: PARTS LOCATION
Page 7326
(a) Pack the upper arm ball joint with MP grease.
Grease capacity:
5.0 to 7.0 g (0.176 to 0.247 oz.)
(b) Using a snap ring expander, install the dust cover set ring.
2. INSTALL FRONT SUSPENSION UPPER ARM BUSH
(a) Using SST and a press, press in a new bush.
SST : 09710-26011
09710-05061
Page 1564
Tire Pressure Warning Reset Switch: Service and Repair Removal
TIRE AND WHEEL: TIRE PRESSURE WARNING RESET SWITCH: REMOVAL
1. REMOVE FRONT DOOR SCUFF PLATE LH (for Regular Cab) See: Body and Frame/Interior
Moulding / Trim/Headliner/Service and
Repair/Roof Headlining (For Regular Cab)/Removal
2. REMOVE FRONT DOOR SCUFF PLATE LH (for Double Cab, for CrewMax) See: Body and
Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For Double Cab)/Removal
3. REMOVE COWL SIDE TRIM BOARD LH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Removal
4. REMOVE INSTRUMENT SIDE PANEL LH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift Type)/Removal
5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Removal
6. REMOVE TIRE PRESSURE WARNING RESET SWITCH
(a) Disconnect the switch connector.
(b) Detach the 2 claws and remove the reset switch.
Recall 10V017000: Accelerator Pedal Sticking
Accelerator Pedal Position Sensor: All Technical Service Bulletins Recall 10V017000: Accelerator
Pedal Sticking
VEHICLE MAKE/MODEL: MODEL YEAR(S): Toyota/Avalon 2005-2010 Toyota/Camry 2007-2010
Toyota/Corolla 2009-2010 Toyota/Corolla Matrix 2009-2010 Toyota/Highlander 2010 Toyota/ RAV4
2009-2010 Toyota/Sequoia 2008-2010 Toyota/Tundra 2007-2010 MANUFACTURER: Toyota
Motor North America, Inc.
MFR'S REPORT DATE: January 21, 2010
NHTSA CAMPAIGN ID NUMBER: 10V017000
NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Accelerator Assembly:
Pedal/Linkage
POTENTIAL NUMBER OF UNITS AFFECTED: ?
SUMMARY: Toyota is recalling certain model year 2005-2010 Avalon, model year 2007-2010
Camry, model year 2009-2010 Corolla, Corolla Matrix, RAV4, model year 2010 Highlander, model
year 2008-2010 Sequoia, and model year 2007-2010 Tundra. due to the manner in which the
friction lever interacts with the sliding surface of the accelerator pedal inside the pedal sensor
assembly, the sliding surface of the lever may become smooth during vehicle operation. In this
condition, if condensation occurs on the surface, as may occur from heater operation (without A/C)
when the pedal assembly is cold, the friction when the accelerator pedal is operated may increase,
which may result in the accelerator pedal becoming harder to depress, slower to return, or, in the
worst case, mechanically stuck in a partially depressed position.
CONSEQUENCE: The accelerator pedal may become hard to depress, slow to return to idle, or, in
the worst case, mechanically stuck in a partially depressed position, increasing the risk of a crash.
REMEDY: Toyota has not yet provided a remedy plan or an owner notification schedule. Owners
may contact Toyota at 1-800-331-4331.
NOTES: Owners may also contact The National Highway Traffic Safety Administration's Vehicle
Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov.
Page 5123
3. Inspect the front differential support bolt for separation.
Repair Procedure
1. If the differential support bolt is separated perform the five steps below.
NOTE
If there is NO damage to the differential support bolt, this TSB does NOT apply. Continue diagnosis
to isolate the cause of the condition.
A. Remove the differential support bolt.
Refer to the Technical Information System (TIS) applicable model and model year Repair Manual:
B. Clean the bracket and surrounding area.
C. Install the NEW differential support bolt.
Refer to TIS applicable model and model year Repair Manual:
Torque: 120 N*m (1224 kgf*cm, 89 ft*lbf)
Page 655
Hood Sensor/Switch (For Alarm): Diagrams
Page 6709
Remove the blown fuse and disconnect all loads of the fuse.
Connect a test light in place of the fuse.
Establish conditions in which the test light comes on.
Example:
- [A] - Ignition SW on
- [B] - Ignition SW and SW1 on
- [C] - Ignition SW, SW1 and Relay on (Connect the Relay) and SW2 off (or Disconnect SW2)
Disconnect and reconnect the connectors while watching the test light.
Locations
Power Distribution Relay: Locations
Instrument Panel (Floor Shift)
Instrument Panel (Column Shift)
Page 6608
3. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE
HINT The diagnostic system in the TOYOTA TUNDRA has various functions.
* The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU
memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a
previous malfunction's DTC can be checked by a technician during troubleshooting.
* Another function is the Input Signal Check, which checks if the signals from various switches are
sent to the ECU correctly.
* By using these functions, the problem areas can be narrowed down and troubleshooting is more
effective. Diagnostic functions are incorporated in the following systems in the TOYOTA TUNDRA.
