Page 1032
j. Measure the fluid pressure at engine speeds of 1,000 rpm and 3,000 rpm. Difference fluid
pressure: 490 kPa (5 kgf/cm2, 71 psi) or less
NOTICE: Do not turn the steering wheel.
k. With the engine idling and valve fully opened, turn the steering wheel to full lock.
Minimum fluid pressure: 8,336 kPa (85 kgf/cm2, 1,209 psi)
NOTICE: ^
Do not maintain lock position for more than 10 seconds.
^ Do not let the fluid temperature become too high.
l. Disconnect the SST. SST 09640-10010 (09641-01010, 09641-01030, 09641-01060)
m. Connect the pressure feed tube. n. 5VZ-FE engine: Install the air cleaner assembly. o. 2UZ-FE
engine: Install the air cleaner assembly with air cleaner hose. p. Bleed the power steering system.
Page 494
Crankshaft Position Sensor: Description and Operation
Crankshaft Position Sensor
Crankshaft position sensor (NE signal) consists of a signal plate and pick up coil.
The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor
generates 34 signals of every engine revolution.
The ECM detects the standard crankshaft angle based on the G signals, and the actual crankshaft
angle the engine speed by the NE signals.
Page 5077
FOR
SPECIAL SERVICE CAMPAIGN
REAR FRAME CROSS MEMBER &
LOAD SENSING PROPORTIONING & BY-PASS VALVE INSPECTION
2000-2003 MODEL YEAR TUNDRA
Page 3106
b. Reinstall a new accelerator pedal position sensor.
1. Check that the throttle valve is under the condition of the opener opening angle (about 4 °). 2.
Install the sensor to the place where is at 20 ° rotated to the left from the specified installation
position. 3. Gradually turn sensor clockwise until it touches the throttle valve shaft, and tighten the
3 set screws.
Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
c. Inspect the accelerator pedal position sensor.
1. Connect the accelerator pedal position sensor connector. 2. Connect the TOYOTA hand-held
tester or OBD II scan tool to the DLC3. 3. Turn the ignition switch ON.
NOTE: After turning the ignition switch ON, do not depress the accelerator pedal.
4. Check that the ACCEL POS #1 (VPA) voltage of the CURRENT DATA shows the standard
value.
Standard accelerator pedal position voltage: 0.35 - 0.85 V
4. AFTER INSTALL THROTTLE BODY, INSPECT SYSTEM OPERATION
Recall - Rear Cross-Member Corrosion
Technical Service Bulletin # SC90M Date: 091116
Page 4134
14. REMOVE OIL SEAL (OUTSIDE)
Using a screwdriver, remove the oil seal (outside) from the steering knuckle.
15. REMOVE BEARING FROM STEERING KNUCKLE
A. Using snap ring pliers, remove the snap ring.
B. Using the following SSTs and a press, remove the bearing from the steering knuckle.
^ 09950-60020 (09951-00810)
^ 09950-70010 (09951-07150)
16. INSTALL NEW BEARING
A. Using the following SSTs and a press, install a NEW bearing to the steering knuckle.
^ 09527-17011
^ 09950-60020 (09951-00910)
B. Using Snap ring pliers, install a NEW snap ring.
17. INSTALL NEW OIL SEAL (OUTSIDE)
A. Using the following SSTs and a plastic hammer, install a NEW oil seal (outside).
^ 09223-15030
Page 6286
Body
Splice Location (Standard Cab)
B1 Speaker Tweeter Wire LH
B2 Front Door LH Wire
B3 Front Door LH Wire
B4 Roof Wire
B5 Speaker Tweeter Wire RH
B6 B7
Front Door RH Wire
B10 Frame Wire
Seat
Page 839
Page 6729
Waterproof Type Connector
B: For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White
: Gray
Black or White : Dark Gray
Gray or White : Black
Waterproof Type Connector
"Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up
to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Waterproof Type Connector
"Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 2906
B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(Connect the Relay) and SW 2 OFF (or Disconnect SW 2)
D. Disconnect and reconnect the connectors while watching the test light.
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
E. Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION:
a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals
are touched, the IC may be destroyed by
static electricity.)
b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact
with the terminals of leads from the IC, etc. of the replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
Special Tool
1. PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown.
2. DISCONNECT CONNECTOR
3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
a. Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the
secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
A: For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
Testing and Inspection
Condenser HVAC: Testing and Inspection
ON-VEHICLE INSPECTION
1. INSPECT CONDENSER FINS FOR BLOCKAGE OR DAMAGE
If the fins are clogged, wash them with water and dry with compressed air.
NOTE: Be careful not to damage the fins.
If the fins are bent, straighten them with a screwdriver or pliers.
2. INSPECT CONDENSER AND FITTINGS FOR LEAKAGE
Using a gas leak detector, check for leakage of refrigerant. If there is leakage, check the tightening
torque at the joints.
Page 722
Crankshaft Position Sensor
Page 4700
Driver Side J/B And Integration Relay Inner Circuit
Page 5809
B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(Connect the Relay) and SW 2 OFF (or Disconnect SW 2)
D. Disconnect and reconnect the connectors while watching the test light.
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
E. Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION:
a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals
are touched, the IC may be destroyed by
static electricity.)
b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact
with the terminals of leads from the IC, etc. of the replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
Special Tool
1. PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown.
2. DISCONNECT CONNECTOR
3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
a. Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the
secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
A: For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
Page 1298
1. Remove the engine under cover.
2. Drain the engine coolant.
3. Remove the intake air connector assembly.
4. Remove the radiator fan shroud.
5. Remove the drive belt, fan, fluid coupling, and fan pulley.
6. Without disconnecting the power steering fluid lines, remove the power steering pump.
HINT: Suspend the power steering pump securely.
7. Remove the drive belt idler pulley.
8. Remove the right hand (RH) No. 3 timing belt cover.
9. Remove the No.2 timing belt cover.
10. Without disconnecting the A/C refrigerant lines, remove the A/C compressor from the mounting
bracket.
HINT: Suspend the A/C compressor securely.
11. Disconnect the A/C compressor mounting bracket.
Page 1030
Power Steering Fluid: Testing and Inspection
INSPECTION
1. CHECK FLUID LEVEL
a. Keep the vehicle level.
b. With the engine stopped, check the fluid level in the oil reservoir.
If necessary, add fluid. Fluid: ATF DEXRON(R) II or III
HINT: Check that the fluid level is within the HOT LEVEL range on the reservoir/reservoir cap
dipstick.
If the fluid is cold, check that it is within the COLD LEVEL range.
c. Start the engine and run it at idle. d. Turn the steering wheel from lock to lock several times to
boost fluid temperature.
Fluid temperature: 80°C (176°F)
e. Check for foaming or emulsification. If there is foaming or emulsification, bleed power steering
system.
f. With the engine idling, measure the fluid level in the oil reservoir.
g. Stop the engine. h. Wait a few minutes and remeasure the fluid level in the oil reservoir.
Maximum fluid level rise: 5 mm (0.20 inch) If a problem is found, bleed power steering system.
i. Check the fluid level.
Page 2442
CHART 26
Testing and Inspection
Door Switch: Testing and Inspection
INSPECT DOOR COURTESY SWITCH CONTINUITY
a. Check that continuity exists between terminals and the switch body with the switch ON (switch
pin released: opened door). b. Check that no continuity exists between terminals and the switch
body with the switch OFF (switch pin pushed in: closed door).
If operation is not as specified, replace the switch.
Page 4980
1. INSTALL SPIRAL CABLE
2. INSTALL UPPER AND LOWER COLUMN COVERS
3. INSTALL STEERING WHEEL
4. INSTALL STEERING WHEEL PAD
Page 5224
a. Disconnect the stator lead wire from the compressor housing.
b. Using SST, remove the snap ring.
SST 95994-10020
NOTE: The snap ring should be installed so that its beveled side faces up.
c. Remove the stator.
REASSEMBLY
Reassembly is in the reverse order of disassembly.
Locations
Engine Room R/B
Page 3437
Steps 1 - 2
Page 2886
Throttle Position Sensor: Service and Repair
Refer to Fuel Delivery and Air Induction / Throttle Body / Service and Repair, for removal and
installation of this component.
Page 4771
Engine Room R/B
Details
Page 183
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 1595
7. Pump the radiator cap tester several times, and check the maximum pressure.
Pumping speed: 1 pump/second
HINT:
Stop pumping when the valve opens and read the gauge. The gauge must be within the standard
values listed below when the pressure valve opens. The cap is considered OK when the pressure
holds steady or falls very slowly, but holds within the standard values listed below for one minute.
Specification:
If the maximum pressure is less than the minimum standard value, replace the radiator cap
sub-assembly.
Type: Plastic Cap, 108 kPa
1. Remove coolant and any foreign material on 0-ring "A."
2. Check that 0-ring "A" is not deformed, cracked, or swollen.
3. Apply engine coolant to 0-ring "A" and rubber point "B" before using the radiator cap tester.
^ Radiator Cap Tester: Snap-On/Sun P/N SVTS262A (or equivalent)
4. Before installing the radiator cap tester, use the applicable radiator cap adaptor provided in the
following SST kits in conjunction with the radiator cap tester:
^ SST P/N 09230-00030-01 (09231-10080-01) or 09230-00020-01 (09231-10060-01) or
09230-00050-01(09231-10110-01
Page 11
Blower Motor Relay: Testing and Inspection
HEATER MAIN RELAY
INSPECTION
1. REMOVE HEATER MAIN RELAY FROM NO.2 RELAY BLOCK
2. INSPECT HEATER MAIN RELAY (Making: HTR) CONTINUITY
If continuity is not as specified, replace the relay.
Page 566
CHART 23
Locations
EFI Main Relay: Locations
Engine Room R/B
Page 2472
A. The Diagnostic Tester displays 17" as a value of the Time $81" (see illustration).
B. Find the Conversion Factor value of Time $81" in the O2S Failure Threshold chart. 0.3906 is
specified for Time $81 in this chart.
C. Multiply "17" in step "A" by 0.3906 (Conversion Factor) in step "B."
17 x 0.3906 = 6.6%
D. If the answer is within the Standard Value of TEST LIMIT, the Time $81" can be confirmed to be
normal.
NOTE:
^ "LOW SW V" indicates the O2S voltage when the O2S status changes from rich to lean.
^ "HIGH SW V" indicates the O2S voltage when the O2S status changes from lean to rich.
^ If the O2S voltage is lower than "LOW SW V," the O2S status is lean.
^ If the O2S voltage is higher than "HIGH SW V," the O2S status is rich.
NOTE:
Before the O2S Monitor completes or after the ignition switch is turned OFF, the Diagnostic Tester
displays the viewable upper limit or a lower limit of the test value (example: 0 V, 1.275 V, Os
[seconds], 10.2s, 0 and 255).
Page 4135
^ 09527-17011
B. Coat MP grease to the oil seal lip.
18. INSTALL NEW DUST COVER AND AXLE HUB TO STEERING KNUCKLE
A. Install the NEW dust cover to the steering knuckle with the 4 bolts.
Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)
B. Using the following SST and a press, install the axle hub to the steering knuckle.
^ 09649-17010
19. INSTALL ABS SPEED SENSOR ROTOR (W/ABS) OR SPACER (W/O ABS)
NOTE:
Take care not to scratch the serration of the speed sensor rotor.
20. 2WD: INSTALL NEW LOCK NUT
A. Using the following SST, install and torque a NEW lock nut to the axle hub.
^ 00002-00909 (09318-12010)
Torque: 274 N.m (2,800 kgf.cm, 203 ft.lbf)
NOTE:
Do NOT use air wrench.
B. Using a chisel and hammer, stake the lock nut.
21. 4WD: INSTALL BEARING SPACER
Page 4755
Waterproof Type Connector
B: For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White
: Gray
Black or White : Dark Gray
Gray or White : Black
Waterproof Type Connector
"Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up
to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Waterproof Type Connector
"Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 3343
A. The new calibration file should be displayed as the current ECU calibration file.
B. Using a permanent marker or ball point pen, enter the required information on the Authorized
Modifications Label (Figures 21 and 22).
C. Affix this label under the hood in the location determined by the specific vehicle TSB or
Campaign.
NOTE:
Wait 60-90 seconds for ink to set before handling.
Page 608
Page 6355
Non-Waterproof Type Connector
"Case 1" Raise the terminal retainer up to the temporary lock position.
Non-Waterproof Type Connector
"Case 2" Open the secondary locking device.
Page 1320
4. REFILL WITH ENGINE OIL
a. Clean and install the oil drain plug with a new gasket.
Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.)
b. Fill with fresh engine oil.
Capacity:
c. Reinstall the oil filler cap.
HINT: Install the oil filler cap facing the direction as shown in the illustration.
5. START ENGINE AND CHECK FOR ENGINE OIL LEAKS 6. RECHECK ENGINE OIL LEVEL 7.
w/Oil filter change: REINSTALL ENGINE UNDER COVER
Page 2428
CHART 14
Page 4565
7. INSPECT FIELD COIL FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity between the lead wire and field coil brush lead. If
there is no continuity, replace the field frame.
8. INSPECT THAT FIELD COIL IS NOT GROUNDED
Using an ohmmeter, check that there is no continuity between the field coil end and field frame. If
there is continuity, repair or replace the field frame.
9. 2.0 kW type
INSPECT SHUNT COIL FOR OPEN CIRCUIT Using an ohmmeter, measure the resistance
between shunt coil terminals (A) and (B).
Resistance: 1.5 - 1.9 ohms at 20 °C (68 °F)
If the resistance is not as specified, replace the field frame.
10. INSPECT BRUSH LENGTH
Page 4536
Generator (Part 1)
Page 4716
Glossary Of Terms And Symbols (Part 1)
Page 1603
Coolant Temperature Sensor/Switch (For Computer): Mechanical Specifications
New gasket and the ECT sensor. Torque: ..........................................................................................
.................................................................................... 20.4 N.m (208 kgf.cm, 15 ft.lbf)
New gasket and the throttle body with the 2 bolts and 2 nuts. Torque: ...............................................
.................................................................................................................................. 18 N.m (185
kgf.cm, 13 ft.lbf)
Page 69
Waterproof Type Connector
B: For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White
: Gray
Black or White : Dark Gray
Gray or White : Black
Waterproof Type Connector
"Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up
to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Waterproof Type Connector
"Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 2689
Crankshaft Position Sensor
Page 167
A. Connect Diagnostic Tester cables DLC (P/N 02001637) and CAN Interface Module / J1962
OBDII together (P/N 01002744).
B. Test for continuity.
^ If there is continuity, the cable is OK. Check steps 1 and 2 above to complete the flash
reprogramming process.
^ If there is no continuity, proceed to CABLE TEST 2.
CABLE TEST 2.
A. Disconnect Diagnostic Tester cables DLC (P/N 02001637) and CAN Interface Module /J1962
OBDII (P/N 01002744).
B. Test DLC cable (P/N 02001637) for continuity.
^ If there is continuity, the cable is OK. Proceed to CABLE TEST 3.
^ If there is no continuity, the cable needs to be replaced.
CABLE TEST 3.
Page 3181
Crankshaft Position Sensor
Page 2777
CHART 28
Trailer Harness - Updated Design/Diagnostics
Trailer Adapter Kit: Technical Service Bulletins Trailer Harness - Updated Design/Diagnostics
ACCESSORIES AX006-02
October 18, 2002
Title: TRAILER WIRE HARNESS
Models: 4Runner, Highlander, land Cruiser, RAV4, Sienna, Tacoma & Tundra
Introduction
Beginning in 2000, the accessory trailer wire harness supplier was changed and a new design was
adopted which incorporated in-line fuses in the tow wire harness in addition to the vehicle fuse.
This bulletin identifies the fuse location to supplement dealer diagnostics troubleshooting. In the
future please reference the accessory trailer wire harness Owner's Guide for the vehicle specific
diagnostic procedures. As a general note please place the towing wire harness Owner's Guide in
glove box after every DIO installation.
Applicable Vehicles ^
4Runner, Highlander, Land Cruiser, RAV4, Sienna, Tacoma, and Tundra vehicles using the
Accessory Towing Receiver Hitch and factory Towing Receiver Hitch option. (See table below for
applicable model years.)
Accessory Wire Harness Kit Information
Warranty Information
Page 6425
Key Reminder Switch: Diagnostic Aids
Voltage Check
Voltage Check
Voltage Check
A. Establish conditions in which voltage is present at the check point.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(SW 2 OFF)
B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or
component terminal. This check can be done with a test light instead of a voltmeter.
Continuity and Resistance Check
Continuity and Resistance Check
Continuity And Resistance Check
A. Disconnect the battery terminal or wire so there is no voltage between the check points. B.
Contact the two leads of an ohmmeter to each of the check points.
Page 2327
Engine Control Module: Specifications
Terminals Of ECU - Connector Pinouts (Part 2)
Testing and Inspection
Door Switch: Testing and Inspection
INSPECT DOOR COURTESY SWITCH CONTINUITY
a. Check that continuity exists between terminals and the switch body with the switch ON (switch
pin released: opened door). b. Check that no continuity exists between terminals and the switch
body with the switch OFF (switch pin pushed in: closed door).
If operation is not as specified, replace the switch.
Page 3474
Transmission Mode Indicator - A/T: Testing and Inspection
ELECTRONICALLY CONTROLLED TRANSMISSION AND A/T INDICATOR
E1 ELECTRONICALLY CONTROLLED TRANSMISSION SOLENOID
4, 7, 8 - GROUND : Approx. 13 Ohms
O4 O/D MAIN SW
3 - 1 : Open with O/D main SW at ON position
Closed with O/D main SW at OFF position
S4 STOP LIGHT SW
1 - 2 : Closed with brake pedal depressed
E3 (A) E4 (B), E5 (C), E6 (D), E7 (E) ENGINE CONTROL MODULE
S1 - E1 : 9 - 14 volts with vehicle not move and shift lever in D position
S2, SL - E1 : 0 - 1.5 volts with vehicle not move
STP - E1 : 7.5 - 14 volts with brake pedal depressed 0 - 1.5 volts with brake pedal released
THW - E1 : 0.2 - 1.0 volts with idling, engine coolant temperature 60 °C (140 °F) -120 °C (248 °F)
OIL - E1 : Below 1.0 volts with fluid temperature 110 °C (230 °F)
VTA - E1 : 0.4 - 1.0 volts with ignition SW on and throttle valve fully closed : 3.2 - 4.8 volts with
ignition SW on and throttle valve fully open
VC - E1 : 4.5 - 5.5 volts with ignition SW at ON or ST position
ODMS - E1 : 9 - 14 volts with O/D main SW turned on : 0 - 3 volts with 0/D main SW turned off
SPD - E1 : Pulse generation with vehicle moving
2 - E1 : 7.5 - 14 volts with shift lever at 2 position : 0 - 1.5 volts with shift lever at except 2 position
L - E1 : 7.5 - 14 volts with shift lever at L position : 0 - 1.5 volts with shift lever at except L position
+B - E1 : 9 - 14 volts with ignition SW at ON or ST position
BATT - E1 : Always 9 - 14 volts
P1 A/T INDICATOR SW [PARK/NEUTRAL POSITION SW]
3 - 1 : Closed with shift lever in P position 3 - 2 : Closed with shift lever in R position 3 - 5 : Closed
with shift lever in N position 3 - 7 : Closed with shift lever in D position 3 - 4 : Closed with shift lever
in 2 position 3 - 8 : Closed with shift lever in L position
Page 3744
Instrument Panel
Connector Location
IA1 Engine Room Main and Cowl Wire (Left Kick Panel)
IA2 Engine Room Main and Cowl Wire (Left Kick Panel)
IA3 Engine Room Main and Cowl Wire (Left Kick Panel)
IA4 Engine Room Main and Cowl Wire (Left Kick Panel)
IB1 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IB2 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IB3 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IC1 Cowl Wire and Roof Wire (Left Side of Instrument Panel)
Instrument Panel
Connector Location
ID1 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH)
ID2 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH)
IE1 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IE2 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IE3 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IF1 Front Door RH Wire and Cowl Wire (Right Kick Panel)
IF2 Front Door RH Wire and Cowl Wire (Right Kick Panel)
IF3 Front Door RH Wire and Cowl Wire (Right Kick Panel)
Page 3269
Step 3
Brakes - Rear Brakes Vibrate Upon Application
Brake Drum: Customer Interest Brakes - Rear Brakes Vibrate Upon Application
BRAKES BR003-02 REVISED
Title: REAR BRAKE VIBRATION
Models" '00 - '05 Tundra
September 16, 2002
TSB REVISION NOTICE:
^ April 4, 2005: Applicable Vehicles has been updated to include 2003 - 2005 model years. Parts
Informations table has been updated. Required SSTs table has been added. The Warranty
Information has been updated. The Diagnosis Procedure and Repair Procedure have been
combined into one Repair Procedure section. The Repair Procedure section has been updated.
PLEASE READ ENTIRE TSB.
The previous TSB should be discarded.
Introduction
New brake drums have been introduced for use as service parts on 2000 - 2005 model year
Tundra trucks to reduce rear brake vibration. The new drum has increased mass and rigidity.
Applicable Vehicles
2000 - 2005 model year Tundra vehicles.
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.
Applicable Warranty*: The replacement of the Rear Axle Shaft 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 correction of a problem based upon a customer's specific
complaint.
Page 3019
a. Disconnect the vacuum hose from intake air resonator. b. Disconnect the fuel return hose from
the pressure regulator.
CAUTION: Put a shop towel under the pressure regulator.
c. Remove the 2 bolts, and pull out the pressure regulator. d. Remove the O-ring from the pressure
regulator.
INSTALLATION
1. INSTALL FUEL PRESSURE REGULATOR
a. Apply a light coat of gasoline to a new O-ring, and install it to the pressure regulator. b. While
turning the pressure regulator left and right, install it to the delivery pipe. c. Install the pressure
regulator with the 2 bolts.
Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf)
Page 2413
^ O2S TEST RESULTS
A list of the available oxygen sensors will be displayed.
2. Select the desired oxygen sensor and press Enter.
NOTE:
The monitor result of the A/F sensor will not be displayed. If you select "Bank 1-Sensor 1" or Bank
2-Sensor 1" for a vehicle equipped with an A/F sensor, the Diagnostic Tester will display "No
parameter to display."
3. Compare the test results with the values listed in the Failure Threshold Chart.
* Although this procedure references the Toyota Diagnostic Tester, the O2S test results can be
checked using a generic OBD II scantool. Refer to your OBD II scantool operator's manual for
specific procedures.
Comparing O2S Test Results to Failure Thresholds
1. Determine the correct O2S Failure Threshold Chart for your vehicle by looking in the "O2S
Application Table," in this bulletin.
2. Select appropriate year, model, and engine for specified O2S Failure Threshold Chart.
3. Compare O2S test results with the specified O2S Failure Threshold Chart. It may be necessary
to convert O2S test results to a specific measurement unit using the conversion factor that is
supplied in the specified table. See example.
Example:
Testing and Inspection
Four Wheel Drive Indicator Lamp: Testing and Inspection
5VZ-FE: INSPECT "4Lo/4Hi", 4WD" INDICATOR LIGHT a. Disconnect the connectors from the
ADD actuator. b. "4WD" indicator: Ground terminal 3 on the wire harness side connector. c. Turn
the ignition switch ON, check that the warning light lights up.
If the warning light does not light up, inspect the bulb or wire harness.
2UZ-FE: INSPECT "4Lo/4Hi", "4WD" INDICATOR LIGHT a. Remove the center cluster finish
panel. b. Disconnect the connectors from the center cluster integration. c. "4Lo" indicator: Ground
terminal 3 on the wire harness side connector. d. "4Hi" indicator: Ground terminal 2 on the wire
harness side connector.
Capacity Specifications
Refrigerant: Capacity Specifications
Charge Volume 600 +/- 50 g
Page 5592
Body
Splice Location (Standard Cab)
B1 Speaker Tweeter Wire LH
B2 Front Door LH Wire
B3 Front Door LH Wire
B4 Roof Wire
B5 Speaker Tweeter Wire RH
B6 B7
Front Door RH Wire
B10 Frame Wire
Seat
Page 6816
Horn: Diagnostic Aids
Voltage Check
Voltage Check
Voltage Check
A. Establish conditions in which voltage is present at the check point.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(SW 2 OFF)
B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or
component terminal. This check can be done with a test light instead of a voltmeter.
Continuity and Resistance Check
Continuity and Resistance Check
Continuity And Resistance Check
A. Disconnect the battery terminal or wire so there is no voltage between the check points. B.
Contact the two leads of an ohmmeter to each of the check points.
Page 6348
The ground points circuit diagram shows the connections from all major parts to the respective
ground points. When troubleshooting a faulty ground point, checking the system circuits which use
a common ground may help you identify the problem ground quickly. The relationship between
ground points (EA, IB and IC) can also be checked this way.
How to Read Power Source
HOW TO READ POWER SOURCE
Page 5385
Air Bag Deactivation Switch: Description and Operation
PASSENGER AIRBAG MANUAL ON-OFF SWITCH
Passenger airbag manual on-off switch is mounted on the center cluster finish panel. By turning the
passenger airbag manual on-0ff switch to OFF with the ignition key, the passenger airbag system
can be disabled. Also, in order to notify the passenger that the front passenger airbag is disabled,
OFF indicator inside the switch will light up.
Page 6006
Page 2679
Engine Coolant Temperature (ECT) Sensor
Page 6388
w/o Tachometer
If resistance value is not as specified, replace the receiver gauge.
Page 4609
Cigarette Lighter And Power Outlet
Page 6495
Splice Location
B11
Testing and Inspection
Wiper Switch: Testing and Inspection
INSPECT FRONT WIPER AND WASHER SWITCH CONTINUITY
w/ MIST
w/ INTERMITTENT
If continuity is not as specified, replace the switch.
Diagram Information and Instructions
Fuse Block: Diagram Information and Instructions
Key to Diagrams
A: System Title
B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to
distinguish it from the J/B
Example: 1 Indicates Relay Block No.1
C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type,
or specification is different.
D: Indicates related system.
Page 2523
A. Connect Diagnostic Tester cables DLC (P/N 02001637) and CAN Interface Module / J1962
OBDII together (P/N 01002744).
B. Test for continuity.
^ If there is continuity, the cable is OK. Check steps 1 and 2 above to complete the flash
reprogramming process.
^ If there is no continuity, proceed to CABLE TEST 2.
CABLE TEST 2.
A. Disconnect Diagnostic Tester cables DLC (P/N 02001637) and CAN Interface Module /J1962
OBDII (P/N 01002744).
B. Test DLC cable (P/N 02001637) for continuity.
^ If there is continuity, the cable is OK. Proceed to CABLE TEST 3.
^ If there is no continuity, the cable needs to be replaced.
CABLE TEST 3.
Page 625
CHART 20
Page 3521
Install the No.1 vehicle speed sensor with the bolt.
Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.)
6. CONNECT NO. I VEHICLE SPEED SENSOR CONNECTOR
Vehicle Speed Sensor NO.2
Vehicle speed Sensor NO.2 on-vehicle repair
1. DISCONNECT NO. 2 VEHICLE SPEED SENSOR CONNECTOR
2. REMOVE NO. 2 VEHICLE SPEED SENSOR
a. Remove the bolt and No. 2 vehicle speed sensor. b. Remove the O-ring from the No. 2 vehicle
speed sensor.
3. INSTALL NO. 2 VEHICLE SPEED SENSOR
a. Coat a new O-ring with ATF and install it to the No. 2 vehicle speed sensor. b. Install the No. 2
vehicle speed sensor with the bolt.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
4. CONNECT NO. 2 VEHICLE SPEED SENSOR CONNECTOR
Page 3018
Fuel Pressure Regulator: Service and Repair
Fuel Pressure Regulator
REMOVAL
REMOVE FUEL PRESSURE REGULATOR
Page 842
Locations
Anti-Lock Brake System
Page 5699
Page 4972
Supplemental Restraint System
Page 4365
8. DISCONNECT LOWER BALL JOINT
Remove the 4 bolts and disconnect the lower ball joint.
9. REMOVE STEERING KNUCKLE
A. Remove the cotter pin and loosen the nut.
B. Using the following SSTs, disconnect the steering knuckle.
09950-40011(09951-04010, 09952-04010, 09553-04020, 09554-04010, 09955-04031,
09958-04011)
C. Remove the nut and steering knuckle.
NOTE:
4WD:
Be careful not to damage the oil seal and drive shaft boot.
HINT: 4WD:
When it is difficult to disconnect the drive shaft, tap the tip of the drive shaft with a plastic hammer.
10. 2WD:
REMOVE GREASE CAP
A. Mount the axle hub in a soft jaw vise.
HINT:
Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further.
B. Using a screwdriver, remove the grease cap.
HINT:
Be careful not to damage the grease cap.
Page 6501
12 - GROUND : Approx. 12 volts for 0.2 seconds with following operations
- Door lock control SW unlocked - Door lock control SW looked with ignition key in cylinder and LH
door open (Ignition key reminder function) - Door lock knob locked with ignition key in cylinder and
LH door open. (Ignition key reminder function) - Unlocking the LH, RH door cylinder with key
13 - GROUND : Approx. 12 volts for 0.2 seconds with following operations
- Door lock control SW locked - Locking the LH, RH door cylinder with key
14 - GROUND : Continuity with front LH door open (Standard cab)
14 - GROUND : Continuity with each LH door open (Access cab)
15 - GROUND : Continuity with front RH door open (Standard cab)
15 - GROUND : Continuity with each RH door open (Access cab)
D16, D17 DOOR COURTESY SW FRONT LH, RH
1 - GROUND : Closed with door open
D22, D23 DOOR KEY LOCK AND UNLOCK SW LH, RH
1 - 2 : Closed with door lock cylinder locked with key 3 - 2 : Closed with door lock cylinder unlocked
with key
D25, D26 DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW LH, RH
4 - 1 : Closed with door lock knob UNLOCK position
U1 UNLOCK WARNING SW
1 - 2 : Closed with key in cylinder
Page 2511
Oxygen Sensor: Description and Operation
Heated Oxygen Sensor
The ECM observes the waveform of the heated oxygen sensor located behind the catalyst to
determine whether the catalyst performance has deteriorated.
If the catalyst is functioning normally, the waveform of the heated oxygen sensor located behind
the catalyst switches back and forth between rich and lean much more slowly.
When the waveform of the heated oxygen sensor located behind the catalyst alternates flutteringly
between rich and lean, it indicates that catalyst performance has deteriorated.
Engine Controls - Error When Reprogramming ECU
Engine Control Module: Customer Interest Engine Controls - Error When Reprogramming ECU
SPECIAL SERVICE TOOLS SS004-01 REVISED
May 25, 2001
Title: ECU FLASH REPROGRAMMING ERROR MESSAGE
Models: Applicable Models
TSB REVISION NOTICE:
September 23, 2003: Models added - 2002 (and later) Solara, 2003 (and later) Corolla and Matrix,
and 2004 models; Test Procedures updated for new CAN Interface Module. The previous TSB
should be discarded.
Introduction
During ECU flash reprogramming, an error message may be displayed on the Diagnostic Tester
that will not allow ECU flash reprogramming to complete. This bulletin provides test procedures to
determine the cause for the error message.
Applicable Vehicles ^
2001 (and later) model year 4Runner, Highlander, Land Cruiser, RAV4, Sequoia and Tundra
vehicles.
^ 2002 (and later) model year Camry, Solara and Tacoma vehicles.
^ 2003 (and later) model year Corolla and Matrix vehicles.
^ All 2004 (and later) model year Toyota vehicles except Celica, MR2 Spyder, Avalon, and Tacoma
(3RZ-FE engine)
Required SSTs
NOTE:
Additional Diagnostic Tester Kits, CAN Interface Modules, Program Cards or other SSTs may be
ordered by calling SPX/OTC at 1-800-933-8335.
Warranty Information
Test Procedure
Ground Locations
Transmission Mode Indicator - A/T: Ground Locations
Engine Compartment
Ground Location
EA Front Left Fender
EB Rear Bank of Right Cylinder
EC Rear Bank of Left Cylinder
Connector Location
EA1 Cowl Wire Harness and Wire Harness (Connector Location)
EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B)
EC1 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC2 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC3 Engine No. 2 Wire and Engine Wire (Near the Starter)
ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission)
Page 408
The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit
breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery
power is supplied to each system are explained. Since all System Circuit diagrams start from the
power source, the power source system must be fully understood.
Page 1993
Page 2430
CHART 16
CHART 17
Diagrams
Radiator: Diagrams
RADIATOR REPLACEMENT AND OVERHAUL W/ RELATED COMPONENTS
Part 1 of 2
Page 3376
Materials System.
Required SSTs
NOTE:
Additional Diagnostic Tester Kits, CAN Interface Modules, Program Cards or SSTs may be ordered
by calling SPX/OTC at 1-800-933-8335.
Process Overview
ECU Flash Reprogramming is a 4-step process:
1. Locate the desired calibration file on TIS (Technical Information System).
Calibration files may be found in two areas:
a. Search by model and year for a Technical Service Bulletin addressing a specific product issue.
b. Search by model under the ECU Flash Reprogramming section.
2. Download the calibration file from TIS to the Diagnostic Tester.
The Calibration Update Wizard (CUW) is an application on TIS which downloads calibration files
from TIS to the Diagnostic Tester Program Card. This step is only required when the calibration file
is not currently stored on the Diagnostic Tester Program Card.
3. Reprogram the vehicle ECU with the Diagnostic Tester.
Diagnostic Tester Software now incorporates a function to update a vehicle's ECU calibration
through flash reprogramming.
4. Confirm successful flash update and affix calibration update sticker.
Modifications to ECU calibration files must be recorded and properly displayed on the vehicle using
the calibration update sticker.
NOTE:
Page 5940
Page 25
Audible Warning Device Control Module: Harness Locations
Engine Compartment
Connector Location
EA1 Cowl Wire Harness and Wire Harness (Connector Location)
EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B)
EC1 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC2 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC3 Engine No. 2 Wire and Engine Wire (Near the Starter)
ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission)
Specifications
Drain Plug: Specifications
Drain Plug 20 Nm
Page 176
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 2841
Heated Oxygen Sensor
Page 3758
B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(Connect the Relay) and SW 2 OFF (or Disconnect SW 2)
D. Disconnect and reconnect the connectors while watching the test light.
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
E. Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION:
a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals
are touched, the IC may be destroyed by
static electricity.)
b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact
with the terminals of leads from the IC, etc. of the replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
Special Tool
1. PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown.
2. DISCONNECT CONNECTOR
3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
a. Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the
secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
A: For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
Testing and Inspection
Hazard Warning Switch: Testing and Inspection
INSPECT HAZARD WARNING SWITCH CONTINUITY
a. Remove the center cluster finish panel. b. Disconnect the connector from the center cluster
integration. c. Check that continuity exists between terminal 17 and terminal 1 with the switch ON.
d. Check that no continuity exists between terminal 17 and terminal 1 with the switch OFF.
If continuity is not as specified, replace the switch.
Page 6818
B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(Connect the Relay) and SW 2 OFF (or Disconnect SW 2)
D. Disconnect and reconnect the connectors while watching the test light.
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
E. Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION:
a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals
are touched, the IC may be destroyed by
static electricity.)
b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact
with the terminals of leads from the IC, etc. of the replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
Special Tool
1. PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown.
2. DISCONNECT CONNECTOR
3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
a. Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the
secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
A: For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
Page 2829
CHART 25
Testing and Inspection
Interior Light Switch: Testing and Inspection
INSPECT FRONT PERSONAL LIGHT SWITCH CONTINUITY
a. Disconnect the connector from the personal light. b. Push the personal light switch ON, check
that continuity exists between terminal 3 and body terminal 1.
c. Turn the light switch to DOOR, check that continuity exists between terminal 2 and 3.
If operation is as specified, replace the switch.
INSPECT ROOM LIGHT SWITCH
a. Disconnect the connector from the interior light assembly. b. Turn the interior light switch ON,
check that continuity exists terminal 2 and body ground.
c. Turn the interior light switch to DOOR, check that continuity exists between terminals 1 and 2.
If operation is not as specified, replace the switch.
Page 5725
Splice Point
J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel,
and "B" for the Body).
The Location of splice Point I5 is shaded.
K: Indicates a shielded cable.
L: Indicates the pin number of the connector.
The numbering system is different for female and male connectors.
M: Indicates a ground point.
The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for
the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body
and Surrounding area.
How to Read Connector List
HOW TO READ CONNECTOR LIST
A: Indicates connector to be connected to a part. (The numeral indicates the pin No.)
Page 4413
20 seconds.
If the brake pedal does not return, replace the ABS actuator because the motor operation is in
failure.
h. Turn the motor relay OFF and release the brake pedal.
4. INSPECT OTHER WHEEL SOLENOIDS OPERATION
Check the solenoids of the other wheels with the same inspection procedure as the right front
wheel solenoids.
HINT: Left front wheel: SFLH and SFLR Both rear wheels: SRRH and SRRR
NOTICE: Never depress the brake pedal under the condition that the reduction solenoid alone is
turned ON as ABS ECU is reset.
5. CLEAR DTC
Page 5045
Page 510
Knock Sensor: Testing and Inspection
INSPECTION
1. REMOVE THROTTLE BODY COVER
2. REMOVE INTAKE AIR CONNECTOR
3. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS
4. REMOVE UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY
5. INSPECT KNOCK SENSOR 1,2
a. Disconnect the knock sensor connectors. b. Using an ohmmeter, check that there is no
continuity between the terminal and body.
If there is continuity, replace the sensor with SST. SST 09816-30010
Torque: 45 N.m (450 kgf.cm, 33 ft.lbf)
c. Reconnect the knock sensor connectors.
6. REINSTALL UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY
7. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS
8. REINSTALL INTAKE AIR CONNECTOR
9. REINSTALL THROTTLE BODY COVER
Page 253
Fuel Pump Relay: Testing and Inspection Circuit Opening Relay
CIRCUIT OPENING RELAY
INSPECTION
1. REMOVE RELAY BOX COVER
2. REMOVE CIRCUIT OPENING RELAY (Marking: CIR OPN)
3. INSPECT CIRCUIT OPENING RELAY CONTINUITY
a. Using an ohmmeter, check that there is continuity between terminals 1 and 2.
If there is no continuity, replace the relay.
b. Check that there is no continuity between terminals 3 and 5.
If there is continuity, replace the relay.
4. INSPECT CIRCUIT OPENING RELAY OPERATION
a. Apply battery positive voltage across terminals 1 and 2. b. Using an ohmmeter, check that there
is continuity between terminals 3 and 5.
If there is no continuity, replace the relay.
5. REINSTALL CIRCUIT OPENING RELAY
6. REINSTALL RELAY BOX COVER
Page 3453
Body
Connector Location (Standard Cab)
BA1 Front Door LH Wire and Speaker Tweeter Wire LH (Inside of Front Door LH)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Seat
Connector Location
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
BJ1 Seat No. 1 Wire and Seat No. 2 Wire (Under the Driver's Seat)
Page 1188
Crankshaft crank pin diameter
Standard sized bearing center wall thickness
Page 1449
Timing Belt Idler Pulley: Service and Repair
For further information regarding this component and the system that it is a part of, please refer to
Timing Belt; Service and Repair.
Page 6658
Instrument Panel
Ground Location
IE Left Kick Panel
IF Left Kick Panel
IG Instrument Panel Brace RH
IH Right Kick Panel
II Right Kick Panel
Body
Ground Location (Access Cab)
Paint - Refinishing Information
Paint: Technical Service Bulletins Paint - Refinishing Information
COLLISION REPAIR INFORMATION FOR THE COLLISION REPAIR PROFESSIONAL
TITLE: TOPCOAT SAND & POLISH
SECTION: REFINISH BULLETIN # 173
MODELS: ALL TOYOTA LEXUS AND SCION
DATE: APRIL 2009
Customers have high expectations for automotive paint finish appearance and expect repairs to
match factory color gloss and texture. Flawed refinish appearance is a cause of concern and will
likely have a negative affect on customer satisfaction and retention.
Toyota recognizes the reality of paint finish application in the shop environment. In addition to color
matching and blending countermeasures to remove paint process intrusion (dirt nibs) are
necessary to achieve an undetectable finish match. This is also common in manufacturing plants
when process intrusion is encountered. Countermeasures are defined as; ultra-fine sanding to level
nibs followed by polishing to a level of gloss and texture consistent with the original finish.
Technicians undertaking these tasks should review applicable technical data sheets for product
process and handling instructions as well as applicable safety information.
Topcoat sand and polish is one of many paint finish repair techniques covered in Toyota T101 and
Lexus L101 Paint Finish Repair training. Please visit for scheduling and registration information.
Page 3919
Transmission Mode Indicator - A/T: Testing and Inspection
ELECTRONICALLY CONTROLLED TRANSMISSION AND A/T INDICATOR
E1 ELECTRONICALLY CONTROLLED TRANSMISSION SOLENOID
4, 7, 8 - GROUND : Approx. 13 Ohms
O4 O/D MAIN SW
3 - 1 : Open with O/D main SW at ON position
Closed with O/D main SW at OFF position
S4 STOP LIGHT SW
1 - 2 : Closed with brake pedal depressed
E3 (A) E4 (B), E5 (C), E6 (D), E7 (E) ENGINE CONTROL MODULE
S1 - E1 : 9 - 14 volts with vehicle not move and shift lever in D position
S2, SL - E1 : 0 - 1.5 volts with vehicle not move
STP - E1 : 7.5 - 14 volts with brake pedal depressed 0 - 1.5 volts with brake pedal released
THW - E1 : 0.2 - 1.0 volts with idling, engine coolant temperature 60 °C (140 °F) -120 °C (248 °F)
OIL - E1 : Below 1.0 volts with fluid temperature 110 °C (230 °F)
VTA - E1 : 0.4 - 1.0 volts with ignition SW on and throttle valve fully closed : 3.2 - 4.8 volts with
ignition SW on and throttle valve fully open
VC - E1 : 4.5 - 5.5 volts with ignition SW at ON or ST position
ODMS - E1 : 9 - 14 volts with O/D main SW turned on : 0 - 3 volts with 0/D main SW turned off
SPD - E1 : Pulse generation with vehicle moving
2 - E1 : 7.5 - 14 volts with shift lever at 2 position : 0 - 1.5 volts with shift lever at except 2 position
L - E1 : 7.5 - 14 volts with shift lever at L position : 0 - 1.5 volts with shift lever at except L position
+B - E1 : 9 - 14 volts with ignition SW at ON or ST position
BATT - E1 : Always 9 - 14 volts
P1 A/T INDICATOR SW [PARK/NEUTRAL POSITION SW]
3 - 1 : Closed with shift lever in P position 3 - 2 : Closed with shift lever in R position 3 - 5 : Closed
with shift lever in N position 3 - 7 : Closed with shift lever in D position 3 - 4 : Closed with shift lever
in 2 position 3 - 8 : Closed with shift lever in L position
Page 5409
1. INSTALL SPIRAL CABLE
2. INSTALL UPPER AND LOWER COLUMN COVERS
3. INSTALL STEERING WHEEL
4. INSTALL STEERING WHEEL PAD
Restraints - Seat Belt Tongue Plate Stopper Replacement
Seat Belt: All Technical Service Bulletins Restraints - Seat Belt Tongue Plate Stopper Replacement
T-SB-0258-08
September 2, 2008
Seat Belt Tongue Plate Stopper Replacement
Service Category Vehicle Interior
Section Seat Belt
Market USA
Applicability
TSB SUPERSESSION NOTICE
The information contained in this TSB supersedes TSB No. BO017-07.
^ Applicability has been updated to include 2008 model year vehicles.
TSB No. BO017-07 is Obsolete and any printed versions should be discarded. Be sure to review
the entire content of this service bulletin before proceeding.
Introduction
For situations where only the seat belt stopper is broken a new service part has been developed to
eliminate the need to replace the entire seat belt assembly. Follow the installation procedure below
to utilize this new part.
ABS/TCS - Zero Point Calibration Information
Steering Angle Sensor: Technical Service Bulletins ABS/TCS - Zero Point Calibration Information
T-SB-0020-08
March 25, 2008
Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment
Service Category Brake
Section Brake Control/Dynamic Control System
Market USA
Applicability
Introduction
The purpose of this TSB is to provide information on when and how to perform the zero point
calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting
the battery is a necessary step for performing the zero point calibration.
Warranty Information
Required Tools & Equipment
^ Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE).
^ The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the
service procedures listed in this bulletin.
Preliminary Information
Perform this procedure if any of these repairs have been performed on the vehicle:
^ Wheel alignment has been adjusted.
^ Any chassis components have been removed/installed or replaced.
Page 4776
Splice Point
J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel,
and "B" for the Body).
The Location of splice Point I5 is shaded.
K: Indicates a shielded cable.
L: Indicates the pin number of the connector.
The numbering system is different for female and male connectors.
M: Indicates a ground point.
The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for
the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body
and Surrounding area.
How to Read Connector List
HOW TO READ CONNECTOR LIST
A: Indicates connector to be connected to a part. (The numeral indicates the pin No.)
Testing and Inspection
Overdrive Indicator Lamp: Testing and Inspection
O/D Main Switch & O/D OFF Indicator Light Circuit
CIRCUIT DESCRIPTION
The O/D main switch contacts go open when the switch is pushed in and go closed when it is
pushed out.
If O/D main switch is at OFF position, the O/D OFF indicator light lights up, and the ECM prohibits
shifting O/D.
Wiring Diagram
INSPECTION PROCEDURE
Testing and Inspection
Windshield Washer Switch: Testing and Inspection
INSPECT FRONT WIPER AND WASHER SWITCH CONTINUITY
w/ MIST
w/ INTERMITTENT
If continuity is not as specified, replace the switch.
Page 1086
B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(Connect the Relay) and SW 2 OFF (or Disconnect SW 2)
D. Disconnect and reconnect the connectors while watching the test light.
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
E. Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION:
a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals
are touched, the IC may be destroyed by
static electricity.)
b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact
with the terminals of leads from the IC, etc. of the replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
Special Tool
1. PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown.
2. DISCONNECT CONNECTOR
3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
a. Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the
secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
A: For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
Testing and Inspection
Dimmer Switch: Testing and Inspection
INSPECT LIGHT CONTROL RHEOSTAT
a. Connect terminals 1 and 3 through a 3.4 W test bulb. b. Connect the positive (+) lead from the
battery to terminal 1 and the negative (-) lead to terminal 2. c. Turn the rheostat knob to fully
counterclockwise, check that the test bulb goes out. d. Gradually turn the rheostat knob to
clockwise, check that the test bulb brightness changes from dark to bright.
If operation is not as specified, replace the rheostat.
Testing and Inspection
Windshield Washer Motor: Testing and Inspection
INSPECT WASHER MOTOR OPERATION Connect the positive (+) lead from the battery to
terminal 2 and the negative (-) lead to terminal 1, and check that the motor operates.