Locations
Alarm Horn Relay: Locations
THEFT DETERRENT: THEFT DETERRENT SYSTEM: PARTS LOCATION
Locations
Transmission Position Switch/Sensor: Locations
A760F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION SYSTEM: PARTS
LOCATION
Page 6602
(a) For an open circuit in the wire harness in Fig. 1, check the resistance or voltage, as described
below.
(b) Check the resistance.
(1) Disconnect connectors A and C and measure the resistance between them.
Standard resistance (Fig. 2):
HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally.
If the results match the examples above, an open circuit exists between terminal 1 of connector A
and terminal 1 of connector C.
(2) Disconnect connector B and measure the resistance between the connectors.
Standard resistance (Fig. 3):
* If the results match the examples above, an open circuit exists between terminal 1 of connector
B2 and terminal 1 of connector C.
(c) Check the voltage.
Page 8348
NOTICE: *
If the front airbag sensor has been dropped, or there are any cracks, dents or other defects in the
case, bracket or connector, replace it with a new one.
* When installing the front airbag sensor, be careful that the SRS wiring does not interfere with
other parts and that it is not pinched between other parts.
(e) Check that there is no looseness in the installation parts of the front airbag sensor.
2. INSTALL BATTERY
(a) Set the battery in the vehicle. Then move the stay onto the battery and tighten the nut to fix the
battery in place.
(b) Connect the cable to the positive (+) battery terminal.
3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
4. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Air Bag Systems/Testing and Inspection/Initial Inspection
and Diagnostic Overview/Diagnosis System.
Page 9106
Use a volt/ohmmeter with high impedance (10 kohms/V minimum) for troubleshooting of the
electrical circuit.
Disconnection of Male and Female Connectors
DISCONNECTION OF MALE AND FEMALE CONNECTORS
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Finding A Short Circuit
FINDING A SHORT CIRCUIT
Page 8286
(c) Remove the 2 bolts and seat belt.
Installation
SEAT BELT: REAR SEAT OUTER BELT ASSEMBLY (for Double Cab): INSTALLATION
HINT *
Use the same procedures for the LH side and RH side.
* The procedures listed below are for the LH side.
1. INSTALL REAR SEAT OUTER BELT ASSEMBLY
(a) Align the vehicle's claws with the seat belt retractor positioning holes.
(b) Install the seat belt with the 2 bolts.
HINT First install bolt A, and then install bolt B.
for bolt A - Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
for bolt B - Torque : 42 Nm (428 kgf-cm, 31 ft-lbf)
(c) Install the shoulder anchor with the bolt.
Torque : 42 Nm (428 kgf-cm, 31 ft-lbf)
2. INSTALL FRONT QUARTER TRIM PANEL ASSEMBLY See: Body and Frame/Interior Moulding
/ Trim/Headliner/Service and Repair/Roof
Headlining (For Double Cab)/Installation
3. INSTALL LOWER QUARTER TRIM PANEL ASSEMBLY
Page 1233
Transmission Position Switch/Sensor: Diagrams
Page 5918
Wheel Speed Sensor: Service and Repair Rear Speed Sensor
Components
BRAKE CONTROL: REAR SPEED SENSOR: COMPONENTS
Removal
BRAKE CONTROL: REAR SPEED SENSOR: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
Page 7649
(1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be
checked by conducting a voltage check.
With each connector still connected, measure the voltage between the body ground and these
terminals (in this order): 1) terminal 1 of connector A; 2) terminal 1 of connector B; and 3) terminal
1 of connector C.
Standard voltage (Fig. 4):
* If the results match the examples above, an open circuit exists in the wire harness between
terminal 1 of connector B and terminal 1 of connector C.
3. CHECK FOR SHORT CIRCUIT
(a) If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance
check with the body ground (below).
(b) Check the resistance with the body ground.
(1) Disconnect connectors A and C and measure the resistance.
Standard resistance (Fig. 6):
HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally.
If your results match the examples above, a short circuit exists between terminal 1 of connector A
and terminal 1 of connector C.
Page 8248
Components
SEAT BELT: FRONT SEAT OUTER BELT ASSEMBLY (for Double Cab): COMPONENTS
Removal
SEAT BELT: FRONT SEAT OUTER BELT ASSEMBLY (for Double Cab): REMOVAL
HINT *
Use the same procedures for the LH side and RH side.
* The procedures listed below are for the LH side.
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION:
Page 2032
Driver Side J/B - Cowl Side Left
Page 291
6. PROBLEM SYMPTOMS TABLE
When a "Normal" code is output during a DTC check but the problem is still occurring, use the
Problem Symptoms Table. The suspected areas (circuits or parts) for each problem symptom are
in the table. The suspected areas are listed in order of probability. A description of each of the
chart's columns is below.
HINT In some cases, the problem is not detected by the diagnostic system even though a problem
symptom is present. It is possible that the problem is occurring outside the detection range of the
diagnostic system, or that the problem is occurring in a completely different system.
7. CIRCUIT INSPECTION
A description of the main areas of each circuit inspection is below.
Page 7646
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: ELECTRONIC
CIRCUIT INSPECTION PROCEDURE
1. BASIC INSPECTION
(a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS
(1) Unless otherwise stated, all resistance measurements should be made at an ambient
temperature of 20°C (68°F). Resistance measurements
may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been
running. Measurements should be made after the engine has cooled down.
(b) HANDLING CONNECTORS
(1) When disconnecting a connector, first squeeze the mating halves tightly together to release the
lock, and then press the lock claw and
separate the connector.
(2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly
and separate it.
(3) Before connecting a connector, check that there are no deformed, damaged, loose or missing
terminals.
(4) When connecting a connector, press firmly until it locks with a "click" sound.
(5) If checking a connector with a TOYOTA electrical tester, check the connector from the backside
(harness side) using a mini test lead.
NOTICE: *
As a waterproof connector cannot be checked from the backside, check it by connecting a
sub-harness.
* Do not damage the terminals by moving the inserted tester needle.
(c) CHECKING CONNECTORS
(1) Checking when a connector is connected: Squeeze the connectors together to confirm that they
are fully connected and locked.
(2) Checking when a connector is disconnected: Check by pulling the wire harness lightly from the
backside of the connector. Look for
unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for
corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or
deformed terminals.
(3) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a
female terminal, and check for ample tension
Page 3322
Components
Knock Sensor: Service and Repair Components
1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: COMPONENTS
Page 6292
Engine Room R/B, J/B - Engine Compartment Left
Page 5549
Four Wheel Drive Selector Switch: Service and Repair Removal
JF1A TRANSFER: 4WD CONTROL SWITCH: REMOVAL
1. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY See: Instrument Panel,
Gauges and Warning Indicators/Instrument Cluster
/ Carrier/Service and Repair/Combination Meter/Removal
2. REMOVE 4WD CONTROL SWITCH
(a) Detach the 3 claws to remove the switch.
Page 3078
Release the locking lug from terminal and pull the terminal out from rear.
INSTALL TERMINAL TO CONNECTOR
Insert the terminal.
HINT: Make sure the terminal is positioned correctly.
Insert the terminal until the locking lug locks firmly.
Insert the terminal with terminal retainer in the temporary lock position.
Page 7366
Page 2942
Knock Sensor: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: KNOCK SENSOR: REMOVAL
1. REMOVE INTAKE MANIFOLD
(a) Remove the intake manifold See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service
and Repair/Removal.
2. REMOVE SEPARATOR CASE
(a) Remove the 4 bolts and separator case.
3. REMOVE KNOCK SENSOR
(a) Disconnect the 4 knock sensor connectors.
(b) Remove the 4 bolts and 4 knock sensors.
Page 732
Seat Heater Switch: Diagrams Seat Heater Switch
Page 4291
1. Test drive the vehicle and confirm there is a harsh shift on acceleration below 20 mph and or
excessive lock-up operation at freeway speeds about 50
- 60 mph.
2. Check for the Authorized Modifications Label affixed to the vehicle in the location shown in
Figure 1. Confirm if the ECM (PCM) calibration has
been updated. If the calibration ID listed is NOT the latest ECM (PCM) calibration - go to step 3.
3. Flash reprogram the ECM (PCM).
NOTE
^ The GR8 Battery Diagnostic Station MUST be used in Power Supply Mode to maintain battery
voltage at 13.5 volts while flash reprogramming the vehicle.
^ For details on how to use the GR8 Battery Diagnostic Station, refer to the GR8 Instruction Manual
located on the Technical Information System (TIS), Diagnostics - Battery.
Follow the procedures outlined in TSB No. T-SB-0064-10, "Techstream ECU Flash
Reprogramming Procedure", and flash the ECM (PCM) with the NEW calibration file update.
4. Start the engine and warm it up to normal operating temperature before test driving.
5. Test drive the vehicle to confirm proper vehicle operation and ECM (PCM) initial learning. Refer
to the Technical Information System (TIS) 2010
Tundra Repair Manual:
Drivetrain - Automatic Transmission/Transaxle - "A760E / A760F Automatic
Transmission/Transaxle: Automatic Transmission System: Initialization"
6. Install the Authorized Modifications Label.
A. Using a permanent marker enter the following information on the label:
^ ECM part number [Refer to the Parts Information section for the CURRENT PART NUMBER]
Page 8887
Collision Avoidance Module: Diagrams
Page 6827
Components
Parking Assist Control Module: Service and Repair Components
PARK ASSIST / MONITORING: CLEARANCE WARNING ECU: COMPONENTS
Page 1652
Power Window Switch: Service and Repair Rear Power Window Switch
Components
WINDSHIELD / WINDOWGLASS: REAR POWER WINDOW SWITCH: COMPONENTS
Page 1708
(b) * for 5 leaf spring
6. INSPECT CAMBER, CASTER AND STEERING AXIS INCLINATION
(a) Install the camber-caster-kingpin gauge or place the front wheels on the center of the wheel
alignment tester.