NOTE: These tests must be performed quickly (within 20 seconds) to prevent the coil from burning
out.
If operation is not as specified, replace the motor.
Locations
Vapor Pressure Sensor
Page 3246
Transmission Mode Indicator - A/T: Description and Operation
ELECTRONICALLY CONTROLLED TRANSMISSION AND A/T INDICATOR
SYSTEM OUTLINE
The electronically controlled transmission electrically controls the, throttle pressure, lock-up
pressure, and accumulator pressure etc. through the solenoid valve.
The electronically controlled transmission is a system which precisely controls the gear shift timing
and lock-up timing in response to the vehicle's driving conditions and the engine condition detected
by various sensors. It makes smooth driving possible by shift selection of the gear which is the
most appropriate to the driving conditions at that time, and by preventing downing, squat and gear
shift shock when starting off.
1. GEAR SHIFT OPERATION
When driving, the engine warm up condition is input as a control signal from the engine coolant
temperature sensor to TERMINAL THW of the engine control module, and the vehicle speed is
input to TERMINAL SP2+ of the engine control module from the vehicle speed sensor. At the same
time, the throttle valve opening signal from the throttle position sensor is input to TERMINALS VTA,
VTA2 of the engine control module as a throttle angle signal. Based on these signals, the engine
control module selects the best shift position for the driving conditions and sends current to the
electronically controlled transmission solenoid.
2. LOCK-UP OPERATION
When the engine control module decides based on each signal that the lock-up condition has been
met, the current flows from the engine control module TERMINAL SL to TERMINAL 7 of the
electronically controlled transmission solenoid to GROUND.
3. STOP LIGHT SW CIRCUIT
If the brake pedal is depressed (Stop light SW on) when driving in lock-up position, a signal is input
to TERMINAL STP of the engine control module. As a result, the engine control module cuts the
current to the solenoid to release the lock-up.
4. OVERDRIVE CIRCUIT
- O/D main SW on When the O/D main SW is switched to ON position, a signal is input to
TERMINAL ODMS of the engine control module, and enables shift change to the overdrive range,
through the control of the engine control module.
- O/D main SW off When the O/D main SW is switched to OFF position, a signal is input to
TERMINAL ODMS of the engine control module, and prohibits shift change to the overdrive range
through the control of the engine control module. When in the overdrive range already, shift down
is made.
Page 1445
31. RECHECK ENGINE COOLANT LEVEL 32. INSTALL ENGINE UNDER COVER
Page 6886
Lamp Control Module: Electrical Diagrams
Service Hints
LIGHT AUTO TURN OFF
HEAD RELAY
2 - 1 : Closed with the light control SW at HEAD position or the dimmer SW at FLASH position.
Closed with the engine running and the parking brake lever released (w/ daytime running light)
C15 LIGHT CONTROL SW [COMB. SW]
13 - 16 : Closed with light control SW at HEAD position
14 - 16 : Closed with light control SW at TAIL or HEAD position
D16 DOOR COURTESY SW FRONT LH
1 - GROUND : Continuity with the front LH door open
INTEGRATION RELAY
9 - GROUND : Approx. 12 volts with the ignition SW at ON position
14 - GROUND : Continuity with the front LH door open
3, 6 - GROUND : Always approx. 12 volts
8 - GROUND : Always continuity
ILLUMINATION
C15 LIGHT CONTROL SW [COMB. SW]
14 - 16 : Closed with light control SW at TAIL or HEAD position
Page 2354
Windows 2000 SP2 or later Windows XP Pro SP1 or later
For more information about the J2534 devices listed above, contact the vendors. To report
compatibility problems with listed hardware/software, please contact the device manufacturer.
For more information about Toyota vehicle reprogramming CDs or to report problems running
Toyota's Calibration Update Wizard software, please contact Toyota.
OBTAINING A CALIBRATION CD
The Calibration CD is compatible with the above mentioned scantools and J2534 interfaces. A
Calibration CD contains all of the most current vehicle calibration files, applicable TSBs, the
Calibration Update Wizard application software for a Windows PC, and instructions for use.
Calibration CDs can be ordered through the Toyota Material Distribution Center; order P/N
00456-REPRG-001.
IMPORTANT NOTICE
It is possible to permanently damage a vehicle controller during the flash reprogramming process.
It is especially important to understand that once started, the reprogramming process must not be
interrupted, reprogramming devices must not be disconnected and PCs must not be allowed to go
into standby, hibernation or similar power management modes. The information provided herein is
intended expressly for use by qualified professional automobile technicians. To prevent damage to
your customer's vehicle and ensure safe service practice, read these materials completely and
thoroughly before servicing the vehicle and be sure to follow all instructions.
Page 3439
Step 4
O/D OFF indicator light does not light up
Steps 1 - 2
O/D OFF indicator light remains ON
Page 5073
Diagram Information and Instructions
Fuse Block: Diagram Information and Instructions
Key to Diagrams
A: System Title
B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to
distinguish it from the J/B
Example: 1 Indicates Relay Block No.1
C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type,
or specification is different.
D: Indicates related system.
Page 1365
11. REINSTALL ENGINE UNDER COVER
Page 2576
B. Continue to update the ECU calibration file following the screen flow (Figure 18). Details for
selected screens are shown in Figure 19.
NOTE:
^ Each flash calibration update will take approximately 15 to 45 minutes.
^ Screens E through J (Figure 18) will need to be repeated for each flash calibration update
(calibration ID number).
^ All updates must display "YES" to complete the entire calibration file update for the vehicle ECU.
^ Failure to complete all updates may result in PERMANENT ECU DAMAGE!
CONFIRM UPDATE
4. Confirm successful flash calibration update and affix calibration update sticker.
Follow these steps to confirm the calibration was reprogrammed to the ECU.
Diagram Information and Instructions
Key Reminder Switch: Diagram Information and Instructions
Key to Diagrams
A: System Title
B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to
distinguish it from the J/B
Example: 1 Indicates Relay Block No.1
C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type,
or specification is different.
D: Indicates related system.
Page 5611
Waterproof Type Connector
B: For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White
: Gray
Black or White : Dark Gray
Gray or White : Black
Waterproof Type Connector
"Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up
to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Waterproof Type Connector
"Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Specifications
Timing Belt: Specifications
Timing Belt Replacement Interval ........................................................................................................
............................................................. 90,000 miles
No.2 Timing Belt Cover Torque ...........................................................................................................
...................................................................... 16 Nm RH No.2 Timing Belt Cover Torque ..................
........................................................................................................................................................ 7.5
Nm LH No.3 Timing Belt Cover Torque ...............................................................................................
........................................................................... 7.5 Nm
Page 5221
1. 5VZ-FE engine
INSTALL COMPRESSOR a. Install the compressor with the 4 bolts.
Torque: 25 N.m (250 kgf.cm, 18 in.lbf)
b. Connect the connector.
2. 2UZ-FE engine
INSTALL COMPRESSOR a. Install the compressor with cooler bracket with the 4 bolts and nut.
Torque: 25 N.m (250 kgf.cm, 18 in.lbf)
b. Connect the connector.
3. 5VZ-FE engine
CONNECT DISCHARGE AND SUCTION HOSES Connect the both hoses with the 2 bolts.
Torque: 10 N.m (100 kgf.cm, 7 in.lbf)
NOTE: Hose should be connected immediately after the caps have been removed.
HINT: Lubricate 2 new O-rings with compressor oil and install them to the hoses.
4. 2UZ-FE engine
CONNECT DISCHARGE AND SUCTION HOSES Connect the both hoses with the 2 nuts.
Torque: 10 N.m (100 kgf.cm, 7 in.lbf)
NOTE: Hose should be connected immediately after the caps have been removed.
HINT: Lubricate 2 new O-rings with compressor oil and install them to the hoses.
5. INSTALL AND CHECK DRIVE BELT
6. 5VZ-FE engine
INSTALL ENGINE UNDER COVER
7. CONNECT NEGATIVE (-) TERMINAL CABLE TO BATTERY
8. EVACUATE AIR FROM REFRIGERATION SYSTEM
9. CHARGE SYSTEM WITH REFRIGERANT
Specified amount: 600 ± 50 g (21.16 ± 1.76 oz.)
10. INSPECT FOR LEAKAGE OF REFRIGERANT
Using a gas leak detector, check for leakage of refrigerant. If there is leakage, check the tightening
torque at the joints.
Locations
Instrument Panel
Page 3490
Steps 1 - 2
Page 4924
Glossary Of Terms And Symbols (Part 1)
Page 2825
Page 99
b. Push the secondary locking device or terminal retainer in to the full lock position.
5. CONNECT CONNECTOR
Disconnection of Male and Female Connectors
Disconnection of Male and Female Connectors
Disconnection Of Male And Female Connectors
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Engine - Squealing Noise On Cold Start Up
Drive Belt: All Technical Service Bulletins Engine - Squealing Noise On Cold Start Up
ENGINE EG003-05
Title: 2UZ-FE ACCESSORY DRIVE BELT NOISE
Models: '00 - '05 Tundra & '01 - '05 Sequoia
February 9, 2005
Introduction
Some customers may experience abnormal squeal noise from the engine accessory drive belt
area, usually during cold start-up. An improved accessory drive belt has been developed to correct
this condition.
Applicable Vehicles
^ 2000 - 2005 model year Tundra vehicles equipped with 2UZ-FE engine produced BEFORE the
Production Change Effective VIN shown below.
^ 2001 - 2005 model year Sequoia vehicles equipped with 2UZ-FE engine produced BEFORE the
Production Change Effective VIN shown below.
Production Change Information
Parts Information
Warranty Information
Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This
warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's
in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Repair Procedure
Replace the accessory drive belt with the improved part.
1. Remove existing accessory drive belt.
Locations
Lower Side Moulding / Trim: Locations
Body Outside Moulding
Page 2122
5. Pinch the fuel return hose.
The pressure in the high pressure line will rise to approx. 392 kPa (4 kgf/sq.cm, 57 psi). In this
state, check to see that there are no leaks from any part of the fuel system.
NOTE: Always pinch the hose. Avoid bending as it may cause the hose to crack.
6. Turn the ignition switch OFF. 7. Disconnect the TOYOTA hand-held tester from the DLC3.
Page 6817
Continuity And Resistance Check
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Continuity And Resistance Check
C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the
electrical circuit.
Finding A Short Circuit
Finding A Short Circuit
Finding A Short Circuit
A. Remove the blown fuse and disconnect all loads of the fuse.
ABS/TCS - Zero Point Calibration Information
Steering Angle Sensor: Technical Service Bulletins ABS/TCS - Zero Point Calibration Information
T-SB-0020-08
March 25, 2008
Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment
Service Category Brake
Section Brake Control/Dynamic Control System
Market USA
Applicability
Introduction
The purpose of this TSB is to provide information on when and how to perform the zero point
calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting
the battery is a necessary step for performing the zero point calibration.
Warranty Information
Required Tools & Equipment
^ Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE).
^ The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the
service procedures listed in this bulletin.
Preliminary Information
Perform this procedure if any of these repairs have been performed on the vehicle:
^ Wheel alignment has been adjusted.
^ Any chassis components have been removed/installed or replaced.
Page 918
13. CONNECT TIMING BELT TO RH CAMSHAFT TIMING PULLEY
a. Remove any oil or water on the RH camshaft timing pulley and water pump pulley, and keep
them clean.
NOTICE: Only wipe the pulleys; do not use any cleansing agent.
b. Turn the RH camshaft timing pulley. Align the installation mark on the timing belt with the timing
mark of the camshaft timing pulley, and
hang the timing belt on the RH camshaft timing pulley.
14. SET TIMING BELT TENSIONER
a. Using a press, slowly press in the push rod using 981 - 9,807 N (100 - 1,000 kgf, 220 - 2,205
lbs.) of pressure. b. Align the holes of the push rod and housing, pass a 1.27 mm hexagon wrench
through the holes to keep the setting position of the push rod. c. Release the press. d. Install the
dust boot to the belt tensioner.
15. INSTALL TIMING BELT TENSIONER
a. Temporarily install the belt tensioner with the 2 bolts. b. Alternately tighten the 2 bolts.
Torque: 26 Nm (270 kgf-cm, 19 ft. lbs.)
c. Using pliers, remove the 1.27 mm hexagon wrench from the belt tensioner.
16. CHECK VALVE TIMING
a. Temporarily install the crankshaft pulley bolt.
b. Slowly turn the crankshaft pulley 2 revolutions from TDC to TDC.
NOTICE: Always turn the crankshaft pulley clockwise.
Page 467
Mass Air Flow Meter: Service and Repair
MASS AIR FLOW (MAF) METER
1. DISCONNECT MAF METER CONNECTOR
2. REMOVE MAF METER
Remove the 2 screws and MAF meter.
3. REINSTALL MAF METER
Install the MAF meter with the 2 screws.
4. RECONNECT MAF METER CONNECTOR
Page 6166
^ To reduce wind noise, the shape of the mouldings has been optimized, and a deflector has been
provided below the front bumper to ensure a smooth
airflow.
Weatherstrip
Page 4514
^ Both share the same charge and discharge principles.
^ Both are safely charged by vehicle charging systems.
^ When discharged, both can be recharged at high current levels.
Battery Charging Information
Damage to AGM batteries becomes an issue when the charge rate is NOT monitored and
controlled by the charger (i.e., quick chargers). The performance of an AGM battery can be
irreversibly reduced if the charge rate remains too high, allowing the battery to overheat and vent.
Once an AGM battery loses water (venting), the glass mats will become dry, causing the battery to
lose conductance, power, and performance.
In most vehicle charging systems, the alternator limits the charging rate by limiting the output
voltage (about 14.4V). For example, an AGM battery may be observed charging at 60A and 13.5V.
As the battery recharges, the charging voltage will increase from 13.5V to approximately 14.4V
(voltage will vary based on temperature, control sophistication, etc.), and the current will decrease
from 60A to about OA. The charging system voltage regulators prevent both AGM and flooded lead
acid batteries from being overcharged and venting. By controlling the voltage, the charging rate
(current) can be controlled.
The discontinued Special Service Tool (SST) Automatic Trickle Charger (SST P/N
00002-YA122-01) maintained a manual charging limit of 10A to accomplish a safe recharge rate for
AGM batteries. This low amp charge was low enough to prevent the AGM battery from overheating
and venting since the charger had no way of monitoring battery temperature/condition.
The GR8 Battery Diagnostic Station (SST P/N 00002-MCGR8) is a customized diagnostic fast
charger that monitors battery temperature/conditions and contains custom charging rates for ALL
model batteries used for Toyota and Scion vehicles. As such, it safely charges good batteries as
fast as possible to a point where they can be returned to service and eliminates wasted charging
time by quickly diagnosing bad batteries.
Based on the characteristics and performance measures of each individual battery (i.e., custom
charging rate), the GR8 Battery Diagnostic Station will apply the fastest charging rate that is safe
for that particular battery.
^ When the GR8 Battery Diagnostic Station pe~ormance measurements indicate that an AGM
battery qualifies for fast-charging, it will be charged at whatever current level it will accept, but the
charging voltage will be controlled so that it does NOT exceed 14.4V, and the battery temperature
will NOT exceed 135°F (57°C).
^ When the GR8 Battery Diagnostic Station performance measurements indicate that an AGM
battery does NOT qualify for fast-charging, the charge session will only continue if the battery
qualifies for "Recovery" mode (part of which means, NO defects or other serious performance
issues were found).
It is recommended that ALL Toyota and Scion vehicle batteries be charged using the GR8 Battery
Diagnostic Station.
NOTE:
^ NEVER connect the GR8 Battery Diagnostic Station to remote battery terminals.
^ ALWAYS connect the GR8 Battery Diagnostic Station DIRECTLY to the vehicle battery.
For assistance on charging procedures, refer to the GR8 Instruction Manual or TSB No. PG001-06,
"Battery Maintenance for In-Stock Vehicles & Pre-Delivery".
The GR8 Instruction Manual can be found on the Technical Information System (TIS), Diagnostics Battery - "GR8 Instruction Manual".
Page 4726
Cigarette Lighter And Power Outlet
Page 3995
20 seconds.
If the brake pedal does not return, replace the ABS actuator because the motor operation is in
failure.
h. Turn the motor relay OFF and release the brake pedal.
4. INSPECT OTHER WHEEL SOLENOIDS OPERATION
Check the solenoids of the other wheels with the same inspection procedure as the right front
wheel solenoids.
HINT: Left front wheel: SFLH and SFLR Both rear wheels: SRRH and SRRR
NOTICE: Never depress the brake pedal under the condition that the reduction solenoid alone is
turned ON as ABS ECU is reset.
5. CLEAR DTC
Page 3202
Spark Plug: Testing and Inspection
ON-VEHICLE INSPECTION
NOTE: "Cold" and "Hot" in these sentences express the temperature of the coils themselves.
"Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F).
INSPECT SPARK PLUGS
a. Remove the ignition coils (with igniter).
b. Using a 16 mm plug wrench, remove the spark plugs.
c. Clean the spark plugs.
If the electrode has traces of wet carbon, allow it to dry and then clean with a spark plug cleaner.
Air pressure: Below 588 kPa (6 kgf/sq.cm, 85 psi)
Duration: 20 seconds or less
HINT: If there are traces of oil, remove it with gasoline before using the spark plug cleaner.
Recommended Spark Plug
Page 1235
4. Match the axis of the connector with axis of the pipe, and push in the connector until the
connector makes a "click" sound. In case that the
connections is tight, apply small amount of fresh engine oil on the tip of the pipe.
5. After having finished the connection, check if the pipe and the connector are securely connected
by pulling them. 6. Check if there is any fuel leakage.
h. Observe these precautions when handling nylon tube.
1. Pay attention not to turn the connected part of the nylon tube and the quick connector by force
when connecting them. 2. Pay attention not to kink the nylon tube. 3. Do not remove the EPDM
protector from the outside of the nylon tube. 4. Must not close the piping with the nylon tube by
bending it.
i. Check that there is any fuel leak after maintenance anywhere on the fuel system. 1. Connect a
TOYOTA hand-held tester to the DLC3. 2. Turn the ignition switch ON and push the TOYOTA
hand-held tester main switch ON.
NOTE: Do not start the engine.
3. Select the ACTIVE TEST mode on the TOYOTA hand-held tester. 4. Please refer to the
TOYOTA hand-held tester operator's manual for further details.
Page 6194
Body
Connector Location (Standard Cab)
BA1 Front Door LH Wire and Speaker Tweeter Wire LH (Inside of Front Door LH)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Seat
Connector Location
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
BJ1 Seat No. 1 Wire and Seat No. 2 Wire (Under the Driver's Seat)
Symptom Related Diagnostic Procedures
Problem Symptoms Table - Ignition Switch And Key Unlock Warning Switch
Page 1022
Engine Oil: Testing and Inspection
For further information regarding this component and the system that it is a part of, please refer to
Engine Lubrication; Testing and Inspection; Procedures.
Page 4323
INSTALL NEW OIL SEAL (INSIDE)
A. Using the following SST and a plastic hammer, install a NEW oil seal (inside).
09527-17011
NOTE:
Lightly strike the SST on its circumference evenly.
B. Coat MP grease to the oil seal lip.
23. INSTALL STEERING KNUCKLE
A. 4WD:
Insert the drive shaft into the axle hub and temporarily tighten the nut.
NOTE:
Be careful not to damage the oil seal and drive shaft boot.
B. Connect the steering knuckle to the upper suspension arm.
C. Install the nut and a NEW cotter pin. If the holes for the cotter pin are not aligned, tighten the nut
further up to 600.
Torque: 105 N.m (1,100 kgf.cm, 77 ft.lbf)
24. CONNECT LOWER BALL JOINT
Connect the lower ball joint to the steering knuckle with 4 bolts.
Torque: 50 N.m (510 kgf.cm, 37 ft.lbf)
25. INSTALL SHOCK ABSORBER WITH COIL SPRING
A. Install the upper side of shock absorber to the chassis frame with the 3 nuts.
Torque: 64 N.m (650 kgf.cm, 47 ft.lbf)
B. Connect the lower side of shock absorber to the lower suspension arm with bolt, washer and
nut.
Torque: 135 N.m (1,400 kgf.cm, 100 ft.lbf)
26. INSPECT AND INSTALL THE BRAKE ROTOR AND INSTALL THE BRAKE CALIPER WITH
NEW MOUNTING BOLTS
A. Inspect the brake rotors, and machine using an on-the-car brake lathe. Replace the rotor if it is
below minimum thickness values
Minimum Thickness: 26.0 mm (1.024 in.)
NOTE:
It is necessary to turn the rotors using the on-the-car brake lathe to ensure even and uniform rotor
run out. DO NOT turn the rotor using an off-the-car brake lathe.
B. Install the disc, brake caliper and 2 NEW bolts.
Torque: 123 N.m (1,259 kgf.cm, 90 ft.lbf)
C. Install the brake line clamp to the steering knuckle with the bolt.
Torque: 28 N.m (285 kgf.cm, 21 ft.lbf)
27. INSTALL NEW BRAKE LINE
Using the SST, connect NEW brake line.
09023-00100
Page 5047
Page 6302
BJ Inside of Rear Door LH
BK Inside of Rear Door RH
BL Surrounding of the Front of the Fuel Tank
Connector Location
BA1 Front Door LH Wire and Wire Harness (Connector Location)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel)
BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel)
BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel)
BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Page 5535
Sample Seat Belt Extender Customer Information Label
Front Seat Belt Extender Applications
Page 5782
Trailer Towing
Page 607
A. The Diagnostic Tester displays 17" as a value of the Time $81" (see illustration).
B. Find the Conversion Factor value of Time $81" in the O2S Failure Threshold chart. 0.3906 is
specified for Time $81 in this chart.
C. Multiply "17" in step "A" by 0.3906 (Conversion Factor) in step "B."
17 x 0.3906 = 6.6%
D. If the answer is within the Standard Value of TEST LIMIT, the Time $81" can be confirmed to be
normal.
NOTE:
^ "LOW SW V" indicates the O2S voltage when the O2S status changes from rich to lean.
^ "HIGH SW V" indicates the O2S voltage when the O2S status changes from lean to rich.
^ If the O2S voltage is lower than "LOW SW V," the O2S status is lean.
^ If the O2S voltage is higher than "HIGH SW V," the O2S status is rich.
NOTE:
Before the O2S Monitor completes or after the ignition switch is turned OFF, the Diagnostic Tester
displays the viewable upper limit or a lower limit of the test value (example: 0 V, 1.275 V, Os
[seconds], 10.2s, 0 and 255).
Page 5926
Page 838
Page 6248
BJ Inside of Rear Door LH
BK Inside of Rear Door RH
BL Surrounding of the Front of the Fuel Tank
Connector Location
BA1 Front Door LH Wire and Wire Harness (Connector Location)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel)
BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel)
BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel)
BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Page 2585
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 662
Vehicle Speed Sensor NO.2
Electrical Specifications
Oxygen Sensor: Electrical Specifications
Air/Fuel Ratio Sensor
Resistance:
at 20°C (68°F): 0.8 - 1.4 ohms
at 800°C (1,472°F): 1.8 - 3.2 ohms
Heated Oxygen Sensor
Resistance Between Terminals +B and HT:
at 20°C (68°F) 11 - 16 Ohms
at 800°C (1,472°F) 23 - 32 Ohms
Page 4800
Wiring Harness Connector
E: Indicates the wiring harness and wiring harness connector. The wiring harness with male
terminal is shown with arrows.
Outside numerals are pin numbers.
The first letter of the code for each wiring harness and wiring harness connector(s) indicates the
component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and
Surrounding area, and "B" for the Body and Surrounding area.
When more than one code has the first and second letters in common, followed by numbers (e.g,
IH1, IH2), this indicates the same type of wiring harness and wiring harness connector.
F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in
parts position.
G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside
it). Junction Blocks are shaded to clearly separate
them from other parts.
H: When 2 parts both use one connector in common, the parts connector name used in wire
routing is shown in square brackets [ ].
Wiring Color
I: Indicates the wiring color.
Wire colors are indicated by an alphabetical code.
B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR =
Brown SB = Sky Blue LG = Light Green GR = Gray
The first letter indicates the basic wire color and the second letter indicates the color of the stripe.
Engine Controls - Bank 1/Bank 2 O2 Sensor identification
Oxygen Sensor: All Technical Service Bulletins Engine Controls - Bank 1/Bank 2 O2 Sensor
identification
ENGINE EG034-07
Title: ENGINE BANK 1 AND BANK 2 A/F AND O2 IDENTIFICATION
Models: '93 - '08 Applicable Models
June 28, 2007
The information contained in this TSB supercedes TSB No. EG037-04. TSB No. EG037-04 is now
obsolete and should be discarded.
Introduction
This service bulletin provides information on the proper identification of engine bank 1 and engine
bank 2 for correct A/F sensor and oxygen sensor replacement.
This bulletin contains information that identifies engine bank 1 and engine bank 2 on the following
engines: 1AZ-FE, 2AZ-FE, 2AZ-FE (PZEV), 1GR-FE, 2GR-FE, 2GR-FSE, 2JZ-GE, 1MZ-FE,
3MZ-FE, 1UR-FSE, 3UR-FE, 2UZ-FE, 3UZ-FE, 5VZ-FE, and 1ZZ-FE.
^ Bank 1 (B1) refers to the bank that includes cylinder No. 1.
^ Bank 2 (B2) refers to the bank opposite bank 1.
^ Sensor 1 (S1) refers to the sensor that is located before the catalytic converters.
^ Sensor 2 (S2) refers to the sensor that is located after the catalytic converters.
Warranty Information
Removal and Installation
Brake Caliper: Service and Repair Removal and Installation
REMOVAL
1. REMOVE FRONT WHEEL
Remove the wheel and temporarily fasten the disc with hub nuts. Torque: 113 Nm (1,150 kgf-cm,
83 ft. lbs.)
2. DISCONNECT BRAKE LINE
Using SST, disconnect the brake line. Use a container to catch the brake fluid. SST 09023-00100
Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.)
Page 6524
Glossary Of Terms And Symbols (Part 2)
Page 2869
Continuity And Resistance Check
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Continuity And Resistance Check
C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the
electrical circuit.
Finding A Short Circuit
Finding A Short Circuit
Finding A Short Circuit
A. Remove the blown fuse and disconnect all loads of the fuse.
Page 836
Repair Procedure
1. Disconnect the cable from the negative (-) battery terminal for MORE THAN two (2) seconds.
2. Reconnect the cable to the negative (-) battery terminal.
3. Perform the applicable zero point calibration of the yaw rate sensor and/or the steering angle
sensor.
HINT Refer to the applicable TSB or Repair Manual for the zero point calibration procedure.
4. Re-initialize all applicable systems available on the vehicle (power window sunroof power lift
door etc.).
Page 6038
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 4982
c. Using a service-purpose wire harness tie down the steering wheel pad to the disc wheel.
Wire harness: Stripped wire harness section 1.25 sq.mm or more (0.0019 sq.in. or more)
CAUTION: If a wire harness which is too thin or some other thing is used to tie down the steering
wheel pad, it may be snapped by the shock when the airbag is deployed. This is highly dangerous.
Always use a wire harness for vehicle use which is at least 1.25 sq.mm (0.0019 sq.in).
HINT: To calculate the square of the stripped wire harness section: Square = 3.14 x sq.(Diameter)
divided by 4
1. Install the 2 bolts with washers in the 2 bolt holes in the steering wheel pad.
Bolt: L: 35. mm (1.387 in.) M: 6.0 mm (0.236 in.) Pitch: 1.0 mm (0.039 in.)
NOTE: Tighten the bolts by hand until the bolts become difficult to turn.
- Do not tighten the bolts too much.
Page 6282
Instrument Panel
Ground Location
IE Left Kick Panel
IF Left Kick Panel
IG Instrument Panel Brace RH
IH Right Kick Panel
II Right Kick Panel
Body
Ground Location (Access Cab)
Description and Operation
Transmission Position Switch/Sensor: Description and Operation
PARK / NEUTRAL POSITION SWITCH
Engine Control System
The park/neutral position switch comes on when the shift lever is in the N or P position. When it
comes on, terminal NSW of the ECM is grounded to the body ground via the starter relay, thus the
terminal NSW voltage becomes 0 V. When the shift lever is in the D, 2, L or R position, the
park/neutral position switch goes off, so the voltage of the terminal NSW becomes battery voltage
and the voltage of the ECM internal power source. If the shift lever is moved from the N position to
the D position, this signal is used for air-fuel ratio correction and for idle speed control (estimated
control), etc.
Transmission Control System
The park/neutral position switch detects the shift lever position and sends signals to the ECM.
The ECM receives signals (NSW, R, D, 2 and L) from the park/neutral position switch.
Page 1919
CHART 11
Page 2775
CHART 27
Page 2240
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 2828
CHART 24
Page 2300
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 911
a. Turn the crankshaft pulley and align its groove with timing mark "0" of the No.1 timing belt cover.
b. Check that the timing marks of the camshaft timing pulleys and timing belt rear plates aligned. If
not, turn the crankshaft 1 revolution (360°). c. Remove the crankshaft pulley bolt.
NOTICE: Do not turn the crankshaft pulley.
17. REMOVE TIMING BELT TENSIONER
HINT:
- When re-using timing belt: If the installation marks have disappeared, before remove the timing
belt, place 2 new installation marks on the timing belt to match the timing marks of the camshaft
timing pulleys.
- When replacing timing belt tensioner only: To avoid meshing of the timing pulley and timing belt,
secure one of them with string. And place matchmarks on the timing belt and RH camshaft timing
pulley.
Page 2500
CHART 26
Page 1607
Torque: 20.4 N.m (208 kgf.cm, 15 ft.lbf)
b. Connect the ECT sensor connector.
8. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS
a. Install a new gasket and the throttle body with the 2 bolts and 2 nuts.
Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)
b. Connect the accelerator cable to the throttle body.
9. REINSTALL INTAKE AIR CONNECTOR
10. REFILL WITH ENGINE COOLANT
11. REINSTALL THROTTLE BODY COVER
Page 869
2. Tighten the union bolt by hand.
3. Using SST, tighten the union bolt to the specified torque.
SST 09612-24014 (09617-24011)
Torque: 33 N.m (340 kgf.cm, 24 ft.lbf) for use with SST 39 N.m (400 kgf.cm, 29 ft.lbf)
HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
c. When connecting the flare nut on the high pressure pipe union, observe these procedures:
1. Apply a light coat of engine oil to the flare nut, and tighten the flare nut by hand. 2. Using SST,
tighten the flare nut to the specified torque.
SST 09023-38400
NOTE: Do not rotate the fuel filter outlet, when tightening the flare nut.
Torque: 28 N.m (285 kgf.cm, 21 ft.lbf) for use with SST 34.3 N.m (350 kgf.cm, 25 ft.lbf)
HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
d. Observe these precautions when removing and installing the injectors.
1. Never reuse the O-ring. 2. When placing a new O-ring on the injector, take care not to damage it
in any way. 3. Coat a new O-ring with spindle oil or gasoline before installing-never use engine,
gear or brake oil.
Page 4540
4. INSPECT STATOR FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity between the coil leads. If there is no continuity,
replace the drive end frame assembly.
5. INSPECT STATOR FOR GROUND
Using an ohmmeter, check that there is no continuity between the coil leads and drive end frame. If
there is continuity, replace the drive end frame assembly.
6. INSPECT EXPOSED BRUSH LENGTH
Using vernier calipers, measure the exposed brush length.
If the exposed length is less than minimum, replace the brush holder assembly.
7. INSPECT POSITIVE RECTIFIER
Page 3191
Knock Sensor: Description and Operation
P0325 - Knock Sensor 1 Circuit Malfunction (Bank 1) CIRCUIT DESCRIPTION
DTC Detection Condition
One of the knock sensors is fitted to the right bank and another to the left bank of the cylinder block
to detect the engine knocking. This sensor contains a piezoelectric element which generates
voltage when it becomes deformed. This occurs when the cylinder block vibrates due to knocking.
If the engine knocking occurs, ignition timing is retarded to suppress it.
Wiring Diagram
Service and Repair
Piston Pin: Service and Repair
For further information regarding this component and the system that it is a part of, please refer to
Cylinder Block Assembly; Service and Repair.
Page 4213
Required Tools & Material
NOTE:
Additional Diagnostic Tester Kits, Program Cards or SSTs may be ordered by calling SPX-OTC at
1-800-933-8335.
Page 2999
4 nuts holding the delivery pipes to the lower intake manifold. Torque:..............18 N.m (185 kgf.cm,
13 ft.lbf)
Page 1436
Alternately loosen the 2 bolts, and remove them, the belt tensioner and dust boot.
18. DISCONNECT TIMING BELT FROM CAMSHAFT TIMING PULLEYS
a. Using SST, loosen the tension spring between the LH and RH camshaft timing pulleys by slightly
turning the LH camshaft timing pulley
clockwise. SST 09960-10010 (09962-01000, 09963-01000)
b. Disconnect the timing belt from the camshaft timing pulleys.
19. REMOVE CAMSHAFT TIMING PULLEYS
Using SST, remove the bolt and timing pulley. Remove the 2 timing pulleys. SST 09960-10010
(09962-01000, 09963-01000)
20. REMOVE GENERATOR 21. REMOVE DRIVE BELT TENSIONER
Remove the bolt, 2 nuts and belt tensioner.
22. REMOVE CRANKSHAFT PULLEY
Using SST, remove the crankshaft pulley. SST 09950-50012 (09951-05010, 09952-05010,
09953-05010, 09953-05020, 09954-05020)
NOTICE: Do not turn the crankshaft pulley.
23. REMOVE NO.1 TIMING BELT COVER
Remove the 4 bolts and timing belt cover.
Page 2246
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 2878
Vehicle Speed Sensor: Service and Repair
Vehicle Speed Sensor NO.1
1. DISCONNECT NO. 1 VEHICLE SPEED SENSOR CONNECTOR
2. REMOVE NO. 1 VEHICLE SPEED SENSOR
Remove the bolt and No.1 vehicle speed sensor.
3. DISASSEMBLE NO. 1 VEHICLE SPEED SENSOR
a. Remove the O-ring from the speedometer driven gear assembly. b. Remove the clip and
speedometer driven gear from the speedometer driven gear sleeve.
4. ASSEMBLE NO. 1 VEHICLE SPEED SENSOR
a. Install the speedometer driven gear and clip to the speedometer driven gear sleeve. b. Coat a
new O-ring with ATF. c. Install the O-ring to the speedometer driven gear assembly.
5. INSTALL NO. 1 VEHICLE SPEED SENSOR
Page 4892
Repair Procedure
1. Disconnect the cable from the negative (-) battery terminal for MORE THAN two (2) seconds.
2. Reconnect the cable to the negative (-) battery terminal.
3. Perform the applicable zero point calibration of the yaw rate sensor and/or the steering angle
sensor.
HINT Refer to the applicable TSB or Repair Manual for the zero point calibration procedure.
4. Re-initialize all applicable systems available on the vehicle (power window sunroof power lift
door etc.).
Page 3749
Wiring Harness Connector
E: Indicates the wiring harness and wiring harness connector. The wiring harness with male
terminal is shown with arrows.
Outside numerals are pin numbers.
The first letter of the code for each wiring harness and wiring harness connector(s) indicates the
component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and
Surrounding area, and "B" for the Body and Surrounding area.
When more than one code has the first and second letters in common, followed by numbers (e.g,
IH1, IH2), this indicates the same type of wiring harness and wiring harness connector.
F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in
parts position.
G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside
it). Junction Blocks are shaded to clearly separate
them from other parts.
H: When 2 parts both use one connector in common, the parts connector name used in wire
routing is shown in square brackets [ ].
Wiring Color
I: Indicates the wiring color.
Wire colors are indicated by an alphabetical code.
B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR =
Brown SB = Sky Blue LG = Light Green GR = Gray
The first letter indicates the basic wire color and the second letter indicates the color of the stripe.
Page 6167
The location and the cross section of the weatherstrips have been optimized to ensure a high level
of sealing performance and sound insulation.
Cab Mounting
Page 5764
Body
Connector Location (Access Cab)
BA1 Front Door LH Wire and Wire Harness (Connector Location)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel)
BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel)
BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel)
BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Page 6333
Instrument Panel
Ground Location
IE Left Kick Panel
IF Left Kick Panel
IG Instrument Panel Brace RH
IH Right Kick Panel
II Right Kick Panel
Body
Ground Location (Access Cab)
Page 2401
Engine Bank Identification
Page 2769
Page 1065
Fuse: Application and ID
Engine Room R/B Fuse Applications (Part 1)
Page 5661
1. LH:
REMOVE FRONT AIRBAG SENSOR
a. 2UZ-FE:
Remove the battery carrier, battery and battery tray.
b. Disconnect the front airbag sensor connector.
NOTE: Disconnect the connector with sensor assembly installed.
c. Remove the 2 bolts and front airbag sensor.
2. RH:
REMOVE FRONT AIRBAG SENSOR
a. Remove the air cleaner assembly. b. Disconnect the front airbag sensor connector.
NOTE: Disconnect the connector with sensor assembly installed.
c. Remove the 2 bolts and front airbag sensor.
INSTALLATION
INSTALL FRONT AIRBAG SENSORS
Page 5945
Specifications
Locations
Impact Sensor: Locations
Front Airbag Sensor
Page 2483
CHART 10
ABS/TCS - Zero Point Calibration Information
Alignment: Technical Service Bulletins ABS/TCS - Zero Point Calibration Information
T-SB-0020-08
March 25, 2008
Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment
Service Category Brake
Section Brake Control/Dynamic Control System
Market USA
Applicability
Introduction
The purpose of this TSB is to provide information on when and how to perform the zero point
calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting
the battery is a necessary step for performing the zero point calibration.
Warranty Information
Required Tools & Equipment
^ Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE).
^ The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the
service procedures listed in this bulletin.
Preliminary Information
Perform this procedure if any of these repairs have been performed on the vehicle:
^ Wheel alignment has been adjusted.
^ Any chassis components have been removed/installed or replaced.
Page 1708
A. Connect Diagnostic Tester cables DLC (P/N 02001637) and CAN Interface Module / J1962
OBDII together (P/N 01002744).
B. Test for continuity.
^ If there is continuity, the cable is OK. Check steps 1 and 2 above to complete the flash
reprogramming process.
^ If there is no continuity, proceed to CABLE TEST 2.
CABLE TEST 2.
A. Disconnect Diagnostic Tester cables DLC (P/N 02001637) and CAN Interface Module /J1962
OBDII (P/N 01002744).
B. Test DLC cable (P/N 02001637) for continuity.
^ If there is continuity, the cable is OK. Proceed to CABLE TEST 3.
^ If there is no continuity, the cable needs to be replaced.
CABLE TEST 3.
Locations
Supplemental Restraint System
Page 2818
CHART 15
Page 5780
Terminal Retainer
Push the terminal retainer down to the temporary lock position.
c. Release the locking lug from terminal and pull the terminal out from rear.
4. INSTALL TERMINAL TO CONNECTOR
a. Insert the terminal.
HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug
locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position.
Engine Controls - ECU Reprogramming Procedure
Technical Service Bulletin # SS002R-01 Date: 030922
Engine Controls - ECU Reprogramming Procedure
SPECIAL SERVICE TOOLS SS002-01 REVISED
March 9, 2001
Title: ECU FLASH REPROGRAMMING PROCESS
Models: Applicable Models
TSB REVISION NOTICE:
^ September 22, 2003: Models added - 2002 (and later) Solara, 2003 (and later) Corolla and
Matrix, and 2004 models; Operation Procedures updated for CAN Interface Module with the latest
Diagnostic Tester software (v. 10.1a and 10.2a), Calibration Update Wizard (v.6.0), and calibration
files.
^ June 20, 2003: Camry and Tacoma models added; Special Service Tools table updated. The
previous TSB should be discarded.
Introduction
Electronic Control Unit (ECU) is a Toyota term used to describe integrated computerized devices
responsible for managing the operation of a system or sub-system. For the purposes of this
bulletin, the term "ECU" is used as a generic label for the following SAE J1930 standard
references:
^ Powertrain Control Module (PCM)
^ Engine Control Module (ECM)
^ Transmission Control Module (TCM)
^ or any other Toyota specific control unit
Flash reprogramming allows the ECU software to be updated for changes in vehicle calibrations
without removing the ECU from the vehicle. Flash calibration updates for specific vehicle
models/ECUs will be released as field fix procedures described in individual service bulletins. This
bulletin details the ECU flash reprogramming process and the applications within the Technical
Information System (TIS) and the Toyota Diagnostic Tester used for reprogramming.
Flash calibration updates can only be applied to the vehicle/ECU combination for which they are
intended. ECUs have internal security that will not allow them to be programmed with another
ECU's information.
Applicable Vehicles ^
2001 (and later) model year 4Runner, Highlander, Land Cruiser, RAV4, Sequoia and Tundra
vehicles.
^ 2002 (and later) model year Camry, Solara and Tacoma vehicles.
^ 2003 (and later) model year Corolla and Matrix vehicles.
^ All 2004 (and later) model year Toyota vehicles except Celica, MR2 Spyder, Avalon, and Tacoma
(3RZ-FE engine)
Warranty Information
Parts Information
NOTE:
Authorized Modifications Labels may be ordered in packages of 25 from the Materials Distribution
Center (MDC) through the TDN Dealer Support
Brakes - Vibration From Front Brakes
Technical Service Bulletin # BR004R-02 Date: 040924
Brakes - Vibration From Front Brakes
BRAKES BR004-02 REVISED
Title: FRONT BRAKE VIBRATION
Models: '00 - '03 Tundra
September 16, 2002
TSB REVISION NOTICE:
^ September 24, 2004: A note has been added, step 26.
^ March 5, 2004: A torque speification, step 24, was changed.
^ September 8, 2003: A torque specification, step 28, was changed.
Previous versions of this TSB should be discarded.
Introduction
Under certain usage conditions, some Tundra trucks may exhibit front brake vibration. Improved
brake caliper assemblies have been introduced to correct this condition.
Applicable Vehicles
2000 - 2003 model year Tundra trucks built before the VIN shown below.
Production Change Information
Warranty Information
Applicable Warranty*:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36
months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
On-Vehicle Inspection
Fuel Injector: Testing and Inspection On-Vehicle Inspection
ON-VEHICLE INSPECTION
1. REMOVE THROTTLE BODY COVER
2. REMOVE INTAKE AIR CONNECTOR
3. INSPECT INJECTOR RESISTANCE
a. Disconnect the 8 injector connectors. b. Using an ohmmeter, measure the resistance between
the terminals.
Resistance: 13.4 - 14.2 ohms at 20 °C (68 °F)
If the resistance is not as specified, replace the injector.
c. Reconnect the 8 injector connectors.
4. REINSTALL INTAKE AIR CONNECTOR
5. REINSTALL THROTTLE BODY COVER
Page 4411
Part 2 of 2
Page 115
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 732
Knock Sensor: Description and Operation
P0325 - Knock Sensor 1 Circuit Malfunction (Bank 1) CIRCUIT DESCRIPTION
DTC Detection Condition
One of the knock sensors is fitted to the right bank and another to the left bank of the cylinder block
to detect the engine knocking. This sensor contains a piezoelectric element which generates
voltage when it becomes deformed. This occurs when the cylinder block vibrates due to knocking.
If the engine knocking occurs, ignition timing is retarded to suppress it.
Wiring Diagram
Page 5571
The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit
breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery
power is supplied to each system are explained. Since all System Circuit diagrams start from the
power source, the power source system must be fully understood.
Page 3293
c. 4HI -> 4LO shift: Connect lines via a relay, then check that the actuator fork shaft moves to 4HI
-> 4LO position.
d. 4LO 4HI shift: Connect lines via a relay, then check that the actuator fork shaft moves to 4LO ->
4HI position.
HINT: When inspecting the operation described, use a heater main relay.
NOTICE: Connect the terminals being careful not to touch the neighboring terminals or metallic
parts of relay housing.
Diagram Information and Instructions
Trailer Connector: Diagram Information and Instructions
Key to Diagrams
A: System Title
B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to
distinguish it from the J/B
Example: 1 Indicates Relay Block No.1
C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type,
or specification is different.
D: Indicates related system.
Page 6062
Warning: Auto Magic © Special Cleaner Concentrate is a corrosive material. Appropriate personal
protection equipment must be worn to protect persons performing the contamination removal
procedure. Please refer to the precautions on the product prior to use.
Caution:
Consult local or state regulations regarding the handling, use, and disposal of Auto Magic ©
Special Cleaner Concentrate prior to use.
Under no circumstances should contamination removal be performed in direct sunlight or
contamination removal solution be allowed to dry on vehicle surfaces, as staining of plastic, rubber,
or painted parts may result.
Repair Procedure
1. Move vehicle out of direct sunlight. Initially rinse with cool water then wash with liquid car wash
detergent. Rinse again thoroughly with fresh
water.
2. Dilute the mixture to a 1:8 ratio for painted surfaces. Use the recommended dilution ratio when
applying to any other surface. Apply the diluted
cleaner so that it evenly covers the affected area. Use an appropriate mitt or sponge to agitate the
surface.
3. Thoroughly rinse vehicle with fresh water.
4. Inspect vehicle carefully both visually and by feel to determine if all iron particles have been
removed. Repeat the wash several times if necessary
to achieve complete removal.
5. Dry vehicle with a soft terry cloth towel and apply a non-abrasive non-silicone glaze to obtain a
high-gloss finish.
Page 3760
Waterproof Type Connector
B: For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White
: Gray
Black or White : Dark Gray
Gray or White : Black
Waterproof Type Connector
"Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up
to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Waterproof Type Connector
"Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 2066
Throttle Position Sensor: Testing and Inspection
ON-VEHICLE INSPECTION
1. REMOVE THROTTLE BODY COVER
2. INSPECT SYSTEM OPERATION
a. Check that the throttle linkage moves smoothly.
b. Inspect the throttle control motor for operating sound.
1. Turn the ignition switch ON. 2. When turning the accelerator pedal position sensor lever, check
the running sound of the motor. Also, check that there is no friction sound.
If operation is not as specified, check the throttle control motor (See step 3), wiring and ECM.
c. Inspect the accelerator pedal position sensor.
1. Connect the TOYOTA hand-held tester to the DLC3. 2. Check that the MIL does not light up. 3.
When turning the accelerator pedal position sensor lever to the full-open position, check that the
throttle valve opening percentage
(THROTTLE POS) of the CURRENT DATA shows the standard value.
Standard throttle valve opening percentage: 60 % or more
If operation is not as specified, check that the accelerator pedal position sensor (See step 5), wiring
and ECM.
Page 5246
1. REMOVE CENTER CLUSTER INTEGRATION PANEL
a. Remove the 3 heater control knobs. b. Remove the 5 screws. c. Remove integration control
panel by pulling the portions indicated by arrows in the illustration. d. Disconnect the connector.