Page 6281
General Information
INTRODUCTION: HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS: GENERAL
INFORMATION
* A large number of ECU controlled systems are used in the TOYOTA TUNDRA. In general, ECU
controlled systems are considered to be very intricate, requiring a high level of technical knowledge
to troubleshoot. However, most problem checking procedures only involve inspecting the ECU
controlled system's circuits one by one. An adequate understanding of the system and a basic
knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and
necessary repairs.
1. TROUBLESHOOTING PROCEDURES
* The troubleshooting procedures consist of diagnosis procedures for when a DTC is stored and
diagnosis procedures for when no DTC is stored. The basic idea is explained in the following table.
* Vehicle systems are complex and use many ECUs that are difficult to inspect independently.
Therefore, a process of elimination is used, where components that can be inspected individually
are inspected, and if no problems are found in these components, the related ECU is identified as
the problem and replaced.
* It is extremely important to ask the customer about the environment and the conditions present
when the problem occurred (Customer Problem Analysis). This makes it possible to simulate the
conditions and confirm the symptom. If the symptom cannot be confirmed or the DTC does not
recur, the malfunctioning part may not be identified using the troubleshooting procedure, and the
ECU for the related system may be replaced even though it is not defective. If this happens, the
original problem will not be solved.
* In order to prevent endless expansion of troubleshooting procedures, the troubleshooting
procedures are written with the assumption that multiple malfunctions do not occur simultaneously
for a single problem symptom.
* To identify the malfunctioning part, troubleshooting procedures narrow down the target by
separating components, ECUs and wire harnesses during the inspection. If the wire harness is
identified as the cause of the problem, it is necessary to inspect not only the connections to
components and ECUs but also all of the wire harness connectors between the component and the
ECU.
DIAGNOSTIC TESTER
2. DESCRIPTION
System data and the Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector
3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the Techstream* to
check for a malfunction and perform repairs.
HINT *: Techstream is the name for the diagnostic tester in North America.
3. DATA LINK CONNECTOR 3 (DLC3)
(a) The vehicle's ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of
the DLC3 complies with SAE J1962 and
matches the ISO 15765-4 format.
Page 7749
Page 7832
Ambient Temperature Sensor / Switch HVAC: Testing and Inspection
AIR CONDITIONING: AMBIENT TEMPERATURE SENSOR: INSPECTION
1. INSPECT AMBIENT TEMPERATURE SENSOR
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
NOTICE: *
Touching the sensor even slightly may change the resistance value. Hold the connector of the
sensor.
* When measuring the resistance, the sensor temperature must be the same as the ambient
temperature.
HINT As the temperature increases, the resistance decreases (see the graph).
(b) If the result is not as specified, replace the ambient temperature sensor.
Page 8460
Page 4091
(d) Remove the gasket from the No. 2 EGR pipe.
NOTICE: Be careful not to damage the installation surface of the gaskets.
(e) Remove the gasket from the intake manifold.
7. REMOVE EGR INLET
(a) Remove the 2 bolts, EGR inlet and gasket.
NOTICE: Be careful not to damage the installation surface of the gaskets.
8. REMOVE NO. 3 EGR PIPE SUB-ASSEMBLY
(a) Remove the 2 nuts, No. 3 EGR pipe and gasket.
NOTICE: Be careful not to damage the installation surface of the gaskets.
9. REMOVE EGR VALVE BRACKET
(a) Remove the 3 bolts and EGR valve bracket.
Page 7056
(c) * for 5 leaf spring
Standard caster inclination (unloaded vehicle):
for Regular Cab of Standard Deck
Page 4277
load while reprogramming.
^ Confirm the hood is open and ensure under hood temperature does NOT exceed 158°F (70°C).
^ Confirm cable connections between the vehicle and Techstream are secure.
^ Do NOT disconnect or turn off Techstream or vehicle ignition during reprogramming.
^ Set parking brake.
^ Complete ALL flash calibration updates provided for each ECU.
^ If the battery's state of charge or capacity are in question, test with SST. No. 00002-8150-KIT
"Digital Battery Analyze," and follow TSB No. PG001-06, "Battery Maintenance for In-Stock
Vehicles & Pre-Delivery" or the appropriate "Maintenance for HV & Auxiliary Batteries" service
bulletin.
^ The GR8 Battery Diagnostic Station MUST be used in Power Supply Mode to maintain battery
voltage at 13.5 volts while flash reprogramming the vehicle. For details on how to use the GR8
Battery Diagnostic Station, refer to the GR8 Instruction Manual located on TIS, Diagnostics - Tools
& Equipment - Battery Diagnostics.
3C. Click Next to start the calibration update process.
D. When using TIS Techstream select Techstream VIM as the desired programming device. Then
click Next.
Page 9009
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION: Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC
terminals are touched, the IC may be destroyed by static electricity.)
When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact with the terminals of leads from the IC, etc. of the
replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown on the left.