2. REMOVE LOWER LH FINISH PANEL
3. REMOVE HEATER TO REGISTER DUCT NO.2
4. REMOVE GLOVE COMPARTMENT DOOR
5. REMOVE LOWER NO.2 FINISH PANEL
6. REMOVE HEATER TO REGISTER DUCT NO.4
7. DISCONNECT HEATER CONTROL CABLES
Page 5581
Key Reminder And Seat Belt Warning
Service and Repair
Fuel Pressure Release: Service and Repair
SFI SYSTEM
PRECAUTION
1. BEFORE WORKING ON FUEL SYSTEM, DISCONNECT NEGATIVE (-) TERMINAL CABLE
FROM BATTERY
HINT: Any diagnostic trouble code retained by the computer will be erased when the negative (-)
terminal cable is removed from the battery.
Therefore, if necessary, read the diagnosis before removing the negative (-) terminal cable from the
battery.
2. DO NOT SMOKE OR WORK NEAR AN OPEN FLAME WHEN WORKING ON THE FUEL
SYSTEM
3. KEEP GASOLINE AWAY FROM RUBBER OR LEATHER PARTS
4. FUEL SYSTEM
a. When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so
observe these procedures:
1. Disconnect the fuel pump connector. 2. Start the engine. After the engine has stopped on its
own, turn the ignition switch OFF.
3. Put a container under the connection. 4. Slowly loosen the connection. 5. Disconnect the
connection. 6. Plug the connection with a rubber plug. 7. Reconnect the fuel pump connector.
b. When connecting the union bolt (fuel pressure pulsation damper) on the high pressure pipe
union, observe these procedures:
1. Always use 2 new gaskets.
Page 1043
Refrigerant Oil: Fluid Type Specifications
Type ND-OIL 8
Page 234
Engine Control Module: Connector Views
Terminals Of ECM - Connector View
Terminals Of ECU - Connector Pinouts (Part 1)
Page 4915
Body
Connector Location (Access Cab)
BA1 Front Door LH Wire and Wire Harness (Connector Location)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel)
BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel)
BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel)
BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Page 3587
Transmission Position Switch/Sensor: Service and Repair
ON-VEHICLE REPAIR
1. DISCONNECT OIL COOLER PIPE 2. REMOVE PARK/NEUTRAL POSITION SWITCH
a. Disconnect the connector. b. Pry off the lock washer and remove the nut. c. Remove the bolt and
park/neutral position switch.
3. INSTALL PARK/NEUTRAL POSITION SWITCH
a. Install the park/neutral position switch and bolt.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)
b. Install a new lock plate and the nut.
Torque: 3.9 Nm (40 kgf-cm, 35 inch lbs.)
c. Bend claws on the lock plate to fix the nut. d. Connect the connector. e. Check that the engine
can be started with the shift lever only in the N or P position, but not in other positions. If not as
stated, carry out the
adjustment procedure. See: Testing and Inspection/Initial Inspection and Diagnostic Overview
4. CONNECT OIL COOLER PIPE 5. FILL ATF AND CHECK FLUID LEVEL 6. TEST DRIVE
VEHICLE
Page 2590
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 1937
CHART 27
Page 86
Wiring Harness Connector
E: Indicates the wiring harness and wiring harness connector. The wiring harness with male
terminal is shown with arrows.
Outside numerals are pin numbers.
The first letter of the code for each wiring harness and wiring harness connector(s) indicates the
component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and
Surrounding area, and "B" for the Body and Surrounding area.
When more than one code has the first and second letters in common, followed by numbers (e.g,
IH1, IH2), this indicates the same type of wiring harness and wiring harness connector.
F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in
parts position.
G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside
it). Junction Blocks are shaded to clearly separate
them from other parts.
H: When 2 parts both use one connector in common, the parts connector name used in wire
routing is shown in square brackets [ ].
Wiring Color
I: Indicates the wiring color.
Wire colors are indicated by an alphabetical code.
B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR =
Brown SB = Sky Blue LG = Light Green GR = Gray
The first letter indicates the basic wire color and the second letter indicates the color of the stripe.
Page 1933
CHART 25
Specifications
Timing Belt: Specifications
Timing Belt Replacement Interval ........................................................................................................
............................................................. 90,000 miles
No.2 Timing Belt Cover Torque ...........................................................................................................
...................................................................... 16 Nm RH No.2 Timing Belt Cover Torque ..................
........................................................................................................................................................ 7.5
Nm LH No.3 Timing Belt Cover Torque ...............................................................................................
........................................................................... 7.5 Nm
Page 1761
DOWNLOAD FILE TO TESTER
2. Download the calibration file to the Diagnostic Tester.
The Calibration Update Wizard (CUW) is a new application on TIS which downloads calibration
files from TIS onto the Diagnostic Tester Program Card.
NOTE:
Before you begin, ensure that the Diagnostic Tester is equipped with software version 8.0a, or
later. Only a 12 MB program card (P/N 01002593-005) may be used for this process.
A. Before downloading a new calibration file from TIS, check the current calibration files stored on
the Diagnostic Tester Program Card by following the screen flow shown (Figure 4).
NOTE:
^ Screen D may be blank if no calibrations are stored on the Diagnostic Tester Program Card.
^ If the desired calibration file is already on the Diagnostic Tester, proceed to Step 3 (Reprogram
ECU with Tester shown).
^ A maximum of two calibration files may be loaded on the tester at one time with Diagnostic Tester
software version 10.2a and later. Prior versions may store up to four calibration files.
Locations
Supplemental Restraint System
Page 2972
Mass Air Flow (MAF) Meter
Page 2595
M. Turn ignition OFF for a minimum of 10 seconds. Then click Next.
N. Turn ignition to the ON position. Then click Next.
0. Confirm all calibrations were updated as specified in the service bulletin. Then click Finish.
Engine - Accessory Drive Belt Squealing Noise
Drive Belt: All Technical Service Bulletins Engine - Accessory Drive Belt Squealing Noise
ENGINE EG026-06 REVISED
Title: 2UZ-FE ACCESSORY DRIVE BELT NOISE
Models: '00 - '06 Tundra
April 21, 2006
TSB REVISION NOTICE:
^ July 9, 2007: The Introduction has been updated. Production Change Effective VINs have been
updated in the Production Change Information table. In the Repair Procedure steps 12 and 13 and
the illustration below step 13 have been updated, and steps 14 - 17 have been renumbered.
Previous versions of this TSB should be discarded.
Introduction
Some customers may experience an abnormal squeal noise from the engine accessory drive belt
area, usually during cold start-up. An improved accessory drive belt tensioner, A/C compressor
bracket, and revised installation procedure have been developed to address this condition.
Applicable Vehicles
^ 2000 - 2006 model year Tundra vehicles produced BEFORE the Production Change Effective
VINs shown below.
Production Change Information
Parts Information
Warranty Information
Applicable Warranty* This repair is covered under the Toyota Comprehensive Warranty. This
warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's
in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Repair Procedure
Page 2393
Engine Bank Identification
Page 2229
A. Test J1962 OBDIII CAN Interface Module (P/N 01002744) for continuity.
^ If there is continuity, the cable and CAN Interface Module are OK. Re-check Cable Tests 1, 2,
and 3 while wiggling and flexing the cables.
^ If there is no continuity, proceed to CABLE TEST 4.
CABLE TEST 4.
A. Disconnect the CAN Interface Module (P/N 01002744) from the J1962 OBDII cable using a
Phillips screwdriver.
B. Test J1962 OBDII cable (P/N 02003180) for continuity.
^ If there is no continuity, the cable needs to be replaced.
^ If there is continuity, proceed to CAN Interface Module Test 5.
CAN INTERFACE MODULE TEST 5.
Page 5576
B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(Connect the Relay) and SW 2 OFF (or Disconnect SW 2)
D. Disconnect and reconnect the connectors while watching the test light.
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
E. Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION:
a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals
are touched, the IC may be destroyed by
static electricity.)
b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact
with the terminals of leads from the IC, etc. of the replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
Special Tool
1. PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown.
2. DISCONNECT CONNECTOR
3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
a. Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the
secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
A: For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
Page 5543
To connect the extender to the seat belt, insert the tab into the seat belt buckle so that the
"PRESS" signs on the buckle-release buttons of the extender and the seat belt are both facing
outward as shown.
You will hear a click when the tab locks into the buckle.
When releasing the seat belt, press on the buckle-release button on the extender, not on the seat
belt. This helps prevent damage to the vehicle interior and extender itself.
When not in use, remove the extender and store in the vehicle for future use.
SRS/Interior - Seat Cover Replacement Caution
Seat Cover: All Technical Service Bulletins SRS/Interior - Seat Cover Replacement Caution
BODY BO014-05
Title: SEAT COVER REPLACEMENT FOR SIDE AIRBAG EQUIPPED VEHICLES
Models: '98 - '06 All Models
November 10, 2005
TSB UPDATE NOTICE:
The information contained in this TSB supercedes TSB No. B0025-97. TSB No. B0025-97 is now
obsolete and should be discarded.
Introduction
Beginning in 1998, Toyota introduced side airbags as optional equipment.
Toyota does NOT recommend replacement of original seat covers* with non-Toyota leather or
other seat cover materials on vehicles due to the following:
^ Seat covers NOT recommended by Toyota may affect side airbag performance, in general or in
part, during an accident.
^ Modifications that negatively affect side airbag performance can result in severe occupant
injuries.
^ Seat covers are an integral part of this safety system. Replacing fabric seat covers* with
non-Toyota leather or other seat cover materials may compromise the effectiveness of this safety
system.
^ The design of the seat is complex, integrating safety and strength with comfort and luxury.
*NOTE:
Toyota original seat covers that were NOT designed for side airbag equipped seats cannot be used
due to the effect on proper airbag performance.
Toyota strongly discourages modifying original equipment seats that have optional side airbags.
Additionally, Toyota strongly advises against the installation or use of aftermarket seat covers,
which could impair the performance of the side airbags in the event of an accident.
Applicable Vehicles
^ All 1998 - 2006 model year Toyota and Scion vehicles equipped with side airbags.
Warranty Information
Page 3583
Transmission Mode Indicator - A/T: Testing and Inspection
ELECTRONICALLY CONTROLLED TRANSMISSION AND A/T INDICATOR
E1 ELECTRONICALLY CONTROLLED TRANSMISSION SOLENOID
4, 7, 8 - GROUND : Approx. 13 Ohms
O4 O/D MAIN SW
3 - 1 : Open with O/D main SW at ON position
Closed with O/D main SW at OFF position
S4 STOP LIGHT SW
1 - 2 : Closed with brake pedal depressed
E3 (A) E4 (B), E5 (C), E6 (D), E7 (E) ENGINE CONTROL MODULE
S1 - E1 : 9 - 14 volts with vehicle not move and shift lever in D position
S2, SL - E1 : 0 - 1.5 volts with vehicle not move
STP - E1 : 7.5 - 14 volts with brake pedal depressed 0 - 1.5 volts with brake pedal released
THW - E1 : 0.2 - 1.0 volts with idling, engine coolant temperature 60 °C (140 °F) -120 °C (248 °F)
OIL - E1 : Below 1.0 volts with fluid temperature 110 °C (230 °F)
VTA - E1 : 0.4 - 1.0 volts with ignition SW on and throttle valve fully closed : 3.2 - 4.8 volts with
ignition SW on and throttle valve fully open
VC - E1 : 4.5 - 5.5 volts with ignition SW at ON or ST position
ODMS - E1 : 9 - 14 volts with O/D main SW turned on : 0 - 3 volts with 0/D main SW turned off
SPD - E1 : Pulse generation with vehicle moving
2 - E1 : 7.5 - 14 volts with shift lever at 2 position : 0 - 1.5 volts with shift lever at except 2 position
L - E1 : 7.5 - 14 volts with shift lever at L position : 0 - 1.5 volts with shift lever at except L position
+B - E1 : 9 - 14 volts with ignition SW at ON or ST position
BATT - E1 : Always 9 - 14 volts
P1 A/T INDICATOR SW [PARK/NEUTRAL POSITION SW]
3 - 1 : Closed with shift lever in P position 3 - 2 : Closed with shift lever in R position 3 - 5 : Closed
with shift lever in N position 3 - 7 : Closed with shift lever in D position 3 - 4 : Closed with shift lever
in 2 position 3 - 8 : Closed with shift lever in L position
Page 3229
Wiring Harness Connector
E: Indicates the wiring harness and wiring harness connector. The wiring harness with male
terminal is shown with arrows.
Outside numerals are pin numbers.
The first letter of the code for each wiring harness and wiring harness connector(s) indicates the
component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and
Surrounding area, and "B" for the Body and Surrounding area.
When more than one code has the first and second letters in common, followed by numbers (e.g,
IH1, IH2), this indicates the same type of wiring harness and wiring harness connector.
F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in
parts position.
G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside
it). Junction Blocks are shaded to clearly separate
them from other parts.
H: When 2 parts both use one connector in common, the parts connector name used in wire
routing is shown in square brackets [ ].
Wiring Color
I: Indicates the wiring color.
Wire colors are indicated by an alphabetical code.
B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR =
Brown SB = Sky Blue LG = Light Green GR = Gray
The first letter indicates the basic wire color and the second letter indicates the color of the stripe.
Page 3614
Part 1 of 2
Part 2 of 2
Page 5071
Service and Repair
Input Shaft: Service and Repair
For further information regarding this component and the system that it is a part of, please refer to
Transfer Case; Service and Repair.
Page 4641
Fuse Block: Connector Views
Engine Room R/B
Page 4973
Steering Wheel: Service Precautions
SRS AIRBAG PRECAUTION
TOYOTA vehicles are equipped with an SRS (Supplemental Restraint System) such as the driver
airbag, front passenger airbag, side airbag, curtain airbag (if equipped), and seat belt pretensioner.
Failure to carry out service operation in the correct sequence could cause the SRS to unexpectedly
deploy during servicing, possibly leading to a serious accident. Before servicing (including removal
or installation of parts, inspection or replacement), be sure to read the precautionary notices in
RESTRAINT SYSTEMS.See: Restraint Systems
Page 22
Splice Location
I1 Cowl Wire
I2 Cowl Wire
I3 Cowl Wire
I4 Cowl Wire
I5 Cowl Wire
I6 Cowl Wire
I7 Engine Wire
I8 Engine Wire
I9 Engine Wire
I10 Engine Wire
I11 Engine Wire
I12 Engine Wire
I13 Engine Wire
I14 Engine Wire
I15 Engine Wire
I16 Cowl Wire
Body
Splice Location (Access Cab)
B1 Speaker Tweeter Wire LH
B2 Front Door LH Wire
B3 Front Door LH Wire
B4 Roof Wire
B5 Speaker Tweeter Wire RH
B6 B7
Front Door RH Wire
B8 Front Door RH Wire
B9 Rear Door No. 1 Wire RH
B10 Frame Wire
Page 3238
B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(Connect the Relay) and SW 2 OFF (or Disconnect SW 2)
D. Disconnect and reconnect the connectors while watching the test light.
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
E. Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION:
a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals
are touched, the IC may be destroyed by
static electricity.)
b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact
with the terminals of leads from the IC, etc. of the replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
Special Tool
1. PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown.
2. DISCONNECT CONNECTOR
3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
a. Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the
secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
A: For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
Page 2216
b. Push the secondary locking device or terminal retainer in to the full lock position.
5. CONNECT CONNECTOR
Disconnection of Male and Female Connectors
Disconnection of Male and Female Connectors
Disconnection Of Male And Female Connectors
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Brakes - Front Brake Caliper Identification
Brake Caliper: All Technical Service Bulletins Brakes - Front Brake Caliper Identification
BRAKES BR001-03 REVISED
January 8, 2003
Title: FRONT BRAKE COMPONENT IDENTIFICATION
Models: '00 - '05 Tundra, '01 - '05 Sequoia
TSB UPDATE NOTICE:
The information contained in this TSB supercedes TSB No. BR003-00. TSB No. BR003-00 is now
obsolete and should be discarded.
TSB REVISION NOTICE:
March 25, 2005: Parts Information - Part titles and part numbers have been updated and "Note"
added.
The previous TSB should be discarded.
Introduction
There are two caliper designs that are in use for Tundra and Sequoia vehicles. The brake pads and
fitting kits for these two calipers are not interchangeable. The pictures and parts lists below are
intended to assist you in identifying and ordering the correct replacement pads and fitting kits.
Applicable Vehicles: ^
2000 - 2005 model year Tundra vehicles.
^ 2001 - 2005 model year Sequoia vehicles.
Warranty Information
Page 6885
b. Push the secondary locking device or terminal retainer in to the full lock position.
5. CONNECT CONNECTOR
Disconnection of Male and Female Connectors
Disconnection of Male and Female Connectors
Disconnection Of Male And Female Connectors
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Page 5929
Page 3127
Camshaft Position Sensor
Page 5515
Seat Belt
Specifications
Engine Controls - ECU Reprogramming Procedure
Technical Service Bulletin # SS002R-01 Date: 030922
Engine Controls - ECU Reprogramming Procedure
SPECIAL SERVICE TOOLS SS002-01 REVISED
March 9, 2001
Title: ECU FLASH REPROGRAMMING PROCESS
Models: Applicable Models
TSB REVISION NOTICE:
^ September 22, 2003: Models added - 2002 (and later) Solara, 2003 (and later) Corolla and
Matrix, and 2004 models; Operation Procedures updated for CAN Interface Module with the latest
Diagnostic Tester software (v. 10.1a and 10.2a), Calibration Update Wizard (v.6.0), and calibration
files.
^ June 20, 2003: Camry and Tacoma models added; Special Service Tools table updated. The
previous TSB should be discarded.
Introduction
Electronic Control Unit (ECU) is a Toyota term used to describe integrated computerized devices
responsible for managing the operation of a system or sub-system. For the purposes of this
bulletin, the term "ECU" is used as a generic label for the following SAE J1930 standard
references:
^ Powertrain Control Module (PCM)
^ Engine Control Module (ECM)
^ Transmission Control Module (TCM)
^ or any other Toyota specific control unit
Flash reprogramming allows the ECU software to be updated for changes in vehicle calibrations
without removing the ECU from the vehicle. Flash calibration updates for specific vehicle
models/ECUs will be released as field fix procedures described in individual service bulletins. This
bulletin details the ECU flash reprogramming process and the applications within the Technical
Information System (TIS) and the Toyota Diagnostic Tester used for reprogramming.
Flash calibration updates can only be applied to the vehicle/ECU combination for which they are
intended. ECUs have internal security that will not allow them to be programmed with another
ECU's information.
Applicable Vehicles ^
2001 (and later) model year 4Runner, Highlander, Land Cruiser, RAV4, Sequoia and Tundra
vehicles.
^ 2002 (and later) model year Camry, Solara and Tacoma vehicles.
^ 2003 (and later) model year Corolla and Matrix vehicles.
^ All 2004 (and later) model year Toyota vehicles except Celica, MR2 Spyder, Avalon, and Tacoma
(3RZ-FE engine)
Warranty Information
Parts Information
NOTE:
Authorized Modifications Labels may be ordered in packages of 25 from the Materials Distribution
Center (MDC) through the TDN Dealer Support
Page 1443
c. Check that each pulley aligns with the timing marks as shown in the illustration. If the timing
marks do not align, remove the timing belt and
reinstall it.
17. TIGHTEN CRANKSHAFT PULLEY BOLT
Using SST, install the pulley bolt. SST 09213-54015 (90119-08216), 09330-00021 Torque: 245 Nm
(2,500 kgf-cm, 181 ft. lbs.)
18. INSTALL FAN BRACKET
Install the fan bracket with the 2 bolts and 2 nuts. Torque:
12 mm head 16 Nm (160 kgf-cm, 12 ft. lbs.) for (A) 14 mm head 32 Nm (330 kgf-cm, 24 ft. lbs.) for
(B)
HINT: Each bolt length is indicated in the illustration.
Bolt Length:
106 mm (4.17 inch) for 12 mm head (A) 114 mm (4.49 inch) for 14 mm head (B)
19. w A/C: INSTALL A/C COMPRESSOR
20. INSTALL NO.2 TIMING BELT COVER
Install the No.2 timing belt cover with the 2 bolts.
Page 5728
The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit
breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery
power is supplied to each system are explained. Since all System Circuit diagrams start from the
power source, the power source system must be fully understood.
Page 2294
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.
Locations
Engine Room R/B
Page 5456
Airbag Sensor Assembly
Page 5276
1. Turn the temperature control knob to the full cold position.
2. Inspect the clearance between the water control valve lever and the lever stop.
If the lever does not contact the lever stop, proceed to step 3.
3. If the lever does not contact the lever stop:
A. Disengage the cable retaining clip.
B. Pull up on the cable sheath until the water control valve lever contacts the lever stop.
C. Re-fasten the cable retaining clip.
Specifications
Engine Oil Pressure: Specifications
Oil Pressure
Oil Pressure at Idle ..............................................................................................................................
........................................................................ 29 kPa Oil Pressure at 3000 rpm ...............................
....................................................................................................................................................
294-588 kPa
Page 4299
11. 4WD: Remove oil seal (inside).
A. Mount the axle hub in a soft jaw vise.
HINT: Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further
(refer to the illustration above).
B. Using a screwdriver, remove the oil seal (inside).
12. 2WD: Remove lock nut and ABS speed sensor rotor (with ABS) or spacer (without ABS). Using
a chisel and hammer, loosen the staked part of the lock nut.
NOTE:
Be careful not to damage the bushing.
A. Using the following SST, remove the lock nut. SST P/N: 00002-00909 (09318-12010)
NOTE:
Do NOT use air wrench.
B. Remove the ABS speed sensor rotor or spacer.
NOTE:
Take care not to scratch the serration of the speed sensor rotor.
13. Remove axle hub from steering knuckle.
A. Remove the 4 bolts and shift the dust cover toward the hub side (outside).
B. Using the following SSTs, remove the axle hub from the steering knuckle.
SST P/N: 09710-28012-01 (09710-07031)
SST P/N: 09950-40011(09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04031,
09957-04010, 09958-04011)
HINT: If necessary, use a press to remove the axle hub from the steering knuckle.
C. Remove the dust cover from the steering knuckle.
D. 4WD: Remove the bearing spacer and ABS speed sensor rotor (with/ABS) or spacer (without
ABS).
NOTE:
Take care not to scratch the serration of the speed sensor rotor.
14. Remove oil seal (outside). Using a screwdriver, remove the oil seal (outside) from the steering
knuckle.
15. Remove bearing from steering knuckle.
Page 4837
Alignment: Service and Repair
NOTICE: For Zero Point Calibration information, please refer to: TSB T-SB-0020-8 (3/25/08).
INSPECTION
1. MEASURE VEHICLE HEIGHT
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 leaf spring front side bushing center D:
Ground clearance of the rear axle shaft center Vehicle height:
Front: A - B Rear: C - D
NOTICE: Before inspecting the wheel alignment, adjust the vehicle height to the specified value.
If the vehicle height is not the specified value, try to adjust it by pushing down on or lifting the body.
2. INSTALL CAMBER-CASTER-KING PIN GAUGE OR POSITION VEHICLE ON WHEEL
ALIGNMENT TESTER
Follow the specific instructions of the equipment manufacturer.
3. INSPECT CAMBER, CASTER AND STEERING AXIS INCLINATION
If the steering axis inclination is not within the specified value, after the camber and caster have
been correctly adjusted, recheck the steering knuckle and front wheel for bearing or looseness.
4. ADJUST CAMBER AND CASTER
Testing and Inspection
Tail Lamp Relay: Testing and Inspection
w/ Daytime running light: INSPECT TAILLIGHT DIMMER RELAY CONTINUITY If continuity is not
as specified, replace the relay.
Page 5136
Page 3469
b. Push the secondary locking device or terminal retainer in to the full lock position.
5. CONNECT CONNECTOR
Disconnection of Male and Female Connectors
Disconnection of Male and Female Connectors
Disconnection Of Male And Female Connectors
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Page 563
CHART 21
Page 3362
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 1984
CHART 12
CHART 13
Page 5378
2. REMOVE AIRBAG SENSOR ASSEMBLY
a. Disconnect the airbag sensor assembly connectors.
NOTE: Disconnect the connectors with the sensor assembly installed.
b. Using a torx wrench, remove the 4 screws.
Torx wrench: T40 (Part No. 09042-00020 or locally manufactured tool)
c. Remove the airbag sensor assembly.
INSTALLATION
NOTE:
- Never use SRS parts from another vehicle. When replacing parts, replace them with new parts.
- Never reuse the airbag sensor assembly involved in a collision when the airbag has deployed.
- Never repair a sensor in order to reuse it.
1. INSTALL AIRBAG SENSOR ASSEMBLY
a. Using a torx wrench, install the airbag sensor assembly with 4 screws.
Torx wrench: T40 (Part No. 09042-00020 or locally manufactured tool) Torque: 20 N.m (205
kgf.cm, 15 ft.lbf)
b. Connect the airbag sensor connectors.
NOTE: Connection of the connector is done after the sensor assembly has been installed.
- Make sure the sensor assembly is installed with the specified torque.
- If the sensor assembly has been dropped, or there are cracks, dents or other defects in the case,
bracket or connector, replace the sensor assembly with a new one.
- When installing the sensor assembly, take care that the SRS wiring does not interfere with other
parts and is not pinched between other parts.
- After installing , shake the sensor assembly to check that there is no looseness.
2. INSTALL LOWER CENTER COVER
Page 913
24. REMOVE TIMING BELT GUIDE 25. REMOVE TIMING BELT COVER SPACER
26. REMOVE TIMING BELT
HINT: If re-using the belt and the installation mark has disappeared from it, place a new installation
mark on the timing belt to the match the dot mark of the crankshaft timing pulley.
27. REMOVE NO.1 IDLER PULLEY AND NO.2 IDLER PULLEY
a. Using a 10 mm hexagon wrench, remove the bolt, No.1 idler pulley and plate washer. b. Remove
the bolt and No.2 idler pulley.
28. REMOVE CRANKSHAFT TIMING PULLEY
Using SST, remove the timing pulley. SST 09950-50012 (09951-05010, 09952-05010,
09953-05010, 09953-05020, 09954-05010)
NOTICE: Do not turn the timing pulley.
INSPECTION
Page 683
Install the No.1 vehicle speed sensor with the bolt.
Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.)
6. CONNECT NO. I VEHICLE SPEED SENSOR CONNECTOR
Vehicle Speed Sensor NO.2
Vehicle speed Sensor NO.2 on-vehicle repair
1. DISCONNECT NO. 2 VEHICLE SPEED SENSOR CONNECTOR
2. REMOVE NO. 2 VEHICLE SPEED SENSOR
a. Remove the bolt and No. 2 vehicle speed sensor. b. Remove the O-ring from the No. 2 vehicle
speed sensor.
3. INSTALL NO. 2 VEHICLE SPEED SENSOR
a. Coat a new O-ring with ATF and install it to the No. 2 vehicle speed sensor. b. Install the No. 2
vehicle speed sensor with the bolt.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
4. CONNECT NO. 2 VEHICLE SPEED SENSOR CONNECTOR
Page 53
Headlamp Relay: Testing and Inspection
POWER SOURCE
HEATER RELAY
1 - 2 : Closed with ignition SW on and heater blower SW on
HEAD RELAY
2 - 1 : Closed with light control SW at HEAD position or dimmer SW at FLASH position Closed with
engine running and parking brake lever released
(w/ daytime running light)
I23 IGNITION SW
2 - 3 : Closed with ignition key at ACC or ON position 2 - 4 : Closed with ignition key at ON or ST
position 7 - 6 : Closed with ignition key at ON or ST position
DIMMER RELAY (w/ DAYTIME RUNNING LIGHT)
4 - 3 : Closed with HEAD relay on and dimmer SW at HIGH or FLASH position
Page 4094
B. Slowly apply the PKB while driving until the brake begins to engage and slow the vehicle. Do not
apply the PKB past this point of initial engagement.
NOTE:
Remember with a foot PKB (on automatic transmission), the pedal must be pressed a second time
to disengage the parking brake.
HINT:
When diagnosing a Tundra with a foot PKB, slowly apply the PKB until the first "click". Then press
the PKB pedal a second time so it will disengage when it is released. At this time the PKB can be
pressed to the desired level for continued diagnosis.
C. Hold the PKB at this point of initial engagement for a few seconds to slowly reduce the vehicle
speed and allow adequate time to monitor the ride condition.
D. Disengage the PKB.
E. If brake vibration is felt during step (C), then it indicates that the rear brake drums are one
source of brake vibration on this vehicle.
Refer to TSB No. BR003-02, "Rear Brake Vibration," for parts and repair information relating to
Tundra rear brake vibration.
F. If no vibration is felt during step (C), then the front brake assemblies are the most likely cause of
brake vibration on this vehicle.
G. Determine if TSB BROO4-02 has already been performed.
Repair Procedure No. 1
1. Remove the front wheel.
2. 2WD:
Using a screwdriver and hammer remove the grease cap.
3. 4WD:
Disconnect drive shaft.
A. Remove the cotter pin and lock cap.
B. While applying the brakes, remove the lock nut.
Page 5155
1. INSTALL NEW BEARING
a. Using Special Service Tool (SST) and a press, install a new bearing to the steering knuckle.
SST 09527-17011, 09950-60020 (09951-00910)
b. Using snap ring pliers, install a new snap ring.
2. INSTALL NEW OIL SEAL (OUTSIDE)
a. Using SST and a plastic hammer, install a new oil seal (outside).
SST 09223-15030, 09527-17011
b. Coat MP grease to the oil seal lip.
3. INSTALL AXLE HUB TO STEERING KNUCKLE
a. Install the dust cover to the steering knuckle with the 4 bolts.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)
b. Using SST and a press, install the axle hub to the steering knuckle.
SST 09649-17010
4. INSTALL ABS SPEED SENSOR ROTOR (w/ ABS)/SPACER (w/o ABS)
NOTICE: Do not scratch the serration of the speed sensor rotor.
5. 2WD: INSTALL NEW LOCK NUT
a. Using SST install and torque a new lock nut to the axle hub.
SST 09318-12010 Torque: 274 Nm (2,800 kgf-cm, 203 ft. lbs.)
b. Using a chisel and hammer, stake the lock nut.
Page 1772
A. The new calibration file should be displayed as the current ECU calibration file.
B. Using a permanent marker or ball point pen, enter the required information on the Authorized
Modifications Label (Figures 21 and 22).
C. Affix this label under the hood in the location determined by the specific vehicle TSB or
Campaign.
NOTE:
Wait 60-90 seconds for ink to set before handling.
Page 3444
Instrument Panel
Ground Location
IE Left Kick Panel
IF Left Kick Panel
IG Instrument Panel Brace RH
IH Right Kick Panel
II Right Kick Panel
Body
Ground Location (Access Cab)
Page 1078
Splice Point
J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel,
and "B" for the Body).
The Location of splice Point I5 is shaded.
K: Indicates a shielded cable.
L: Indicates the pin number of the connector.
The numbering system is different for female and male connectors.
M: Indicates a ground point.
The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for
the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body
and Surrounding area.
How to Read Connector List
HOW TO READ CONNECTOR LIST
A: Indicates connector to be connected to a part. (The numeral indicates the pin No.)
Page 5615
B7 (A), (B) BUCKLE SW LH
(A) 1 - (A) 2, (B) 2 - (B) 1 : Closed with driver's seat belt in use
D16 DOOR COURTESY SW FRONT LH
1 - GROUND : Closed with front LH door open
U1 UNLOCK WARNING SW
1 - 2 : Closed with ignition key in cylinder
C11 (A), C12 (B), C13 (C) COMBINATION METER
(A) 12, (B) 15 - GROUND : Always continuity (B) 10 - GROUND
: Continuity with the front LH door open (Standard cab) : Continuity with the each LH door open
(Access cab)
(C) 1 - GROUND : Continuity with the ignition key in cylinder
(B) 9 - GROUND : Continuity with the driver's seat belt in use
(B) 5 - GROUND : Always approx. 12 volts
(A) 7 - GROUND : Approx. 12 volts with the ignition SW at ON or ST position
Page 2425
CHART 10
Page 4720
B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(Connect the Relay) and SW 2 OFF (or Disconnect SW 2)
D. Disconnect and reconnect the connectors while watching the test light.
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
E. Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION:
a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals
are touched, the IC may be destroyed by
static electricity.)
b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact
with the terminals of leads from the IC, etc. of the replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
Special Tool
1. PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown.
2. DISCONNECT CONNECTOR
3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
a. Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the
secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
A: For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
Locations
Page 3222
Splice Location
B11
Page 1625
Temperature Gauge: Testing and Inspection
INSPECT ENGINE COOLANT TEMPERATURE RECEIVER GAUGE OPERATION
a. Disconnect the connector from the sender gauge. b. Turn the ignition switch ON, check that the
receiver gauge needle indicates COOL.
c. Ground terminal on the wire harness side connector through a 3.4 W test bulb. d. Turn the
ignition switch ON, check that the bulb lights up and the receiver gauge needle moves to the hot
side.
If operation is as specified, replace the sender gauge. Then, recheck the system. If operation is not
as specified, measure the receiver gauge resistance.
INSPECT ENGINE COOLANT TEMPERATURE RECEIVER GAUGE RESISTANCE
Measure the resistance between terminals.
w/ Tachometer
Page 1141
8. REMOVE STEERING KNUCKLE
a. Remove the coffer pin and loosen the nut. b. Using Special Service Tool (SST), disconnect the
steering knuckle.
SST 09950-40011 (09951-04010, 09952-04010, 09553-04020, 09554-04010, 09955-04031,
09958-04011)
c. Remove the nut and steering knuckle.
NOTICE: 4WD: Be careful not to damage the oil seal and drive shaft boot.
HINT: 4WD: When it is difficult to disconnect the drive shaft, tap the tip of the drive shaft with a
plastic hammer.
INSTALLATION
1. INSTALL STEERING KNUCKLE
a. 4WD: Insert the drive shaft into the axle hub and temporarily tighten the nut.
NOTICE: Be careful not to damage the oil seal and drive shaft boot.
b. Connect the steering knuckle to the upper suspension arm. c. Install the nut and a new cotter
pin.
If the holes for the cotter pin are not aligned, tighten the nut further up to 60°. Torque: 105 Nm
(1,100 kgf-cm, 77 ft. lbs.)
2. CONNECT LOWER BALL JOINT
Connect the lower ball joint to the steering knuckle with 4 bolts. Torque: 80 Nm (820 kgf-cm, 59 ft.
lbs.)
3. INSTALL SHOCK ABSORBER 4. INSTALL BRAKE CALIPER
a. Install the disc, brake caliper and 2 bolts.
Torque: 123 Nm (1,250 kgf-cm, 90 ft. lbs.)
b. Install the brake line clamp to the steering knuckle with bolt.
Torque: 28 Nm (285 kgf-cm, 21 ft. lbs.)
5. w/ ABS: CONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP
Connect the ABS speed sensor and wire harness clamp to the steering knuckle with 2 bolts.
Torque: 8.0 Nm (82 kgf-cm, 71 ft. lbs.)
6. 4WD: INSTALL DRIVE SHAFT LOCK NUT
a. While applying the brakes, tighten the nut.
Torque: 235 Nm (2,400 kgf-cm, 173 ft. lbs.)
b. Install the lock cap and a new cotter pin.
If the holes for the cotter pin are not aligned, tighten the nut further up to 60°.
7. INSTALL GREASE CAP 8. INSTALL FRONT WHEEL
Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.)
9. DEPRESS BRAKE PEDAL SEVERAL TIMES
10. CHECK FRONT WHEEL ALIGNMENT 11. CHECK ABS SPEED SENSOR SIGNAL
Disassembly and Reassembly
Page 4962
REASSEMBLY
NOTICE: When using a vise, do not overtighten it.
1. COAT PARTS INDICATED BY ARROWS WITH POWER STEERING FLUID OR
MOLYBDENUM DISULFIDE LITHIUM BASE
GREASE
2. INSTALL OIL SEAL
a. Coat a new oil seal lip with power steering fluid. b. Using Special Service Tool (SST), press in
the oil seal.
SST 09950-60010 (09951-00330, 09951-00490, 09952-06010), 09950-70010 (09951-07360)
NOTICE: ^
Make sure to install the oil seal facing in the correct direction.
^ Take care that the oil seal does not get reversed as you install it.
3. INSTALL STEERING RACK
a. Install SST to the rack.
SST 09631-20051
HINT: If necessary, scrape the burrs off the rack teeth end and burnish.
b. Coat the SST with power steering fluid. c. Install the steering rack into the rack housing.
NOTICE: Be careful not to damage the oil seal lip.
d. Remove the SST
SST 09631-20051
Page 2416
Page 5716
Body
Splice Location (Standard Cab)
B1 Speaker Tweeter Wire LH
B2 Front Door LH Wire
B3 Front Door LH Wire
B4 Roof Wire
B5 Speaker Tweeter Wire RH
B6 B7
Front Door RH Wire
B10 Frame Wire
Seat
Page 962
5. Pinch the fuel return hose.
The pressure in the high pressure line will rise to approx. 392 kPa (4 kgf/sq.cm, 57 psi). In this
state, check to see that there are no leaks from any part of the fuel system.
NOTE: Always pinch the hose. Avoid bending as it may cause the hose to crack.
6. Turn the ignition switch OFF. 7. Disconnect the TOYOTA hand-held tester from the DLC3.
Page 801
Transmission Speed Sensor: Service and Repair
Vehicle Speed Sensor NO.1
1. DISCONNECT NO. 1 VEHICLE SPEED SENSOR CONNECTOR
2. REMOVE NO. 1 VEHICLE SPEED SENSOR
Remove the bolt and No.1 vehicle speed sensor.
3. DISASSEMBLE NO. 1 VEHICLE SPEED SENSOR
a. Remove the O-ring from the speedometer driven gear assembly. b. Remove the clip and
speedometer driven gear from the speedometer driven gear sleeve.
4. ASSEMBLE NO. 1 VEHICLE SPEED SENSOR
a. Install the speedometer driven gear and clip to the speedometer driven gear sleeve. b. Coat a
new O-ring with ATF. c. Install the O-ring to the speedometer driven gear assembly.
5. INSTALL NO. 1 VEHICLE SPEED SENSOR
Page 2683
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
1. DRAIN ENGINE COOLANT
2. REMOVE THROTTLE BODY COVER
3. REMOVE INTAKE AIR CONNECTOR
4. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS
a. Disconnect the accelerator cable from the throttle body. b. Remove the 2 bolts and 2 nuts, and
disconnect the throttle body from the intake manifold. c. Remove the gasket
5. REMOVE ECT SENSOR
a. Disconnect the ECT sensor connector. b. Remove the ECT sensor and gasket.
6. REINSTALL ECT SENSOR
a. Install a new gasket and the ECT sensor.
Torque: 20.4 N.m (208 kgf.cm, 15 ft.lbf)
b. Connect the ECT sensor connector.
7. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS
a. Install a new gasket and the throttle body with the 2 bolts and 2 nuts.
Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)
b. Connect the accelerator cable to the throttle body.
8. REINSTALL INTAKE AIR CONNECTOR
9. REFILL WITH ENGINE COOLANT
10. REINSTALL THROTTLE BODY COVER
Page 4203
11. 4WD: Remove oil seal (inside).
A. Mount the axle hub in a soft jaw vise.
HINT: Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further
(refer to the illustration above).
B. Using a screwdriver, remove the oil seal (inside).
12. 2WD: Remove lock nut and ABS speed sensor rotor (with ABS) or spacer (without ABS). Using
a chisel and hammer, loosen the staked part of the lock nut.
NOTE:
Be careful not to damage the bushing.
A. Using the following SST, remove the lock nut. SST P/N: 00002-00909 (09318-12010)
NOTE:
Do NOT use air wrench.
B. Remove the ABS speed sensor rotor or spacer.
NOTE:
Take care not to scratch the serration of the speed sensor rotor.
13. Remove axle hub from steering knuckle.
A. Remove the 4 bolts and shift the dust cover toward the hub side (outside).
B. Using the following SSTs, remove the axle hub from the steering knuckle.
SST P/N: 09710-28012-01 (09710-07031)
SST P/N: 09950-40011(09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04031,
09957-04010, 09958-04011)
HINT: If necessary, use a press to remove the axle hub from the steering knuckle.
C. Remove the dust cover from the steering knuckle.
D. 4WD: Remove the bearing spacer and ABS speed sensor rotor (with/ABS) or spacer (without
ABS).
NOTE:
Take care not to scratch the serration of the speed sensor rotor.
14. Remove oil seal (outside). Using a screwdriver, remove the oil seal (outside) from the steering
knuckle.
15. Remove bearing from steering knuckle.
Page 917
10. CHECK CRANKSHAFT PULLEY POSITION
Check that the timing mark of the crankshaft pulley is aligned with timing mark "0" of the No.1
timing belt cover.
11. INSTALL RH, LH CAMSHAFT TIMING PULLEYS
a. Align the camshaft knock pin with the knock pin groove of the timing pulley, and slide on the
timing pulley. b. Using SST, install the pulley bolt.
SST 09960-10010 (09962-01000, 09963-01000) Torque: 108 Nm (1,100 kgf-cm, 80 ft. lbs.)
12. CONNECT TIMING BELT TO LH CAMSHAFT TIMING PULLEY
a. Remove any oil or water on the LH camshaft timing pulley, and keep it clean.
NOTICE: Only wipe the pulleys; do not use any cleansing agent.
b. Turn the LH camshaft timing pulley. Align the installation mark on the timing belt with the timing
mark of the camshaft timing pulley, and
hang the timing belt on the LH camshaft timing pulley.
c. Turn the LH camshaft timing pulley counterclockwise until there is tension between the
crankshaft timing pulley and LH camshaft timing
pulley.
Page 61
The ground points circuit diagram shows the connections from all major parts to the respective
ground points. When troubleshooting a faulty ground point, checking the system circuits which use
a common ground may help you identify the problem ground quickly. The relationship between
ground points (EA, IB and IC) can also be checked this way.
How to Read Power Source
HOW TO READ POWER SOURCE
Page 2244
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.
Paint - Iron Rust Contamination Repair
Paint: Technical Service Bulletins Paint - Iron Rust Contamination Repair
PAINT PA005-04 REVISED
November 16, 2004
Title IRON PARTICLE RUST CONTAMINATION REPAIR
Models '94 - Current Toyota & '04 - Current Scion
TSB REVISION NOTICE: ^ December16, 2004: Text has been revised to more accurately describe
cleaner (Auto Magic © Special Cleaner Concentrate is not an oxalic acid solution); Applicable
Vehicles has been defined more clearly. The previous TSB should be discarded.
Introduction The purpose of this bulletin is to provide information regarding the proper procedures
to clean vehicles that may have been subjected to contamination by airborne iron particles such as
rail dust.
Applicable Vehicles ^ 1994 - Current model year Toyota vehicles. ^ 2004 - Current model year
Scion vehicles.
Condition During rail transportation or extended storage near industrial areas vehicles may
occasionally be subjected to contamination by airborne iron particles shed from railroad tracks train
wheels exposure to heavy machinery facilities gnnding welding etc.
Inspection This type of contamination can be identified by the presence of small red or brown
particles on the paint surface. These particles are often difficult to see on dark color paints but can
be easily felt when brushing a hand across horizontal body surfaces such as hood roof or deck lid.
Caution: Because of the abrasiveness of these small iron particles, polishing or buffing procedures
should not be affempted to repair the paint surface of an affected vehicle. This will result in further
paint damage and detract from vehicle appearance.
Repair Washing the affected paint surfaces with Auto Magic © Special Cleaner Concentrate is the
recommended method to dislodge embedded iron particles and remove the surrounding rust
stains. The correct usage of Auto Magic © Special Cleaner Concentrate is described in this bulletin.
Warranty Information
Required Tools & Materials
General Precautions
Ground Locations
Clock: Ground Locations
Engine Compartment
Ground Location
EA Front Left Fender
EB Rear Bank of Right Cylinder
EC Rear Bank of Left Cylinder
Connector Location
EA1 Cowl Wire Harness and Wire Harness (Connector Location)
EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B)
EC1 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC2 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC3 Engine No. 2 Wire and Engine Wire (Near the Starter)
ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission)
Page 3129
Camshaft Position Sensor: Testing and Inspection
ON-VEHICLE INSPECTION
NOTE: "Cold" and "Hot" in these sentences express the temperature of the coils themselves.
"Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F).
INSPECT CAMSHAFT POSITION SENSOR
a. Disconnect the camshaft position sensor connector.
Resistance
b. Using an ohmmeter, measure the resistance between terminals.
If the resistance is not as specified, replace the camshaft position sensor.
c. Reconnect the camshaft position sensor connector.
Page 4078
1. REMOVE FRONT WHEEL
2. 4WD: REMOVE GREASE CAP
Using a screwdriver and hammer remove the grease cap.
3. 4WD: DISCONNECT DRIVE SHAFT
A. Remove the cotter pin and lock cap.
B. While applying the brakes, remove the lock nut.
4. W/ABS DISCONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP FROM
STEERING KNUCKLE
Remove the 2 bolts and disconnect the ABS speed sensor and wire harness clamp from the
steering knuckle.
5. DISCONNECT BRAKE LINE
Using the SST, disconnect the brake line. Use a container to catch the brake fluid.
^ 09023-00100
6. REMOVE BRAKE,CALIPER AND DISC
Page 3450
Transmission Mode Indicator - A/T: Harness Locations
Engine Compartment
Connector Location
EA1 Cowl Wire Harness and Wire Harness (Connector Location)
EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B)
EC1 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC2 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC3 Engine No. 2 Wire and Engine Wire (Near the Starter)
ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission)
Page 2001
CHART 27
Page 1311
Engine Oil Pressure: Testing and Inspection
INSPECTION
1. CHECK ENGINE OIL QUALITY
Check the oil for deterioration, entry of water, discoloring or thinning. If the quality is visibly poor,
replace the oil. Oil grade: Use API SJ, Energy-Conserving or ILSAC multi-grade engine oil. SAE
5W-30 is the best choice for your vehicle, for good fuel economy, and good starting in cold
weather.
2. CHECK ENGINE OIL LEVEL
The oil level should be between the "L" and "F" marks on the dipstick. If low, check for leakage and
add oil up to the "F" mark.
NOTICE: Do not fill with engine oil above the "F" mark.
3. REMOVE ENGINE UNDER COVER
4. REMOVE OIL PRESSURE SWITCH 5. INSTALL OIL PRESSURE GAUGE 6. WARM UP
ENGINE
Allow the engine to warm up to normal operating temperature.
7. CHECK OIL PRESSURE
Oil pressure:
8. REMOVE OIL PRESSURE GAUGE
9. REINSTALL OIL PRESSURE SWITCH
a. Apply adhesive to 2 or 3 threads of the oil pressure switch.
Adhesive: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
b. Reinstall the oil pressure switch.
10. START ENGINE, AND CHECK FOR ENGINE OIL LEAKS
Page 1870
Knock Sensor (Part 2)
Page 419
Key Reminder Switch: Description and Operation
KEY REMINDER AND SEAT BELT WARNING
SYSTEM OUTLINE
Current always flows to TERMINAL (B) 5 of the combination meter through the DOME fuse.
1. SEAT BELT WARNING SYSTEM
When the ignition SW is turned on, current flows from the GAUGE fuse to TERMINAL (A) 7 of the
combination meter. This current activates the combination meter and the current flowing through
the seat belt warning light flows from TERMINAL (A) 12 to GROUND, causing the warning light to
light up. A buckle SW off signal is input to TERMINAL (B) 9 of the combination meter to TERMINAL
(A) 12 to GROUND, causing the warning light to light up. A buckle SW off signal is input to
TERMINAL (B) 9 of the combination meter, the current flowing to TERMINAL (B) 5 of the
combination meter flows from TERMINAL (A) 12 to GROUND and the seat belt warning buzzer
sounds. However, if the seat belt is put on during this period (While the buzzer is sounding), signal
input to TERMINAL (B) 9 of the combination meter stops and the current flow from TERMINAL (B)
5 of the combination meter to TERMINAL (A) 12 to GROUND is cut, causing the buzzer to stop.
2. KEY REMINDER SYSTEM
With the ignition key inserted in the key cylinder (Unlock warning SW on), the ignition SW still off
and driver's door open (Door courtesy SW on), when a signal is input to TERMINAL (B) 10 of the
combination meter, the combination meter operates, current flows from TERMINAL (B) 5 of the
combination meter to TERMINAL (A) 12 to GROUND and key reminder buzzer sounds.
Description and Operation
Brake Switch - TCC: Description and Operation
Stop Light Switch Signal
Engine
This signal is used to detect when the brakes have been applied. The STP signal voltage is the
same as the voltage supplied to the stop lights.
The STP signal is used mainly to control the fuel cut-off engine speed (The fuel cut-off engine
speed is reduced slightly when the vehicle is braking.).
Automatic Transaxle
The purpose of this circuit is to prevent the engine from stalling, while driving in lock-up condition,
when brakes are suddenly applied.
When the brake pedal is operated, this switch sends a signal to ECM. Then the ECM cancels
operation of the lock-up clutch while braking is in progress.
Locations
Engine Room R/B
Page 4116
^ 09023-00100
6. REMOVE BRAKE CALIPER AND DISC
A. Remove the bolt and brake line clamp from the steering knuckle.
B. Remove the 2 bolts, brake caliper and disc.
7. REMOVE SHOCK ABSORBER
A. Disconnect Shock Absorber from lower suspension arm.
B. Remove the shock absorber lower side set nut and washer.
NOTE:
Do not remove the bolt.
C. Wrap the bolt's head with vinyl tape to prevent the drive shaft boot from being damaged.
D. Pry down the lower suspension arm to remove the bolt and disconnect the shock absorber.
E. Remove the 3 nuts and shock absorber with the coil spring.
NOTE:
Do not damage the brake tube.
Page 121
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 2835
CHART 28
Page 6810
Splice Point
J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel,
and "B" for the Body).
The Location of splice Point I5 is shaded.
K: Indicates a shielded cable.
L: Indicates the pin number of the connector.
The numbering system is different for female and male connectors.
M: Indicates a ground point.
The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for
the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body
and Surrounding area.
How to Read Connector List
HOW TO READ CONNECTOR LIST
A: Indicates connector to be connected to a part. (The numeral indicates the pin No.)
Page 3567
B: Junction Connector
Indicates a connector which is connected to a short terminal.
Junction connector in this include a short terminal which is connected to a number of wire
harnesses. Always perform inspection with the short terminal installed. (When installing the wire
harnesses, the harnesses can be connected to any position within the short terminal grouping.
Accordingly, in other vehicles, the same position in the short terminal may be connected to wire
harness from a different part.) Wire harness sharing the same short terminal grouping ha the same
color.
C: Parts Code
The first letter of the code is taken from the first letter of part, and the numbers indicates its order in
parts which start with the same letter.
D: Connector Color
Connectors not indicated are milky white in color.
How to Read Ground Points
HOW TO READ GROUND POINTS
Page 2947
Voltage: 4.2 - 4.8 V
d. Turn the ignition switch OFF. e. Reconnect the vacuum hose to the vapor pressure sensor.
Page 4748
The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit
breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery
power is supplied to each system are explained. Since all System Circuit diagrams start from the
power source, the power source system must be fully understood.
Page 1885
Page 5557
Seat Belt Reminder Buzzer: Splice Locations
Engine Compartment
Splice Location
E1 Engine Room Main Wire
E2 Engine Room Main Wire
E3 Engine Room Main Wire
E4 Engine No. 2 Wire
E5 Engine Wire
E6 Engine Wire
E7 Engine Wire
E8 Engine Wire
Instrument Panel
Specifications
Overdrive Assembly: Specifications
O/D Support x Transmission Case 25 Nm
Page 5902
Page 1157
Wheel Fastener: Service and Repair Rear
REPLACEMENT
1. REMOVE REAR WHEEL 2. REMOVE BRAKE DRUM AND GASKET
3. REMOVE REAR HUB BOLT
Using Special Service Tool (SST) and a brass bar or an equivalent, remove the hub bolt. SST
09650-17011
4. INSTALL HUB BOLT
a. Install a washer and nut to a new hub bolt as shown in the illustration. b. Using a brass bar or an
equivalent to hold, install the hub bolt by torquing the nut. c. Remove the nut and washer.
5. INSTALL NEW GASKET AND BRAKE DRUM 6. INSTALL REAR WHEEL
Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.)
Page 405
Splice Point
J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel,
and "B" for the Body).
The Location of splice Point I5 is shaded.
K: Indicates a shielded cable.
L: Indicates the pin number of the connector.
The numbering system is different for female and male connectors.
M: Indicates a ground point.
The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for
the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body
and Surrounding area.
How to Read Connector List
HOW TO READ CONNECTOR LIST
A: Indicates connector to be connected to a part. (The numeral indicates the pin No.)
Page 5970
Page 615
CHART 5
CHART 6
Component Locations
Ignition Switch And Key Unlock Warning Switch
Page 3239
Non-Waterproof Type Connector
"Case 1" Raise the terminal retainer up to the temporary lock position.
Non-Waterproof Type Connector
"Case 2" Open the secondary locking device.
Page 1312
11. REINSTALL ENGINE UNDER COVER
Page 3404
Clutch: Specifications
Forward Clutch Pack Clearance 0.4 - 0.8 mm
Drum Bushing Inside Diameter 24.08 mm
Sun Gear Input Drum and Direct Clutch Drum Distance 5.3 - 7.3 mm
Flange Thickness No.61 3.0 mm
No.60 3.2 mm
No.45 3.4 mm
No.62 3.6 mm
No.44 3.8 mm
No.42 4.0 mm
No.63 4.2 mm
No.64 4.4 mm
1st & Reverse Brake Piston Return Spring Standard Free Length 12.9 mm mm
Pack Clearance 0.50 - 1.02 mm
Flange Thickness No.50 5.0 mm
No.51 4.8 mm
No.52 4.6 mm
No.53 4.4 mm
No.54 4.2 mm
No.55 4.0 mm
Page 2826
CHART 23
Page 5638
a. Install the retractor of front seat outer belt.
1. Install the retractor of front seat outer belt with the 2 bolts.
Torque: Upper bolt: 8.3 N.m (85 kgf.cm, 74 in.lbf) Lower bolt: 42 N.m (430 kgf.cm, 31 ft.lbf)
2. Connect the pretensioner connector as shown in the illustration.
b. Install the quarter trim.
1. Install the quarter trim. 2. Install the front seat outer belt shoulder anchor with the bolt.
Torque: 42 N.m (430 kgf.cm, 31 ft.lbf)
3. Install the cap. 4. Install the quarter trim belt hole cover.
c. Install the front seat outer belt floor anchor with the bolt.
d. Install the back panel upper garnish.
Page 6408
Key Reminder Switch: Splice Locations
Engine Compartment
Splice Location
E1 Engine Room Main Wire
E2 Engine Room Main Wire
E3 Engine Room Main Wire
E4 Engine No. 2 Wire
E5 Engine Wire
E6 Engine Wire
E7 Engine Wire
E8 Engine Wire
Instrument Panel
Page 1591
5. Before installing the radiator cap tester, use the applicable radiator cap adaptor provided in the
following SST kits in conjunction with the radiator cap tester:
^ SST P/N 09230-00030-01 (09231-10080-01) or 09230-00020-01 (09231-10060-01) or
09230-00050-01 (09231-10110-01
6. When using the radiator cap tester, tilt it more than 30 degrees.
7. Pump the radiator cap tester several times, and check the maximum pressure.
Pumping speed: 1 pump/second
HINT:
Stop pumping when the valve opens and read the gauge. The gauge must be within the standard
values listed below when the pressure valve opens. The cap is considered OK when the pressure
holds steady or falls very slowly, but holds within the standard values listed below for one minute.
Specification:
If the maximum pressure is less than the minimum standard value, replace the radiator cap
sub-assembly.
Type: N-cap, 108 kPa
Page 3951
Transmission Speed Sensor: Description and Operation
Vehicle Speed Sensor NO.1
Vehicle Speed Sensor NO.1 Circuit Description
The vehicle speed sensor outputs a 4-pulse signal for every revolution of the rotor shaft, which is
rotated by the transmission output shaft via the driven gear. After this signal is converted into a
more precise rectangular waveform by the waveform shaping circuit inside the combination meter,
it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency
of these pulse signals.
Vehicle Speed Sensor NO.2
Vehicle Speed Sensor NO.2 Circuit Description
The No.2 vehicle speed sensor detects the rotation speed of the transmission output shaft and
sends signals to the ECM. The ECM determines the vehicle speed based on these signals.
Page 4053
SST P/N: 09527-17011
B. Coat MP grease to the oil seal lip.
18. Install new dust cover and axle hub to steering knuckle.
A. Install the NEW dust cover to the steering knuckle with the 4 bolts.
Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)
B. Using the following SST and a press, install the axle hub to the steering knuckle.
SST P/N: 09649-17010
19. Install ABS speed sensor rotor (with ABS) or spacer (without ABS).
NOTE:
Take care not to scratch the serration of the speed sensor rotor and ensure the speed sensor is
installed completely.
20. 2WD:
Install new lock nut.
A. Using the following SST, install and torque a NEW lock nut to the axle hub.
SST P/N: 00002-00909 (09318-12010)
Torque: 274 N.m (2,800 kgf.cm, 203 ft.lbf)
NOTE:
Do NOT use air wrench.
B. Using a chisel and hammer, stake the lock nut.
Page 698
Mass Air Flow Meter: Service and Repair
MASS AIR FLOW (MAF) METER
1. DISCONNECT MAF METER CONNECTOR
2. REMOVE MAF METER
Remove the 2 screws and MAF meter.
3. REINSTALL MAF METER
Install the MAF meter with the 2 screws.
4. RECONNECT MAF METER CONNECTOR
Page 3568
The ground points circuit diagram shows the connections from all major parts to the respective
ground points. When troubleshooting a faulty ground point, checking the system circuits which use
a common ground may help you identify the problem ground quickly. The relationship between
ground points (EA, IB and IC) can also be checked this way.
How to Read Power Source
HOW TO READ POWER SOURCE
Steering/Suspension - Ball Joint Inspection
Ball Joint: Technical Service Bulletins Steering/Suspension - Ball Joint Inspection
PRODUCT GENERAL INFORMATION PG027-02
December 4, 2002
Title: SUSPENSION BALL JOINT INSPECTION
Models: See Applicable Models
Introduction
This bulletin describes the inspection method and free play specification figures for suspension ball
joints. The on-vehicle inspection methods have been standardized.
Applicable Vehicles
Warranty Information
Page 5750
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 6288
Audible Warning Device Control Module: Harness Locations
Engine Compartment
Connector Location
EA1 Cowl Wire Harness and Wire Harness (Connector Location)
EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B)
EC1 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC2 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC3 Engine No. 2 Wire and Engine Wire (Near the Starter)
ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission)
Page 3020
d. Connect the vacuum hose to intake air resonator. e. Connect the fuel return hose to the pressure
regulator.
2. CHECK FOR FUEL LEAKS
Page 6193
Body
Connector Location (Access Cab)
BA1 Front Door LH Wire and Wire Harness (Connector Location)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel)
BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel)
BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel)
BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Page 3425
Fluid - A/T: Service and Repair
1. Drain transaxle fluid, then install drain plug and new gasket.
2. With engine Off, add fluid through dipstick tube.
Do not overfill.
3. Start engine, then move shift selector through all positions, ensuring smooth operation.
4. Allow to idle, then check at COOL level.
5. Allow to reach normal operating temperature, then recheck.
Page 3459
The ground points circuit diagram shows the connections from all major parts to the respective
ground points. When troubleshooting a faulty ground point, checking the system circuits which use
a common ground may help you identify the problem ground quickly. The relationship between
ground points (EA, IB and IC) can also be checked this way.
How to Read Power Source
HOW TO READ POWER SOURCE
Page 1935
CHART 26
Page 6164
Page 4499
Repair Procedure
1. Disconnect the cable from the negative (-) battery terminal for MORE THAN two (2) seconds.
2. Reconnect the cable to the negative (-) battery terminal.
3. Perform the applicable zero point calibration of the yaw rate sensor and/or the steering angle
sensor.
HINT Refer to the applicable TSB or Repair Manual for the zero point calibration procedure.
4. Re-initialize all applicable systems available on the vehicle (power window sunroof power lift
door etc.).
Instruments - Coolant Temperature Gauge Inaccurate
Temperature Gauge: All Technical Service Bulletins Instruments - Coolant Temperature Gauge
Inaccurate
ELECTRICAL EL009-01
October 12, 2001
Title: TEMPERATURE GAUGE INACCURATE
Models: '00 - '01 Tundra
Introduction Some 2000 - 2001 model year Tundra trucks may experience a condition in which the
engine coolant temperature gauge displays an abnormally high reading during normal engine
operating temperatures. To address this condition, an updated Temperature Gauge has been
made available.
Applicable Vehicles ^
2000 - 2001 model year Tundra trucks, built prior to the VIN shown.
Production Change Information
Parts Information
Repair Procedure
IMPORTANT:
Verify that the engine is operating at a normal temperature with the Scan Tool before replacing the
temperature gauge.
1. Remove the four bolts securing the combination meter assembly.
2. Replace the Temperature Gauge.
3. Reassemble the combination meter.
Warranty Information
Applicable Warranty *:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36
months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Page 3569
The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit
breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery
power is supplied to each system are explained. Since all System Circuit diagrams start from the
power source, the power source system must be fully understood.
Page 6339
Clock: Harness Locations
Engine Compartment
Connector Location
EA1 Cowl Wire Harness and Wire Harness (Connector Location)
EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B)
EC1 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC2 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC3 Engine No. 2 Wire and Engine Wire (Near the Starter)
ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission)
Page 3211
Step 3
Engine Controls - ECU Reprogramming Procedure
Technical Service Bulletin # SS002R-01 Date: 030922
Engine Controls - ECU Reprogramming Procedure
SPECIAL SERVICE TOOLS SS002-01 REVISED
March 9, 2001
Title: ECU FLASH REPROGRAMMING PROCESS
Models: Applicable Models
TSB REVISION NOTICE:
^ September 22, 2003: Models added - 2002 (and later) Solara, 2003 (and later) Corolla and
Matrix, and 2004 models; Operation Procedures updated for CAN Interface Module with the latest
Diagnostic Tester software (v. 10.1a and 10.2a), Calibration Update Wizard (v.6.0), and calibration
files.
^ June 20, 2003: Camry and Tacoma models added; Special Service Tools table updated. The
previous TSB should be discarded.
Introduction
Electronic Control Unit (ECU) is a Toyota term used to describe integrated computerized devices
responsible for managing the operation of a system or sub-system. For the purposes of this
bulletin, the term "ECU" is used as a generic label for the following SAE J1930 standard
references:
^ Powertrain Control Module (PCM)
^ Engine Control Module (ECM)
^ Transmission Control Module (TCM)
^ or any other Toyota specific control unit
Flash reprogramming allows the ECU software to be updated for changes in vehicle calibrations
without removing the ECU from the vehicle. Flash calibration updates for specific vehicle
models/ECUs will be released as field fix procedures described in individual service bulletins. This
bulletin details the ECU flash reprogramming process and the applications within the Technical
Information System (TIS) and the Toyota Diagnostic Tester used for reprogramming.
Flash calibration updates can only be applied to the vehicle/ECU combination for which they are
intended. ECUs have internal security that will not allow them to be programmed with another
ECU's information.
Applicable Vehicles ^
2001 (and later) model year 4Runner, Highlander, Land Cruiser, RAV4, Sequoia and Tundra
vehicles.
^ 2002 (and later) model year Camry, Solara and Tacoma vehicles.
^ 2003 (and later) model year Corolla and Matrix vehicles.
^ All 2004 (and later) model year Toyota vehicles except Celica, MR2 Spyder, Avalon, and Tacoma
(3RZ-FE engine)
Warranty Information
Parts Information
NOTE:
Authorized Modifications Labels may be ordered in packages of 25 from the Materials Distribution
Center (MDC) through the TDN Dealer Support
Page 696
Mass Air Flow Meter: Testing and Inspection
MASS AIR FLOW (MAF) METER
INSPECTION
1. DISCONNECT MAF METER CONNECTOR
2. REMOVE MAF METER
Remove the 2 screws and MAF meter.
3. INSPECT MAF METER
a. Using an ohmmeter, measure the resistance between terminals THA and E2.
If the resistance is not as specified, replace the MAF meter.
b. Inspect for operation.
1. Connect the MAF meter connector. 2. Connect the negative (-) terminal cable to the battery. 3.
Turn the ignition switch ON. 4. Using a voltmeter, connect the positive (+) tester probe to terminal
VG, and negative (-) tester probe to terminal E2G. 5. Blow air into the MAF meter, and check that
the voltage fluctuates.
Page 1982
CHART 10
Page 1011
Fluid - Differential: Service and Repair Rear
FILL DIFFERENTIAL WITH HYPOID GEAR OIL
Page 5050
Page 5783
Trailer Connector: Testing and Inspection
TRAILER TOWING
T6 TRAILER SOCKET
2 - GROUND : Approx. 12 volts with light control SW at TAIL or HEAD position 1 - GROUND :
Approx. 12 volts with ignition SW at ON position and shift level in R position 4 - GROUND : Always
continuity
Page 4376
Required Tools & Material
NOTE:
Additional Diagnostic Tester Kits, Program Cards or SSTs may be ordered by calling SPX-OTC at
1-800-933-8335.
Page 1608
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
1. DRAIN ENGINE COOLANT
2. REMOVE THROTTLE BODY COVER
3. REMOVE INTAKE AIR CONNECTOR
4. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS
a. Disconnect the accelerator cable from the throttle body. b. Remove the 2 bolts and 2 nuts, and
disconnect the throttle body from the intake manifold. c. Remove the gasket
5. REMOVE ECT SENSOR
a. Disconnect the ECT sensor connector. b. Remove the ECT sensor and gasket.
6. REINSTALL ECT SENSOR
a. Install a new gasket and the ECT sensor.
Torque: 20.4 N.m (208 kgf.cm, 15 ft.lbf)
b. Connect the ECT sensor connector.
7. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS
a. Install a new gasket and the throttle body with the 2 bolts and 2 nuts.
Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)
b. Connect the accelerator cable to the throttle body.
8. REINSTALL INTAKE AIR CONNECTOR
9. REFILL WITH ENGINE COOLANT
10. REINSTALL THROTTLE BODY COVER
Page 6264
Glossary Of Terms And Symbols (Part 1)
Page 4001
DISASSEMBLY
1. DISCONNECT CONNECTOR
(a) Remove the screw and clamp from the ABS actuator.
Torque: 2.9 Nm (30 kgf-cm, 26 inch lbs.)
(b) Disconnect the connector.
2. REMOVE ABS ECU
Using a hexagon wrench (4 mm), remove the 4 bolts and ABS ECU. Torque: 4.4 Nm (45 kgf-cm,
39 inch lbs.)
NOTICE: Protect the actuator in order to prevent sealing surface from getting dirty and causing
damage on the valve body. If the dirt and the like is stuck to the sealing surface, use plastic tools or
soft objects to remove the dirt. Do not use chemical solvents.
REASSEMBLY
Reassembly is in the reverse order of disassembly.
Page 4246
Required SSTs
Repair Procedure
1. Confirm the customer complaint.
2. Determine if vibration is from front or rear (while brakes are still warm from confirmation driving).
The following procedure will isolate the drum brakes from the rest of the hydraulic system by using
the parking brake (PKB).
NOTE:
Remember with a foot PKB (on an automatic transmission), the pedal must be pressed a second
time to disengage the parking brake.
HINT:
When diagnosing a Tundra with a foot PKB, slowly apply the PKB until the first "click" and then
press the PKB pedal a second time so it will disengage when it is released. At this time, the PKB
can be pressed to the desired level for continued diagnosis.
A. Drive the Tundra along a smooth, level section of road at approximately 40 - 50 mph.
B. Slowly apply the PKB while driving until the brake begins to engage and slow the vehicle. Do not
apply the PKB past this point of initial engagement.
C. Hold the PKB at this point of initial engagement for a few seconds to slowly reduce the vehicle
speed and allow adequate time to monitor the ride condition.
D. Disengage the PKB.
E. If brake vibration is felt during step C, then it indicates that the rear brake drums are one source
of brake vibration on this vehicle.
Proceed to the Repair Procedures that follow.
F. If no vibration is felt during step C, then the front brake assemblies are the cause of brake
vibration on this vehicle.
Refer to TSB No. BR004-02, "Front Brake Vibration," for parts and repair information relating to
Tundra front brake vibration.
3. Measure the rear axle shaft centering area diameter. If the measured value deviates from the
standard (105.946 - 106 mm [4.171 - 4.173 in.]), replace the rear axle shaft (Standard: Refer to
Figure 1).
Page 4196
Warranty Information
Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This
warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's
in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Page 1869
Knock Sensor: Locations
Knock Sensor (Part 1)
Service and Repair
Sun Gear: Service and Repair
For further information regarding this component and the system that it is a part of, please refer to
Automatic Transmission/Transaxle; Service and Repair.
Specifications
Page 2543
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 5613
b. Push the secondary locking device or terminal retainer in to the full lock position.
5. CONNECT CONNECTOR
Disconnection of Male and Female Connectors
Disconnection of Male and Female Connectors
Disconnection Of Male And Female Connectors
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Page 6497
Instrument Panel
Connector Location
IA1 Engine Room Main and Cowl Wire (Left Kick Panel)
IA2 Engine Room Main and Cowl Wire (Left Kick Panel)
IA3 Engine Room Main and Cowl Wire (Left Kick Panel)
IA4 Engine Room Main and Cowl Wire (Left Kick Panel)
IB1 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IB2 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IB3 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IC1 Cowl Wire and Roof Wire (Left Side of Instrument Panel)
Instrument Panel
Connector Location
ID1 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH)
ID2 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH)
IE1 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IE2 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IE3 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IF1 Front Door RH Wire and Cowl Wire (Right Kick Panel)
IF2 Front Door RH Wire and Cowl Wire (Right Kick Panel)
IF3 Front Door RH Wire and Cowl Wire (Right Kick Panel)
Page 154
memory, the CUW will ask you to select the calibration file(s) to delete from the Diagnostic Tester
Program Card to make room for the new calibration file.
If necessary, check the calibration file(s) to delete, as shown in Figure 11. Click DELETE.
NOTE:
If there is adequate memory to store the calibration file, skip to Step J.
I. The CUW will now delete the calibration file(s) selected (see Figure 12).
Page 554
CHART 10
Page 1691
^ 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 4616
Engine Room R/B Fuse Applications (Part 2)
Engine Room Fuse Details
Page 119
^ 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 1189
Connecting Rod Bearing: Service and Repair
For further information regarding this component and the system that it is a part of, please refer to
Cylinder Block Assembly; Service and Repair.
Page 3685
3. 4WD: DISCONNECT DRIVE SHAFT
a. Remove the cotter pin and lock cap. b. While applying the brakes, remove the lock nut.
4. w/ABS: DISCONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP FROM
STEERING KNUCKLE
Remove the 2 bolts and disconnect the ABS speed sensor and wire harness clamp from the
steering knuckle.
5. REMOVE BRAKE CALIPER AND DISC
a. Remove the bolt and brake line clamp from the steering knuckle. b. Remove the 2 bolts, brake
caliper and disc.
NOTICE: Do not damage the brake tube.
c. Support the brake caliper securely.
6. REMOVE SHOCK ABSORBER
7. DISCONNECT LOWER BALL JOINT
Remove the 4 bolts and disconnect the lower ball joint.
Page 4829
Replacement Requirements
Airbag Sensor Assembly: Service and Repair Replacement Requirements
REPLACEMENT REQUIREMENTS
In the following cases, replace the airbag sensor assembly.
- If the SRS has been deployed in a collision.
- If the airbag sensor assembly has been found to be faulty in troubleshooting.
- If the airbag sensor assembly has been dropped.
CAUTION: For removal and installation of the airbag sensor assembly. Be sure to follow the correct
procedure.
Diagram Information and Instructions
Lamp Control Module: Diagram Information and Instructions
Key to Diagrams
A: System Title
B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to
distinguish it from the J/B
Example: 1 Indicates Relay Block No.1
C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type,
or specification is different.
D: Indicates related system.
Page 6190
Splice Location
B11
Page 3557
Body
Splice Location (Standard Cab)
B1 Speaker Tweeter Wire LH
B2 Front Door LH Wire
B3 Front Door LH Wire
B4 Roof Wire
B5 Speaker Tweeter Wire RH
B6 B7
Front Door RH Wire
B10 Frame Wire
Seat
Page 3242
b. Push the secondary locking device or terminal retainer in to the full lock position.
5. CONNECT CONNECTOR
Disconnection of Male and Female Connectors
Disconnection of Male and Female Connectors
Disconnection Of Male And Female Connectors
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Page 1225
Valve Clearance: Testing and Inspection
INSPECTION
HINT: Inspect and adjust the valve clearance when the engine is cold.
1. REMOVE BATTERY CLAMP COVER 2. REMOVE THROTTLE BODY COVER 3. REMOVE AIR
CLEANER AND INTAKE AIR CONNECTOR ASSEMBLY 4. REMOVE NO.3 TIMING BELT
COVERS 5. REMOVE IGNITION COILS 6. REMOVE RH CYLINDER HEAD COVER
Remove the 9 bolts, seal washers and cylinder head cover.
7. REMOVE LH CYLINDER HEAD COVER
a. Remove the oil dipstick for the transmission. b. Disconnect the PCV hose. c. Disconnect the
engine wire clamp from the wire bracket on the cylinder head cover. d. Remove the 9 bolts, 9 seal
washers and cylinder head cover.
8. SET NO.1 CYLINDER TO TDC/COMPRESSION
a. Turn the crankshaft pulley, and align its groove with timing mark "0" of the No.1 timing belt cover.
b. Check that the timing marks of the camshaft timing pulleys and timing belt rear plates are
aligned.
If not, turn the crankshaft 1 revolution (360°) and align the mark.
9. INSPECT VALVE CLEARANCE
Page 4932
b. Push the secondary locking device or terminal retainer in to the full lock position.
5. CONNECT CONNECTOR
Disconnection of Male and Female Connectors
Disconnection of Male and Female Connectors
Disconnection Of Male And Female Connectors
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Testing and Inspection
Igniter: Testing and Inspection
ON-VEHICLE INSPECTION
NOTE: "Cold" and "Hot" in these sentences express the temperature of the coils themselves.
"Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F).
INSPECT IGNITION COIL (WITH IGNITER) AND SPARK TEST
Check that the spark occurs.
1. Remove the ignition coils (with igniter). 2. Remove the spark plugs. 3. Install the spark plugs to
each ignition coil (with igniter), and connect the ignition coil (with igniter) connector. 4. Disconnect
the 8 injector connectors. 5. Ground the spark plug. 6. Check that spark occurs while engine is
being cranked.
NOTE: To prevent gasoline from being injected out of injectors during this test, crank the engine for
no more than 5 - 10 seconds at a time.
If the spark does not occur, do the test as per the given flow chart.
7. Using a 16 mm plug wrench, install the spark plugs.
Torque: 17.5 N.m (180 kgf.cm, 13 ft.lbf)
8. Reinstall the ignition coils (with igniter).
Page 1467
Idle Speed: Testing and Inspection
INSPECTION
1. INITIAL CONDITIONS
a. Engine at normal operating temperature b. Air cleaner installed c. All pipes and hoses of air
induction system connected d. All accessories switched OFF e. All vacuum lines properly
connected f.
SFI system wiring connectors fully plugged
g. Ignition timing checked correctly h. Transmission in neutral position i.
Air conditioning switched OFF
2. CONNECT TOYOTA HAND-HELD TESTER OR OBD II SCAN TOOL 3. INSPECT IDLE SPEED
a. Race the engine speed at 2,500 rpm for approximately 90 seconds. b. Check the idle speed.
Idle speed: 700 ± 50 rpm If the idle speed is not as specified, check the air intake system.
4. DISCONNECT TOYOTA HAND-HELD TESTER OR OBD II SCAN TOOL
Page 5450
SRS Warning Light: Component Tests and General Diagnostics
SRS WARNING LIGHT CHECK
a. Turn the ignition switch to the ACC or ON position and check that the SRS warning light lights
up. b. Check that the SRS warning light goes out after approx. 6 seconds.
HINT: When the ignition switch is at ACC or ON and the SRS warning light remains on or flashes, the
airbag sensor assembly has detected a malfunction code.
- If, after approx. 6 seconds have elapsed, the SRS warning light sometimes lights up or the SRS
warning light lights up even when the ignition switch is OFF, a short in the SRS warning light circuit
can be considered likely. Proceed to "SRS warning light circuit malfunction".
Page 1077
Wiring Harness Connector
E: Indicates the wiring harness and wiring harness connector. The wiring harness with male
terminal is shown with arrows.
Outside numerals are pin numbers.
The first letter of the code for each wiring harness and wiring harness connector(s) indicates the
component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and
Surrounding area, and "B" for the Body and Surrounding area.
When more than one code has the first and second letters in common, followed by numbers (e.g,
IH1, IH2), this indicates the same type of wiring harness and wiring harness connector.
F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in
parts position.
G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside
it). Junction Blocks are shaded to clearly separate
them from other parts.
H: When 2 parts both use one connector in common, the parts connector name used in wire
routing is shown in square brackets [ ].
Wiring Color
I: Indicates the wiring color.
Wire colors are indicated by an alphabetical code.
B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR =
Brown SB = Sky Blue LG = Light Green GR = Gray
The first letter indicates the basic wire color and the second letter indicates the color of the stripe.
Page 5394
- There should be no interference between the steering wheel pad and steering wheel, and the
clearance should be uniform all the way around when the new steering wheel pad is installed on
the steering wheel.
CAUTION: Be sure to follow the correct procedure, for removal and installation of the steering
wheel pad.
VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED
a. Do a diagnostic system check. b. Do a visual check which includes the following items with the
steering wheel pad (with airbag) removed from the vehicle.
- Check the deformation on the horn button contact plate of the steering wheel.
- Check the damage on the spiral cable connector and wire harness.
HINT: If the horn button contact plate of the steering wheel is deformed, never repair it. Always replace
the steering wheel assembly with a new one.
- There should be no interference between the steering wheel pad and steering wheel, and the
clearance should be uniform all the way around when the new steering wheel pad is installed on
the steering wheel.
Page 6420
B: Junction Connector
Indicates a connector which is connected to a short terminal.
Junction connector in this include a short terminal which is connected to a number of wire
harnesses. Always perform inspection with the short terminal installed. (When installing the wire
harnesses, the harnesses can be connected to any position within the short terminal grouping.
Accordingly, in other vehicles, the same position in the short terminal may be connected to wire
harness from a different part.) Wire harness sharing the same short terminal grouping ha the same
color.
C: Parts Code
The first letter of the code is taken from the first letter of part, and the numbers indicates its order in
parts which start with the same letter.
D: Connector Color
Connectors not indicated are milky white in color.
How to Read Ground Points
HOW TO READ GROUND POINTS
Page 723
Crankshaft Position Sensor: Description and Operation
Crankshaft Position Sensor
Crankshaft position sensor (NE signal) consists of a signal plate and pick up coil.
The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor
generates 34 signals of every engine revolution.
The ECM detects the standard crankshaft angle based on the G signals, and the actual crankshaft
angle the engine speed by the NE signals.
Page 6493
Splice Location
I1 Cowl Wire
I2 Cowl Wire
I3 Cowl Wire
I4 Cowl Wire
I5 Cowl Wire
I6 Cowl Wire
I7 Engine Wire
I8 Engine Wire
I9 Engine Wire
I10 Engine Wire
I11 Engine Wire
I12 Engine Wire
I13 Engine Wire
I14 Engine Wire
I15 Engine Wire
I16 Cowl Wire
Body
Splice Location (Access Cab)
B1 Speaker Tweeter Wire LH
B2 Front Door LH Wire
B3 Front Door LH Wire
B4 Roof Wire
B5 Speaker Tweeter Wire RH
B6 B7
Front Door RH Wire
B8 Front Door RH Wire
B9 Rear Door No. 1 Wire RH
B10 Frame Wire
Page 3473
Transmission Mode Indicator - A/T: Description and Operation
ELECTRONICALLY CONTROLLED TRANSMISSION AND A/T INDICATOR
SYSTEM OUTLINE
The electronically controlled transmission electrically controls the, throttle pressure, lock-up
pressure, and accumulator pressure etc. through the solenoid valve.
The electronically controlled transmission is a system which precisely controls the gear shift timing
and lock-up timing in response to the vehicle's driving conditions and the engine condition detected
by various sensors. It makes smooth driving possible by shift selection of the gear which is the
most appropriate to the driving conditions at that time, and by preventing downing, squat and gear
shift shock when starting off.
1. GEAR SHIFT OPERATION
When driving, the engine warm up condition is input as a control signal from the engine coolant
temperature sensor to TERMINAL THW of the engine control module, and the vehicle speed is
input to TERMINAL SP2+ of the engine control module from the vehicle speed sensor. At the same
time, the throttle valve opening signal from the throttle position sensor is input to TERMINALS VTA,
VTA2 of the engine control module as a throttle angle signal. Based on these signals, the engine
control module selects the best shift position for the driving conditions and sends current to the
electronically controlled transmission solenoid.
2. LOCK-UP OPERATION
When the engine control module decides based on each signal that the lock-up condition has been
met, the current flows from the engine control module TERMINAL SL to TERMINAL 7 of the
electronically controlled transmission solenoid to GROUND.
3. STOP LIGHT SW CIRCUIT
If the brake pedal is depressed (Stop light SW on) when driving in lock-up position, a signal is input
to TERMINAL STP of the engine control module. As a result, the engine control module cuts the
current to the solenoid to release the lock-up.
4. OVERDRIVE CIRCUIT
- O/D main SW on When the O/D main SW is switched to ON position, a signal is input to
TERMINAL ODMS of the engine control module, and enables shift change to the overdrive range,
through the control of the engine control module.
- O/D main SW off When the O/D main SW is switched to OFF position, a signal is input to
TERMINAL ODMS of the engine control module, and prohibits shift change to the overdrive range
through the control of the engine control module. When in the overdrive range already, shift down
is made.
Page 5790
Trailer Connector: Splice Locations
Engine Compartment
Splice Location
E1 Engine Room Main Wire
E2 Engine Room Main Wire
E3 Engine Room Main Wire
E4 Engine No. 2 Wire
E5 Engine Wire
E6 Engine Wire
E7 Engine Wire
E8 Engine Wire
Instrument Panel
Page 2615
memory, the CUW will ask you to select the calibration file(s) to delete from the Diagnostic Tester
Program Card to make room for the new calibration file.
If necessary, check the calibration file(s) to delete, as shown in Figure 11. Click DELETE.
NOTE:
If there is adequate memory to store the calibration file, skip to Step J.
I. The CUW will now delete the calibration file(s) selected (see Figure 12).
Page 721
Crankshaft Position Sensor: Mechanical Specifications
Torque: ................................................................................................................................................
.................................. 6.5 N.m (65 kgf.cm, 58 in.lbf)
Symptom Related Diagnostic Procedures
Clock: Symptom Related Diagnostic Procedures
Problem Symptoms Table
CLOCK TROUBLESHOOTING
HINT: Troubleshoot the clock according to the table.
Troubleshooting No. 1
Step 1
Page 2470
2. Start the engine.
3. Perform the drive pattern to run and complete the Oxygen Sensor (O2S) Monitor.
HINT:
The 02S Monitor is completed when the following conditions are met:
^ Two (2) minutes or more passed after the engine start.
^ The Engine Coolant Temperature (ECT) is 167°F (75°C) or more.
^ Cumulative running time at 30 mph (48 km/h) or more exceeds 6 minutes.
^ Vehicle is in closed loop.
^ The fuel-cut is operated for 8 seconds or more (for Rear O2S Monitor).
A. Allow the engine to idle for two minutes.
B. Warm up the engine until the Engine Coolant Temperature (ECT) reaches 167°F (75°C).
C. Drive the vehicle over 30 mph (48 km/h) for more than 40 seconds.
D. Stop the vehicle and allow the engine to idle for more than 20 seconds.
E. Repeat steps C and D at least 8 times in one driving cycle. (Do not cycle the ignition key.)
In addition, perform the following steps for the Rear O2S Readiness Monitor:
A. Select second gear.
B. Allow the vehicle to run at 30 mph (48 km/h) or more.
C. Keep the accelerator pedal "off-idle" for more than 10 seconds.
D. Immediately after step C, release the accelerator pedal for at least 10 seconds without
depressing the brake pedal (to execute the fuel-cut).
E. Decelerate the vehicle until the vehicle speed reaches less than 6mph (10km/h).
F. Repeat steps B - E at least twice in one driving cycle.
Accessing O2S Test Results
1. On the Diagnostic Tester* screen, select the following menus:
^ DIAGNOSTICS
^ CARB OBD II
Page 5930
Page 2836
CHART 29
Page 216
Engine Control Module: Locations
Instrument Panel
Page 1325
3. REMOVE OIL COOLER
a. Disconnect the 2 oil cooler hoses from the oil cooler. b. Remove the union bolt, plate washer and
oil cooler. c. Remove the O-ring from the oil cooler.
INSPECTION
INSPECT OIL COOLER
Check the oil cooler for damage or clogging. If necessary, replace the oil cooler.
INSTALLATION
1. INSTALL OIL COOLER
a. Clean the oil cooler contact surface on the cooler mounting.
b. Place a new O-ring to the oil cooler. c. Apply a light coat of engine oil on the threads and under
the head of the union bolt.
d. Install the oil cooler and plate washer with the union bolt.
Torque: 68.6 Nm (700 kgf-cm, 51 ft. lbs.)
e. Connect the 2 oil cooler hoses to the oil cooler.
2. INSTALL OIL FILTER 3. FILL WITH ENGINE COOLANT 4. START ENGINE AND CHECK FOR
ENGINE OIL LEAKS 5. CHECK ENGINE OIL LEVEL
Page 6290
Body
Connector Location (Access Cab)
BA1 Front Door LH Wire and Wire Harness (Connector Location)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel)
BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel)
BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel)
BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Page 120
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 4901
- Do not release the airbag activation prevention mechanism unless specifically directed by the
troubleshooting procedure.
- If the inserted paper is too thick the terminal and short spring may be damaged, so always use
paper with the same thickness as the male terminal.
Page 2688
Crankshaft Position Sensor: Mechanical Specifications
Torque: ................................................................................................................................................
.................................. 6.5 N.m (65 kgf.cm, 58 in.lbf)
Page 3405
Clutch: Specifications
O/D Brake Piston Return Spring Standard Free Length 17.82 mm
Piston Stroke 1.32 - 1.62 mm
Flange Thickness No.77 3.3 mm
No.78 3.5 mm
No.79 3.6 mm
No.80 3.7 mm
No.81 3.8 mm
No.82 3.9 mm
None 4.0 mm
Page 1961
Applicable Vehicles
Page 5616
Seat Belt Reminder Lamp: Description and Operation
KEY REMINDER AND SEAT BELT WARNING
SYSTEM OUTLINE
Current always flows to TERMINAL (B) 5 of the combination meter through the DOME fuse.
1. SEAT BELT WARNING SYSTEM
When the ignition SW is turned on, current flows from the GAUGE fuse to TERMINAL (A) 7 of the
combination meter. This current activates the combination meter and the current flowing through
the seat belt warning light flows from TERMINAL (A) 12 to GROUND, causing the warning light to
light up. A buckle SW off signal is input to TERMINAL (B) 9 of the combination meter to TERMINAL
(A) 12 to GROUND, causing the warning light to light up. A buckle SW off signal is input to
TERMINAL (B) 9 of the combination meter, the current flowing to TERMINAL (B) 5 of the
combination meter flows from TERMINAL (A) 12 to GROUND and the seat belt warning buzzer
sounds. However, if the seat belt is put on during this period (While the buzzer is sounding), signal
input to TERMINAL (B) 9 of the combination meter stops and the current flow from TERMINAL (B)
5 of the combination meter to TERMINAL (A) 12 to GROUND is cut, causing the buzzer to stop.
2. KEY REMINDER SYSTEM
With the ignition key inserted in the key cylinder (Unlock warning SW on), the ignition SW still off
and driver's door open (Door courtesy SW on), when a signal is input to TERMINAL (B) 10 of the
combination meter, the combination meter operates, current flows from TERMINAL (B) 5 of the
combination meter to TERMINAL (A) 12 to GROUND and key reminder buzzer sounds.
Page 3061
EFI Main Relay: Testing and Inspection
EFI MAIN RELAY
INSPECTION
1. REMOVE RELAY BOX COVER
2. REMOVE EFI MAIN RELAY (Marking: EFI)
3. INSPECT EFI MAIN RELAY CONTINUITY
a. Using an ohmmeter, check that there is continuity between terminals 1 and 2.
If there is no continuity, replace the relay.
b. Check that there is no continuity between terminals 3 and 5.
If there is continuity, replace the relay.
4. INSPECT EFI MAIN RELAY OPERATION
a. Apply battery voltage across terminals 1 and 2. b. Using an ohmmeter, check that there is
continuity between terminals 3 and 5.
If there is no continuity, replace the relay.
5. REINSTALL EFI MAIN RELAY
6. REINSTALL RELAY BOX COVER
Page 1651
Catalytic Converter: Testing and Inspection
THREE-WAY CATALYTIC CONVERTER (TWC) SYSTEM
ON-VEHICLE INSPECTION
1. CHECK EXHAUST PIPE ASSEMBLY
a. Check the connections for looseness or damage. b. Check the clamps for weakness, cracks or
damage.
2. INSPECT TWC
Check for dents or damage. If any part of protector is damaged or dented to the extent that it
contacts the TWC, repair or replace it.
3. INSPECT HEAT INSULATOR
a. Check the heat insulator for damage. b. Check for adequate clearance between the TWC and
heat insulator.
Page 6719
Splice Point
J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel,
and "B" for the Body).
The Location of splice Point I5 is shaded.
K: Indicates a shielded cable.
L: Indicates the pin number of the connector.
The numbering system is different for female and male connectors.
M: Indicates a ground point.
The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for
the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body
and Surrounding area.
How to Read Connector List
HOW TO READ CONNECTOR LIST
A: Indicates connector to be connected to a part. (The numeral indicates the pin No.)
Page 646
Oxygen Sensor: Description and Operation
Heated Oxygen Sensor
The ECM observes the waveform of the heated oxygen sensor located behind the catalyst to
determine whether the catalyst performance has deteriorated.
If the catalyst is functioning normally, the waveform of the heated oxygen sensor located behind
the catalyst switches back and forth between rich and lean much more slowly.
When the waveform of the heated oxygen sensor located behind the catalyst alternates flutteringly
between rich and lean, it indicates that catalyst performance has deteriorated.
Page 4734
Driver Side J/B And Integration Relay Fuse Applications (Part 1)
Page 556
CHART 12
CHART 13
Page 3096
If you have no TOYOTA hand-held tester, measure voltage between terminals VPA and E2 of the
ECM connector.
d. Inspect the air assist system.
1. Start the engine and check that the MIL does not light up. 2. Allow the engine to warm up to
normal operating temperature. 3. Turn the A/C compressor ON to OFF, and check the idle speed.
Idle speed (Transmission in neutral): 700 ± 50 rpm
NOTE: Perform inspection under condition without electrical load.
e. After checking the above (b) to (d), perform the driving test and check that there is no sense of
incongruity.
3. INSPECT THROTTLE CONTROL MOTOR
a. Disconnect the throttle control motor connector. b. Using an ohmmeter, measure the motor
resistance between terminal 1 (M+) and 2 (M-).
Motor resistance: 0.3 - 100 ohms at 20 °C (68 °F)
If the resistance is not as specified, replace the throttle control motor.
c. Using an ohmmeter, measure the clutch resistance between terminal 3 (CL-) and 4 (CL+).
Clutch resistance: 4.2 - 5.2 ohms at 20 °C (68 °F)
If the resistance is not as specified, replace the throttle control motor.
d. Reconnect the throttle control motor connector.
Page 1092
Driver Side J/B And Integration Relay
Page 6191
Cruise Control: Harness Locations
Engine Compartment
Connector Location
EA1 Cowl Wire Harness and Wire Harness (Connector Location)
EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B)
EC1 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC2 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC3 Engine No. 2 Wire and Engine Wire (Near the Starter)
ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission)
Page 1278
1. Remove the engine under cover.
2. Drain the engine coolant.
3. Remove the intake air connector assembly.
4. Remove the radiator fan shroud.
5. Remove the drive belt, fan, fluid coupling, and fan pulley.
6. Without disconnecting the power steering fluid lines, remove the power steering pump.
HINT: Suspend the power steering pump securely.
7. Remove the drive belt idler pulley.
8. Remove the right hand (RH) No. 3 timing belt cover.
9. Remove the No.2 timing belt cover.
10. Without disconnecting the A/C refrigerant lines, remove the A/C compressor from the mounting
bracket.
HINT: Suspend the A/C compressor securely.
11. Disconnect the A/C compressor mounting bracket.
Testing and Inspection
Tail Lamp Relay: Testing and Inspection
w/ Daytime running light: INSPECT TAILLIGHT DIMMER RELAY CONTINUITY If continuity is not
as specified, replace the relay.