DISCONNECT CONNECTOR
Page 3646
Body Control Module: Diagrams
Page 3233
Push the secondary locking device or terminal retainer in to the full lock position.
CONNECT CONNECTOR
Voltage Check
VOLTAGE CHECK
Page 4355
NOTICE: *
Make sure that there are no scratches or foreign matter in or around the insertion hole of the
delivery pipe.
* When inserting the injector, be careful not to damage the O-ring.
* Attach the part of the injector labeled B between the parts of the delivery pipe labeled A.
(f) Check that each injector is installed to the delivery pipe facing the direction shown in the
illustration.
2. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY LH
(a) Install the 2 delivery pipe spacers and 4 insulators to the cylinder head LH.
(b) Install the delivery pipe (with injectors) to the cylinder head LH.
(c) Install the 2 bolts.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
NOTICE:
Make sure that the part of the injector labeled B is between the parts of the delivery pipe labeled A.
(d) Connect the No. 7 wire harness connector.
3. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY RH
Page 6335
Page 1701
(a) Bounce the vehicle up and down at the corners to stabilize the suspension, and then inspect the
toe-in.
Standard toe-in (unloaded vehicle):
for Regular Cab of Standard Deck
Standard toe-in (unloaded vehicle):
for Regular Cab of Long Deck
Standard toe-in (unloaded vehicle):
for Double Cab of Standard Deck
Page 1375
Impact Sensor: Diagrams Door Side Airbag Sensor
Page 8241
(a) Remove the nut and bolt, and then detach the 2 claws and remove the seat belt.
Installation
SEAT BELT: FRONT SEAT OUTER BELT ASSEMBLY (for Center Seat): INSTALLATION
1. INSTALL CENTER FRONT SEAT BELT ASSEMBLY RH
(a) Align the seat frame's claws with the seat belt retractor positioning holes.
(b) Install the seat belt with the nut and bolt.
HINT First install the bolt, and then install the nut.
for bolt - Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
for nut - Torque : 42 Nm (428 kgf-cm, 31 ft-lbf)
2. INSTALL FRONT SEAT HEADREST SUPPORT See: Body and Frame/Seats/Service and
Repair/Overhaul/Front Seat Assembly (for Center
Seat)/Reassembly
3. INSTALL FRONT SEATBACK BOARD SUB-ASSEMBLY See: Body and Frame/Seats/Service
and Repair/Overhaul/Front Seat Assembly (for
Center Seat)/Reassembly
4. INSTALL SEAT FASTENER COVER See: Body and Frame/Seats/Service and
Repair/Overhaul/Front Seat Assembly (for Center
Seat)/Reassembly
5. INSTALL CENTER FRONT SEAT ARMREST COVER See: Body and Frame/Seats/Service and
Repair/Overhaul/Front Seat Assembly (for
Center Seat)/Reassembly
6. INSTALL FRONT SEAT TRAY See: Body and Frame/Seats/Service and Repair/Overhaul/Front
Seat Assembly (for Center Seat)/Reassembly
7. INSTALL RECLINING REMOTE CONTROL BEZEL See: Body and Frame/Seats/Service and
Repair/Overhaul/Front Seat Assembly (for
Center Seat)/Reassembly
8. INSTALL LOWER FRONT SEAT SHOULDER BELT COVER See: Body and
Frame/Seats/Service and Repair/Overhaul/Front Seat Assembly
(for Center Seat)/Reassembly
9. INSTALL UPPER REAR SEATBACK LOCK BEZEL See: Body and Frame/Seats/Service and
Repair/Overhaul/Front Seat Assembly (for
Center Seat)/Reassembly
10. INSTALL FRONT SEAT SHOULDER BELT COVER See: Body and Frame/Seats/Service and
Repair/Overhaul/Front Seat Assembly (for
Center Seat)/Reassembly
11. INSTALL FRONT SEAT HEADREST ASSEMBLY
Page 6955
Instrument Panel (Floor Shift)
Instrument Panel (Column Shift)
Page 348
Parts Information
Required Tools & Equipment
Repair Procedure
1. Confirm the condition matches the Introduction.
Page 6269
"Case2" Open the secondary locking device.
[B] For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray
Gray or White : Black
Diagram Information and Instructions
Blower Motor: Diagram Information and Instructions
Wiring Color Codes
Abbreviations Used Within Diagrams
Abbreviations Used Within Diagrams
Page 5300
Use the same installation procedure for the universal joint spider bearing on the opposite side.
(i) Temporarily install the spider and 2 universal joint spider bearings into the shaft yoke.
(j) Using SST, press the universal joint spider bearing into the shaft yoke until the groove can be
seen.
SST : 09950-40011
09951-04020
09952-04010
09953-04020
09954-04020
09955-04051
09957-04010
SST : 09950-60010
09951-00290
SST : 09336-16010
NOTICE: *
Position SST (09336-16010) so that the cutout faces the shaft tube.
* Confirm that the universal joint spider moves smoothly while pressing in the bearing.