Engine Controls - ECU Reprogramming Procedure
Technical Service Bulletin # SS002R-01 Date: 030922
Engine Controls - ECU Reprogramming Procedure
SPECIAL SERVICE TOOLS SS002-01 REVISED
March 9, 2001
Title: ECU FLASH REPROGRAMMING PROCESS
Models: Applicable Models
TSB REVISION NOTICE:
^ September 22, 2003: Models added - 2002 (and later) Solara, 2003 (and later) Corolla and
Matrix, and 2004 models; Operation Procedures updated for CAN Interface Module with the latest
Diagnostic Tester software (v. 10.1a and 10.2a), Calibration Update Wizard (v.6.0), and calibration
files.
^ June 20, 2003: Camry and Tacoma models added; Special Service Tools table updated. The
previous TSB should be discarded.
Introduction
Electronic Control Unit (ECU) is a Toyota term used to describe integrated computerized devices
responsible for managing the operation of a system or sub-system. For the purposes of this
bulletin, the term "ECU" is used as a generic label for the following SAE J1930 standard
references:
^ Powertrain Control Module (PCM)
^ Engine Control Module (ECM)
^ Transmission Control Module (TCM)
^ or any other Toyota specific control unit
Flash reprogramming allows the ECU software to be updated for changes in vehicle calibrations
without removing the ECU from the vehicle. Flash calibration updates for specific vehicle
models/ECUs will be released as field fix procedures described in individual service bulletins. This
bulletin details the ECU flash reprogramming process and the applications within the Technical
Information System (TIS) and the Toyota Diagnostic Tester used for reprogramming.
Flash calibration updates can only be applied to the vehicle/ECU combination for which they are
intended. ECUs have internal security that will not allow them to be programmed with another
ECU's information.
Applicable Vehicles ^
2001 (and later) model year 4Runner, Highlander, Land Cruiser, RAV4, Sequoia and Tundra
vehicles.
^ 2002 (and later) model year Camry, Solara and Tacoma vehicles.
^ 2003 (and later) model year Corolla and Matrix vehicles.
^ All 2004 (and later) model year Toyota vehicles except Celica, MR2 Spyder, Avalon, and Tacoma
(3RZ-FE engine)
Warranty Information
Parts Information
NOTE:
Authorized Modifications Labels may be ordered in packages of 25 from the Materials Distribution
Center (MDC) through the TDN Dealer Support
Page 948
A. Using a breaker bar or ratchet with a 14 mm socket, apply counterclockwise force on the
accessory drive belt tensioner to release tension and remove the accessory drive belt.
HINT:
The pulley bolt for the belt tensioner has a left hand thread.
B. Using the accessory drive belt routing label located on the passenger side of the radiator core
support as a guide, install the new accessory drive belt.
2. Check belt tensioner operation.
A. Check that the belt tensioner moves downward when the drive belt is pressed down at the points
indicated in the illustration with approximately 98 N (10 kgf, 22.0 lbf) of force.
B. Ensure proper alignment of the belt with the ribbed grooves of each pulley.
C. Check by hand to ensure that the belt has not slipped out of the groove on the bottom of each
pulley.
D. Check that the arrow mark on the belt tensioner falls within area "A" of the scale (see
illustration).
E. If the arrow mark falls outside area "A," the drive belt is incorrect.
HINT:
When a new belt is installed, it should lie within area "B." If not, the drive belt is incorrect.
Page 6406
Instrument Panel
Ground Location
IE Left Kick Panel
IF Left Kick Panel
IG Instrument Panel Brace RH
IH Right Kick Panel
II Right Kick Panel
Body
Ground Location (Access Cab)
Service Precautions
Air Bag(s) Arming and Disarming: Service Precautions
SRS AIRBAG PRECAUTION
CAUTION: TOYOTA trucks are equipped with SRS, which comprises a driver airbag, front
passenger airbag and failure to carry out service operations in the correct sequence could cause
the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Further, if
a mistake is made in servicing the SRS, it is possible that the SRS may fail to operate when
required. Before performing servicing (including removal or installation of parts, inspection or
replacement), be sure to read the following items carefully, then follow the correct procedures
described.
Work must be started 90 seconds after the ignition switch is turned to the "LOCK" position and the
negative (-) terminal cable is disconnected from the battery.
The SRS is equipped with a back-up power source so that if work is started within 90 seconds from
disconnecting the negative (-) terminal cable of the battery, the SRS may be deployed.)
Do not expose the steering wheel pad, front passenger airbag assembly, airbag sensor assembly
or front airbag sensor directly to hot air or flames.
NOTE: Malfunction symptoms of the SRS are difficult to confirm, so the DTCs become the most
important source of information when troubleshooting. When troubleshooting the SRS, always
inspect the DTCs before disconnecting the battery.
Even in cases of a minor collision where the SRS does not deploy, the steering wheel pad, front
passenger airbag assembly, airbag sensor assembly and front airbag sensor should be inspected.
Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during
repairs.
Never use SRS parts from another vehicle. When replacing parts, replace them with new parts.
Never disassemble and repair the steering wheel pad, front passenger airbag assembly, airbag
sensor assembly or front airbag sensor, in order to reuse it.
If the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag
sensor, has been dropped, or if there are cracks, dents or other defects in the case, bracket or
connector, replace it with new one.
Use a volt/ohmmeter with high impedance (10 Kohms/V minimum) for troubleshooting the system's
electrical circuits.
Information labels are attached to the periphery of the SRS components. Follow the instructions on
the notices.
After work on the SRS is completed, check the SRS warning light check.
When the negative (-) terminal cable is disconnected from the battery, the memory of the clock and
audio system will be canceled. So before starting work, make a record of the contents memorized
in the audio memory system. When work is finished, reset the audio systems as they were before
and adjust the clock. To avoid erasing the memory in each memory system, never use a back-up
power supply from outside the vehicle.
If the vehicle is equipped with a mobile communication system, refer to the precaution.
Page 3378
DOWNLOAD FILE TO TESTER
2. Download the calibration file to the Diagnostic Tester.
The Calibration Update Wizard (CUW) is a new application on TIS which downloads calibration
files from TIS onto the Diagnostic Tester Program Card.
NOTE:
Before you begin, ensure that the Diagnostic Tester is equipped with software version 8.0a, or
later. Only a 12 MB program card (P/N 01002593-005) may be used for this process.
A. Before downloading a new calibration file from TIS, check the current calibration files stored on
the Diagnostic Tester Program Card by following the screen flow shown (Figure 4).
NOTE:
^ Screen D may be blank if no calibrations are stored on the Diagnostic Tester Program Card.
^ If the desired calibration file is already on the Diagnostic Tester, proceed to Step 3 (Reprogram
ECU with Tester shown).
^ A maximum of two calibration files may be loaded on the tester at one time with Diagnostic Tester
software version 10.2a and later. Prior versions may store up to four calibration files.
Page 3232
The ground points circuit diagram shows the connections from all major parts to the respective
ground points. When troubleshooting a faulty ground point, checking the system circuits which use
a common ground may help you identify the problem ground quickly. The relationship between
ground points (EA, IB and IC) can also be checked this way.
How to Read Power Source
HOW TO READ POWER SOURCE
Page 1024
4. REFILL WITH ENGINE OIL
a. Clean and install the oil drain plug with a new gasket.
Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.)
b. Fill with fresh engine oil.
Capacity:
c. Reinstall the oil filler cap.
HINT: Install the oil filler cap facing the direction as shown in the illustration.
5. START ENGINE AND CHECK FOR ENGINE OIL LEAKS 6. RECHECK ENGINE OIL LEVEL 7.
w/Oil filter change: REINSTALL ENGINE UNDER COVER
Page 4784
B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(Connect the Relay) and SW 2 OFF (or Disconnect SW 2)
D. Disconnect and reconnect the connectors while watching the test light.
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
E. Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION:
a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals
are touched, the IC may be destroyed by
static electricity.)
b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact
with the terminals of leads from the IC, etc. of the replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
Special Tool
1. PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown.
2. DISCONNECT CONNECTOR
3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
a. Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the
secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
A: For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
Page 228
Continuity And Resistance Check
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Continuity And Resistance Check
C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the
electrical circuit.
Finding A Short Circuit
Finding A Short Circuit
Finding A Short Circuit
A. Remove the blown fuse and disconnect all loads of the fuse.
Page 4292
Warranty Information
Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This
warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's
in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Page 485
Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
INSPECTION
1. DRAIN ENGINE COOLANT
2. REMOVE THROTTLE BODY COVER
3. REMOVE INTAKE AIR CONNECTOR
4. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS
a. Disconnect the accelerator cable from the throttle body. b. Remove the 2 bolts and 2 nuts, and
disconnect the throttle body from the intake manifold. c. Remove the gasket
5. REMOVE ECT SENSOR
a. Disconnect the ECT sensor connector. b. Remove the ECT sensor and gasket.
6. INSPECT ECT SENSOR
Using an ohmmeter, measure the resistance between the terminals.
Resistance: Refer to the graph
If the resistance is not as specified, replace the ECT sensor.
7. REINSTALL ECT SENSOR
a. Install a new gasket and the ECT sensor.
Page 6665
Instrument Panel
Connector Location
IA1 Engine Room Main and Cowl Wire (Left Kick Panel)
IA2 Engine Room Main and Cowl Wire (Left Kick Panel)
IA3 Engine Room Main and Cowl Wire (Left Kick Panel)
IA4 Engine Room Main and Cowl Wire (Left Kick Panel)
IB1 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IB2 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IB3 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IC1 Cowl Wire and Roof Wire (Left Side of Instrument Panel)
Instrument Panel
Connector Location
ID1 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH)
ID2 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH)
IE1 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IE2 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IE3 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IF1 Front Door RH Wire and Cowl Wire (Right Kick Panel)
IF2 Front Door RH Wire and Cowl Wire (Right Kick Panel)
IF3 Front Door RH Wire and Cowl Wire (Right Kick Panel)
Testing and Inspection
Temperature Sensor (Gauge): Testing and Inspection
INSPECT ENGINE COOLANT TEMPERATURE SENDER GAUGE RESISTANCE Connect the
wire harness as shown in the illustration, and adjust the ammeter pointer to indicate "0" using the
slide rheostat, then read the rheostat indication.
If resistance value is not as specified, replace the engine coolant sender gauge.
Page 2346
b. Push the secondary locking device or terminal retainer in to the full lock position.
5. CONNECT CONNECTOR
Disconnection of Male and Female Connectors
Disconnection of Male and Female Connectors
Disconnection Of Male And Female Connectors
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Page 4189
Using the following SSTs and a press, install the bearing spacer.
^ 09950-60010 (09951-00650)
^ 09950-70010 (09951-07150)
22. 4WD: INSTALL NEW OIL SEAL (INSIDE)
A. Using the following SST and a plastic hammer, install a NEW oil seal (inside).
^ 09527-17011
NOTE:
Lightly strike the SST on its circumference evenly.
B. Coat MP grease to the oil seal lip.
23. INSTALL STEERING KNUCKLE
A. 4WD: Insert the drive shaft into the axle hub and temporarily tighten the nut.
NOTE:
Be careful not to damage the oil seal and drive shaft boot.
B. Connect the steering knuckle to the upper suspension arm.
C. Install the nut and a NEW cotter pin. If the holes for the cotter pin are not aligned, tighten the nut
further up to 60°.
Torque: 105 N.m (1,100 kgf.cm, 77 ft.lbf)
24. CONNECT LOWER BALL JOINT
Connect the lower ball joint to the steering knuckle with 4 bolts.
Torque: 50 N.m (510 kgf.cm, 37 ft.lbf)
25. INSTALL SHOCK ABSORBER WITH COIL SPRING
A. Install the upper side of shock absorber to the chassis frame with the 3 nuts.
Page 5365
Air Bag Harness: Testing and Inspection
INSPECTION
HINT: The SRS wire harness is integrated with the instrument panel wire harness assembly. All the
connectors in the system are a standard yellow color.
1. VEHICLES NOT INVOLVED IN COLLISION
Do a diagnostic system check. *
2. VEHICLES INVOLVED IN COLLISION
a. Do a diagnostic system check. * b. Check breaks in all wires of the SRS wire harness, and
exposed conductors. c. Check to see if the SRS wire harness connectors are cracked or chipped.
* Refer to SRS Warning Light Check, and How to Display and Read Diagnostic Codes
See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Displaying & Reading
Trouble Codes
Page 5059
Brakes - Front Brakes Vibrating
Technical Service Bulletin # BR004R-02 Date: 040305
Brakes - Front Brakes Vibrating
BRAKES BR004-02 REVISED
September 16, 2002
Title: FRONT BRAKE VIBRATION
Models: '00 - '03 Tundra
TSB REVISION NOTICE: ^
March 5, 2004: A torque specification in, step 24, was changed.
^ September 8, 2003: A torque specification in, step 28, was changed.
The previous TSB should be discarded.
Introduction
Under certain usage conditions, some Tundra trucks may exhibit front brake vibration. Improved
brake caliper assemblies have been introduced to correct this condition.
Applicable Vehicles ^
2000 - 2003 model year Tundra trucks built before the VIN shown below.
Production Change Information
Warranty Information
Applicable Warranty:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36
months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Page 3145
Ignition Coil: Testing and Inspection
ON-VEHICLE INSPECTION
NOTE: "Cold" and "Hot" in these sentences express the temperature of the coils themselves.
"Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F).
INSPECT IGNITION COIL (WITH IGNITER) AND SPARK TEST
Check that the spark occurs.
1. Remove the ignition coils (with igniter). 2. Remove the spark plugs. 3. Install the spark plugs to
each ignition coil (with igniter), and connect the ignition coil (with igniter) connector. 4. Disconnect
the 8 injector connectors. 5. Ground the spark plug. 6. Check that spark occurs while engine is
being cranked.
NOTE: To prevent gasoline from being injected out of injectors during this test, crank the engine for
no more than 5 - 10 seconds at a time.
If the spark does not occur, do the test as per the given flow chart.
7. Using a 16 mm plug wrench, install the spark plugs.
Torque: 17.5 N.m (180 kgf.cm, 13 ft.lbf)
8. Reinstall the ignition coils (with igniter).
Specifications
Camshaft Gear/Sprocket: Specifications
Tightening Torque
Crankshaft Pulley ................................................................................................................................
...................................................................... 245 Nm LH, RH Camshaft Timing Pulleys ...................
..........................................................................................................................................................
108 Nm
Page 6671
Splice Point
J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel,
and "B" for the Body).
The Location of splice Point I5 is shaded.
K: Indicates a shielded cable.
L: Indicates the pin number of the connector.
The numbering system is different for female and male connectors.
M: Indicates a ground point.
The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for
the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body
and Surrounding area.
How to Read Connector List
HOW TO READ CONNECTOR LIST
A: Indicates connector to be connected to a part. (The numeral indicates the pin No.)
Page 4789
Relay Box: Connector Views
Engine Room R/B
Capacity Specifications
Fluid - Transfer Case: Capacity Specifications
Transfer Case
Capacity ...............................................................................................................................................
............................................................. 1.0L (1.1 Qt)
Engine Controls - A/F And O2 Sensor Identification
Oxygen Sensor: All 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 2005
CHART 30
Page 2864
The ground points circuit diagram shows the connections from all major parts to the respective
ground points. When troubleshooting a faulty ground point, checking the system circuits which use
a common ground may help you identify the problem ground quickly. The relationship between
ground points (EA, IB and IC) can also be checked this way.
How to Read Power Source
HOW TO READ POWER SOURCE
Testing and Inspection
Seat Belt Buckle Switch: Testing and Inspection
Bench Type and Passenger Side: INSPECT BUCKLE SWITCH CONTINUITY a. Check that
continuity exists between terminals 1 and 2 on the switch side connector with the switch ON (belt
fastened). b. Check that no continuity exists between terminal 1 an 2 on the switch side connector
with the switch OFF (belt unfastened).
If operation is not as specified, replace the seat belt inner.
(w/o Bench Type (Driver Side): INSPECT BUCKLE SWITCH CONTINUITY a. Check that continuity
exists between terminals 3 and 4 on the switch side connector with the switch ON (elt fastened). b.
Check that no continuity exists between terminal 3 an 4 on the switch side connector with the
switch OFF (belt unfastened).
If operation is not as specified, replace the seat belt inner.
Separate Type (w/ Power Seat): INSPECT BUCKLE SWITCH CONTINUITY a. Check that
continuity exists between terminals 1 and 2 on the switch side connector with the switch ON (belt
fastened). b. Check that no continuity exists between terminal 1 an 2 on the switch side connector
with the switch OFF (belt unfastened).
If operation is not as specified, replace the seat belt inner.
Page 2181
Engine Coolant Temperature (ECT) Sensor
Page 997
Fluid - A/T: Service Precautions
DO NOT over fill transmission beyond normal fluid level markings. Fluid foaming and transmission
damage may occur.
Page 2372
EFI Main Relay: Testing and Inspection
EFI MAIN RELAY
INSPECTION
1. REMOVE RELAY BOX COVER
2. REMOVE EFI MAIN RELAY (Marking: EFI)
3. INSPECT EFI MAIN RELAY CONTINUITY
a. Using an ohmmeter, check that there is continuity between terminals 1 and 2.
If there is no continuity, replace the relay.
b. Check that there is no continuity between terminals 3 and 5.
If there is continuity, replace the relay.
4. INSPECT EFI MAIN RELAY OPERATION
a. Apply battery voltage across terminals 1 and 2. b. Using an ohmmeter, check that there is
continuity between terminals 3 and 5.
If there is no continuity, replace the relay.
5. REINSTALL EFI MAIN RELAY
6. REINSTALL RELAY BOX COVER
Page 2400
Engine Controls - A/F And O2 Sensor Identification
Oxygen Sensor: All 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 542
^ O2S TEST RESULTS
A list of the available oxygen sensors will be displayed.
2. Select the desired oxygen sensor and press Enter.
NOTE:
The monitor result of the A/F sensor will not be displayed. If you select "Bank 1-Sensor 1" or Bank
2-Sensor 1" for a vehicle equipped with an A/F sensor, the Diagnostic Tester will display "No
parameter to display."
3. Compare the test results with the values listed in the Failure Threshold Chart.
* Although this procedure references the Toyota Diagnostic Tester, the O2S test results can be
checked using a generic OBD II scantool. Refer to your OBD II scantool operator's manual for
specific procedures.
Comparing O2S Test Results to Failure Thresholds
1. Determine the correct O2S Failure Threshold Chart for your vehicle by looking in the "O2S
Application Table," in this bulletin.
2. Select appropriate year, model, and engine for specified O2S Failure Threshold Chart.
3. Compare O2S test results with the specified O2S Failure Threshold Chart. It may be necessary
to convert O2S test results to a specific measurement unit using the conversion factor that is
supplied in the specified table. See example.
Example:
Page 4899
Air Bag(s) Arming and Disarming: Service and Repair Release Method of Airbag Activation
Prevention Mechanism
RELEASE METHOD OF AIRBAG ACTIVATION PREVENTION MECHANISM
Component Locations
Audible Warning Device Control Module: Component Locations
Instrument Panel
Page 553
CHART 8
CHART 9
Page 1433
6. REMOVE DRIVE BELT, FAN, FLUID COUPLING AND FAN PULLEY
a. Loosen the 4 nuts holding the fluid coupling to the fan bracket. b. Remove the drive belt. c.
Remove the 4 nuts, the fan, fluid coupling assembly and fan pulley.
7. DISCONNECT PS PUMP
Remove the 3 bolts, and disconnect the PS pump from the engine.
HINT: Suspend the PS pump securely.
8. REMOVE DRIVE BELT IDLER PULLEY
Remove the pulley bolt, cover plate and idler pulley.
9. REMOVE RH NO.3 TIMING BELT COVER
Remove the 3 bolts, nut and RH No.3 timing belt cover.
10. REMOVE LH NO.3 TIMING BELT COVER
a. Disconnect the engine wire from the 2 wire clamps. b. Remove the 4 bolts and nut. c. Disconnect
the camshaft position sensor wire from the wire clamp on the LH No.3 timing belt cover. d.
Disconnect the camshaft position sensor connector from the connector bracket. e. Disconnect the
camshaft position sensor connector. f.
Remove the wire grommet from the LH No.3 timing belt cover.
g. Remove the LH No.3 timing belt cover. h. Remove the bolt, nut and oil cooler pipe
Page 1745
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 2959
e. Install the injector to the delivery pipe and lower intake manifold as shown in the illustration.
Before installing the injector, must apply spindle oil or gasoline on the place where a delivery pipe
or an intake manifold touches an O-ring of the injector.
f. Observe these precautions when disconnecting the fuel tube connector (quick type): 1. Check
that there is any dirt or the like on the pipe and around the connector before disconnecting them
and clean the dirt away. 2. Be sure to disconnect by hands. 3. When the connector and the pipe
are stuck, turn and pull the connector to free to disconnect and pull it out. Do not use any tools at
this
time.
4. Inspect if there is any dirt or the like on the seal surface of the disconnected pipe and clean it
away.
5. Prevent the disconnected pipe and connector from being damaged or mixed with foreign objects
by covering them with a vinyl bag.
g. Observe these precautions when connecting the fuel tube connector (quick type):
1. Do not reuse the retainer removed from the pipe. 2. Must use hands to remove the retainer from
the pipe. 3. Check that there is any damage or foreign objects on the connected part of the pipe.
Page 5061
Page 2262
A. Connect Diagnostic Tester cables DLC (P/N 02001637) and CAN Interface Module / J1962
OBDII together (P/N 01002744).
B. Test for continuity.
^ If there is continuity, the cable is OK. Check steps 1 and 2 above to complete the flash
reprogramming process.
^ If there is no continuity, proceed to CABLE TEST 2.
CABLE TEST 2.
A. Disconnect Diagnostic Tester cables DLC (P/N 02001637) and CAN Interface Module /J1962
OBDII (P/N 01002744).
B. Test DLC cable (P/N 02001637) for continuity.
^ If there is continuity, the cable is OK. Proceed to CABLE TEST 3.
^ If there is no continuity, the cable needs to be replaced.
CABLE TEST 3.
Engine Controls - MIL ON/DTC's P0135/P0155 Stored
Oxygen Sensor: Customer Interest Engine Controls - MIL ON/DTC's P0135/P0155 Stored
ENGINE EG019-02 REVISED
October 3, 2002
Title M.I.L. "ON" P0135 AND/OR P0155
Models: '00 - '02 Tundra (2UZ-FE) & '01 - '02 Sequoia
TSB REVISION NOTICE:
January 14, 2004: A Previous Part Number in the Parts Information table and one OFP number in
the Warranty Information table has been changed. All previous versions of this TSB should be
discarded.
Introduction
Certain 2000 - 2002 model year Tundra trucks (2UZ-FE) and 2001 - 2002 model year Sequoia
vehicles may exhibit a M.I.L. ON" condition with Diagnostic Trouble Code P0135 and/or P0155 in
the Engine Control Module (ECM)/SAE equivalent (PCM). The oxygen sensors have been
improved to correct this condition.
Applicable Vehicles ^
2000 - 2002 model year Tundra trucks with 2UZ-FE engines produced BEFORE the Production
Change Effective VINs listed below.
^ 2001 - 2002 model year Sequoia vehicles produced BEFORE the Production Change Effective
VINs listed below.
Production Change Information
Parts Information
Warranty Information
Applicable Warranty*:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36
months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Page 4361
Required Tools & Material
Page 2238
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 1694
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 2572
J. The top half of the CUW screen displays the calibrations currently stored on the Diagnostic
Tester Program Card. The bottom half of the screen displays the new calibration to be loaded onto
the Diagnostic Tester Program Card (see Figure 13). Click NEXT to continue the process.
K. Confirm the calibration file to be sent to the Diagnostic Tester Program Card (Figure 14). Click
SEND.
Service and Repair
Transmission Temperature Sensor/Switch: Service and Repair
ON-VEHICLE REPAIR
1. 5VZ-FE:
DISCONNECT OIL COOLER PIPE
a. Remove the 3 bolts and clamps.
b. Disconnect the oil cooler pipe. c. Remove the elbow from the transmission.
2. DISCONNECT ATF TEMPERATURE SENSOR CONNECTOR 3. REMOVE ATF
TEMPERATURE SENSOR
a. Remove the ATF temperature sensor. b. Remove the O-ring from the ATF temperature sensor.
4. INSTALL ATF TEMPERATURE SENSOR
a. Coat a new O-ring with ATF and install it to the ATF temperature sensor. b. Install the ATF
temperature sensor.
Torque: 15 Nm (150 kgf-cm, 11 ft. lbs.)
5. CONNECT ATF TEMPERATURE SENSOR CONNECTOR
NOTICE: Be careful not to twist the wire harness.
6. CONNECT OIL COOLER PIPE
a. Install the elbow to the transmission.
Page 222
B: Junction Connector
Indicates a connector which is connected to a short terminal.
Junction connector in this include a short terminal which is connected to a number of wire
harnesses. Always perform inspection with the short terminal installed. (When installing the wire
harnesses, the harnesses can be connected to any position within the short terminal grouping.
Accordingly, in other vehicles, the same position in the short terminal may be connected to wire
harness from a different part.) Wire harness sharing the same short terminal grouping ha the same
color.
C: Parts Code
The first letter of the code is taken from the first letter of part, and the numbers indicates its order in
parts which start with the same letter.
D: Connector Color
Connectors not indicated are milky white in color.
How to Read Ground Points
HOW TO READ GROUND POINTS
Page 2661
Mass Air Flow Meter: Testing and Inspection
MASS AIR FLOW (MAF) METER
INSPECTION
1. DISCONNECT MAF METER CONNECTOR
2. REMOVE MAF METER
Remove the 2 screws and MAF meter.
3. INSPECT MAF METER
a. Using an ohmmeter, measure the resistance between terminals THA and E2.
If the resistance is not as specified, replace the MAF meter.
b. Inspect for operation.
1. Connect the MAF meter connector. 2. Connect the negative (-) terminal cable to the battery. 3.
Turn the ignition switch ON. 4. Using a voltmeter, connect the positive (+) tester probe to terminal
VG, and negative (-) tester probe to terminal E2G. 5. Blow air into the MAF meter, and check that
the voltage fluctuates.
Page 6020
INSPECT DOOR KEY LOCK AND UNLOCK SWITCH CONTINUITY
If continuity is not as specified, replace the switch.
INSPECT DOOR UNLOCK DETECTION SWITCH CONTINUITY
If continuity is not as specified, replace the switch.
Page 2137
d. Check the spark plug for thread damage and insulator damage.
If abnormal, replace the spark plug.
e. Adjust the spark plug electrode gap.
Electrode gap: 0.8 mm (0.031 in.)
f. Using a 16 mm plug wrench, install the spark plugs. Torque: 17.5 N.m (180 kgf.cm, 13 ft.lbf)
g. Reinstall the ignition coils (with igniter).
Page 1438
1. INSPECT TIMING BELT
NOTICE: Do not bend, twist or turn the timing belt inside out.
- Do not allow the timing belt to come into contact with oil, water or steam.
- Do not utilize timing belt tension when installing or removing the mount bolt of the camshaft timing
pulley.
If there is any defect, as shown in the illustration, check these points:
a. Premature parting
- Check for proper installation.
- Check the timing cover gasket for damage and proper installation.
b. If the belt teeth are cracked or damaged, check to see if either camshaft is locked. c. If there is
noticeable wear or cracks on the belt face, check to see if there are nicks on the side of the idler
pulley lock and water pump. d. If there is wear or damage on even one side of the belt, check the
belt guide and the alignment of each pulley. e. If there is noticeable wear on the belt teeth, check
timing cover for damage and for foreign material on the pulley teeth.
If necessary, replace the timing belt.
2. INSPECT IDLER PULLEYS
a. Visually check the seal portion of the idler pulley for oil leakage.
If leakage is found, replace the idler pulley.
b. Check that the idler pulley turns smoothly.
If necessary, replace the idler pulley.
3. INSPECT TIMING BELT TENSIONER
a. Visually check the seal portion of the tensioner for oil leakage.
HINT: If there is only the faintest trace of oil on the seal on the push rod side, the tensioner is all
right. If leakage is found, replace the tensioner.
Axle Shaft, Conventional Fixed/Floating
Page 484
Coolant Temperature Sensor/Switch (For Computer): Description and Operation
Engine Coolant Temperature Sensor
A thermistor that is built into the engine coolant temperature sensor changes the resistance value
according to the engine coolant temperature.
The lower the engine coolant temperature sensor, the greater the thermistor resistance value, and
the higher the engine coolant temperature sensor temperature, the lower the thermistor resistance
value.
The engine coolant temperature sensor is connected to the ECM. The 5 V power source voltage in
the ECM is applied to the engine coolant temperature sensor from the terminal THA via a resistor
R. That is, the resistor R and the engine coolant temperature sensor are connected in series.
When the resistance value of the engine coolant temperature sensor changes in accordance with
changes in the engine coolant temperature, the potential at terminal THA also changes. Based on
this signal, the ECM increases the fuel injection volume to improve driveability during cold engine
operation.
Testing and Inspection
Power Window Switch: Testing and Inspection
Driver's Switch
Passenger's Switch : Window Unlock
Passenger's Switch : Window Lock
INSPECT POWER WINDOW MASTER SWITCH CONTINUITY
If continuity is not as specified, replace the switch.
Page 207
memory, the CUW will ask you to select the calibration file(s) to delete from the Diagnostic Tester
Program Card to make room for the new calibration file.
If necessary, check the calibration file(s) to delete, as shown in Figure 11. Click DELETE.
NOTE:
If there is adequate memory to store the calibration file, skip to Step J.
I. The CUW will now delete the calibration file(s) selected (see Figure 12).
Diagram Information and Instructions
Vehicle Speed Sensor: Diagram Information and Instructions
Key to Diagrams
A: System Title
B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to
distinguish it from the J/B
Example: 1 Indicates Relay Block No.1
C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type,
or specification is different.
D: Indicates related system.
Page 6085
Paint: Technical Service Bulletins Paint - Refinishing Information
COLLISION REPAIR INFORMATION FOR THE COLLISION REPAIR PROFESSIONAL
TITLE: TOPCOAT SAND & POLISH
SECTION: REFINISH BULLETIN # 173
MODELS: ALL TOYOTA LEXUS AND SCION
DATE: APRIL 2009
Customers have high expectations for automotive paint finish appearance and expect repairs to
match factory color gloss and texture. Flawed refinish appearance is a cause of concern and will
likely have a negative affect on customer satisfaction and retention.
Toyota recognizes the reality of paint finish application in the shop environment. In addition to color
matching and blending countermeasures to remove paint process intrusion (dirt nibs) are
necessary to achieve an undetectable finish match. This is also common in manufacturing plants
when process intrusion is encountered. Countermeasures are defined as; ultra-fine sanding to level
nibs followed by polishing to a level of gloss and texture consistent with the original finish.
Technicians undertaking these tasks should review applicable technical data sheets for product
process and handling instructions as well as applicable safety information.
Topcoat sand and polish is one of many paint finish repair techniques covered in Toyota T101 and
Lexus L101 Paint Finish Repair training. Please visit for scheduling and registration information.
Page 6142
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Parts Information
Repair Procedure
1. Remove the seat cushion cover following the instructions in the FRONT SEAT (Separate Type:
Power Adjuster) section of the applicable service manual.
2. Apply one piece of 1 mm thick felt tape (80 mm x 40 mm) to the seat cushion frame in the
location shown below.
3. Reassemble the front seat with the new seat cushion cover.
NOTE:
Do not use air tools when installing the seat assembly back into the vehicle.
Locations
Fuse: Locations
Driver Side J/B And Integration Relay
Page 1545
1. Turn the temperature control knob to the full cold position.
2. Inspect the clearance between the water control valve lever and the lever stop.
If the lever does not contact the lever stop, proceed to step 3.
3. If the lever does not contact the lever stop:
A. Disengage the cable retaining clip.
B. Pull up on the cable sheath until the water control valve lever contacts the lever stop.
C. Re-fasten the cable retaining clip.
Locations
Intake Air Temperature Sensor: Locations
Mass Air Flow (MAF) Meter
The Intake Air Temperature (IAT) Sensor is installed in the Mass Air Flow (MAF) Meter.
Page 6556
Glossary Of Terms And Symbols (Part 1)
Page 576
CHART 29
Page 2506
CHART 30
Page 3304
^ 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 4062
Parts Information
Diagnosis Procedure
1. Confirm the customer complaint.
2. Determine if vibration is from front or rear (while brakes are still warm from confirmation driving).
The following procedure will isolate the drum brakes from the rest of the hydraulic system by using
the parking brake (PKB).
NOTE:
Remember, with a foot PKB (on automatic transmission) the pedal must be pressed a second time
to disengage the parking brake.
HINT:
When diagnosing a Tundra with a foot PKB, slowly apply the PKB until the first "click, " then press
the PKB pedal a second time so it will disengage if it is released.
At this time the PKB can be pressed to the desired level for continued diagnosis.
A. Drive the Tundra along a smooth, level section of road at approximately 40 mph - 50 mph.
B. Slowly apply the PKB while driving until the brake begins to engage and slow the vehicle. Do not
apply the PKB past this point of initial engagement.
C. Hold the PKB at this point of initial engagement for a few seconds to slowly reduce the vehicle
speed and allow adequate time to monitor the ride condition.
D. Disengage the PKB.
E. If brake vibration is felt during step (C), then it indicates that the rear brake drums are one
source of brake vibration on this vehicle.
Refer to TSB BR003-02 for parts and repair information relating to Tundra rear brake vibration.
F. If no vibration is felt during step (C), then the front brake assemblies are the cause of brake
vibration on this vehicle.
Proceed to the following repair procedure.
Page 3349
During ECU flash reprogramming, the Error screen shown may be displayed on the Diagnostic
Tester for one of the following reasons:
1. Immobilizer key not properly registered or auto-registration mode left open.
2. Ignition ON/OFF cycling not followed correctly during the flash reprogramming procedure.
3. The Diagnostic Tester cable is damaged, causing an open communication circuit.
NOTE:
The Diagnostic Tester may operate properly in other modes such as OBD, OBDII, or CARB, with a
damaged cable.
To eliminate the possibility of the first 2 reasons causing the error message, do the following:
1. Confirm the Immobilizer Transponder Master Key is properly registered and auto registration
mode is closed. Follow the appropriate Repair Manual procedure and consult TSB SS001-99,
"Scan tool Immobilizer key Code Utility
2. Conduct the ECU flash reprogramming process explicitly following key operation instructions.
Refer to TSB SS002-01, "ECU Flash Reprogramming Process, "for more details.
To determine if the Diagnostic Tester cable is damaged, follow the test procedures below to check
the electrical integrity of the cable. Conduct all continuity tests with an Ohm meter. For all five test
procedures, the resistance values must be below 6.0 ohms to pass.
Test CABLE TEST 1.
Page 3547
Transmission Cooler: Service and Repair
REMOVAL
Page 5234
Heater Control Assembly
Page 2156
Mass Air Flow Meter: Testing and Inspection
MASS AIR FLOW (MAF) METER
INSPECTION
1. DISCONNECT MAF METER CONNECTOR
2. REMOVE MAF METER
Remove the 2 screws and MAF meter.
3. INSPECT MAF METER
a. Using an ohmmeter, measure the resistance between terminals THA and E2.
If the resistance is not as specified, replace the MAF meter.
b. Inspect for operation.
1. Connect the MAF meter connector. 2. Connect the negative (-) terminal cable to the battery. 3.
Turn the ignition switch ON. 4. Using a voltmeter, connect the positive (+) tester probe to terminal
VG, and negative (-) tester probe to terminal E2G. 5. Blow air into the MAF meter, and check that
the voltage fluctuates.
Testing and Inspection
Parking Brake Warning Switch: Testing and Inspection
INSPECT PARKING BRAKE SWITCH CONTINUITY a. Check that there is continuity terminals
with the switch ON (switch pin released). b. Check that there is no continuity between terminals
with the switch OFF (switch pin pushed in).
If operation is not as specified, replace the switch.
Locations
Hose/Line HVAC: Locations
Refrigerant Line (Part 1)
Page 6596
Wiring Harness Connector
E: Indicates the wiring harness and wiring harness connector. The wiring harness with male
terminal is shown with arrows.
Outside numerals are pin numbers.
The first letter of the code for each wiring harness and wiring harness connector(s) indicates the
component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and
Surrounding area, and "B" for the Body and Surrounding area.
When more than one code has the first and second letters in common, followed by numbers (e.g,
IH1, IH2), this indicates the same type of wiring harness and wiring harness connector.
F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in
parts position.
G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside
it). Junction Blocks are shaded to clearly separate
them from other parts.
H: When 2 parts both use one connector in common, the parts connector name used in wire
routing is shown in square brackets [ ].
Wiring Color
I: Indicates the wiring color.
Wire colors are indicated by an alphabetical code.
B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR =
Brown SB = Sky Blue LG = Light Green GR = Gray
The first letter indicates the basic wire color and the second letter indicates the color of the stripe.
Page 91
Glossary Of Terms And Symbols (Part 1)
Page 5813
b. Push the secondary locking device or terminal retainer in to the full lock position.
5. CONNECT CONNECTOR
Disconnection of Male and Female Connectors
Disconnection of Male and Female Connectors
Disconnection Of Male And Female Connectors
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Page 371
Oil Pressure Sender: Testing and Inspection
INSPECT OIL PRESSURE SWITCH CONTINUITY a. Disconnect the connector from the switch. b.
Check that continuity exists between terminal and ground with the engine stopped. c. Check that
no continuity exists between terminal and ground with the engine running.
HINT: Oil pressure should be over 24.5 kPa (0.25 kgf/sq.cm, 3.55 psi).
If operation is not as specified, replace the switch.
5VZ-FE (Access cab) and 2UZ-FE: INSPECT OIL PRESSURE SENDER GAUGE CONTINUITY a.
Disconnect the connector from the sender gauge. b. Check that no continuity exists between the
terminal and ground with the engine stopped. c. Check that continuity exists between the terminal
and ground with the engine running.
HINT: The oil pressure should be over 29.0 kPa (0.3 kgf/cm2, 4.2 psi).
If the continuity is not as specified, replace the sender gauge.
Page 6200
The ground points circuit diagram shows the connections from all major parts to the respective
ground points. When troubleshooting a faulty ground point, checking the system circuits which use
a common ground may help you identify the problem ground quickly. The relationship between
ground points (EA, IB and IC) can also be checked this way.
How to Read Power Source
HOW TO READ POWER SOURCE
Page 1675
A. Test J1962 OBDIII CAN Interface Module (P/N 01002744) for continuity.
^ If there is continuity, the cable and CAN Interface Module are OK. Re-check Cable Tests 1, 2,
and 3 while wiggling and flexing the cables.
^ If there is no continuity, proceed to CABLE TEST 4.
CABLE TEST 4.
A. Disconnect the CAN Interface Module (P/N 01002744) from the J1962 OBDII cable using a
Phillips screwdriver.
B. Test J1962 OBDII cable (P/N 02003180) for continuity.
^ If there is no continuity, the cable needs to be replaced.
^ If there is continuity, proceed to CAN Interface Module Test 5.
CAN INTERFACE MODULE TEST 5.
Page 5996
a. Remove the bolt and front seat outer belt floor anchor.
Torque: 42 N.m (430 kgf.cm, 31 ft.lbf)
b. Using a screwdriver, remove the cap. c. Remove the bolt and front seat outer belt shoulder
anchor.
Torque: 42 N.m (430 kgf.cm, 31 ft.lbf)
d. Employ the same manner described above to the other side.
8. Access cab:
REMOVE ROOF SIDE RAIL GARNISH
a. Using a screwdriver, remove the caps. b. Using a torx driver, remove the 2 torx screws and
assist grip.
c. Using a screwdriver, remove the roof side rail garnish.
9. REMOVE SUN VISORS
a. Remove the 4 screws and 2 sun visors. b. w/ Light:
Disconnect the connector.
10. REMOVE SUB-VISORS
Remove the 4 screws and 2 sub-visors.
11. REMOVE FRONT PERSONAL LIGHT
Page 4772
Engine Compartment
Instrument Panel
Locations
Page 2505
CHART 29
Electrical Specifications
Oxygen Sensor: Electrical Specifications
Air/Fuel Ratio Sensor
Resistance:
at 20°C (68°F): 0.8 - 1.4 ohms
at 800°C (1,472°F): 1.8 - 3.2 ohms
Heated Oxygen Sensor
Resistance Between Terminals +B and HT:
at 20°C (68°F) 11 - 16 Ohms
at 800°C (1,472°F) 23 - 32 Ohms
Page 996
Fluid - A/T: Fluid Type Specifications
Transmission Fluid ..............................................................................................................................
................................................. ATF Dexron II or III
Collision / Non-Collision Inspections
Airbag Sensor Assembly: Testing and Inspection Collision / Non-Collision Inspections
VEHICLE NOT INVOLVED IN COLLISION
Check a diagnostic system.
VEHICLE INVOLVED IN COLLISION WITH AIRBAG NOT DEPLOYED
Check a diagnostic system. *
VEHICLE INVOLVED IN COLLISION WITH AIRBAG DEPLOYED
Replace the airbag sensor assembly. *
* Refer to SRS Warning Light Check, and How to Display and Read Diagnostic Trouble Codes.
See: Restraint Systems/Air Bag Systems/Testing and Inspection/Reading and Clearing Diagnostic
Trouble Codes/Displaying & Reading Trouble Codes
Page 3311
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 2085
Crankshaft Position Sensor: Mechanical Specifications
Torque: ................................................................................................................................................
.................................. 6.5 N.m (65 kgf.cm, 58 in.lbf)
Page 4624
Engine Compartment
Instrument Panel
Locations
Testing and Inspection
Wiper Motor: Testing and Inspection
Low Speed:
INSPECT WIPER MOTOR OPERATION
Connect the positive (+) lead from the battery to terminal 5 and the negative (-) lead from the
battery to the motor body or terminal 4, and check that the motor operates at low speed. If
operation is not as specified, replace the motor.
High Speed:
INSPECT WIPER MOTOR OPERATION
Connect the positive (+) lead from the battery to terminal 3 and the negative (-) lead from the
battery to the motor body or terminal 4, and check that the motor operates at high speed. If
operation is not as specified, replace the motor.
Stopping at Stop Position:
INSPECT WIPER MOTOR OPERATION
a. Operate the motor at low speed and stop the motor operation anywhere except at the stop
position by disconnecting positive (+) lead from
terminal 5.
Page 4977
Steering Wheel: Testing and Inspection Replacement Requirements
REPLACEMENT REQUIREMENTS
CAUTION: Be sure to follow the correct procedure, for removal and installation of the steering
wheel pad.
Page 6423
Glossary Of Terms And Symbols (Part 1)
Page 3137
Crankshaft Position Sensor
Page 2206
The ground points circuit diagram shows the connections from all major parts to the respective
ground points. When troubleshooting a faulty ground point, checking the system circuits which use
a common ground may help you identify the problem ground quickly. The relationship between
ground points (EA, IB and IC) can also be checked this way.
How to Read Power Source
HOW TO READ POWER SOURCE
Page 6548
Body
Connector Location (Standard Cab)
BA1 Front Door LH Wire and Speaker Tweeter Wire LH (Inside of Front Door LH)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Seat
Connector Location
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
BJ1 Seat No. 1 Wire and Seat No. 2 Wire (Under the Driver's Seat)
Page 2288
^ 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.
Engine Controls - O2 Sensor Monitor Threshold Values
Oxygen Sensor: All Technical Service Bulletins Engine Controls - O2 Sensor Monitor Threshold
Values
SPECIAL SERVICE TOOLS SS002-03
December 17, 2003
Title O2S TEST RESULTS (MODE 05)
Models All '96 - '03, '04 Corolla, ECHO, Matrix, Sienna & Scion xA & xB
Introduction
This Service Bulletin contains Oxygen Sensor (O2S) Monitor threshold values for all models from
1996 to 2003 and some 2004 models. Starting in 2004, the O2S Monitor threshold values can be
found in the repair manual. These values are used when analyzing the O2S test results to
determine the O2S condition.
Applicable Vehicles ^
All 1996 - 2003 model year Toyota vehicles.
^ 2004 model year Corolla, ECHO, Matrix and Sienna vehicles.
^ 2004 model year Scion xA and xB vehicles.
Function Description
Checking O2S Test Results
To view O2S test results, the O2S Monitor must be completed and the test results must be
checked within the same key cycle. If the ignition key is cycled OFF, the O2S test results will be set
to the minimum or maximum limits, and all test results will be erased. The O2S test results are
stored in the ECU (SAE term: Powertrain Control Module/PCM) when the monitor is completed.
The test results are static and will not change once the monitor is complete.
The process for checking 02S test results is described in the following three basic steps:
1. Completing the O2S Readiness Monitor.
2. Accessing O2S Test Results.
3. Comparing O2S Test Results to Failure Thresholds.
Required SSTs
NOTE:
Additional Diagnostic Tester Kits, Program Cards or other SSTs may be ordered by calling
SPX-OTC at 1-800-933-8335.
Warranty Information
Completing O2S Readiness Monitor
1. Clear any stored Diagnostic Trouble Codes (DTCs) using the Toyota Diagnostic Tester.
Specifications
Fuel Tank And Line
Page 4329
Required Tools & Material
NOTE:
Additional Diagnostic Tester Kits, Program Cards or SSTs may be ordered by calling SPX-OTC at
1-800-933-8335.
Page 4561
Antenna - Loose Mast
Antenna Mast: All Technical Service Bulletins Antenna - Loose Mast
AUDIO AU002-01
June 1, 2001
Title: ANTENNA MAST DURABILITY
Models: '00 - '01 Tundra
Introduction
Some customers may experience a loose Tundra antenna mast due to the breakage of the
antenna holder. A revised antenna holder assembly is available to resolve this issue.
Applicable Vehicles ^
2000 - 2001 model year Tundra vehicles.
Production Change Information
Parts Information
Repair Procedure
Replace antenna holder assembly.
Warranty Information
Applicable Warranty*:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36
months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Page 6079
SEQUOIA 5R5 (Overfender. Bumper. Running Board)
SIENNA XLE (Cladding)
LANDCRUISER (Bumper Colors)
RAV4 "L" PACKAGE (P-Molding)
4RUNNER SR5 (Over Fender)
Page 5078
II. Identification of Affected Vehicles
Description and Operation
Braking Sensor/Switch: Description and Operation
Stop Light Switch
This stop light switch senses whether the brake pedal is depressed or released, and sends the
signal to the ECU.
Page 2067
If you have no TOYOTA hand-held tester, measure voltage between terminals VPA and E2 of the
ECM connector.
d. Inspect the air assist system.
1. Start the engine and check that the MIL does not light up. 2. Allow the engine to warm up to
normal operating temperature. 3. Turn the A/C compressor ON to OFF, and check the idle speed.
Idle speed (Transmission in neutral): 700 ± 50 rpm
NOTE: Perform inspection under condition without electrical load.
e. After checking the above (b) to (d), perform the driving test and check that there is no sense of
incongruity.
3. INSPECT THROTTLE CONTROL MOTOR
a. Disconnect the throttle control motor connector. b. Using an ohmmeter, measure the motor
resistance between terminal 1 (M+) and 2 (M-).
Motor resistance: 0.3 - 100 ohms at 20 °C (68 °F)
If the resistance is not as specified, replace the throttle control motor.
c. Using an ohmmeter, measure the clutch resistance between terminal 3 (CL-) and 4 (CL+).
Clutch resistance: 4.2 - 5.2 ohms at 20 °C (68 °F)
If the resistance is not as specified, replace the throttle control motor.
d. Reconnect the throttle control motor connector.
Page 4217
Remove the 4 bolts and disconnect the lower ball joint.
9. REMOVE STEERING KNUCKLE
A. Remove the cotter pin and loosen the nut.
B. Using the following SSTs, disconnect the steering knuckle.
^ 09950-40011 (09951-04010, 09952-04010, 09553-04020, 09554-04010, 09955-04031,
09958-04011)
C. Remove the nut and steering knuckle.
NOTE:
4WD: Be careful not to damage the oil seal and drive shaft boot.
HINT:
4WD: When it is difficult to disconnect the drive shaft, tap the tip of the drive shaft with a plastic
hammer.
10. 2WD: REMOVE GREASE CAP
A. Mount the axle hub in a soft jaw vise.
HINT:
Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further.
B. Using a screwdriver, remove the grease cap.
HINT:
Be careful not to damage the grease cap.
11. 4WD: REMOVE OIL SEAL (INSIDE)
A. Mount the axle hub in a soft jaw vise.
HINT:
Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further.
B. Using a screwdriver, remove the oil seal (inside).
Page 2673
4. REMOVE CAMSHAFT POSITION SENSOR
Remove the bolt, stud bolt and camshaft position sensor.
INSTALLATION
1. INSTALL CAMSHAFT POSITION SENSOR
Install the camshaft position sensor with the bolt and stud bolt Torque: 7.5 N.m (80 kgf.cm, 66
in.lbf)
2. INSTALL LH NO.3 TIMING BELT COVER
3. INSTALL DRIVE BELT
4. FILL ENGINE COOLANT
5. CHECK ENGINE COOLANT FOR LEAKS
6. CHECK IGNITION TIMING
Page 4118
11. 4WD:
REMOVE OIL SEAL (INSIDE)
A. Mount the axle hub in a soft jaw vise.
HINT:
Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further.
B. Using a screwdriver, remove the oil seal (inside).
12. 2WD:
REMOVE LOCK NUT AND ABS
SPEED SENSOR ROTOR (W/ABS) OR SPACER (W/O ABS) Using a chisel and hammer, loosen
the staked part of the lock nut.
NOTE:
Be careful not to damage the bushing.
A. Using the following SST, remove the lock nut. 00002-00909 (09318-12010)
NOTE:
Do NOT use air wrench.
B. Remove the ABS speed sensor rotor or spacer.
NOTE:
Take care not to scratch the serration of the speed sensor rotor.
13. REMOVE AXLE HUB FROM STEERING KNUCKLE
A. Remove the 4 bolts and shift the dust cover toward the hub side (outside).
B. Using the following SSTs, remove the axle hub from the steering knuckle.
Page 4334
12. 2WD: REMOVE LOCK NUT AND ABS SPEED SENSOR ROTOR (W/ABS) OR SPACER (W/O
ABS)
Using a chisel and hammer, loosen the staked part of the lock nut.
NOTE:
Be careful not to damage the bushing.
A. Using the following SST, remove the lock nut.
^ 00002-00909 (09318-12010)
NOTE:
Do NOT use air wrench.
B. Remove the ABS speed sensor rotor or spacer.
NOTE:
Take care not to scratch the serration of the speed sensor rotor.
13. REMOVE AXLE HUB FROM STEERING KNUCKLE
A. Remove the 4 bolts and shift the dust cover toward the hub side (outside).
B. Using the following SSTs, remove the axle hub from the steering knuckle.
^ 09710-28012-01 (09710-07031)
^ 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04031,
09957-04010, 09958-04011)
HINT
If necessary, use a press to remove the axle hub from the steering knuckle.
C. Remove the dust cover from the steering knuckle.
D. 4WD: Remove the bearing spacer and ABS speed sensor rotor (W/ABS) or spacer (W/O ABS).
NOTE:
Take care not to scratch the serration of the speed sensor rotor.
Page 6963
Back Window Glass: Service and Repair
REMOVAL
HINT: For step 2 to 10, refer to Headliner.
1. Access cab:
REMOVE REAR SEAT
2. Standard cab:
REMOVE FRONT DOOR SCUFF PLATES
3. Access cab:
REMOVE ACCESS DOOR SCUFF PLATES
4. REMOVE ASSIST GRIPS 5. Standard cab:
REMOVE FRONT PILLAR GARNISHES
6. Access cab:
REMOVE ROOF SIDE RAIL GARNISHES
7. REMOVE ROOM LIGHT 8. Standard cab:
REMOVE COAT HOOK
9. Standard cab:
REMOVE BACK PANEL UPPER GARNISH
10. REMOVE QUARTER TRIMS 11. REMOVE REAR PART OF ROOF HEADLINING
a. Standard cab:
Remove the 2 clips and rear part of the roof headlining.
b. Access cab:
Remove the 3 clips and rear part of the roof headlining.
12. REMOVE BACK WINDOW GLASS
a. Remove the 4 nuts. b. Using a screwdriver, loosen the weatherstrip from the body.
NOTE: Be careful not to damage the body paint.
HINT: Tape the screwdriver tip before use.
Airbag(s) Arming and Disarming
Air Bag(s) Arming and Disarming: Service and Repair Airbag(s) Arming and Disarming
CAUTION: *
Work must be started 90 seconds after the ignition switch is turned to the "LOCK" position and the
negative (-) terminal cable is disconnected from the battery. (The SRS is equipped with a back-up
power source so that if work is started within 90 seconds of disconnecting the negative (-) terminal
cable of the battery, the SRS may be deployed.)
* When the negative (-) terminal cable is disconnected from the battery, the memory of the clock
and audio system will be canceled. So before starting work, make a record of the contents
memorized in the audio memory system. When work is finished, reset the audio systems as before
and adjust the clock. To avoid erasing the memory of each memory system, never use a backup
power supply from outside the vehicle.
* Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during
repairs.
* Do not expose the steering wheel pad, front passenger airbag assembly, airbag sensor assembly
or front airbag sensor directly to hot air or flames.
AIR BAG SYSTEM DISARMING
The Air Bag/Supplemental Restraint System (SRS) incorporates a backup energy source that
maintains sufficient deployment voltage for up to 90 seconds after the ignition is turned Off and the
battery has been disconnected. Before disconnecting battery, note radio station settings, since all
vehicle memory will be lost. Never use a backup power source from outside the vehicle.
1. Turn ignition to Lock, then disconnect battery ground cable. 2. Wait at least 90 seconds after
disconnection before beginning service or diagnostic procedures.
AIR BAG SYSTEM ARMING
1. Ensure ignition is in Lock position. 2. Connect battery ground cable. 3. Wait at least 10 seconds
before turning ignition from Lock position. 4. Turn ignition to ACC or On position and ensure SRS
lamp lights, then goes off after approximately six seconds. If lamp remains lit, an SRS
condition is indicated. Refer to Restraint Systems, Air Bag Systems, Testing And Inspection. See:
Testing and Inspection
Page 3647
Seals and Gaskets: Service and Repair Rear Differential
REPLACEMENT
1. DRAIN DIFFERENTIAL OIL 2. DISCONNECT REAR PROPELLER SHAFT
2WD: See Propeller Shaft; Service and Repair. 4WD: See Propeller Shaft; Service and Repair.
3. REMOVE COMPANION FLANGE
a. Using a chisel and hammer, loosen the staked part of the nut. b. Using Special Service Tool
(SST) to hold the flange, remove the nut.
SST 09330-00021
c. Using SST, remove the companion flange.
SST 09950-30011 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03050)
Page 4093
Required SSTs
Diagnosis Procedure
1. Confirm the customer complaint.
2. Determine if vibration is from front or rear (while brakes are still warm from confirmation test
driving).
The following procedure will isolate the drum brakes from the rest of the hydraulic system by using
the parking brake (PKB).
A. Drive the Tundra along a smooth, level section of road at approximately 40 mph - 50 mph.
Page 3026
Fuel Pressure: Specifications Volume Specification
Information not supplied by the manufacturer.
Page 3872
5. INSPECT ACTUATOR OPERATION
a. 2WD 4HI shift: Connect lines via a relay, then check that the actuator fork shaft moves to 2WD
-> 4HI position.
b. 4HI -> 2WD shift: Connect lines via a relay, then check that the actuator fork shaft moves to 4HI
-> 2WD position.
Ground Locations
Radio/Stereo: Ground Locations
Engine Compartment
Ground Location
EA Front Left Fender
EB Rear Bank of Right Cylinder
EC Rear Bank of Left Cylinder
Connector Location
EA1 Cowl Wire Harness and Wire Harness (Connector Location)
EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B)
EC1 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC2 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC3 Engine No. 2 Wire and Engine Wire (Near the Starter)
ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission)
Specifications
Axle Nut: Specifications
Front Drive Shaft Lock Nut 235 Nm (173 ft.lb)
Page 3314
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 2806
Page 67
B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(Connect the Relay) and SW 2 OFF (or Disconnect SW 2)
D. Disconnect and reconnect the connectors while watching the test light.
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
E. Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION:
a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals
are touched, the IC may be destroyed by
static electricity.)
b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact
with the terminals of leads from the IC, etc. of the replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
Special Tool
1. PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown.
2. DISCONNECT CONNECTOR
3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
a. Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the
secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
A: For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
Page 2587
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 5251
Control Assembly: Service and Repair Air Conditioning / Heater Control Assembly
Removal and Installation
Air Conditioning Control Assembly (Center Cluster Integration)
REMOVAL
Page 4780
Glossary Of Terms And Symbols (Part 1)
Page 5751
Perform the procedure shown if there is any lamp malfunction.
Page 5775
Trailer Connector: Diagnostic Aids
Voltage Check
Voltage Check
Voltage Check
A. Establish conditions in which voltage is present at the check point.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(SW 2 OFF)
B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or
component terminal. This check can be done with a test light instead of a voltmeter.
Continuity and Resistance Check
Continuity and Resistance Check
Continuity And Resistance Check
A. Disconnect the battery terminal or wire so there is no voltage between the check points. B.
Contact the two leads of an ohmmeter to each of the check points.
Page 6411
Splice Location
B11
Page 915
b. Hold the tensioner with both hands and push the push rod strongly as shown to check that it
doesn't move. If the push rod moves, replace the
tensioner.
NOTICE: Never hold the tensioner push rod facing downward.
c. Measure the protrusion of the push rod from the housing end.
Protrusion: 10.5 - 11.5 mm (0.413 - 0.453 inch) If the protrusion is not as specified, replace the
tensioner.
4. INSPECT WATER PUMP
INSTALLATION
1. INSTALL CRANKSHAFT TIMING PULLEY
a. Align the timing pulley set key with the key groove of the pulley. b. Using SST and a hammer,
tap in the timing pulley, facing the flange side inward.
SST 09223-46011
2. INSTALL NO.1 IDLER PULLEY AND NO.2 IDLER PULLEY
a. Apply adhesive 2 or 3 threads of the pivot bolt.
Adhesive: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
b. Using a 10 mm hexagon wrench, install the plate washer and No.1 idler pulley with the pivot bolt.
Torque: 34.5 Nm (350 kgf-cm, 25 ft. lbs.)
c. Install the No.2 idler pulley with the bolt.
Torque: 34.5 Nm (350 kgf-cm, 25 ft. lbs.)
d. Check that the No.1 and No.2 idler pulleys moves smoothly.
Page 3128
Camshaft Position Sensor: Description and Operation
The Camshaft Position Sensor
Camshaft position sensor (G signal) consists of a magnet iron core and pickup coil.
The G signal plate has 1 tooth on its outer circumference and is installed on the LH camshaft timing
pulley. When the camshafts rotate, protrusion on the signal plate and air gap on the pickup coil
change, causing fluctuations in the magnetic field and generating an electromotive force in the
pickup coil.
The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor
generates 34 signals at every engine revolution. The ECM detects the standard angle of the
crankshaft based on the G signal and the actual angle of the crankshaft and the engine speed by
the NE signal.
Page 2921
Catalytic Converter: Testing and Inspection
THREE-WAY CATALYTIC CONVERTER (TWC) SYSTEM
ON-VEHICLE INSPECTION
1. CHECK EXHAUST PIPE ASSEMBLY
a. Check the connections for looseness or damage. b. Check the clamps for weakness, cracks or
damage.
2. INSPECT TWC
Check for dents or damage. If any part of protector is damaged or dented to the extent that it
contacts the TWC, repair or replace it.
3. INSPECT HEAT INSULATOR
a. Check the heat insulator for damage. b. Check for adequate clearance between the TWC and
heat insulator.
Locations
Vehicle Speed Sensor: Locations
Vehicle Speed Sensor NO.1
Vehicle Speed Sensor NO.2
Vehicle Speed Sensor NO.1
Page 4679
Engine Room R/B
Details
Page 1633
1. PLACE THERMOSTAT IN WATER INLET HOUSING
a. Install a new gasket to the thermostat. b. Insert the thermostat into the water inlet housing with
the jiggle valve facing straight upward.
HINT: The jiggle valve may be set within 30° of either side of the prescribed position.
2. INSTALL WATER INLET
Install the water inlet with the 3 nuts. Torque: 19 Nm (195 kgf-cm, 14 ft. lbs.)
3. FILL WITH ENGINE COOLANT 4. START ENGINE AND CHECK FOR COOLANT LEAKS 5.
RECHECK ENGINE COOLANT LEVEL
Page 6676
Glossary Of Terms And Symbols (Part 2)
Page 6201
The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit
breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery
power is supplied to each system are explained. Since all System Circuit diagrams start from the
power source, the power source system must be fully understood.
Page 5700
Wireless Transmitter Identification
Fuel Pump Relay
Fuel Pump Relay: Testing and Inspection Fuel Pump Relay
INSPECTION
1. REMOVE RELAY BOX COVER
2. REMOVE FUEL PUMP RELAY (Marking: FUEL PUMP)
3. INSPECT FUEL PUMP RELAY CONTINUITY
a. Using an ohmmeter, check that there is continuity between terminals 1 and 2.
If there is no continuity, replace the relay.
b. Check that there is continuity between terminals 3 and 4.
If there is no continuity, replace the relay.
4. INSPECT FUEL PUMP RELAY OPERATION
a. Apply battery positive voltage across terminals 1 and 2. b. Using an ohmmeter, check that there
is no continuity between terminals 3 and 4.
If there is continuity, replace the relay.
5. REINSTALL FUEL PUMP RELAY
6. REINSTALL RELAY BOX COVER
Page 4379
A. Remove the bolt and brake line clamp from the steering knuckle.
B. Remove the 2 bolts, brake caliper and disc.
7. REMOVE SHOCK ABSORBER
A. Disconnect Shock Absorber from lower suspension arm.
B. Remove the shock absorber lower side set nut and washer.
NOTE:
Do not remove the bolt.
C. Wrap the bolt's head with vinyl tape to prevent the drive shaft boot from being damaged.
D. Pry down the lower suspension arm to remove the bolt and disconnect the shock absorber.
E. Remove the 3 nuts and shock absorber with the coil spring.
NOTE:
Do not damage the brake tube.
8. DISCONNECT LOWER BALL JOINT
Page 3212
Step 4
O/D OFF indicator light does not light up
Steps 1 - 2
O/D OFF indicator light remains ON
Page 3335
E. Confirm the Diagnostic Tester has the appropriate software for the type of calibration file that
was downloaded.
NOTE:
The calibration type is specific to the software version loaded on your Diagnostic Tester. If you
selected the wrong version when downloading the calibration file, you will receive an error when
attempting to install the file on the Diagnostic Tester.
Page 1427
Timing Belt: Diagrams
TIMING BELT REPLACEMENT W/ RELATED COMPONENTS
Part 1 of 4
Page 3915
Transmission Mode Indicator - A/T: Electrical Diagrams
Electronically Controlled Transmission And A/T Indicator (Part 1)
Page 5802
B: Junction Connector
Indicates a connector which is connected to a short terminal.
Junction connector in this include a short terminal which is connected to a number of wire
harnesses. Always perform inspection with the short terminal installed. (When installing the wire
harnesses, the harnesses can be connected to any position within the short terminal grouping.
Accordingly, in other vehicles, the same position in the short terminal may be connected to wire
harness from a different part.) Wire harness sharing the same short terminal grouping ha the same
color.
C: Parts Code
The first letter of the code is taken from the first letter of part, and the numbers indicates its order in
parts which start with the same letter.
D: Connector Color
Connectors not indicated are milky white in color.
How to Read Ground Points
HOW TO READ GROUND POINTS
Page 1048
3. BLEED BRAKE LINE
(a) Connect the vinyl tube to the caliper. (b) Depress the brake pedal several times, then loosen the
bleeder plug with the pedal held down.
SST 09751-36011
(c) At the point when fluid stops coming out, tighten the bleeder plug, then release the brake pedal.
(d) Repeat (b) and (c) until all the air in the fluid has been bled out.
Torque: (Bleeder plug) 11 Nm (110 kgf-cm, 8 ft. lbs.)
(e) Repeat the procedure on the previous page to bleed the air out of brake line for each wheel.
4. CHECK FLUID LEVEL IN RESERVOIR
Check the fluid level and add fluid if necessary. Fluid: SAE J1703 or FMVSS No. 116 DOT3
LOAD SENSING PROPORTIONING AND BY-PASS VALVE ON-VEHICLE INSPECTION
1. SET REAR AXLE LOAD
Rear axle load (includes vehicle weight): Standard cab: 950 kg (2,094 lbs.) Access cab:
5VZ-FE engine: 1,000 kg (2,205 lbs.) 2UZ-FE engine: 1,050 kg (2,315 lbs.)
2. INSTALL LSPV GAUGE (SST) AND BLEED AIR
SST 09709-29018
3. RAISE FRONT BRAKE PRESSURE TO 7,845 kPa (80 kgf/cm2, 1,138 psi) AND CHECK REAR
BRAKE PRESSURE
Rear brake pressure: 5,110 ± 490 kPa (52.1 ± 5 kgf/cm2, 741 ± 71 psi)
Page 3422
Fluid - A/T: Fluid Type Specifications
Transmission Fluid ..............................................................................................................................
................................................. ATF Dexron II or III
Page 4554
b. Install the terminal insulator with the nut.
Torque: 4.1 N.m (41.5 kgf.cm, 36 in.lbf)
8. CHECK THAT ROTOR ROTATES SMOOTHLY
REPLACEMENT
1. REPLACE FRONT BEARING
a. Remove the 4 screws and bearing retainer.
b. Using SST and a press, press out the bearing.
SST 09950-60010 (09951-00260, 09952-06010)
c. Using SST and a press, press in a new bearing.
SST 09950-60010 (09951-00520)
d. Install the bearing retainer with the 4 screws.
Torque: 3.0 N.m (31 kgf.cm, 27 in.lbf)
2. REPLACE REAR BEARING
Page 3496
7. INSTALL PARKING LOCK PAWL BRACKET
Install the parking lock pawl bracket with the 3 bolts. Torque: 7.4 Nm (75 kgf-cm, 65 inch lbs.)
HINT: Push the lock rod fully forward.
- Check that the parking lock pawl operates smoothly.
8. INSTALL VALVE BODY
Testing and Inspection
Hazard Warning Switch: Testing and Inspection
INSPECT HAZARD WARNING SWITCH CONTINUITY
a. Remove the center cluster finish panel. b. Disconnect the connector from the center cluster
integration. c. Check that continuity exists between terminal 17 and terminal 1 with the switch ON.
d. Check that no continuity exists between terminal 17 and terminal 1 with the switch OFF.
If continuity is not as specified, replace the switch.
Page 2608
Materials System.
Required SSTs
NOTE:
Additional Diagnostic Tester Kits, CAN Interface Modules, Program Cards or SSTs may be ordered
by calling SPX/OTC at 1-800-933-8335.
Process Overview
ECU Flash Reprogramming is a 4-step process:
1. Locate the desired calibration file on TIS (Technical Information System).
Calibration files may be found in two areas:
a. Search by model and year for a Technical Service Bulletin addressing a specific product issue.
b. Search by model under the ECU Flash Reprogramming section.
2. Download the calibration file from TIS to the Diagnostic Tester.
The Calibration Update Wizard (CUW) is an application on TIS which downloads calibration files
from TIS to the Diagnostic Tester Program Card. This step is only required when the calibration file
is not currently stored on the Diagnostic Tester Program Card.
3. Reprogram the vehicle ECU with the Diagnostic Tester.
Diagnostic Tester Software now incorporates a function to update a vehicle's ECU calibration
through flash reprogramming.
4. Confirm successful flash update and affix calibration update sticker.
Modifications to ECU calibration files must be recorded and properly displayed on the vehicle using
the calibration update sticker.
NOTE:
Page 1846
Coolant Temperature Sensor/Switch (For Computer): Mechanical Specifications
New gasket and the ECT sensor. Torque: ..........................................................................................
.................................................................................... 20.4 N.m (208 kgf.cm, 15 ft.lbf)
New gasket and the throttle body with the 2 bolts and 2 nuts. Torque: ...............................................
.................................................................................................................................. 18 N.m (185
kgf.cm, 13 ft.lbf)
Page 2998
Injector (Part 2)
Front fuel pipe with the bolt, 4 new gaskets and 2 union bolts. Torque:..............39 N.m (400 kgf.cm,
29 ft.lbf) for union bolts Torque:..............7.5 N.m (80 kgf.cm, 66 in.lbf) for bolt
Bolt holding the clamp on the fuel return pipe to the LH delivery pipe. Torque:..............7.5 N.m (80
kgf.cm, 66 in.lbf)
Page 4362
Parts Information
Diagnosis Procedure
1. Confirm the customer complaint.
2. Determine if vibration is from front or rear (while brakes are still warm from confirmation driving).
The following procedure will isolate the drum brakes from the rest of the hydraulic system by using
the parking brake (PKB).
NOTE:
Remember, with a foot PKB (on automatic transmission) the pedal must be pressed a second time
to disengage the parking brake.
HINT:
When diagnosing a Tundra with a foot PKB, slowly apply the PKB until the first "click, " then press
the PKB pedal a second time so it will disengage if it is released.
At this time the PKB can be pressed to the desired level for continued diagnosis.
A. Drive the Tundra along a smooth, level section of road at approximately 40 mph - 50 mph.
B. Slowly apply the PKB while driving until the brake begins to engage and slow the vehicle. Do not
apply the PKB past this point of initial engagement.
C. Hold the PKB at this point of initial engagement for a few seconds to slowly reduce the vehicle
speed and allow adequate time to monitor the ride condition.
D. Disengage the PKB.
E. If brake vibration is felt during step (C), then it indicates that the rear brake drums are one
source of brake vibration on this vehicle.
Refer to TSB BR003-02 for parts and repair information relating to Tundra rear brake vibration.
F. If no vibration is felt during step (C), then the front brake assemblies are the cause of brake
vibration on this vehicle.
Proceed to the following repair procedure.
Testing and Inspection
Power Seat Switch: Testing and Inspection
Slide Switch
Front Tilt Switch
Rear Lifter Switch
Reclining Switch
INSPECT POWER SEAT SWITCH CONTINUITY
If continuity is not as specified, replace the switch.
Page 4722
Waterproof Type Connector
B: For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White
: Gray
Black or White : Dark Gray
Gray or White : Black
Waterproof Type Connector
"Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up
to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Waterproof Type Connector
"Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 4147
3. REMOVE CALIPER
Remove the 2 mounting bolts and caliper. Torque: 123 Nm (1,250 kgf-cm, 90 ft. lbs.)
4. REMOVE CLIP, 2 PINS AND ANTI-RATTLE SPRING 5. REMOVE 2 PADS AND 4
ANTI-SQUEAL SHIMS
NOTICE: The anti-rattle spring and clip can be used again provided that they have sufficient
rebound, no deformation, cracks or wear, and have had all rust, dirt and foreign particles cleaned
off.
INSTALLATION
Installation is in the reverse order of removal.
HINT: After installation, fill brake reservoir with brake fluid and bleed brake system.
- Check for leaks.
Page 6090
Paint: Application and ID
Page 5951
Page 2043
Vehicle Speed Sensor: Description and Operation
Vehicle Speed Sensor NO.1
Vehicle Speed Sensor NO.1 Circuit Description
The vehicle speed sensor outputs a 4-pulse signal for every revolution of the rotor shaft, which is
rotated by the transmission output shaft via the driven gear. After this signal is converted into a
more precise rectangular waveform by the waveform shaping circuit inside the combination meter,
it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency
of these pulse signals.
Vehicle Speed Sensor NO.2
Vehicle Speed Sensor NO.2 Circuit Description
The No.2 vehicle speed sensor detects the rotation speed of the transmission output shaft and
sends signals to the ECM. The ECM determines the vehicle speed based on these signals.
Page 5173
3. 4WD: DISCONNECT DRIVE SHAFT
a. Remove the cotter pin and lock cap. b. While applying the brakes, remove the lock nut.
4. w/ABS: DISCONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP FROM
STEERING KNUCKLE
Remove the 2 bolts and disconnect the ABS speed sensor and wire harness clamp from the
steering knuckle.
5. REMOVE BRAKE CALIPER AND DISC
a. Remove the bolt and brake line clamp from the steering knuckle. b. Remove the 2 bolts, brake
caliper and disc.
NOTICE: Do not damage the brake tube.
c. Support the brake caliper securely.
6. REMOVE SHOCK ABSORBER
7. DISCONNECT LOWER BALL JOINT
Remove the 4 bolts and disconnect the lower ball joint.
Electrical Specifications
Resistance
Electrical Specifications
Specifications
Wheel Bearing: Specifications
On models with serviceable wheel bearings, use a Lithium Multipurpose Grease.
Page 6358
b. Push the secondary locking device or terminal retainer in to the full lock position.
5. CONNECT CONNECTOR
Disconnection of Male and Female Connectors
Disconnection of Male and Female Connectors
Disconnection Of Male And Female Connectors
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Page 1372
Intake Manifold: Service and Repair
For further information regarding this component and the system that it is a part of, please refer to
Cylinder Head Assembly; Service and Repair.
Page 5058
Page 3591
Vehicle Speed Sensor NO.2
Diagram Information and Instructions
Transmission Mode Indicator - A/T: Diagram Information and Instructions
Key to Diagrams
A: System Title
B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to
distinguish it from the J/B
Example: 1 Indicates Relay Block No.1
C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type,
or specification is different.
D: Indicates related system.
Page 3897
Body
Connector Location (Access Cab)
BA1 Front Door LH Wire and Wire Harness (Connector Location)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel)
BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel)
BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel)
BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Page 1955
Engine Bank Identification
Heater Control Assembly
Control Assembly: Service and Repair Heater Control Assembly
Removal and Installation
Heater Control Assembly
REMOVAL
Capacity Specifications
Coolant: Capacity Specifications Drain and Refill
Drain and Refill
With Manual Transmission 10.6 qt (US)
With Automatic Transmission 12.3 qt (US)
Locations
Fuse Block: Locations
Driver Side J/B And Integration Relay
Page 5788
Instrument Panel
Ground Location
IE Left Kick Panel
IF Left Kick Panel
IG Instrument Panel Brace RH
IH Right Kick Panel
II Right Kick Panel
Body
Ground Location (Access Cab)
Page 960
e. Install the injector to the delivery pipe and lower intake manifold as shown in the illustration.
Before installing the injector, must apply spindle oil or gasoline on the place where a delivery pipe
or an intake manifold touches an O-ring of the injector.
f. Observe these precautions when disconnecting the fuel tube connector (quick type): 1. Check
that there is any dirt or the like on the pipe and around the connector before disconnecting them
and clean the dirt away. 2. Be sure to disconnect by hands. 3. When the connector and the pipe
are stuck, turn and pull the connector to free to disconnect and pull it out. Do not use any tools at
this
time.
4. Inspect if there is any dirt or the like on the seal surface of the disconnected pipe and clean it
away.
5. Prevent the disconnected pipe and connector from being damaged or mixed with foreign objects
by covering them with a vinyl bag.
g. Observe these precautions when connecting the fuel tube connector (quick type):
1. Do not reuse the retainer removed from the pipe. 2. Must use hands to remove the retainer from
the pipe. 3. Check that there is any damage or foreign objects on the connected part of the pipe.
Page 201
The calibration file contains the Calibration ID number(s) for a specific vehicle ECU (see Figure 1).
NOTE:
The total number of Calibration ID numbers corresponds to the number of reprogrammable
processors in the ECU (see Figure 2).
Operation Procedure
LOCATE CALIBRATION FILE
The following steps in this bulletin describe how to properly flash reprogram an ECU.
1. Locate calibration file on TIS.
Calibration files may be found in two areas (see Figure 3):
A. Search by model and year for a Technical Service Bulletin addressing a specific Product issue.
^ Within the TSB, click on the link for the calibration file.
B. Search by model under the ECU Flash Reprogramming Section.
^ Under the ECU Flash Reprogramming section on TIS, a drop-down list of the latest calibration
files will be displayed.
C. Proceed to step 2 for instructions on how to download the calibration file from TIS to the
Diagnostic Tester Program Card.
Page 3323
A. Connect Diagnostic Tester cables DLC (P/N 02001637) and CAN Interface Module / J1962
OBDII together (P/N 01002744).
B. Test for continuity.
^ If there is continuity, the cable is OK. Check steps 1 and 2 above to complete the flash
reprogramming process.
^ If there is no continuity, proceed to CABLE TEST 2.
CABLE TEST 2.
A. Disconnect Diagnostic Tester cables DLC (P/N 02001637) and CAN Interface Module /J1962
OBDII (P/N 01002744).
B. Test DLC cable (P/N 02001637) for continuity.
^ If there is continuity, the cable is OK. Proceed to CABLE TEST 3.
^ If there is no continuity, the cable needs to be replaced.
CABLE TEST 3.
Page 217
Engine Control Module (ECM)
Page 598
Page 2044
An AC voltage is generated in the No.2 vehicle speed sensor coil as the rotor mounted on the
output shaft rotates, and this voltage is sent to the ECM.
The gear shift point and lock-up timing are controlled by the ECM based on the signals from this
vehicle speed sensor and the throttle position sensor signal.
If the No.2 vehicle speed sensor malfunctions, the ECM uses input signals from the No.1 vehicle
speed sensor as a back-up signal.
Page 6407
BJ Inside of Rear Door LH
BK Inside of Rear Door RH
BL Surrounding of the Front of the Fuel Tank
Connector Location
BA1 Front Door LH Wire and Wire Harness (Connector Location)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel)
BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel)
BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel)
BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Page 4922
The ground points circuit diagram shows the connections from all major parts to the respective
ground points. When troubleshooting a faulty ground point, checking the system circuits which use
a common ground may help you identify the problem ground quickly. The relationship between
ground points (EA, IB and IC) can also be checked this way.
How to Read Power Source
HOW TO READ POWER SOURCE
Page 5965
Page 2765
CHART 21
Page 4121
20. 2WD: INSTALL NEW LOCK NUT
A. Using the following SST, install and torque a NEW lock nut to the axle hub.
00002-00909 (09318-12010)
Torque: 274 N.m (2,800 kgf.cm, 203 ft.lbf)
NOTE:
Do NOT use air wrench.
B. Using a chisel and hammer, stake the lock nut.
21. 4WD:
INSTALL BEARING SPACER
Using the following SSTs and a press, install the bearing spacer.
^ 09950-60010 (09951-00650)
^ 09950-70010 (09951-07150)
22. 4WD:
Page 1359
Oil Pressure Sender: Testing and Inspection
INSPECT OIL PRESSURE SWITCH CONTINUITY a. Disconnect the connector from the switch. b.
Check that continuity exists between terminal and ground with the engine stopped. c. Check that
no continuity exists between terminal and ground with the engine running.
HINT: Oil pressure should be over 24.5 kPa (0.25 kgf/sq.cm, 3.55 psi).
If operation is not as specified, replace the switch.
5VZ-FE (Access cab) and 2UZ-FE: INSPECT OIL PRESSURE SENDER GAUGE CONTINUITY a.
Disconnect the connector from the sender gauge. b. Check that no continuity exists between the
terminal and ground with the engine stopped. c. Check that continuity exists between the terminal
and ground with the engine running.
HINT: The oil pressure should be over 29.0 kPa (0.3 kgf/cm2, 4.2 psi).
If the continuity is not as specified, replace the sender gauge.
Page 6553
B: Junction Connector
Indicates a connector which is connected to a short terminal.
Junction connector in this include a short terminal which is connected to a number of wire
harnesses. Always perform inspection with the short terminal installed. (When installing the wire
harnesses, the harnesses can be connected to any position within the short terminal grouping.
Accordingly, in other vehicles, the same position in the short terminal may be connected to wire
harness from a different part.) Wire harness sharing the same short terminal grouping ha the same
color.
C: Parts Code
The first letter of the code is taken from the first letter of part, and the numbers indicates its order in
parts which start with the same letter.
D: Connector Color
Connectors not indicated are milky white in color.
How to Read Ground Points
HOW TO READ GROUND POINTS
Page 5112
Page 4302
21. 4WD:
Using the following SSTs and a press, install the bearing spacer.
SST P/N: 09950-60010 (09951-00650)
SST P/N: 09950-70010 (09951-07150)
22. 4WD:
Install new oil seal (inside).
A. Using the following SST and a plastic hammer, install a NEW oil seal (inside).
SST P/N: 09527-17011
NOTE:
Lightly strike the SST on its circumference evenly.
B. Coat MP grease to the oil seal lip.
23. Install steering knuckle.
A. 4WD:
Insert the drive shaft into the axle hub and temporarily tighten the nut.
NOTE:
Be careful not to damage the oil seal and drive shaft boot.
B. Connect the steering knuckle to the upper suspension arm.
C. Install the nut and a NEW cotter pin. If the holes for the cotter pin are not aligned, tighten the nut
further up to 600.
Torque: 105 N.m (1,100 kgf.cm, 77 ft.lbf)
24. Connect the lower ball joint to the steering knuckle with 4 bolts.
Page 6736
Brake Lamp: Component Tests and General Diagnostics
INSPECTION
1. w/o Cruise Control:
INSPECT STOP LIGHT SWITCH CONTINUITY If continuity is not as specified, replace the switch.
2. w/ Cruise Control:
INSPECT STOP LIGHT SWITCH CONTINUITY If continuity is not as specified, replace the switch.
3. INSPECT HI-MOUNTED STOP LIGHT ASSEMBLY CONTINUITY
Using the ohmmeter, check that continuity exists between terminal 1 and terminal 2. If continuity is
not as specified, replace the light assembly or bulb.
Page 1594
Specification:
If the maximum pressure is less than the minimum standard value, replace the radiator cap
sub-assembly.
Type: Compact Cap, 108 kPa
1. Remove coolant and any foreign material on rubber points "A," "B," and "C."
2. Check that points "A" and "B" are not deformed, cracked, or swollen.
3. Check that points "B" and "C" are not stuck together.
4. Apply engine coolant to point "B" before using the radiator cap tester.
^ Radiator Cap Tester: Snap-On/Sun P/N SVTS262A (or equivalent)
5. Before installing the radiator cap tester, use the applicable radiator cap adaptor provided in the
following SST kits in conjunction with the radiator cap tester:
^ SST P/N 09230-00030-01 (09231-10080-01) or 09230-00020-01 (09231-10060-01) or
09230-00050-01 (09231-10110-01)
6. When using the radiator cap tester, tilt it more than 30 degrees.
Page 3112
4. INSPECT THROTTLE POSITION SENSOR
a. Disconnect the throttle position sensor connector. b. Using an ohmmeter, measure the
resistance between terminals VC and E2.
Resistance: 1.25 - 2.35 kohms at 20 °C (68 °F)
If the resistance is not as specified, replace the throttle position sensor.
c. Reconnect the throttle position sensor connector.
5. INSPECT ACCELERATOR PEDAL POSITION SENSOR
a. Disconnect the pedal position sensor connector. b. Using an ohmmeter, measure the resistance
between terminals VC and E2.
Resistance: 1.64 - 3.28 kohms at 20 °C (68 °F)
If the resistance is not as specified, replace the accelerator pedal position sensor.
c. Reconnect the pedal position sensor connector.
6. REINSTALL THROTTLE BODY COVER
Page 1827
Mass Air Flow (MAF) Meter
Page 3009
Injector (Part 2)
REMOVAL
1. REMOVE THROTTLE BODY COVER
2. REMOVE INTAKE AIR CONNECTOR
Page 2641
b. Push the secondary locking device or terminal retainer in to the full lock position.
5. CONNECT CONNECTOR
Disconnection of Male and Female Connectors
Disconnection of Male and Female Connectors
Disconnection Of Male And Female Connectors
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Page 4955
4. REMOVE RIGHT-HAND AND LEFT-HAND CLIPS, RACK BOOTS AND CLAMPS
a. Using a screwdriver, loosen the 2 clamps. b. Remove the 2 clips and boots.
HINT: Mark the Right-Hand and Left-Hand boots.
NOTICE: Be careful not to damage the boot.
5. REMOVE RIGHT-HAND AND LEFT-HAND RACK ENDS AND CLAW WASHERS
a. Using a screwdriver and hammer, unstake the washer.
NOTICE: Avoid any impact on the steering rack.
b. Using a spanner to hold the steering rack steadily, and using SST, remove the rack end.
SST 09922-10010
HINT: Mark the Right-Hand and Left-Hand rack ends.
NOTICE: Use SST 09922-10010 in the direction shown in the illustration.
c. Remove the washer from the rack end. d. Employ the same manner described to the other side.
Page 3795
Step 4
O/D OFF indicator light does not light up
Steps 1 - 2
O/D OFF indicator light remains ON
Page 4314
Required Tools & Material
Page 1760
The calibration file contains the Calibration ID number(s) for a specific vehicle ECU (see Figure 1).
NOTE:
The total number of Calibration ID numbers corresponds to the number of reprogrammable
processors in the ECU (see Figure 2).
Operation Procedure
LOCATE CALIBRATION FILE
The following steps in this bulletin describe how to properly flash reprogram an ECU.
1. Locate calibration file on TIS.
Calibration files may be found in two areas (see Figure 3):
A. Search by model and year for a Technical Service Bulletin addressing a specific Product issue.
^ Within the TSB, click on the link for the calibration file.
B. Search by model under the ECU Flash Reprogramming Section.
^ Under the ECU Flash Reprogramming section on TIS, a drop-down list of the latest calibration
files will be displayed.
C. Proceed to step 2 for instructions on how to download the calibration file from TIS to the
Diagnostic Tester Program Card.
Page 4412
Hydraulic Control Assembly - Antilock Brakes: Testing and Inspection
NOTE: This article contains corrected data processed from TSB# PG001-05.
ABS ACTUATOR ON-VEHICLE INSPECTION
1. CONNECT TOYOTA HAND-HELD TESTER
a. Connect the TOYOTA hand-held tester to the DLC3. b. Start the engine and run it at idle. c.
Select the ACTIVE TEST mode on the TOYOTA hand- held tester.
HINT: Please refer to the TOYOTA hand-held tester operator's manual for further details.
2. INSPECT ABS ACTUATOR MOTOR OPERATION
a. Check that the operation sound of the ABS actuator motor can be heard when the motor relay is
turned ON by the TOYOTA hand-held tester.
NOTICE: Do not keep motor relay ON for more than 5 seconds continuously. When operating it
continuously, set the interval of more than 20 seconds.
If the operation sound cannot be heard, replace the ABS actuator because the motor operation is in
failure.
b. Turn the motor relay OFF.
3. INSPECT RIGHT FRONT WHEEL SOLENOID
a. Depress the brake pedal and hold it for about 15 seconds, and check that the brake pedal does
not go down further.
If the brake pedal goes down, replace the ABS actuator because the sealing condition of the
reduction solenoid valve is abnormal.
b. Check that the brake pedal does not pulsate when the motor relay is turned ON by the TOYOTA
hand-held tester.
NOTICE: Do not keep motor relay ON for more than 5 seconds continuously. When operating it
continuously, set the interval of more than 20 seconds.
If there is a pulsation in the brake pedal, replace the ABS actuator because the sealing condition of
the reduction solenoid valve is abnormal.
c. Turn the motor relay OFF. d. Depress the brake pedal and hold it until the step (g) is completed.
e. Check that the brake pedal does not go down further when the SFRH solenoid is turned ON by
the TOYOTA hand-held tester.
NOTICE: Do not keep solenoid ON for more than 2 seconds continuously. When operating it
continuously, set the interval of more than 20 seconds.
If the brake pedal goes down, replace the ABS actuator because the holding solenoid valve
operation is abnormal.
HINT: To prevent the solenoids, TOYOTA hand-held tester turns OFF automatically 2 secs. after
has been turned ON simultaneously.
f. Check that the brake pedal goes down further when the SFRR solenoid is turned ON by the
TOYOTA hand-held tester.
If the brake pedal does not go down, replace the ABS actuator because the reduction solenoid
valve operation is abnormal.
g. Check that the brake pedal returns when the motor relay is turned ON by the TOYOTA
hand-held tester.
NOTICE: Do not keep motor relay ON for more than 5 seconds continuously. When operating it
continuously, set the interval of more than
Specifications
Piston Ring: Specifications
Ring Groove Clearance No.1 ..............................................................................................................
............................................................................................. 0.030 - 0.080 mm No.2 ..........................
..............................................................................................................................................................
................... 0.030 - 0.070 mm
Standard End Gap No.1 ......................................................................................................................
..................................................................................... 0.300 - 0.400 mm No.2 ..................................
..............................................................................................................................................................
........... 0.400 - 0.550 mm Oil (side rail) ...............................................................................................
............................................................................................... 0.130 - 0.380 mm
Maximum End Gap No.1 .....................................................................................................................
..................................................................................................... 1.10 mm No.2 ................................
..............................................................................................................................................................
............................ 1.20 mm Oil (side rail) ............................................................................................
................................................................................................................ 1.15 mm
Page 2040
Waterproof Type Connector
B: For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White
: Gray
Black or White : Dark Gray
Gray or White : Black
Waterproof Type Connector
"Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up
to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Waterproof Type Connector
"Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 3173
Camshaft Position Sensor: Testing and Inspection
ON-VEHICLE INSPECTION
NOTE: "Cold" and "Hot" in these sentences express the temperature of the coils themselves.
"Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F).
INSPECT CAMSHAFT POSITION SENSOR
a. Disconnect the camshaft position sensor connector.
Resistance
b. Using an ohmmeter, measure the resistance between terminals.
If the resistance is not as specified, replace the camshaft position sensor.
c. Reconnect the camshaft position sensor connector.
Page 186
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 1906
^ O2S TEST RESULTS
A list of the available oxygen sensors will be displayed.
2. Select the desired oxygen sensor and press Enter.
NOTE:
The monitor result of the A/F sensor will not be displayed. If you select "Bank 1-Sensor 1" or Bank
2-Sensor 1" for a vehicle equipped with an A/F sensor, the Diagnostic Tester will display "No
parameter to display."
3. Compare the test results with the values listed in the Failure Threshold Chart.
* Although this procedure references the Toyota Diagnostic Tester, the O2S test results can be
checked using a generic OBD II scantool. Refer to your OBD II scantool operator's manual for
specific procedures.
Comparing O2S Test Results to Failure Thresholds
1. Determine the correct O2S Failure Threshold Chart for your vehicle by looking in the "O2S
Application Table," in this bulletin.
2. Select appropriate year, model, and engine for specified O2S Failure Threshold Chart.
3. Compare O2S test results with the specified O2S Failure Threshold Chart. It may be necessary
to convert O2S test results to a specific measurement unit using the conversion factor that is
supplied in the specified table. See example.
Example:
Page 267
Supplemental Restraint System
Page 6132
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Parts Information
Repair Procedure
1. Remove the seat cushion cover following the instructions in the FRONT SEAT (Separate Type:
Power Adjuster) section of the applicable service manual.
2. Apply one piece of 1 mm thick felt tape (80 mm x 40 mm) to the seat cushion frame in the
location shown below.
3. Reassemble the front seat with the new seat cushion cover.
NOTE:
Do not use air tools when installing the seat assembly back into the vehicle.
Locations
Page 397
Splice Location
B11
Page 5370
Airbag Sensor Assembly
Page 5635
1. Disconnect the pretensioner connector as shown in the illustration.
CAUTION: When removing the seat belt pretensioner, work must be started 90 seconds after the
ignition switch is turned to the "LOCK" position and the negative (-) terminal cable is disconnected
from the battery.
2. Remove the 2 bolts and retractor of front seat outer belt.
2. Access cab:
REMOVE FRONT SEAT OUTER BELT
a. Remove the 4 screws and front door scuff plate. b. Remove the 3 screws and rear door scuff
plate. c. Remove the bolt and front seat outer belt floor anchor.
d. Remove the front seat outer belt shoulder anchor.
1. Using a screwdriver, remove the cap.
HINT: Tape the screwdriver tip before use.
2. Remove the bolt and front seat outer belt shoulder anchor.
e. Remove the roof side rail garnish.
1. Using a screwdriver, remove the caps.
HINT: Tape the screwdriver tip before use.
2. Using a torx driver, remove the 2 torx screws and assist grip.
Torx driver: T30 (Part No. 09041-00030 or locally manufactured tool)
Page 114
^ 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 702
Throttle Position Sensor: Testing and Inspection
ON-VEHICLE INSPECTION
1. REMOVE THROTTLE BODY COVER
2. INSPECT SYSTEM OPERATION
a. Check that the throttle linkage moves smoothly.
b. Inspect the throttle control motor for operating sound.
1. Turn the ignition switch ON. 2. When turning the accelerator pedal position sensor lever, check
the running sound of the motor. Also, check that there is no friction sound.
If operation is not as specified, check the throttle control motor (See step 3), wiring and ECM.
c. Inspect the accelerator pedal position sensor.
1. Connect the TOYOTA hand-held tester to the DLC3. 2. Check that the MIL does not light up. 3.
When turning the accelerator pedal position sensor lever to the full-open position, check that the
throttle valve opening percentage
(THROTTLE POS) of the CURRENT DATA shows the standard value.
Standard throttle valve opening percentage: 60 % or more
If operation is not as specified, check that the accelerator pedal position sensor (See step 5), wiring
and ECM.
Page 2147
Intake: N = T + (A - 0.20 mm (0.008 inch))
Page 5285
Heater Control Valve: Testing and Inspection
WATER VALVE
ON-VEHICLE INSPECTION
1. WARM UP ENGINE
2. DISCONNECT WATER VALVE CONTROL CABLE
3. INSPECT WATER VALVE OPERATION
a. Check that warm air blown out the vent when the water valve lever is moved to "WARM"
position. b. Check that cool air blown out when the water valve is moved to the "COOL" position.