(k) Using needle-nose pliers, install the previously selected snap ring into the groove on the shaft
yoke.
HINT Use the same installation procedure for the universal joint spider bearing on the opposite
side.
2. INSTALL NO. 1 CENTER SUPPORT BEARING ASSEMBLY (for 3 Joint Type)
(a) Coat the splines of the intermediate shaft with MP grease.
(b) Install the center support bearing to the intermediate shaft.
Page 2825
HINT The wavelength becomes shorter as the engine rpm increases.
(f) WAVEFORM 5:
HINT *
The wavelength becomes shorter as the engine rpm increases.
* The waveforms and amplitudes displayed differ slightly depending on the vehicle.
(g) WAVEFORM 6:
HINT The wavelength becomes shorter as engine rpm increases.
(h) WAVEFORM 7:
Page 6598
Push the secondary locking device or terminal retainer in to the full lock position.
CONNECT CONNECTOR
Voltage Check
VOLTAGE CHECK
Page 7605
6. PROBLEM SYMPTOMS TABLE
When a "Normal" code is output during a DTC check but the problem is still occurring, use the
Problem Symptoms Table. The suspected areas (circuits or parts) for each problem symptom are
in the table. The suspected areas are listed in order of probability. A description of each of the
chart's columns is below.
HINT In some cases, the problem is not detected by the diagnostic system even though a problem
symptom is present. It is possible that the problem is occurring outside the detection range of the
diagnostic system, or that the problem is occurring in a completely different system.
7. CIRCUIT INSPECTION
A description of the main areas of each circuit inspection is below.
Page 2834
Engine Control Module: Service and Repair Removal
1UR-FE ENGINE CONTROL SYSTEM: ECM: REMOVAL
1. REMOVE V-BANK COVER SUB-ASSEMBLY See: Engine, Cooling and Exhaust/Engine/Service
and Repair/Removal and
Replacement/Engine Assembly/Removal
2. REMOVE AIR CLEANER ASSEMBLY See: Ignition System/Ignition Coil/Service and
Repair/Removal
3. DISCONNECT CONNECTOR HOLDER BLOCK
(a) Remove the connector holder block cover.
(b) Remove the 3 bolts and move the connector holder block so that the ECM can be removed in
the next step.
4. REMOVE ECM
(a) Disconnect the wire harness clamp.
(b) Raise the 2 levers while pushing the locks on the 2 levers shown in the illustration.
NOTICE: Make sure that the lock lever is raised 90° as shown in the illustration before
disconnecting the connectors. Failure to do this may cause the connectors to break.
(c) Disconnect the 2 connectors.
(d) Remove the 4 bolts and ECM.
5. REMOVE GASKET
(a) Peel off the rubber part of the gasket.
Page 2189
Tire Pressure Module: Service and Repair Installation
TIRE AND WHEEL: TIRE PRESSURE WARNING ECU: INSTALLATION
1. INSTALL TIRE PRESSURE WARNING ECU
(a) Install the ECU with the 2 nuts.
Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
(b) Connect the ECU connector.
2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH See: Body and
Frame/Interior Moulding / Trim/Dashboard
/ Instrument Panel/Service and Repair/Removal and Replacement/Instrument Panel Safety Pad
(for Column Shift Type)/Installation
3. INSTALL INSTRUMENT SIDE PANEL RH See: Body and Frame/Interior Moulding /
Trim/Dashboard / Instrument Panel/Service and
Repair/Removal and Replacement/Instrument Panel Safety Pad (for Column Shift
Type)/Installation
4. INSTALL COWL SIDE TRIM BOARD RH
(a) Install the cowl side trim board RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Installation.
HINT Use the same procedures described for the LH side.
5. INSTALL FRONT DOOR SCUFF PLATE RH (for Double Cab, for CrewMax)
(a) Install the front door scuff plate RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Double Cab)/Installation.
HINT Use the same procedures described for the LH side.
6. INSTALL FRONT DOOR SCUFF PLATE RH (for Regular Cab)
(a) Install the front door scuff plate RH See: Body and Frame/Interior Moulding /
Trim/Headliner/Service and Repair/Roof Headlining (For
Regular Cab)/Installation.
HINT Use the same procedures described for the LH side.
7. REGISTRATION OF TRANSMITTER ID
(a) Register the transmitter ID See: Testing and Inspection/Programming and
Relearning/Registration.
8. PERFORM INITIALIZATION
(a) Perform initialization See: Testing and Inspection/Programming and Relearning/Initialization.
NOTICE: Be sure to inflate all tires to the proper inflation pressure before initialization.
9. CHECK TIRE PRESSURE AFTER REPAIRS
Page 5893
Traction Control Switch: Locations From 11/2009
BRAKE CONTROL: VEHICLE STABILITY CONTROL SYSTEM: PARTS LOCATION
Locations
Lock Cylinder Switch: Locations
THEFT DETERRENT: THEFT DETERRENT SYSTEM: PARTS LOCATION
Page 3485
Standard resistance:
NG -- REPAIR OR REPLACE CAN BRANCH WIRE OR CONNECTOR (BUS BUFFER ECU)
OK -- REPLACE BUS BUFFER ECU
10. CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (CENTER AIRBAG SENSOR)
(a) Disconnect the J46 center airbag sensor connector.
(b) Reconnect the cable to the negative (-) battery terminal.
(c) Select "CAN Bus Check" on the Techstream.
Result
B -- CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (4WD CONTROL ECU) A -Continue to next step.
11. CHECK FOR OPEN IN ONE SIDE OF CAN BRANCH WIRE (CENTER AIRBAG SENSOR
BRANCH WIRE)
(a) Measure the resistance according to the value(s) in the table below.
Standard resistance:
Page 6998
J/B No.4 - Instrument Panel Center
Page 6211
(a) for AC Power Supply:
Disconnect the clamp.
(b) Remove the 3 screws and bezel.
3. REMOVE REAR POWER OUTLET SOCKET (for Standard)
(a) Detach the claw and remove the power outlet socket.
4. REMOVE REAR POWER OUTLET SOCKET COVER (for Standard)
(a) Detach the 2 claws and remove the power outlet socket cover.
5. REMOVE REAR POWER POINT SOCKET (for AC Power Supply)
(a) Detach the 2 claws and remove the power outlet socket.
Page 2481
Cylinder Head Gasket: Service and Repair Cylinder Head Gasket (for Bank 2)
Components
1UR-FE ENGINE MECHANICAL: CYLINDER HEAD GASKET (for Bank 2): COMPONENTS
Removal
1UR-FE ENGINE MECHANICAL: CYLINDER HEAD GASKET (for Bank 2): REMOVAL
1. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH
(a) Remove the exhaust manifold RH See: Exhaust System/Exhaust Manifold/Service and
Repair/Removal.
2. REMOVE CAMSHAFTS (for Bank 2)
(a) Remove the camshafts See: Camshaft, Lifters and Push Rods/Camshaft/Service and
Repair/Camshaft (for Bank 2)/Removal.
3. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
(a) Remove the 16 valve rocker arms from the cylinder head.
HINT Arrange the removed parts in the correct order.
4. REMOVE VALVE LASH ADJUSTER ASSEMBLY
(a) Remove the 16 valve lash adjusters from the cylinder head.
HINT Arrange the removed parts in the correct order.
5. REMOVE VALVE STEM CAP
(a) Remove the 16 valve stem caps from the cylinder head.
HINT Arrange the removed parts in the correct order.
6. REMOVE CYLINDER HEAD SUB-ASSEMBLY RH
(a) Uniformly loosen and remove the 2 bolts in the sequence shown in the illustration.
Page 9247
Page 6288
(2) CONNECTORS
Slightly shake the connector vertically and horizontally.
(3) WIRE HARNESS
Slightly shake the wire harness vertically and horizontally.
HINT The connector joint and fulcrum of the vibration are the major areas that should be checked
thoroughly.
(b) HEAT METHOD:
When a malfunction seems to occur when the area in question is heated.
(1) Heat the component that is the possible cause of the malfunction with a hair dryer or similar
device. Check if the malfunction occurs.
NOTICE: *
Do not heat to more than 60°C (140°F). Exceeding this temperature may damage components.
* Do not apply heat directly to the parts in the ECU.
(c) WATER SPRINKLING METHOD:
When a malfunction seems to occur on a rainy day or in high-humidity.
(1) Sprinkle water onto the vehicle and check if the malfunction occurs.
NOTICE: *
Never sprinkle water directly into the engine compartment. Indirectly change the temperature and
humidity by spraying water onto the front of the radiator.
* Never apply water directly onto the electronic components.
HINT If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU
or connections. Look for evidence of corrosion or short circuits. Proceed with caution during water
tests.
(d) HIGH ELECTRICAL LOAD METHOD:
When a malfunction seems to occur when the electrical load is excessive.
(1) Turn on the heater blower, headlights, rear window defogger and all other electrical loads.
Check if the malfunction reoccurs.
5. DIAGNOSTIC TROUBLE CODE CHART
Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate
section's Diagnostic Trouble Code Chart. Use the chart to determine the trouble area and the
proper inspection procedure. A description of each of the chart's columns is below.
Testing and Inspection
Parking Assist Switch: Testing and Inspection
PARK ASSIST / MONITORING: CLEARANCE SONAR MAIN SWITCH: INSPECTION
1. INSPECT DRIVE MONITOR SWITCH
(a) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(b) If the result is not as specified, replace the monitor switch.
(c) Inspect the switch illumination.
(1) Connect the positive (+) lead of the battery to terminal 1 (ILL+) and the negative (-) lead to
terminal 6 (ILL-).
(2) Check that the LED comes on.
OK:
LED comes on.
(3) If the result is not as specified, replace the monitor switch.
Page 7635
Remove the blown fuse and disconnect all loads of the fuse.
Connect a test light in place of the fuse.