If operation is not as specified, replace the water valve.
4. CONNECT WATER VALVE CONTROL CABLE
Page 175
^ 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 4927
Continuity And Resistance Check
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Continuity And Resistance Check
C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the
electrical circuit.
Finding A Short Circuit
Finding A Short Circuit
Finding A Short Circuit
A. Remove the blown fuse and disconnect all loads of the fuse.
Page 2172
Camshaft Position Sensor: Description and Operation
The Camshaft Position Sensor
Camshaft position sensor (G signal) consists of a magnet iron core and pickup coil.
The G signal plate has 1 tooth on its outer circumference and is installed on the LH camshaft timing
pulley. When the camshafts rotate, protrusion on the signal plate and air gap on the pickup coil
change, causing fluctuations in the magnetic field and generating an electromotive force in the
pickup coil.
The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor
generates 34 signals at every engine revolution. The ECM detects the standard angle of the
crankshaft based on the G signal and the actual angle of the crankshaft and the engine speed by
the NE signal.
A/T - Fluid Requirements
Fluid - A/T: Technical Service Bulletins A/T - Fluid Requirements
TRANSMISSION & CLUTCH TC001-02
May 24, 2002
Title: AUTOMATIC TRANSMISSION FLUID REQUIREMENTS
Models: All '00 - '02 Models & '03 Corolla & Matrix
Introduction
Please refer to the table for correct application of Dexron(R) III (Dexron(R) II) and Toyota Type T-IV
Automatic Transmission Fluids or equivalent.
Parts Information
Warranty Information
ABS/TCS - Zero Point Calibration Information
Steering Angle Sensor: Technical Service Bulletins ABS/TCS - Zero Point Calibration Information
T-SB-0020-08
March 25, 2008
Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment
Service Category Brake
Section Brake Control/Dynamic Control System
Market USA
Applicability
Introduction
The purpose of this TSB is to provide information on when and how to perform the zero point
calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting
the battery is a necessary step for performing the zero point calibration.
Warranty Information
Required Tools & Equipment
^ Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE).
^ The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the
service procedures listed in this bulletin.
Preliminary Information
Perform this procedure if any of these repairs have been performed on the vehicle:
^ Wheel alignment has been adjusted.
^ Any chassis components have been removed/installed or replaced.
Page 5113
Page 6499
Body
Connector Location (Standard Cab)
BA1 Front Door LH Wire and Speaker Tweeter Wire LH (Inside of Front Door LH)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Seat
Connector Location
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
BJ1 Seat No. 1 Wire and Seat No. 2 Wire (Under the Driver's Seat)
Pressure Specification
Fuel Pressure: Specifications
Fuel Pressure No Vacuum 38 to 44 psi
Page 4841
Wheel turning angle:
If the right and left wheel turning angles differ from the specified value, readjust the toe-in and
wheel angle within the specified value. At this time, make sure that the lengths of the right and left
rack ends are the same. Rack end length difference: 1.5 mm (0.059 inch) or less
Page 755
1. LH:
REMOVE FRONT AIRBAG SENSOR
a. 2UZ-FE:
Remove the battery carrier, battery and battery tray.
b. Disconnect the front airbag sensor connector.
NOTE: Disconnect the connector with sensor assembly installed.
c. Remove the 2 bolts and front airbag sensor.
2. RH:
REMOVE FRONT AIRBAG SENSOR
a. Remove the air cleaner assembly. b. Disconnect the front airbag sensor connector.
NOTE: Disconnect the connector with sensor assembly installed.
c. Remove the 2 bolts and front airbag sensor.
INSTALLATION
INSTALL FRONT AIRBAG SENSORS
Page 4848
Repair Procedure
1. Disconnect the cable from the negative (-) battery terminal for MORE THAN two (2) seconds.
2. Reconnect the cable to the negative (-) battery terminal.
3. Perform the applicable zero point calibration of the yaw rate sensor and/or the steering angle
sensor.
HINT Refer to the applicable TSB or Repair Manual for the zero point calibration procedure.
4. Re-initialize all applicable systems available on the vehicle (power window sunroof power lift
door etc.).
Page 6663
Splice Location
B11
Page 2706
Knock Sensor: Testing and Inspection
INSPECTION
1. REMOVE THROTTLE BODY COVER
2. REMOVE INTAKE AIR CONNECTOR
3. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS
4. REMOVE UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY
5. INSPECT KNOCK SENSOR 1,2
a. Disconnect the knock sensor connectors. b. Using an ohmmeter, check that there is no
continuity between the terminal and body.
If there is continuity, replace the sensor with SST. SST 09816-30010
Torque: 45 N.m (450 kgf.cm, 33 ft.lbf)
c. Reconnect the knock sensor connectors.
6. REINSTALL UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY
7. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS
8. REINSTALL INTAKE AIR CONNECTOR
9. REINSTALL THROTTLE BODY COVER
Page 1762
B. You have the option to delete calibrations off the tester before downloading a new calibration.
The CUW also provides this option if there is not enough memory for the new calibration. To delete
one or all of the calibrations, follow the screen flow shown (Figure 5).
C. If this is the first time you have downloaded a calibration file from TIS to the Diagnostic Tester
Program Card, you MUST first install the latest version of the Calibration Update Wizard (CUW)
onto your TIS workstation PC, as shown in Figure 6.
This step is also required if you are using a version of CUW earlier than version 6.0. CUW 6.0 is
the only version compatible with Diagnostic Tester software version 10.2a and later. If necessary,
select the link to the TIS Diagnostic Applications Installer and follow the on-screen prompts to
install or reinstall CUW.
Page 1140
3. 4WD: DISCONNECT DRIVE SHAFT
a. Remove the cotter pin and lock cap. b. While applying the brakes, remove the lock nut.
4. w/ABS: DISCONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP FROM
STEERING KNUCKLE
Remove the 2 bolts and disconnect the ABS speed sensor and wire harness clamp from the
steering knuckle.
5. REMOVE BRAKE CALIPER AND DISC
a. Remove the bolt and brake line clamp from the steering knuckle. b. Remove the 2 bolts, brake
caliper and disc.
NOTICE: Do not damage the brake tube.
c. Support the brake caliper securely.
6. REMOVE SHOCK ABSORBER
7. DISCONNECT LOWER BALL JOINT
Remove the 4 bolts and disconnect the lower ball joint.
Page 5792
Body
Splice Location (Standard Cab)
B1 Speaker Tweeter Wire LH
B2 Front Door LH Wire
B3 Front Door LH Wire
B4 Roof Wire
B5 Speaker Tweeter Wire RH
B6 B7
Front Door RH Wire
B10 Frame Wire
Seat
Page 5903
Page 2336
The ground points circuit diagram shows the connections from all major parts to the respective
ground points. When troubleshooting a faulty ground point, checking the system circuits which use
a common ground may help you identify the problem ground quickly. The relationship between
ground points (EA, IB and IC) can also be checked this way.
How to Read Power Source
HOW TO READ POWER SOURCE
Page 6831
The ground points circuit diagram shows the connections from all major parts to the respective
ground points. When troubleshooting a faulty ground point, checking the system circuits which use
a common ground may help you identify the problem ground quickly. The relationship between
ground points (EA, IB and IC) can also be checked this way.
How to Read Power Source
HOW TO READ POWER SOURCE
Page 6197
Wiring Harness Connector
E: Indicates the wiring harness and wiring harness connector. The wiring harness with male
terminal is shown with arrows.
Outside numerals are pin numbers.
The first letter of the code for each wiring harness and wiring harness connector(s) indicates the
component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and
Surrounding area, and "B" for the Body and Surrounding area.
When more than one code has the first and second letters in common, followed by numbers (e.g,
IH1, IH2), this indicates the same type of wiring harness and wiring harness connector.
F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in
parts position.
G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside
it). Junction Blocks are shaded to clearly separate
them from other parts.
H: When 2 parts both use one connector in common, the parts connector name used in wire
routing is shown in square brackets [ ].
Wiring Color
I: Indicates the wiring color.
Wire colors are indicated by an alphabetical code.
B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR =
Brown SB = Sky Blue LG = Light Green GR = Gray
The first letter indicates the basic wire color and the second letter indicates the color of the stripe.
Specifications
Idle Speed: Specifications
Idle Speed 700 +/- 50 rpm
Page 6209
Terminal Retainer
Push the terminal retainer down to the temporary lock position.
c. Release the locking lug from terminal and pull the terminal out from rear.
4. INSTALL TERMINAL TO CONNECTOR
a. Insert the terminal.
HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug
locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position.
Page 3294
6. INSPECT LIMIT SWITCH CONTINUITY
a. Start the engine and raise the vehicle. b. With the actuator connector connected, shift the
transfer shift lever and after checking the operating sound, disconnect the connector and
inspect the continuity between each terminal.
HINT: When shifting the actuator fork shaft, connect the connectors.
7. INSPECT VEHICLE SPEED SENSOR 8. INSPECT 4HI AND 4LO INDICATOR LIGHT Check
the combination meter.
9. INSPECT 4WD CONTROL ECU
Connect the wire harness side connector to the 4WD control ECU and inspect wire harness side
connector from the back side.
Page 1931
Page 127
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 645
Heated Oxygen Sensor
Removal and Installation
Blower Motor: Service and Repair Removal and Installation
Blower Unit
REMOVAL
1. REMOVE COOLING UNIT
2. REMOVE BLOWER UNIT
a. Disconnect the connector from the blower motor. b. Disconnect the air inlet damper control cable
from the blower unit.
HINT: At the time of installation, please refer to the following item.
Page 967
Oil Filter: Tools and Equipment
Toyota Oil Filter Wrench Set
AST tool# TOY 300
This set includes our tool numbers TOY640, TOY730, and M0219. With the TOY300 you have
every gas engine Toyota/Lexus model covered between 1980 and 2009.
- Covers all Toyota and Lexus vehicles 1980-2009, based on factory filters.
Contact AST for pricing.
Assenmacher Specialty Tools 1-800-525-2943
This Kit Contains the Following Tools:
TOY 640 - Toyota Oil Filter Wrench
Page 5476
An airbag activation prevention mechanism is built into the connector for the squib circuit of the
SRS.
When release of the airbag activation prevention mechanism is directed in the troubleshooting
procedure, as shown in the illustration of the connectors, insert paper which has the same
thickness as the male terminal, between the terminal and the short spring.
CAUTION: Never release the airbag activation prevention mechanism on the steering wheel pad
connector.
NOTE:
Page 5215
Compressor And Magnetic Clutch (Part 2)
Page 2680
Coolant Temperature Sensor/Switch (For Computer): Description and Operation
Engine Coolant Temperature Sensor
A thermistor that is built into the engine coolant temperature sensor changes the resistance value
according to the engine coolant temperature.
The lower the engine coolant temperature sensor, the greater the thermistor resistance value, and
the higher the engine coolant temperature sensor temperature, the lower the thermistor resistance
value.
The engine coolant temperature sensor is connected to the ECM. The 5 V power source voltage in
the ECM is applied to the engine coolant temperature sensor from the terminal THA via a resistor
R. That is, the resistor R and the engine coolant temperature sensor are connected in series.
When the resistance value of the engine coolant temperature sensor changes in accordance with
changes in the engine coolant temperature, the potential at terminal THA also changes. Based on
this signal, the ECM increases the fuel injection volume to improve driveability during cold engine
operation.
Page 6267
Continuity And Resistance Check
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Continuity And Resistance Check
C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the
electrical circuit.
Finding A Short Circuit
Finding A Short Circuit
Finding A Short Circuit
A. Remove the blown fuse and disconnect all loads of the fuse.
Page 3659
4. REMOVE DRIVE SHAFT LOCK NUT
a. Using a screwdriver and hammer, remove the grease cap. b. Remove the cotter pin and lock
cap. c. While applying the brakes, remove the lock nut.
5. DISCONNECT LOWER SUSPENSION ARM FROM LOWER BALL JOINT
a. Remove the cotter pin and nut. b. Using Special Service Tool (SST), disconnect the lower
suspension arm from the lower ball joint.
SST 09628-62011
6. DISCONNECT DRIVE SHAFT FROM STEERING KNUCKLE
a. Using a plastic hammer, disengage the drive shaft from the axle hub. b. Push the steering
knuckle outward and disconnect the drive shaft from the steering knuckle.
NOTICE: Be careful not to damage the oil seal, boots and dust seal.
7. Left-Hand drive shaft: REMOVE LEFT-HAND SHOCK ABSORBER
Page 4080
Remove the 4 bolts and disconnect the lower ball joint.
9. REMOVE STEERING KNUCKLE
A. Remove the cotter pin and loosen the nut.
B. Using the following SSTs, disconnect the steering knuckle.
^ 09950-40011 (09951-04010, 09952-04010, 09553-04020, 09554-04010, 09955-04031,
09958-04011)
C. Remove the nut and steering knuckle.
NOTE:
4WD: Be careful not to damage the oil seal and drive shaft boot.
HINT:
4WD: When it is difficult to disconnect the drive shaft, tap the tip of the drive shaft with a plastic
hammer.
10. 2WD: REMOVE GREASE CAP
A. Mount the axle hub in a soft jaw vise.
HINT:
Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further.
B. Using a screwdriver, remove the grease cap.
HINT:
Be careful not to damage the grease cap.
11. 4WD: REMOVE OIL SEAL (INSIDE)
A. Mount the axle hub in a soft jaw vise.
HINT:
Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further.
B. Using a screwdriver, remove the oil seal (inside).
Page 3306
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 1580
REMOVAL
1. REMOVE ENGINE UNDER COVER 2. DRAIN ENGINE COOLANT 3. DISCONNECT
RADIATOR RESERVOIR HOSE FROM RADIATOR 4. DISCONNECT UPPER RADIATOR HOSE
FROM RADIATOR 5. DISCONNECT LOWER RADIATOR HOSE FROM RADIATOR 6.
DISCONNECT A/T OIL COOLER HOSES FROM RADIATOR 7. REMOVE NO.2 FAN SHROUD
Remove the 2 clips and No.2 fan shroud.
Page 2420
CHART 1
Page 6491
BJ Inside of Rear Door LH
BK Inside of Rear Door RH
BL Surrounding of the Front of the Fuel Tank
Connector Location
BA1 Front Door LH Wire and Wire Harness (Connector Location)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel)
BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel)
BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel)
BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Page 5250
3. REMOVE DEF. MODE SWITCH
Release the 2 claws, then remove the switch.
HINT: Tape the screwdriver tip before use.
REASSEMBLY
1. INSTALL DEF. MODE SWITCH
Install the switch.
HINT: After installation, check the fitting 2 claws.
2. INSTALL BLOWER SPEED CONTROL SWITCH
a. Install the switch with the 2 screws. b. Connect the connector.
3. INSTALL HEATER CONTROL CABLES
Install the heater control cables to the heater control assembly.
Specifications
Knock Sensor: Specifications
SST 09816-30010
Torque: ................................................................................................................................................
................................. 45 N.m (450 kgf.cm, 33 ft.lbf)
Page 2088
Crankshaft Position Sensor: Testing and Inspection
INSPECTION
NOTE: "Cold" and "Hot" in these sentences express the temperature of the coils themselves.
"Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F).
INSPECT CRANKSHAFT POSITION SENSOR
Resistance
Using an ohmmeter, measure the resistance between the terminals.
If the resistance is not as specified, replace the crankshaft position sensor.
Page 907
Page 2281
B. Continue to update the ECU calibration file following the screen flow (Figure 18). Details for
selected screens are shown in Figure 19.
NOTE:
^ Each flash calibration update will take approximately 15 to 45 minutes.
^ Screens E through J (Figure 18) will need to be repeated for each flash calibration update
(calibration ID number).
^ All updates must display "YES" to complete the entire calibration file update for the vehicle ECU.
^ Failure to complete all updates may result in PERMANENT ECU DAMAGE!
CONFIRM UPDATE
4. Confirm successful flash calibration update and affix calibration update sticker.
Follow these steps to confirm the calibration was reprogrammed to the ECU.
Page 6604
Continuity And Resistance Check
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Continuity And Resistance Check
C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the
electrical circuit.
Finding A Short Circuit
Finding A Short Circuit
Finding A Short Circuit
A. Remove the blown fuse and disconnect all loads of the fuse.
Page 3047
Fuel Tank And Line
Removal and Installation
Hydraulic Control Assembly - Antilock Brakes: Service and Repair Removal and Installation
Page 103
Driver Side J/B And Integration Relay Inner Circuit
Page 622
CHART 15
Page 4907
Instrument Panel
Ground Location
IE Left Kick Panel
IF Left Kick Panel
IG Instrument Panel Brace RH
IH Right Kick Panel
II Right Kick Panel
Body
Ground Location (Access Cab)
Page 508
Step 1
Page 6835
Lamp Control Module: Diagnostic Aids
Voltage Check
Voltage Check
Voltage Check
A. Establish conditions in which voltage is present at the check point.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(SW 2 OFF)
B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or
component terminal. This check can be done with a test light instead of a voltmeter.
Continuity and Resistance Check
Continuity and Resistance Check
Continuity And Resistance Check
A. Disconnect the battery terminal or wire so there is no voltage between the check points. B.
Contact the two leads of an ohmmeter to each of the check points.
Page 5872
a. Tie both piano wire ends to wooden blocks or similar objects.
b. Cut the adhesive tape by pulling the piano wire as shown in the illustration.
NOTE: If reusing the moulding, take care not to damage the moulding.
- Do not damage the body.
c. Remove the moulding.
INSTALLATION
1. CLEAN BODY MOUNTING SURFACE
a. Using a heat light, heat the body mounting surface to 40 - 60 °C (104 - 140 °F).
NOTE: Do not heat the body excessively.
b. Remove the adhesive tape from the body. c. Wipe off stains with cleaner.
Page 1177
Camshaft Gear/Sprocket: Service and Repair
For further information regarding this component and the system that it is a part of, please refer to
Cylinder Head Assembly; Service and Repair.
Page 3571
Glossary Of Terms And Symbols (Part 2)
Page 4937
Key Reminder Switch: Component Tests and General Diagnostics
INSPECTION
1. INSPECT IGNITION SWITCH CONTINUITY
If continuity is not as specified, replace the switch.
2. INSPECT KEY UNLOCK WARNING SWITCH CONTINUITY
If continuity is not as specified, replace the switch.
3. Key unlock warning system:
INSPECT COMBINATION METER OPERATION a. Disconnect the connector from the combination
meter. b. Ground terminal 1 and 10 on the wire harness side connector. c. Check the buzzer
sounds.
Page 2422
CHART 5
CHART 6
Page 2313
Materials System.
Required SSTs
NOTE:
Additional Diagnostic Tester Kits, CAN Interface Modules, Program Cards or SSTs may be ordered
by calling SPX/OTC at 1-800-933-8335.
Process Overview
ECU Flash Reprogramming is a 4-step process:
1. Locate the desired calibration file on TIS (Technical Information System).
Calibration files may be found in two areas:
a. Search by model and year for a Technical Service Bulletin addressing a specific product issue.
b. Search by model under the ECU Flash Reprogramming section.
2. Download the calibration file from TIS to the Diagnostic Tester.
The Calibration Update Wizard (CUW) is an application on TIS which downloads calibration files
from TIS to the Diagnostic Tester Program Card. This step is only required when the calibration file
is not currently stored on the Diagnostic Tester Program Card.
3. Reprogram the vehicle ECU with the Diagnostic Tester.
Diagnostic Tester Software now incorporates a function to update a vehicle's ECU calibration
through flash reprogramming.
4. Confirm successful flash update and affix calibration update sticker.
Modifications to ECU calibration files must be recorded and properly displayed on the vehicle using
the calibration update sticker.
NOTE:
Page 4519
The battery is now being tested. The progress bar fills in across the screen while testing.
12. Read or print the battery test results (press the PRINT soft key to print).
Battery Inspection Results
Once the test completes, proceed with one of the 5 procedures below according to the BATTERY
CONDITION results.
1. Battery Condition: "GOOD BATTERY" Return the battery to service.
2. Battery Condition: "GOOD-RECHARGE"
Fully charge the battery using the GR8 Battery Diagnostic Station (P/N 00002-MCGR8) and return
it to service.
3. Battery Condition: "CHARGE & RETEST"
Fully charge the battery using the GR8 Battery Diagnostic Station (P/N 00002-MCGR8) and retest.
NOTE:
Failure to fully charge the battery before retesting may cause false readings.
4. Battery Condition: "REPLACE BATTERY" Replace the battery.
NOTE:
A REPLACE BATTERY result may also mean a poor connection between the battery cables and
the battery. Retest the battery using the out-of-vehicle test before replacing it.
5. Battery Condition: "BAD CELL-REPLACE"
Replace the battery. The decision indicates a bad cell within the battery.
CAUTION:
^ If "FROZEN BATTERY" is displayed as the test result, allow the battery to reach a temperature of
40°F (4°C) before retesting.
^ NEVER CHARGE A FROZEN BATTERY GASES MAY FORM, CRACKING THE CASE AND
CAUSING BATTERY ACID TO LEAK.
Page 5796
Body
Connector Location (Access Cab)
BA1 Front Door LH Wire and Wire Harness (Connector Location)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel)
BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel)
BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel)
BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Page 276
2. REMOVE AIRBAG SENSOR ASSEMBLY
a. Disconnect the airbag sensor assembly connectors.
NOTE: Disconnect the connectors with the sensor assembly installed.
b. Using a torx wrench, remove the 4 screws.
Torx wrench: T40 (Part No. 09042-00020 or locally manufactured tool)
c. Remove the airbag sensor assembly.
INSTALLATION
NOTE:
- Never use SRS parts from another vehicle. When replacing parts, replace them with new parts.
- Never reuse the airbag sensor assembly involved in a collision when the airbag has deployed.
- Never repair a sensor in order to reuse it.
1. INSTALL AIRBAG SENSOR ASSEMBLY
a. Using a torx wrench, install the airbag sensor assembly with 4 screws.
Torx wrench: T40 (Part No. 09042-00020 or locally manufactured tool) Torque: 20 N.m (205
kgf.cm, 15 ft.lbf)
b. Connect the airbag sensor connectors.
NOTE: Connection of the connector is done after the sensor assembly has been installed.
- Make sure the sensor assembly is installed with the specified torque.
- If the sensor assembly has been dropped, or there are cracks, dents or other defects in the case,
bracket or connector, replace the sensor assembly with a new one.
- When installing the sensor assembly, take care that the SRS wiring does not interfere with other
parts and is not pinched between other parts.
- After installing , shake the sensor assembly to check that there is no looseness.
2. INSTALL LOWER CENTER COVER
Page 3008
Fuel Injector: Service and Repair
Injector (Part 1)
Page 1068
Driver Side J/B And Integration Relay Fuse Applications (Part 2)
Driver Side J/B And Integration Relay Fuse Applications (Part 3)
Page 5081
Page 640
CHART 29
Body - Bumper Component Repair
Rear Bumper Reinforcement: Technical Service Bulletins Body - Bumper Component Repair
COLLISION REPAIR INFORMATION FOR THE COLLISION REPAIR PROFESSIONAL
TITLE: BUMPER COMPONENT REPAIR
SECTION: EXTERIOR BULLETIN # 172
MODELS: ALL TOYOTA LEXUS and SCION
DATE: MARCH 2009
While it may seem cost effective to repair damaged bumper components specifically impact energy
absorbers and reinforcements there is no way to certify that a repaired part will function as
originally intended under all future operating conditions and subsequent collisions. Original
Equipment bumper components comply with Federal Motor Vehicle Safety Standards established
under the National Highway Traffic Safety Administration Title 49 Part 581. Therefore it is
recommended to replace damaged bumper impact energy absorbers and reinforcements with
genuine new original equipment replacement parts only.
For more information on collision damage repair topics please refer to Collision Repair Information
Bulletin # 161 Collision Damage Repair Precautions and plan to attend Toyota Collision Repair &
Refinish Training. Visit www.crrtraining.com for training information.
Page 1107
Wiring Harness Connector
E: Indicates the wiring harness and wiring harness connector. The wiring harness with male
terminal is shown with arrows.
Outside numerals are pin numbers.
The first letter of the code for each wiring harness and wiring harness connector(s) indicates the
component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and
Surrounding area, and "B" for the Body and Surrounding area.
When more than one code has the first and second letters in common, followed by numbers (e.g,
IH1, IH2), this indicates the same type of wiring harness and wiring harness connector.
F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in
parts position.
G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside
it). Junction Blocks are shaded to clearly separate
them from other parts.
H: When 2 parts both use one connector in common, the parts connector name used in wire
routing is shown in square brackets [ ].
Wiring Color
I: Indicates the wiring color.
Wire colors are indicated by an alphabetical code.
B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR =
Brown SB = Sky Blue LG = Light Green GR = Gray
The first letter indicates the basic wire color and the second letter indicates the color of the stripe.
Page 4056
32. Depress brake pedal several times.
33. Fill the brake reservoir with brake fluid and bleed brake system.
34. Check ABS Speed Sensor Signal (refer to the Technical Information System (TIS):
2000 - 2005 model year Tundra Repair Manual: Diagnostics: Anti-lock Brake System: Pre-Check).
Repair Procedure No. 2
1. Resurface the disc rotors with the "On-Car Lathe" to within serviceable limits.
NOTE:
It is necessary to turn the rotors using only an on-the-car brake lathe to ensure even and uniform
rotor run out. DO NOT turn the rotor using an off-the-car brake lathe.
2. If the disc rotors are unserviceable or below minimum thickness (per specification stamped on
the rotor), replace the rotors using the service parts from the Parts Information table.
3. Check any new disc rotor for runout.
4. If the disc rotor runout is over 0.03 mm (0.0012 in.), perform a phase matching procedure.
5. Replace the front brake caliper LH and RH assemblies using the service parts from the Parts
Information table.
6. Perform a road test.
Testing and Inspection
Temperature Sensor (Gauge): Testing and Inspection
INSPECT ENGINE COOLANT TEMPERATURE SENDER GAUGE RESISTANCE Connect the
wire harness as shown in the illustration, and adjust the ammeter pointer to indicate "0" using the
slide rheostat, then read the rheostat indication.
If resistance value is not as specified, replace the engine coolant sender gauge.
Page 3742
Splice Location
B11
Removal and Installation
Throttle Body: Service and Repair Removal and Installation
Throttle Body (Part 1)
Page 413
B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(Connect the Relay) and SW 2 OFF (or Disconnect SW 2)
D. Disconnect and reconnect the connectors while watching the test light.
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
E. Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION:
a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals
are touched, the IC may be destroyed by
static electricity.)
b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact
with the terminals of leads from the IC, etc. of the replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
Special Tool
1. PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown.
2. DISCONNECT CONNECTOR
3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
a. Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the
secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
A: For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
Page 2768
CHART 23
Page 1472
2. Tighten the union bolt by hand.
3. Using SST, tighten the union bolt to the specified torque.
SST 09612-24014 (09617-24011)
Torque: 33 N.m (340 kgf.cm, 24 ft.lbf) for use with SST 39 N.m (400 kgf.cm, 29 ft.lbf)
HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
c. When connecting the flare nut on the high pressure pipe union, observe these procedures:
1. Apply a light coat of engine oil to the flare nut, and tighten the flare nut by hand. 2. Using SST,
tighten the flare nut to the specified torque.
SST 09023-38400
NOTE: Do not rotate the fuel filter outlet, when tightening the flare nut.
Torque: 28 N.m (285 kgf.cm, 21 ft.lbf) for use with SST 34.3 N.m (350 kgf.cm, 25 ft.lbf)
HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
d. Observe these precautions when removing and installing the injectors.
1. Never reuse the O-ring. 2. When placing a new O-ring on the injector, take care not to damage it
in any way. 3. Coat a new O-ring with spindle oil or gasoline before installing-never use engine,
gear or brake oil.
Testing and Inspection
Power Seat Motor: Testing and Inspection
INSPECT SLIDE MOTOR OPERATION
a. Connect the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal
2, check that the motor turns clockwise. b. Reverse the polarity, check that the motor turns
counterclockwise.
If operation is not as specified, replace the seat adjuster.
INSPECT SLIDE MOTOR PTC THERMISTOR OPERATION
a. Connect the positive (+) lead from the battery to terminal 2, the positive (+) lead from the
ammeter to terminal 1 and the negative (-) lead to the
battery negative (-) terminal, then move the seat cushion to the rear position.
b. Continue to apply voltage, check that current changes to less than 1 ampere within 4 to 90
seconds.
c. Disconnect the leads from terminals. d. Approximately 60 seconds later, connect the positive (+)
lead from the battery to terminal 1 and the negative (-) lead to terminal 2, check that the
seat cushion begins to move forward. If operation is not as specified, replace the seat adjuster
Page 4987
- The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30
minutes after deployment.
- Use gloves and safety glasses when handling a steering wheel pad with the deployed airbag.
- Always wash your hands with water after completing the operation.
- Do not apply water, etc. to a steering wheel pad with the deployed airbag.
AIRBAG DEPLOYMENT WHEN SCRAPPING VEHICLE
HINT: Have a battery ready as the power source to deploy the airbag.
a. Check functioning of the SST.
CAUTION: When deploying the airbag, always use the specified SST: SRS Airbag Deployment
Tool.
SST 09082-00700
1. Connect the SST to the battery.
Connect the red clip of the SST to the battery positive (+) terminal and the black clip to the battery
negative (-) terminal.
HINT: Do not connect the yellow connector which will be connected with the supplemental restraint
system.
2. Check functioning of the SST.
Press the SST activation switch, and check that the LED of the SST activation switch lights up.
CAUTION: If the LED lights up when the activation switch is not being pressed, SST malfunction is
probable, so definitely do not use the
Page 2566
DOWNLOAD FILE TO TESTER
2. Download the calibration file to the Diagnostic Tester.
The Calibration Update Wizard (CUW) is a new application on TIS which downloads calibration
files from TIS onto the Diagnostic Tester Program Card.
NOTE:
Before you begin, ensure that the Diagnostic Tester is equipped with software version 8.0a, or
later. Only a 12 MB program card (P/N 01002593-005) may be used for this process.
A. Before downloading a new calibration file from TIS, check the current calibration files stored on
the Diagnostic Tester Program Card by following the screen flow shown (Figure 4).
NOTE:
^ Screen D may be blank if no calibrations are stored on the Diagnostic Tester Program Card.
^ If the desired calibration file is already on the Diagnostic Tester, proceed to Step 3 (Reprogram
ECU with Tester shown).
^ A maximum of two calibration files may be loaded on the tester at one time with Diagnostic Tester
software version 10.2a and later. Prior versions may store up to four calibration files.
Page 3333
B. You have the option to delete calibrations off the tester before downloading a new calibration.
The CUW also provides this option if there is not enough memory for the new calibration. To delete
one or all of the calibrations, follow the screen flow shown (Figure 5).
C. If this is the first time you have downloaded a calibration file from TIS to the Diagnostic Tester
Program Card, you MUST first install the latest version of the Calibration Update Wizard (CUW)
onto your TIS workstation PC, as shown in Figure 6.
This step is also required if you are using a version of CUW earlier than version 6.0. CUW 6.0 is
the only version compatible with Diagnostic Tester software version 10.2a and later. If necessary,
select the link to the TIS Diagnostic Applications Installer and follow the on-screen prompts to
install or reinstall CUW.
Page 2738
Required Tools & Material
NOTE:
Additional Diagnostic Tester Kits, Program Cards or SSTs may be ordered by calling SPX-OTC at
1-800-933-8335.
Repair Procedure
Using the chart, refer to the Diagnostic Section (DI-###) in the appropriate Repair Manual and
follow the diagnostic procedure for the specific DTC.
Page 1067
Driver Side J/B And Integration Relay Fuse Applications (Part 1)
Page 2574
^ Confirm cable connections between the vehicle and Diagnostic Tester are secure. (Reference
TSB No. SS004-01, "ECU Flash Reprogramming Error Message.")
^ Do not disconnect or turn off the Diagnostic Tester or the vehicle ignition during reprogramming.
^ Set the parking brake.
^ Complete ALL flash calibration updates provided for each ECU.
If the battery's state of charge or capacity are in question, test with SST No. 00002-MP815-T,
"Midtronics Battery Tester," and follow TSB No. PG017-02, "Battery Maintenance for In-Stock
Vehicles & Pre-Delivery."
To ensure stable battery voltage, a battery charger may be connected during reprogramming if:
^ Voltage does not fall below 11.4 volts.
^ Voltage does not rise above 16.0 volts.
^ Setting is on SLOW charge and not BOOST.
A. Connect the Diagnostic Tester to the vehicle and select CURRENT ECU CAL from the ECU
REPROGRAM MAIN MENU. Determine the vehicle's current ECU calibration. (See Figure 17.)
NOTE:
The vehicle may contain up to 3 separate calibration ID numbers. In the example shown, the
vehicle ECU contains only 2 calibration IDs.
Page 4667
B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(Connect the Relay) and SW 2 OFF (or Disconnect SW 2)
D. Disconnect and reconnect the connectors while watching the test light.
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
E. Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION:
a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals
are touched, the IC may be destroyed by
static electricity.)
b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact
with the terminals of leads from the IC, etc. of the replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
Special Tool
1. PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown.
2. DISCONNECT CONNECTOR
3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
a. Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the
secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
A: For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
Page 4854
Repair Procedure
1. Disconnect the cable from the negative (-) battery terminal for MORE THAN two (2) seconds.
2. Reconnect the cable to the negative (-) battery terminal.
3. Perform the applicable zero point calibration of the yaw rate sensor and/or the steering angle
sensor.
HINT Refer to the applicable TSB or Repair Manual for the zero point calibration procedure.
4. Re-initialize all applicable systems available on the vehicle (power window sunroof power lift
door etc.).
Page 6492
Audible Warning Device Control Module: Splice Locations
Engine Compartment
Splice Location
E1 Engine Room Main Wire
E2 Engine Room Main Wire
E3 Engine Room Main Wire
E4 Engine No. 2 Wire
E5 Engine Wire
E6 Engine Wire
E7 Engine Wire
E8 Engine Wire
Instrument Panel
Page 483
Engine Coolant Temperature (ECT) Sensor
Specifications
Crankshaft Gear/Sprocket: Specifications
Crankshaft Pulley Bolt Torque .............................................................................................................
.................................................... 245 Nm (181 ft.lb)
Wheels/Tires - Spare Tire Carrier Operation Information
Spare Tire Carrier: Technical Service Bulletins Wheels/Tires - Spare Tire Carrier Operation
Information
PRODUCT GENERAL INFORMATION PG005-03 REVISED
Title: SPARE TIRE CARRIER OPERATION
Models: '91 - '08 Land Cruiser, '96 - '08 4Runner & Tacoma, '98 - '08 Sienna, '00 - '08 Tundra, '01 '08 Sequoia
August 19, 2003
TSB REVISION NOTICE:
^ October 4, 2007: 2007 - 2008 model years have been added to Applicable Vehicles.
^ September 27, 2005: 2005 - 2006 model years have been added to Applicable Vehicles.
The previous TSB should be discarded.
Introduction The spare tire carrier may become damaged if an impact wrench or any other type of
power tool is used to raise or lower the spare tire. The Owner's Manual, as well as a label near the
drive nut, warns against the usage of an impact wrench or other power tools.
Applicable Vehicles
^ 1991 - 2008 model year Land Cruiser vehicles.
^ 1996 - 2008 model year 4Runner and Tacoma vehicles.
^ 1998 - 2008 model year Sienna vehicles.
^ 2000 - 2008 model year Tundra vehicles.
^ 2001 - 2008 model year Sequoia vehicles.
Operation Procedure
Refer to the vehicle's Owner's Manual for vehicle specific instructions.
1. Locate the drive nut for the spare tire carrier. Refer to the vehicle's Owner's Manual for specific
location.
2. Using the hub nut box wrench from the vehicle's tire tools kit, lower the spare tire to the ground.
3. Remove the tire from the carrier.
4. Installation of the spare tire is the reverse of removal.
Warranty Information
Page 6082
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 5624
- Check for cuts and minute cracks in wire harness or marked discoloration on the front seat outer
belt.
CAUTION: For removal and installation of the front seat outer belt,. Be sure to follow the correct
procedure.
2. PRETENSIONER IS ACTIVATED
a. Perform a diagnostic system check.
b. Perform a visual check which includes the following items with the front seat outer belt removed
from the vehicle.
- Standard cab: Check for deformation of the quarter panel.
- Access cab: Check for deformation of the ELR bracket.
- Check for damage on the connector and wire harness.
Page 624
CHART 18
CHART 19
Testing and Inspection
Four Wheel Drive Indicator Lamp: Testing and Inspection
5VZ-FE: INSPECT "4Lo/4Hi", 4WD" INDICATOR LIGHT a. Disconnect the connectors from the
ADD actuator. b. "4WD" indicator: Ground terminal 3 on the wire harness side connector. c. Turn
the ignition switch ON, check that the warning light lights up.
If the warning light does not light up, inspect the bulb or wire harness.
2UZ-FE: INSPECT "4Lo/4Hi", "4WD" INDICATOR LIGHT a. Remove the center cluster finish
panel. b. Disconnect the connectors from the center cluster integration. c. "4Lo" indicator: Ground
terminal 3 on the wire harness side connector. d. "4Hi" indicator: Ground terminal 2 on the wire
harness side connector.
Page 1928
CHART 22
Page 897
Intake: N = T + (A - 0.20 mm (0.008 inch))
Page 348
Coolant Temperature Sensor/Switch (For Computer): Mechanical Specifications
New gasket and the ECT sensor. Torque: ..........................................................................................
.................................................................................... 20.4 N.m (208 kgf.cm, 15 ft.lbf)
New gasket and the throttle body with the 2 bolts and 2 nuts. Torque: ...............................................
.................................................................................................................................. 18 N.m (185
kgf.cm, 13 ft.lbf)
Instruments - Oil Pressure Gauge Reads Abnormally Low
Oil Pressure Gauge: Customer Interest Instruments - Oil Pressure Gauge Reads Abnormally Low
ELECTRICAL EL017-03
December 23, 2503
Title OIL PRESSURE GAUGE READS LOW
Models '01 - '04 Sequoia & '00 - '02 Tundra
TSB UPDATE NOTICE:
This TSB updates EL006-03. TSB EL006-03 is now obsolete and should be discarded.
Introduction
Some customers with Sequoia or Tundra vehicles may encounter an oil pressure gauge that reads
abnormally low at idle. An updated oil pressure sender has been created to address this condition.
Applicable Vehicles ^
2001 - 2004 model year Sequoia vehicles produced BEFORE the Production Change Effective
VINs shown below.
^ 2000 - 2002 model year Tundra vehicles produced BEFORE the Production Change Effective
VIN shown below.
Production Change Information
Parts Information
Repair Procedure
1. Replace the Oil Pressure Sender.
2. Verify proper operation of the Oil Pressure Gauge.
Warranty Information
Applicable Warranty*:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36
months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Page 1116
B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(Connect the Relay) and SW 2 OFF (or Disconnect SW 2)
D. Disconnect and reconnect the connectors while watching the test light.
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
E. Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION:
a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals
are touched, the IC may be destroyed by
static electricity.)
b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact
with the terminals of leads from the IC, etc. of the replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
Special Tool
1. PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown.
2. DISCONNECT CONNECTOR
3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
a. Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the
secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
A: For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
Page 6359
Clock
Page 6338
Splice Location
B11
Page 3451
Instrument Panel
Connector Location
IA1 Engine Room Main and Cowl Wire (Left Kick Panel)
IA2 Engine Room Main and Cowl Wire (Left Kick Panel)
IA3 Engine Room Main and Cowl Wire (Left Kick Panel)
IA4 Engine Room Main and Cowl Wire (Left Kick Panel)
IB1 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IB2 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IB3 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IC1 Cowl Wire and Roof Wire (Left Side of Instrument Panel)
Instrument Panel
Connector Location
ID1 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH)
ID2 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH)
IE1 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IE2 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IE3 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IF1 Front Door RH Wire and Cowl Wire (Right Kick Panel)
IF2 Front Door RH Wire and Cowl Wire (Right Kick Panel)
IF3 Front Door RH Wire and Cowl Wire (Right Kick Panel)
Page 3794
Step 3
Page 1171
8. Push in the camshaft oil seal.
9. Apply a light coat of engine oil on the threads and under the heads (D and E) of the bearing cap
bolts.
HINT: Do not apply engine oil under the heads of the bearing cap bolt (A), (B) and (C).
10. Install the oil feed pipe the 22 bearing cap bolts as shown.
HINT: Each bolt length is indicated in the illustration.
Bolt length:
25 mm (0.98 inch) for A 38 mm (1.50 inch) for B 52 mm (2.05 inch) for C 72 mm (2.83 inch) for D
94 mm (3.70 inch) for E
11. Uniformly tighten the 22 bearing cap bolts in several passes, in the sequence shown.
Torque:
Bolt A: 7.5 Nm (80 kgf-cm, 69 inch lbs.) Others: 16 Nm (160 kgf-cm, 12 ft. lbs.)
12. Boring the service bolt installed in the driven subgear upward by turning the hexagon wrench
head portion of the camshaft with a wrench. 13. Remove the service bolt.
Description and Operation
Brake Switch - TCC: Description and Operation
Stop Light Switch Signal
Engine
This signal is used to detect when the brakes have been applied. The STP signal voltage is the
same as the voltage supplied to the stop lights.
The STP signal is used mainly to control the fuel cut-off engine speed (The fuel cut-off engine
speed is reduced slightly when the vehicle is braking.).
Automatic Transaxle
The purpose of this circuit is to prevent the engine from stalling, while driving in lock-up condition,
when brakes are suddenly applied.
When the brake pedal is operated, this switch sends a signal to ECM. Then the ECM cancels
operation of the lock-up clutch while braking is in progress.
Page 653
4. INSPECT THROTTLE POSITION SENSOR
a. Disconnect the throttle position sensor connector. b. Using an ohmmeter, measure the
resistance between terminals VC and E2.
Resistance: 1.25 - 2.35 kohms at 20 °C (68 °F)
If the resistance is not as specified, replace the throttle position sensor.
c. Reconnect the throttle position sensor connector.
5. INSPECT ACCELERATOR PEDAL POSITION SENSOR
a. Disconnect the pedal position sensor connector. b. Using an ohmmeter, measure the resistance
between terminals VC and E2.
Resistance: 1.64 - 3.28 kohms at 20 °C (68 °F)
If the resistance is not as specified, replace the accelerator pedal position sensor.
c. Reconnect the pedal position sensor connector.
6. REINSTALL THROTTLE BODY COVER
Page 2316
B. You have the option to delete calibrations off the tester before downloading a new calibration.
The CUW also provides this option if there is not enough memory for the new calibration. To delete
one or all of the calibrations, follow the screen flow shown (Figure 5).
C. If this is the first time you have downloaded a calibration file from TIS to the Diagnostic Tester
Program Card, you MUST first install the latest version of the Calibration Update Wizard (CUW)
onto your TIS workstation PC, as shown in Figure 6.
This step is also required if you are using a version of CUW earlier than version 6.0. CUW 6.0 is
the only version compatible with Diagnostic Tester software version 10.2a and later. If necessary,
select the link to the TIS Diagnostic Applications Installer and follow the on-screen prompts to
install or reinstall CUW.
Page 4654
Engine Room R/B
Details
Page 4055
Torque: 50 N.m (510 kgf.cm, 37 ft.lbf)
25. Install shock absorber with coil spring.
A. Install the upper side of shock absorber to the chassis frame with the 3 nuts.
Torque: 64 N.m (650 kgf.cm, 47 ft.lbf)
B. Connect the lower side of shock absorber to the lower suspension arm with bolt, washer, and
nut.
Torque: 135 N.m (1,400 kgf.cm, 100 ft.lbf)
26. Inspect and install the brake rotor and install the brake caliper with new mounting bolts.
A. Inspect the brake rotors and machine using an on-the-car brake lathe. Replace the rotor if it is
below minimum thickness values
Minimum Thickness: 26.0 mm (1.024 in.)
NOTE:
It is necessary to turn the rotors using the on-the-car brake lathe to ensure even and uniform rotor
run out. DO NOT turn the rotor using an off-the-car brake lathe.
B. Install the disc, brake caliper, and 2 NEW bolts.
Torque: 123 N.m (1,259 kgf.cm, 90 ft.lbf)
C. Install the brake line clamp to the steering knuckle with the bolt.
Torque: 28 N.m (285 kgf.cm, 21 ft.lbf)
27. Install new brake line.
Using the SST, connect NEW brake line.
SST P/N: 09023-00100
Torque: 15 N.m (155 kgf.cm, 11 ft.lbf)
28. With ABS:
Connect the ABS speed sensor and wire harness clamp to the steering knuckle with the 2 bolts.
Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
29. 4WD:
Install drive shaft lock nut.
A. While applying the brakes, tighten the nut.
Torque: 235 N.m (2,400 kgf.cm, 173 ft.lbf)
B. Install the lock cap and a NEW cotter pin. If the holes for the cotter pin are not aligned, tighten
the nut further up to 600.
30. 2WD:
Install grease cap.
31. Install front wheel.
NOTE:
Do NOT use an air wrench.
Torque: 110 N.m (1,150 kgf.cm, 83 ft.lbf)
Page 1718
B. You have the option to delete calibrations off the tester before downloading a new calibration.
The CUW also provides this option if there is not enough memory for the new calibration. To delete
one or all of the calibrations, follow the screen flow shown (Figure 5).
C. If this is the first time you have downloaded a calibration file from TIS to the Diagnostic Tester
Program Card, you MUST first install the latest version of the Calibration Update Wizard (CUW)
onto your TIS workstation PC, as shown in Figure 6.
This step is also required if you are using a version of CUW earlier than version 6.0. CUW 6.0 is
the only version compatible with Diagnostic Tester software version 10.2a and later. If necessary,
select the link to the TIS Diagnostic Applications Installer and follow the on-screen prompts to
install or reinstall CUW.
Diagram Information and Instructions
Seat Belt Reminder Lamp: Diagram Information and Instructions
Key to Diagrams
A: System Title
B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to
distinguish it from the J/B
Example: 1 Indicates Relay Block No.1
C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type,
or specification is different.
D: Indicates related system.
Page 4398
3. MEASURE DISC RUNOUT
Using a dial indicator, measure the disc runout at a position 10 mm (0.39 inch) from the outside
edge. Maximum disc runout: 0.07 mm (0.0028 inch) If the runout is greater than the maximum,
replace the disc or grind it on a "On-Car" brake lathe.
HINT: Before measuring the runout, confirm that the front hub bearing play is within the
specification.