Establish conditions in which the test light comes on.
Example:
- [A] - Ignition SW on
- [B] - Ignition SW and SW1 on
- [C] - Ignition SW, SW1 and Relay on (Connect the Relay) and SW2 off (or Disconnect SW2)
Disconnect and reconnect the connectors while watching the test light.
Removal and Replacement
Hydraulic Control Assembly - Antilock Brakes: Removal and Replacement
Components
BRAKE CONTROL: BRAKE ACTUATOR: COMPONENTS
Removal
BRAKE CONTROL: BRAKE ACTUATOR: REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery
terminal to disable the SRS system.
2. DISCONNECT VSC ACTUATOR CONNECTOR
(a) Pull the release bar and disconnect the VSC actuator connector.
3. REMOVE BRAKE TUBE
(a) Use tags or make a note to identify the reconnection locations.
Page 7951
Tire size:
Must exceed the following dimensions
Width 185 mm (7.28 in.)
Inner diameter 360 mm (1.18 ft.)
(2) Tie the front passenger airbag to the tire with several wire harnesses.
CAUTION: *
Make sure that the wire harnesses are tight. If there is slack in the wire harnesses, the front
passenger airbag may become loose due to the shock when the airbag is deployed.
* Always tie down the front passenger airbag with the airbag deployment side facing inside the tire.
NOTICE: As the tires may be damaged by the airbag deployment, use a tire that you are planning
to throw away.
(e) Place the tires.
(1) Place at least 2 tires under the tire which the front passenger airbag is tied to.
(2) Place at least 2 tires over the tire which the front passenger airbag is tied to. The top tire should
have a disc wheel installed.
NOTICE: *
Do not place the SST connector under the tire because it could be damaged.
* As the disc wheel may be damaged by the airbag deployment, use a disc wheel that you are
planning to throw away.
* As the tires may be damaged by the airbag deployment, use a tire that you are planning to throw
away.
(3) Tie the tires together with 2 wire harnesses.
Page 3464
Information Bus: Testing and Inspection
LIN Communication System
MULTIPLEX COMMUNICATION: LIN COMMUNICATION SYSTEM: HOW TO PROCEED WITH
TROUBLESHOOTING
HINT *
Use these procedures to troubleshoot the LIN communication system.
* *: Use the Techstream.
1. VEHICLE BROUGHT TO WORKSHOP
NEXT -- Continue to next step.
2. INSPECT BATTERY VOLTAGE
Standard voltage:
11 to 14 V
If the voltage is below 11 V, recharge or replace the battery before proceeding.
NEXT -- Continue to next step.
3. CHECK COMMUNICATION FUNCTION OF CAN COMMUNICATION SYSTEM*
(a) Using the Techstream, inspect the CAN communication function to ensure there are no
malfunctions in the CAN communication system
See: Initial Inspection and Diagnostic Overview/CAN Communication System/How to Proceed With
Troubleshooting.
B -- GO TO CAN COMMUNICATION SYSTEM See: Initial Inspection and Diagnostic
Overview/CAN Communication System/How to Proceed With Troubleshooting A -- Continue to
next step.
4. PROBLEM SYMPTOMS TABLE
(a) Refer to the problem symptoms table See: Symptom Related Diagnostic Procedures/LIN
Communication System/Problem Symptoms
Table.
B -- Go to step 6 A -- Continue to next step.
5. OVERALL ANALYSIS AND TROUBLESHOOTING*
(a) Terminals of ECU See: Pinout Values and Diagnostic Parameters/LIN Communication System
(b) Data List / Active Test See: Scan Tool Testing and Procedures
NEXT -- Continue to next step.
6. REPAIR OR REPLACE
NEXT -- END
How to Proceed With Troubleshooting
Page 7821
(a) for Manual Air Conditioning System:
Disconnect the 2 connectors.
(b) for Automatic Air Conditioning System:
Disconnect the 3 connectors.
(c) Remove the 2 screws and amplifier.
Page 6110
(b) Check the movement of the clutch pinion gear.
(1) Rotate the clutch pinion gear clockwise, and check that it turns freely.
(2) Try to rotate the clutch pinion gear counterclockwise, and check that it locks.
If the clutch pinion gear cannot be turned clockwise smoothly, or does not lock in the
counterclockwise direction, replace the starter center bearing clutch sub-assembly.
7. INSPECT MAGNET STARTER SWITCH ASSEMBLY
(a) Inspect the pull-in coil.
(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(2) If the result is not as specified, replace the magnet starter switch assembly.
(b) Inspect the holding coil.
(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:
(2) If the result is not as specified, replace the magnet starter switch assembly.
Page 9220
(b) Attach the 2 clips to install the front armrest upper base panel.
8. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH
(a) Attach the 4 claws to install the bezel plug.
9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
10. CHECK SRS WARNING LIGHT
(a) Check the SRS warning light See: Restraint Systems/Air Bag Systems/Testing and
Inspection/Initial Inspection and Diagnostic
Overview/Diagnosis System.