4. IF NECESSARY, ADJUST DISC RUNOUT
(a) Remove the hub nuts and disc. Reinstall the disc 1/6 of a turnround from its original position on
the hub. Install and torque the hub nuts.
Torque: 113 Nm (1,150 kgf-cm, 83 ft. lbs.)
(b) Remeasure the disc runout. Make a note of the runout and the disc's position on the hub. (c)
Repeat (a) and (b) until the disc has been installed on the 4 remaining hub positions.
If the minimum runout recorded in (a) to (c) is less than the maximum disc runout, install the disc in
that position. If the minimum runout recorded in (a) to (c) is greater than the maximum disc runout,
replace the disc and repeat step 3.
REASSEMBLY
Reassembly is in the reverse order of disassembly.
NOTICE: Apply lithium soap tease glycol grease end disc brake grease to the parts indicated by
the arrows.
Page 3553
Instrument Panel
Ground Location
IE Left Kick Panel
IF Left Kick Panel
IG Instrument Panel Brace RH
IH Right Kick Panel
II Right Kick Panel
Body
Ground Location (Access Cab)
Page 1875
Knock Sensor: Service and Repair
1. REMOVE THROTTLE BODY COVER
2. REMOVE INTAKE AIR CONNECTOR
3. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS
4. REMOVE UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY
5. INSPECT KNOCK SENSOR 1,2
Disconnect the knock sensor connectors.
1. REPLACE THE SENSOR WITH SST.
SST 09816-30010
Torque: 45 N.m (450 kgf.cm, 33 ft.lbf)
Reconnect the knock sensor connectors.
2. REINSTALL UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY
3. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS
4. REINSTALL INTAKE AIR CONNECTOR
5. REINSTALL THROTTLE BODY COVER
Page 6859
Fog/Driving Lamp Relay: Testing and Inspection
INSPECT FOG LIGHT RELAY CONTINUITY If continuity is not as specified, replace the relay.
Page 6271
Terminal Retainer
Push the terminal retainer down to the temporary lock position.
c. Release the locking lug from terminal and pull the terminal out from rear.
4. INSTALL TERMINAL TO CONNECTOR
a. Insert the terminal.
HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug
locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position.
Page 6301
Instrument Panel
Ground Location
IE Left Kick Panel
IF Left Kick Panel
IG Instrument Panel Brace RH
IH Right Kick Panel
II Right Kick Panel
Body
Ground Location (Access Cab)
Page 4176
32. Depress brake pedal several times.
33. Fill the brake reservoir with brake fluid and bleed brake system.
34. Check ABS Speed Sensor Signal (refer to the Technical Information System (TIS):
2000 - 2005 model year Tundra Repair Manual: Diagnostics: Anti-lock Brake System: Pre-Check).
Repair Procedure No. 2
1. Resurface the disc rotors with the "On-Car Lathe" to within serviceable limits.
NOTE:
It is necessary to turn the rotors using only an on-the-car brake lathe to ensure even and uniform
rotor run out. DO NOT turn the rotor using an off-the-car brake lathe.
2. If the disc rotors are unserviceable or below minimum thickness (per specification stamped on
the rotor), replace the rotors using the service parts from the Parts Information table.
3. Check any new disc rotor for runout.
4. If the disc rotor runout is over 0.03 mm (0.0012 in.), perform a phase matching procedure.
5. Replace the front brake caliper LH and RH assemblies using the service parts from the Parts
Information table.
6. Perform a road test.
Page 3579
Transmission Mode Indicator - A/T: Electrical Diagrams
Electronically Controlled Transmission And A/T Indicator (Part 1)
Page 4830
Page 6882
Non-Waterproof Type Connector
"Case 1" Raise the terminal retainer up to the temporary lock position.
Non-Waterproof Type Connector
"Case 2" Open the secondary locking device.
Page 5572
Glossary Of Terms And Symbols (Part 1)
Page 4113
Required Tools & Material
Page 1871
Knock Sensor: Description and Operation
P0325 - Knock Sensor 1 Circuit Malfunction (Bank 1) CIRCUIT DESCRIPTION
DTC Detection Condition
One of the knock sensors is fitted to the right bank and another to the left bank of the cylinder block
to detect the engine knocking. This sensor contains a piezoelectric element which generates
voltage when it becomes deformed. This occurs when the cylinder block vibrates due to knocking.
If the engine knocking occurs, ignition timing is retarded to suppress it.
Wiring Diagram
Page 3027
Fuel Pressure: Testing and Inspection
CHECK FUEL PRESSURE
a. Check the battery positive voltage is above 12 V. b. Disconnect the negative (-) terminal cable
from the battery. c. Remove the front fuel pipe from the LH delivery pipe.
d. Install the front fuel pipe and SST (pressure gauge) to the delivery pipe with 3 lower gaskets and
SST (adapter).
SST 09268-45014 (09268-1190, 90405-06167)
Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)
e. Wipe off any splattered gasoline. f.
Reconnect the negative (-) terminal cable to the battery.
g. Connect a TOYOTA hand-held tester to the DLC3. (See step 1 in check fuel pump operation (a)
to (e)) h. Measure the fuel pressure.
Fuel pressure: 265 - 304 kPa (2.7 - 3.1 kgf/sq.cm, 38 - 44 psi)
If pressure is high, replace the fuel pressure regulator. If pressure is low, check the fuel hoses and
connections, fuel pump, fuel filter and fuel pressure regulator.
i. Disconnect the TOYOTA hand-held tester from the DLC3.
j. Start the engine.
k. Measure the fuel pressure at idle.
Fuel pressure: 265 - 304 kPa (2.7 - 3.1 kgf/sq.cm, 38 - 44 psi)
l. Stop the engine.
m. Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped.
Fuel pressure: 147 kPa (1.5 kgf/sq.cm, 21 psi) or more
If pressure is not as specified, check the fuel pump, pressure regulator and/or injectors.
n. After checking fuel pressure, disconnect the negative (-) terminal cable from the battery and
carefully remove the SST to prevent gasoline from
splashing. SST 09268-45014
o. Reinstall the front fuel pipe to the LH delivery pipe. p. Reconnect the negative (-) terminal cable
to the battery. q. Check for fuel leaks.
Page 5977
Page 1143
3. 2WD: REMOVE LOCK NUT AND ABS SPEED SENSOR ROTOR/SPACER
a. Using a chisel and hammer, loosen the staked part of the lock nut.
NOTICE: Be careful not to damage the bushing.
b. Using Special Service Tool (SST), remove the lock nut.
SST 09318-12010
c. Remove the ABS speed sensor rotor/spacer.
NOTICE: Take care not to scratch the serration of the speed sensor rotor.
4. REMOVE AXLE HUB FROM STEERING KNUCKLE
a. Remove the 4 bolts and shift the dust cover towards the hub side (outside). b. Using SST,
remove the axle hub from the steering knuckle.
SST 09710-30021 (09710-03051), 09950-40011 (09951-04020, 09952-04010, 09953-04020,
09954-04010, 09955-04031, 09957-04010, 09958-04011)
c. Remove the dust cover from the steering knuckle. d. 4WD: Remove the bearing spacer and ABS
speed sensor rotor (w/ABS)/spacer (w/o ABS).
NOTICE: Take care not to scratch the serration of the speed sensor rotor.
5. REMOVE OIL SEAL (OUTSIDE)
Using a screwdriver, remove the oil seal (outside) from the steering knuckle.
6. REMOVE BEARING FROM STEERING KNUCKLE
a. Using snap ring pliers, remove the snap ring. b. Using SST and a press, remove the bearing
from the steering knuckle.
SST 09950-60020 (09951-00810), 09950-70010 (09951-07150)
REASSEMBLY
Page 2558
A. Test J1962 OBDIII CAN Interface Module (P/N 01002744) for continuity.
^ If there is continuity, the cable and CAN Interface Module are OK. Re-check Cable Tests 1, 2,
and 3 while wiggling and flexing the cables.
^ If there is no continuity, proceed to CABLE TEST 4.
CABLE TEST 4.
A. Disconnect the CAN Interface Module (P/N 01002744) from the J1962 OBDII cable using a
Phillips screwdriver.
B. Test J1962 OBDII cable (P/N 02003180) for continuity.
^ If there is no continuity, the cable needs to be replaced.
^ If there is continuity, proceed to CAN Interface Module Test 5.
CAN INTERFACE MODULE TEST 5.
Page 1994
CHART 23
Page 3462
Glossary Of Terms And Symbols (Part 2)
Page 6839
Waterproof Type Connector
B: For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White
: Gray
Black or White : Dark Gray
Gray or White : Black
Waterproof Type Connector
"Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up
to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Waterproof Type Connector
"Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 1921
CHART 14
Page 2317
D. The Calibration Update Wizard (CUW) launches automatically when a calibration file link is
selected (or clicked). Verify that the CUW version is 6.0 or higher. If not, refer to the Note below.
The CUW will guide you through the steps to download the calibration file to the Diagnostic Tester
Program Card. Click NEXT on the first screen (Figure 7).
NOTE:
If the CUW does not launch, or the version is older than 6.0, install Diagnostic Software (TIS
Diagnostic Applications Installer). Specific installation instructions (Reprogramming with CUW 6.0)
are located under Diagnostics ECU Flash Reprogramming (Figure 6).
Page 3615
Valve Body: Service and Repair Lower Valve Body
1. COMPONENTS
2. SPRING, RETAINER AND CLIP
Page 1144
1. INSTALL NEW BEARING
a. Using Special Service Tool (SST) and a press, install a new bearing to the steering knuckle.
SST 09527-17011, 09950-60020 (09951-00910)
b. Using snap ring pliers, install a new snap ring.
2. INSTALL NEW OIL SEAL (OUTSIDE)
a. Using SST and a plastic hammer, install a new oil seal (outside).
SST 09223-15030, 09527-17011
b. Coat MP grease to the oil seal lip.
3. INSTALL AXLE HUB TO STEERING KNUCKLE
a. Install the dust cover to the steering knuckle with the 4 bolts.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)
b. Using SST and a press, install the axle hub to the steering knuckle.
SST 09649-17010
4. INSTALL ABS SPEED SENSOR ROTOR (w/ ABS)/SPACER (w/o ABS)
NOTICE: Do not scratch the serration of the speed sensor rotor.
5. 2WD: INSTALL NEW LOCK NUT
a. Using SST install and torque a new lock nut to the axle hub.
SST 09318-12010 Torque: 274 Nm (2,800 kgf-cm, 203 ft. lbs.)
b. Using a chisel and hammer, stake the lock nut.
Page 6533
Seat Belt Reminder Buzzer: Description and Operation
KEY REMINDER AND SEAT BELT WARNING
SYSTEM OUTLINE
Current always flows to TERMINAL (B) 5 of the combination meter through the DOME fuse.
1. SEAT BELT WARNING SYSTEM
When the ignition SW is turned on, current flows from the GAUGE fuse to TERMINAL (A) 7 of the
combination meter. This current activates the combination meter and the current flowing through
the seat belt warning light flows from TERMINAL (A) 12 to GROUND, causing the warning light to
light up. A buckle SW off signal is input to TERMINAL (B) 9 of the combination meter to TERMINAL
(A) 12 to GROUND, causing the warning light to light up. A buckle SW off signal is input to
TERMINAL (B) 9 of the combination meter, the current flowing to TERMINAL (B) 5 of the
combination meter flows from TERMINAL (A) 12 to GROUND and the seat belt warning buzzer
sounds. However, if the seat belt is put on during this period (While the buzzer is sounding), signal
input to TERMINAL (B) 9 of the combination meter stops and the current flow from TERMINAL (B)
5 of the combination meter to TERMINAL (A) 12 to GROUND is cut, causing the buzzer to stop.
2. KEY REMINDER SYSTEM
With the ignition key inserted in the key cylinder (Unlock warning SW on), the ignition SW still off
and driver's door open (Door courtesy SW on), when a signal is input to TERMINAL (B) 10 of the
combination meter, the combination meter operates, current flows from TERMINAL (B) 5 of the
combination meter to TERMINAL (A) 12 to GROUND and key reminder buzzer sounds.
Page 1775
Engine Control Module: Locations
Instrument Panel
Page 4953
DISASSEMBLY
NOTICE: When using a vise, do not overtighten it.
Page 5283
1. Turn the temperature control knob to the full cold position.
2. Inspect the clearance between the water control valve lever and the lever stop.
If the lever does not contact the lever stop, proceed to step 3.
3. If the lever does not contact the lever stop:
A. Disengage the cable retaining clip.
B. Pull up on the cable sheath until the water control valve lever contacts the lever stop.
C. Re-fasten the cable retaining clip.
Removal and Installation
Hydraulic Control Assembly - Antilock Brakes: Service and Repair Removal and Installation
Page 3172
Camshaft Position Sensor: Description and Operation
The Camshaft Position Sensor
Camshaft position sensor (G signal) consists of a magnet iron core and pickup coil.
The G signal plate has 1 tooth on its outer circumference and is installed on the LH camshaft timing
pulley. When the camshafts rotate, protrusion on the signal plate and air gap on the pickup coil
change, causing fluctuations in the magnetic field and generating an electromotive force in the
pickup coil.
The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor
generates 34 signals at every engine revolution. The ECM detects the standard angle of the
crankshaft based on the G signal and the actual angle of the crankshaft and the engine speed by
the NE signal.
Page 2338
Glossary Of Terms And Symbols (Part 1)
Page 4240
Applicable Warranty*:
This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or
36,000 miles, whichever occurs first, from the vehicle's in-service date.
*Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Page 6557
Glossary Of Terms And Symbols (Part 2)
Page 6326
b. Push the secondary locking device or terminal retainer in to the full lock position.
5. CONNECT CONNECTOR
Disconnection of Male and Female Connectors
Disconnection of Male and Female Connectors
Disconnection Of Male And Female Connectors
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Page 5769
Splice Point
J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel,
and "B" for the Body).
The Location of splice Point I5 is shaded.
K: Indicates a shielded cable.
L: Indicates the pin number of the connector.
The numbering system is different for female and male connectors.
M: Indicates a ground point.
The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for
the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body
and Surrounding area.
How to Read Connector List
HOW TO READ CONNECTOR LIST
A: Indicates connector to be connected to a part. (The numeral indicates the pin No.)
Page 5805
Glossary Of Terms And Symbols (Part 1)
Specifications
Vacuum Brake Booster: Specifications
Brake Booster Mounting Bolts 13 Nm
Page 3382
F. Confirm the Diagnostic Tester software version and connections to the TIS workstation are
correct.
* NOTE:
This screen displays the required version of Diagnostic Tester software that is compatible with the
selected calibration file, and the other required steps to properly connect the Diagnostic Tester to
your PC.
^ Type I calibration files are only compatible with software version 10.1a and older versions.
^ Type II calibration files are only compatible with software version 10.2a and newer versions.
G. Place the Diagnostic Tester in the "GET CAL FROM PC" mode to receive the calibration file
(Figure 10).
Click NEXT on the TIS workstation. Once communications begin between the PC and the
Diagnostic Tester, the Diagnostic Tester display will flash CONNECTED.
H. The CUW determines if there is enough memory to store the calibration file on the Diagnostic
Tester Program Card. If there is insufficient
Page 5153
DISASSEMBLY
1. 2WD: REMOVE GREASE CAP
a. Mount the axle hub in a soft jaw vise.
HINT: Close the vise until it holds hub bolts. Do not tighten further.
b. Using a screwdriver, remove the grease cap.
2. 4WD: REMOVE OIL SEAL (INSIDE)
a. Mount the axle hub in a soft jaw vise.
HINT: Close the vise until it holds hub bolts. Do not tighten further.
b. Using a screwdriver, remove the oil seal (inside).
Page 4084
Using the following SSTs and a press, install the bearing spacer.
^ 09950-60010 (09951-00650)
^ 09950-70010 (09951-07150)
22. 4WD: INSTALL NEW OIL SEAL (INSIDE)
A. Using the following SST and a plastic hammer, install a NEW oil seal (inside).
^ 09527-17011
NOTE:
Lightly strike the SST on its circumference evenly.
B. Coat MP grease to the oil seal lip.
23. INSTALL STEERING KNUCKLE
A. 4WD: Insert the drive shaft into the axle hub and temporarily tighten the nut.
NOTE:
Be careful not to damage the oil seal and drive shaft boot.
B. Connect the steering knuckle to the upper suspension arm.
C. Install the nut and a NEW cotter pin. If the holes for the cotter pin are not aligned, tighten the nut
further up to 60°.
Torque: 105 N.m (1,100 kgf.cm, 77 ft.lbf)
24. CONNECT LOWER BALL JOINT
Connect the lower ball joint to the steering knuckle with 4 bolts.
Torque: 50 N.m (510 kgf.cm, 37 ft.lbf)
25. INSTALL SHOCK ABSORBER WITH COIL SPRING
A. Install the upper side of shock absorber to the chassis frame with the 3 nuts.
Page 3190
Knock Sensor (Part 2)
Page 6168
The spring properties of the rubber cushion of each of the body mounts have been optimized in
order to improve the vehicle's riding comfort and to reduce noise and vibration.
Page 3705
c. Suspend the front side of the propeller shaft. d. Place matchmarks on the transfer and propeller
shaft flanges. e. Remove the 4 nuts and washers. f.
Remove the propeller shaft from the transfer.
2. REMOVE REAR PROPELLER SHAFT
a. Place matchmarks on the transfer and propeller shaft flanges. b. Remove the 4 nuts and
washers, and disconnect the propeller shaft from the transfer. c. Suspend the front side of the
propeller shaft.
d. Remove the 2 mounting bolts and center support bearing. e. Place matchmarks on the
differential and propeller shaft flanges. f.
Remove the 4 bolts, washers and nuts.
g. Remove the propeller shaft from the differential.
DISASSEMBLY
NOTICE: Be careful not to grip the propeller shaft tube too tightly in a vise as this will cause
deformation.
1. Rear propeller shaft: SEPARATE PROPELLER SHAFT AND INTERMEDIATE SHAFT
a. Place the matchmarks on the flanges. b. Remove the 4 nuts, bolts and washers.
2. Rear propeller shaft:
REMOVE CENTER SUPPORT BEARING FROM INTERMEDIATE SHAFT a. Using a hammer and
chisel, loosen the staked part of the nut.
Testing and Inspection
Volt Meter Gauge: Testing and Inspection
INSPECT VOLT GAUGE SYSTEM
Measure the resistance between terminals A and B.
Resistance: Approx. 347 ohms
If resistance value is not as specified, replace the gauge.
Page 2567
B. You have the option to delete calibrations off the tester before downloading a new calibration.
The CUW also provides this option if there is not enough memory for the new calibration. To delete
one or all of the calibrations, follow the screen flow shown (Figure 5).
C. If this is the first time you have downloaded a calibration file from TIS to the Diagnostic Tester
Program Card, you MUST first install the latest version of the Calibration Update Wizard (CUW)
onto your TIS workstation PC, as shown in Figure 6.
This step is also required if you are using a version of CUW earlier than version 6.0. CUW 6.0 is
the only version compatible with Diagnostic Tester software version 10.2a and later. If necessary,
select the link to the TIS Diagnostic Applications Installer and follow the on-screen prompts to
install or reinstall CUW.
Brakes - Front Brakes Vibrate Upon Application
Technical Service Bulletin # BR004R-02 Date: 050404
Brakes - Front Brakes Vibrate Upon Application
BRAKES BR004-02 REVISED
Title: FRONT BRAKE VIBRATION
Models: '00 - '05 Tundra
September 12, 2002
TSB REVISION NOTICE:
^ April 4, 2005: Applicable Vehicles has been updated to include 2003 - 2005 model years. The
following sections have been updated, expanded, or added: Introduction, Warranty Information,
Production Change Information, Parts Information, Required SSTs, Diagnosis Procedure, Repair
Procedure No.1, and Repair Procedure No.2. PLEASE READ ENTIRE TSB.
^ September 24, 2004: A note has been added, step 26.
^ March 5, 2004: A torque specification in step 24, was changed.
^ September 8, 2003: A torque specification in step 28, was changed.
Previous versions of this TSB should be discarded.
Introduction
Under certain usage conditions, some Tundra trucks may exhibit front brake vibration.
Improvements have been made to various brake components to help improve this condition.
Applicable Vehicles
^ 2000 - 2005 model year Tundra vehicles produced BEFORE the Production Change Effective
VINs shown.
Production Change Information
Locations
Fusible Link: Locations
Driver Side J/B And Integration Relay
Page 5789
BJ Inside of Rear Door LH
BK Inside of Rear Door RH
BL Surrounding of the Front of the Fuel Tank
Connector Location
BA1 Front Door LH Wire and Wire Harness (Connector Location)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel)
BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel)
BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel)
BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Page 6212
Cruise Control (Part 1)
Page 1502
g. Reinstall the camshafts. h. Reinstall the timing belt. i.
Recheck the valve clearance.
11. REINSTALL CYLINDER HEAD COVERS 12. REINSTALL IGNITION COILS 13. REINSTALL
NO.3 TIMING BELT COVERS 14. REINSTALL AIR CLEANER AND INTAKE AIR CONNECTOR
ASSEMBLY 15. REINSTALL THROTTLE BODY COVER 16. REINSTALL BATTERY CLAMP
COVER
Page 5488
NOTE:
Affix the fluorocarbon resin tape on the shoulder belt anchor to the other side following the same
procedure.
NOTE:
If the seat belt requires cleaning to remove dirt, only use a neutral detergent or lukewarm water to
clean. Use the seat belt after it is completely dried, to confirm proper operation.
Page 6705
Brake Lamp: Ground Locations
Engine Compartment
Ground Location
EA Front Left Fender
EB Rear Bank of Right Cylinder
EC Rear Bank of Left Cylinder
Connector Location
EA1 Cowl Wire Harness and Wire Harness (Connector Location)
EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B)
EC1 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC2 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC3 Engine No. 2 Wire and Engine Wire (Near the Starter)
ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission)
Page 2099
Knock Sensor: Testing and Inspection
INSPECTION
1. REMOVE THROTTLE BODY COVER
2. REMOVE INTAKE AIR CONNECTOR
3. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS
4. REMOVE UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY
5. INSPECT KNOCK SENSOR 1,2
a. Disconnect the knock sensor connectors. b. Using an ohmmeter, check that there is no
continuity between the terminal and body.
If there is continuity, replace the sensor with SST. SST 09816-30010
Torque: 45 N.m (450 kgf.cm, 33 ft.lbf)
c. Reconnect the knock sensor connectors.
6. REINSTALL UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY
7. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS
8. REINSTALL INTAKE AIR CONNECTOR
9. REINSTALL THROTTLE BODY COVER
Page 333
Wheel Speed Sensor: Diagrams
Page 6412
Key Reminder Switch: Harness Locations
Engine Compartment
Connector Location
EA1 Cowl Wire Harness and Wire Harness (Connector Location)
EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B)
EC1 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC2 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC3 Engine No. 2 Wire and Engine Wire (Near the Starter)
ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission)
Page 6661
Splice Location
I1 Cowl Wire
I2 Cowl Wire
I3 Cowl Wire
I4 Cowl Wire
I5 Cowl Wire
I6 Cowl Wire
I7 Engine Wire
I8 Engine Wire
I9 Engine Wire
I10 Engine Wire
I11 Engine Wire
I12 Engine Wire
I13 Engine Wire
I14 Engine Wire
I15 Engine Wire
I16 Cowl Wire
Body
Splice Location (Access Cab)
B1 Speaker Tweeter Wire LH
B2 Front Door LH Wire
B3 Front Door LH Wire
B4 Roof Wire
B5 Speaker Tweeter Wire RH
B6 B7
Front Door RH Wire
B8 Front Door RH Wire
B9 Rear Door No. 1 Wire RH
B10 Frame Wire
Page 2278
L. The calibration file will now be downloaded to the Diagnostic Tester Program Card. This process
takes approximately 2-6 minutes (see Figure 15).
M. The CUW will prompt when the calibration file is completely downloaded. Click OK to close the
CUW (Figure 16).
NOTE:
With the calibration file loaded on the Diagnostic Tester Program Card, it is not necessary to repeat
the above steps to reprogram a different vehicle needing the same calibration file. The steps above
are only required when a new calibration file must be loaded onto the Diagnostic Tester Program
Card.
The Diagnostic Tester now has the calibration file stored and you may proceed to the next step to
reprogram the vehicle ECU.
REPROGRAM ECU WITH TESTER
3. Reprogram the vehicle ECU with the Diagnostic Tester.
NOTICE:
Errors during the flash reprogramming process can permanently damage the vehicle ECU.
Minimize the risks by following the steps below.
^ Battery voltage MUST NOT FALL BELOW 11.4 volts during reprogramming.
^ Confirm battery voltage is higher than 11.4 volts, but be sure voltage DOES NOT RISE ABOVE
16.0 volts during reprogramming.
^ Turn off all electrical accessories (e.g. Audio system, A/C, interior lights, DRL, etc.).
^ Do not add to or significantly change the vehicle's electrical load while reprogramming.
^ Confirm the hood is open and ensure under hood temperatures do not exceed 158°F.
Page 6418
Wiring Harness Connector
E: Indicates the wiring harness and wiring harness connector. The wiring harness with male
terminal is shown with arrows.
Outside numerals are pin numbers.
The first letter of the code for each wiring harness and wiring harness connector(s) indicates the
component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and
Surrounding area, and "B" for the Body and Surrounding area.
When more than one code has the first and second letters in common, followed by numbers (e.g,
IH1, IH2), this indicates the same type of wiring harness and wiring harness connector.
F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in
parts position.
G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside
it). Junction Blocks are shaded to clearly separate
them from other parts.
H: When 2 parts both use one connector in common, the parts connector name used in wire
routing is shown in square brackets [ ].
Wiring Color
I: Indicates the wiring color.
Wire colors are indicated by an alphabetical code.
B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR =
Brown SB = Sky Blue LG = Light Green GR = Gray
The first letter indicates the basic wire color and the second letter indicates the color of the stripe.
Page 704
4. INSPECT THROTTLE POSITION SENSOR
a. Disconnect the throttle position sensor connector. b. Using an ohmmeter, measure the
resistance between terminals VC and E2.
Resistance: 1.25 - 2.35 kohms at 20 °C (68 °F)
If the resistance is not as specified, replace the throttle position sensor.
c. Reconnect the throttle position sensor connector.
5. INSPECT ACCELERATOR PEDAL POSITION SENSOR
a. Disconnect the pedal position sensor connector. b. Using an ohmmeter, measure the resistance
between terminals VC and E2.
Resistance: 1.64 - 3.28 kohms at 20 °C (68 °F)
If the resistance is not as specified, replace the accelerator pedal position sensor.
c. Reconnect the pedal position sensor connector.
6. REINSTALL THROTTLE BODY COVER
Page 4356
32. Depress brake pedal several times.
33. Fill the brake reservoir with brake fluid and bleed brake system.
34. Check ABS Speed Sensor Signal (refer to the Technical Information System (TIS):
2000 - 2005 model year Tundra Repair Manual: Diagnostics: Anti-lock Brake System: Pre-Check).
Repair Procedure No. 2
1. Resurface the disc rotors with the "On-Car Lathe" to within serviceable limits.
NOTE:
It is necessary to turn the rotors using only an on-the-car brake lathe to ensure even and uniform
rotor run out. DO NOT turn the rotor using an off-the-car brake lathe.
2. If the disc rotors are unserviceable or below minimum thickness (per specification stamped on
the rotor), replace the rotors using the service parts from the Parts Information table.
3. Check any new disc rotor for runout.
4. If the disc rotor runout is over 0.03 mm (0.0012 in.), perform a phase matching procedure.
5. Replace the front brake caliper LH and RH assemblies using the service parts from the Parts
Information table.
6. Perform a road test.
Page 1220
Piston Ring: Service and Repair
For further information regarding this component and the system that it is a part of, please refer to
Cylinder Block Assembly; Service and Repair.
Testing and Inspection
Power Seat Switch: Testing and Inspection
Slide Switch
Front Tilt Switch
Rear Lifter Switch
Reclining Switch
INSPECT POWER SEAT SWITCH CONTINUITY
If continuity is not as specified, replace the switch.
Page 1370
Throttle Body (Part 1)
Page 5399
a. Check functioning of the SST.
CAUTION: When deploying the airbag, always use the specified SST: SRS Airbag Deployment
Tool.
SST 09082-00700
1. Connect the SST to the battery.
Connect the red clip of the SST to the battery positive (+) terminal and the black clip to the battery
negative (-) terminal.
HINT: Do not connect the yellow connector which will be connected with the supplemental restraint
system.
2. Check functioning of the SST.
Press the SST activation switch, and check that the LED of the SST activation switch lights up.
CAUTION: If the LED lights up when the activation switch is not being pressed, SST malfunction is
probable, so definitely do not use the SST.
3. Disconnect the SST from the battery.
b. Install the SST.
CAUTION: Check that there is no looseness in the steering wheel and steering wheel pad.
1. While turning the steering wheel right / left, remove the 3 screws and column lower cover. 2.
Disconnect the airbag connector of the spiral cable.
Page 3237
Continuity And Resistance Check
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Continuity And Resistance Check
C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the
electrical circuit.
Finding A Short Circuit
Finding A Short Circuit
Finding A Short Circuit
A. Remove the blown fuse and disconnect all loads of the fuse.
Page 4395
3. REMOVE CALIPER
Remove the 2 mounting bolts and caliper. Torque: 123 Nm (1,250 kgf-cm, 90 ft. lbs.)
4. REMOVE CLIP, 2 PINS AND ANTI-RATTLE SPRING 5. REMOVE 2 PADS AND 4
ANTI-SQUEAL SHIMS
NOTICE: The anti-rattle spring and clip can be used again provided that they have sufficient
rebound, no deformation, cracks or wear, and have had all rust, dirt and foreign particles cleaned
off.
INSTALLATION
Installation is in the reverse order of removal.
HINT: After installation, fill brake reservoir with brake fluid and bleed brake system.
- Check for leaks.
Engine - Accessory Drive Belt Squealing Noise
Drive Belt: All Technical Service Bulletins Engine - Accessory Drive Belt Squealing Noise
ENGINE EG026-06 REVISED
Title: 2UZ-FE ACCESSORY DRIVE BELT NOISE
Models: '00 - '06 Tundra
April 21, 2006
TSB REVISION NOTICE:
^ July 9, 2007: The Introduction has been updated. Production Change Effective VINs have been
updated in the Production Change Information table. In the Repair Procedure steps 12 and 13 and
the illustration below step 13 have been updated, and steps 14 - 17 have been renumbered.
Previous versions of this TSB should be discarded.
Introduction
Some customers may experience an abnormal squeal noise from the engine accessory drive belt
area, usually during cold start-up. An improved accessory drive belt tensioner, A/C compressor
bracket, and revised installation procedure have been developed to address this condition.
Applicable Vehicles
^ 2000 - 2006 model year Tundra vehicles produced BEFORE the Production Change Effective
VINs shown below.
Production Change Information
Parts Information
Warranty Information
Applicable Warranty* This repair is covered under the Toyota Comprehensive Warranty. This
warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's
in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Repair Procedure
Page 1592
1. Remove coolant and any foreign material on rubber points "A," "B," and "C."
2. Check that points "A," "B " and "C" are not deformed, cracked, or swollen.
3. Check that points "C" and "D" are not stuck together.
4. Apply engine coolant to points "B" and "C" before using the radiator cap tester.
^ Radiator Cap Tester: Snap-On/Sun P/N SVTS262A (or equivalent)
5. Before installing the radiator cap tester, use the applicable radiator cap adaptor provided in the
following SST kits in conjunction with the radiator cap tester:
^ SST P/N 09230-00030-01 (09231-10080-01) or 09230-00020-01 (09231-10060-01) or
09230-00050-01(09231-10110-01
6. When using the radiator cap tester, tilt it more than 30 degrees.
7. Pump the radiator cap tester several times, and check the maximum pressure.
Pumping speed: 1 pump/second
HINT:
Stop pumping when the valve opens and read the gauge. The gauge must be within the standard
values listed below when the pressure valve opens. The cap is considered OK when the pressure
holds steady or falls very slowly, but holds within the standard values listed below for one minute.
Specification:
If the maximum pressure is less than the minimum standard value, replace the radiator cap
sub-assembly.
Type: Compact Cap, 88 kPa
Page 1970
^ O2S TEST RESULTS
A list of the available oxygen sensors will be displayed.
2. Select the desired oxygen sensor and press Enter.
NOTE:
The monitor result of the A/F sensor will not be displayed. If you select "Bank 1-Sensor 1" or Bank
2-Sensor 1" for a vehicle equipped with an A/F sensor, the Diagnostic Tester will display "No
parameter to display."
3. Compare the test results with the values listed in the Failure Threshold Chart.
* Although this procedure references the Toyota Diagnostic Tester, the O2S test results can be
checked using a generic OBD II scantool. Refer to your OBD II scantool operator's manual for
specific procedures.
Comparing O2S Test Results to Failure Thresholds
1. Determine the correct O2S Failure Threshold Chart for your vehicle by looking in the "O2S
Application Table," in this bulletin.
2. Select appropriate year, model, and engine for specified O2S Failure Threshold Chart.
3. Compare O2S test results with the specified O2S Failure Threshold Chart. It may be necessary
to convert O2S test results to a specific measurement unit using the conversion factor that is
supplied in the specified table. See example.
Example:
Diagram Information and Instructions
Horn: Diagram Information and Instructions
Key to Diagrams
A: System Title
B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to
distinguish it from the J/B
Example: 1 Indicates Relay Block No.1
C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type,
or specification is different.
D: Indicates related system.
Specifications
Brake Pedal Assy: Specifications
Brake Pedal Assembly Pedal Height 164-174 mm
Reserve Pedal Height >95 mm
Pedal Free Play (1) 1-3 mm
Free play to the first point of resistance (between the
clevis and the pin)
Pedal Free Play (2) 1-6 mm
Total pedal free play
Stop Light Switch Clearence 0.5-2.4 mm
Push Rod Lock Nut 25 Nm
Page 5053
II. Identification of Affected Vehicles
Testing and Inspection
Daytime Running Lamp Resistor: Testing and Inspection
INSPECT DAYTIME RESISTOR CONTINUITY If continuity is not as specified, replace the resistor.
Page 4816
Driver Side J/B And Integration Relay
Page 6534
Seat Belt Reminder Buzzer: Testing and Inspection
KEY REMINDER AND SEAT BELT WARNING
B7 (A), (B) BUCKLE SW LH
(A) 1 - (A) 2, (B) 2 - (B) 1 : Closed with driver's seat belt in use
D16 DOOR COURTESY SW FRONT LH
1 - GROUND : Closed with front LH door open
U1 UNLOCK WARNING SW
1 - 2 : Closed with ignition key in cylinder
C11 (A), C12 (B), C13 (C) COMBINATION METER
(A) 12, (B) 15 - GROUND : Always continuity (B) 10 - GROUND
: Continuity with the front LH door open (Standard cab) : Continuity with the each LH door open
(Access cab)
(C) 1 - GROUND : Continuity with the ignition key in cylinder
(B) 9 - GROUND : Continuity with the driver's seat belt in use
(B) 5 - GROUND : Always approx. 12 volts
(A) 7 - GROUND : Approx. 12 volts with the ignition SW at ON or ST position
Replacement Requirements
Clockspring Assembly / Spiral Cable: Service and Repair Replacement Requirements
REPLACEMENT REQUIREMENTS
CAUTION: Be sure to follow the correct procedure, for removal and installation of the steering
wheel pad.
Page 1305
1. Remove the engine under cover.
2. Drain the engine coolant.
3. Remove the intake air connector assembly.
4. Remove the radiator fan shroud.
5. Remove the drive belt, fan, fluid coupling, and fan pulley.
6. Without disconnecting the power steering fluid lines, remove the power steering pump.
HINT: Suspend the power steering pump securely.
7. Remove the drive belt idler pulley.
8. Remove the right hand (RH) No. 3 timing belt cover.
9. Remove the No.2 timing belt cover.
10. Without disconnecting the A/C refrigerant lines, remove the A/C compressor from the mounting
bracket.
HINT: Suspend the A/C compressor securely.
11. Disconnect the A/C compressor mounting bracket.
Front
Fluid - Differential: Service and Repair Front
FILL DIFFERENTIAL WITH HYPOID GEAR OIL
Page 5575
Continuity And Resistance Check
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Continuity And Resistance Check
C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the
electrical circuit.
Finding A Short Circuit
Finding A Short Circuit
Finding A Short Circuit
A. Remove the blown fuse and disconnect all loads of the fuse.
Locations
Instrument Panel
Testing and Inspection
Idle Up Control Valve: Testing and Inspection
INSPECTION
1. TURN AIR CONDITIONING SWITCH OFF
2. CHECK IDLE-UP
a. Start the engine and run it at idle. b. Fully turn the steering wheel. c. Check that the engine
rotations decrease when the vacuum hose of the air control valve is pinched. d. Check that the
engine rotations increase when the hose is released.
Page 5992
Roof Headlining
Locations
Page 2432
CHART 20
Page 942
1. Remove the engine under cover.
2. Drain the engine coolant.
3. Remove the intake air connector assembly.
4. Remove the radiator fan shroud.
5. Remove the drive belt, fan, fluid coupling, and fan pulley.
6. Without disconnecting the power steering fluid lines, remove the power steering pump.
HINT: Suspend the power steering pump securely.
7. Remove the drive belt idler pulley.
8. Remove the right hand (RH) No. 3 timing belt cover.
9. Remove the No.2 timing belt cover.
10. Without disconnecting the A/C refrigerant lines, remove the A/C compressor from the mounting
bracket.
HINT: Suspend the A/C compressor securely.
11. Disconnect the A/C compressor mounting bracket.
Page 2121
4. Match the axis of the connector with axis of the pipe, and push in the connector until the
connector makes a "click" sound. In case that the
connections is tight, apply small amount of fresh engine oil on the tip of the pipe.
5. After having finished the connection, check if the pipe and the connector are securely connected
by pulling them. 6. Check if there is any fuel leakage.
h. Observe these precautions when handling nylon tube.
1. Pay attention not to turn the connected part of the nylon tube and the quick connector by force
when connecting them. 2. Pay attention not to kink the nylon tube. 3. Do not remove the EPDM
protector from the outside of the nylon tube. 4. Must not close the piping with the nylon tube by
bending it.
i. Check that there is any fuel leak after maintenance anywhere on the fuel system. 1. Connect a
TOYOTA hand-held tester to the DLC3. 2. Turn the ignition switch ON and push the TOYOTA
hand-held tester main switch ON.
NOTE: Do not start the engine.
3. Select the ACTIVE TEST mode on the TOYOTA hand-held tester. 4. Please refer to the
TOYOTA hand-held tester operator's manual for further details.
Page 2648
Engine Control Module: Service and Repair
VEHICLE REPROGRAMMING
Beginning with some 2001 models and expanding to all models by 2007, Toyota/Scion and Lexus
vehicles are equipped with flash reprogrammable Powertrain Control Modules (PCM).
Reprogramming should only be performed if a Technical Service Bulletin or Service Campaign
provides direction to do so.
Flash reprogramming may be accomplished using one of the following methods: Toyota/Lexus factory scantool
- Vetronix Mastertech
- J2534 Compatible Vehicle Interface (Toyota validated and approved)
REPROGRAMMING WITH SCANTOOL
Toyota/Scion/Lexus ECMs can be reprogrammed using either the Toyota/Lexus factory scantool,
or the Vetronix Mastertech scantool. The ECM reprogramming function is only available with the
authentic Toyota factory scantool software which runs on either of the above mentioned scantools.
Scantool software version requirements are specified in applicable Technical Service Bulletin
(TSB)/Service Communication (SC) documents.
The Toyota/Lexus factory scantool and/or authentic factory software program cards can be
purchased through the official Toyota and Lexus Special Service Tool provider, SPX Corp. To
order, call (800) 933-8335 and request either: P/N 01001271 for the Toyota/Lexus factory scantool including factory software program card
- P/N 01002593-005 for the "stand alone" program card
Program cards are provided with the latest production version software available at time of
purchase.
Vehicle recalibration using a scantool requires use of the following: Personal Computer running a Microsoft Windows 2000 or Windows XP operating system
- Toyota Diagnostic Tester or Vetronix Mastertech Scantool with Toyota factory software
- Toyota/Lexus factory scantool program card
- PC Interface Cable (P/N 01001090) to transfer data from PC to scantool
- Calibration CD (00456-REPRG-001)
REPROGRAMMING WITH J2534 INTERFACE
Toyota/Scion/Lexus ECMs that can be reprogrammed with a scantool can also be reprogrammed
using a Toyota validated J2534-1 interface. Vehicle recalibration requires the use of the following: Toyota validated J2534 interface
- Toyota Calibration Update Wizard software (available on calibration CD)
- Personal Computer running Microsoft Windows 2000/XP or later operating system
- Calibration CD (00456-REPRG-001)
Toyota strongly recommends USING ONLY VALIDATED INTERFACE DEVICES that appear on
this list.
Validated J2534 Devices Toyota works closely with J2534 interface manufacturers to ensure that
their hardware works safely and efficiently with their products. Every device listed on this page has
been thoroughly tested and validated on Toyota, Scion and Lexus vehicles.
It is important to understand that only the specific devices, firmware, DLLs and APIs listed here
have been tested by Toyota. Toyota does not recommend use of any other J2534 device, firmware,
DLL or API that is not listed here. Changes to J2534 hardware/software is outside of Toyota's
control; in some cases, changes made to device hardware/software can negatively impact
reprogramming performance. Toyota makes every effort to continue to work with J2534 interface
manufacturers to ensure continued product compatibility as the respective products evolve.
Requirement for device:
Supplier Device Name Version (Firmware* / DLL* / API*)
Drew Technologies CarDAQ Plus (01.08.06 / 01.08.06 / 04.04)
Actia PassThru+ XS (02.01 / 02.01 / 04.04)
Vetronix Corporation ES6510 Flasher (06.12 / 04.23 / 04.04)
EASE Diagnostics Universal Reprogrammer (JPI1_11b / 1.3.0.13 / 04.04)
Snap-On Pass Thru Pro (02.01 / 02.01 / 04.04)
Blue Streak Electronics Inc. BSE-2534 Global Programmer (01.21 / 02.27 / 04.04)
* Original validated firmware/DLL versions may be superceded by the device manufacturer.
Contact the device manufacturer if you are unable to find the versions listed above.
Support OS:
OS Name and Version:
Page 6431
b. Push the secondary locking device or terminal retainer in to the full lock position.
5. CONNECT CONNECTOR
Disconnection of Male and Female Connectors
Disconnection of Male and Female Connectors
Disconnection Of Male And Female Connectors
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Page 4527
Battery: Testing and Inspection
ON-VEHICLE INSPECTION
CAUTION:
- Check that the battery cables are connected to the correct terminals.
- Disconnect the battery cables when the battery is given a quick charge.
- Do not perform tests with a high voltage insulation resistance tester.
- Never disconnect the battery while the engine is running.
1. CHECK BATTERY ELECTROLYTE LEVEL
Check the electrolyte quantity of each cell.
Maintenance-Free Battery: If under the lower level, replace the battery (or add distilled water if
possible) and check the charging system.
Except Maintenance-Free Battery: If under the lower level, add distilled water.
2. Except Maintenance-Free Battery:
CHECK BATTERY SPECIFIC GRAVITY Check the specific gravity of each cell.
Standard specific gravity: 1.25 - 1.29 at 20 °C (68 °F)
If the specific gravity is less than specification, charge the battery.
3. Maintenance-Free Battery:
CHECK BATTERY VOLTAGE a. After having driven the vehicle and in the case that 20 minutes
have not passed after having stopped the engine, turn the ignition switch ON
and turn on the electrical system (headlight, blower motor, rear defogger etc.) for 60 seconds to
remove the surface charge.
b. Turn the ignition switch OFF and turn off the electrical systems.
Page 4732
Fuse: Application and ID
Engine Room R/B Fuse Applications (Part 1)
Page 4172
A. Using snap ring pliers, remove the snap ring.
B. Using the following SSTs and a press, remove the bearing from the steering knuckle.
SST P/N: 09950-60020
(09951-00810)
SST P/N: 09950-70010
(09951-07150)
16. Install new bearing.
A. Using the following SSTs and a press, install a NEW bearing to the steering knuckle.
SST P/N: 09527-17011
SST P/N: 09950-60020 (09951-00910)
B. Using snap ring pliers, install a NEW snap ring.
17. Install new oil seal (outside).
A. Using the following SSTs and a plastic hammer, install a NEW oil seal (outside).
SST P/N: 09223-15030
Page 410
Glossary Of Terms And Symbols (Part 2)
Page 919
c. Check that each pulley aligns with the timing marks as shown in the illustration. If the timing
marks do not align, remove the timing belt and
reinstall it.
17. TIGHTEN CRANKSHAFT PULLEY BOLT
Using SST, install the pulley bolt. SST 09213-54015 (90119-08216), 09330-00021 Torque: 245 Nm
(2,500 kgf-cm, 181 ft. lbs.)
18. INSTALL FAN BRACKET
Install the fan bracket with the 2 bolts and 2 nuts. Torque:
12 mm head 16 Nm (160 kgf-cm, 12 ft. lbs.) for (A) 14 mm head 32 Nm (330 kgf-cm, 24 ft. lbs.) for
(B)
HINT: Each bolt length is indicated in the illustration.
Bolt Length:
106 mm (4.17 inch) for 12 mm head (A) 114 mm (4.49 inch) for 14 mm head (B)
19. w A/C: INSTALL A/C COMPRESSOR
20. INSTALL NO.2 TIMING BELT COVER
Install the No.2 timing belt cover with the 2 bolts.
Page 4069
20. 2WD: INSTALL NEW LOCK NUT
A. Using the following SST, install and torque a NEW lock nut to the axle hub.
00002-00909 (09318-12010)
Torque: 274 N.m (2,800 kgf.cm, 203 ft.lbf)
NOTE:
Do NOT use air wrench.
B. Using a chisel and hammer, stake the lock nut.
21. 4WD:
INSTALL BEARING SPACER
Using the following SSTs and a press, install the bearing spacer.
^ 09950-60010 (09951-00650)
^ 09950-70010 (09951-07150)
22. 4WD:
Page 6990
- Let the primer coating dry for 3 minutes or more.
- Do not keep any of the opened Primer G for later use.
9. APPLY ADHESIVE
a. Cut off the tip of the cartridge nozzle.
Part No. 08850-00801 or equivalent
HINT: After cutting off the tip, use all adhesive within the time described in the table.
b. Load the cartridge into the sealer gun.
c. Coat the glass with adhesive as shown in the illustration.
A: 12 mm (0.47 in.) B: 8 mm (0.31 in.)
10. INSTALL WINDSHIELD GLASS AND MOULDING
a. Install the glass, aligning the reference marks using a suction rubber.
HINT: Check that stoppers engage correctly viewing.
b. Lightly press the glass front surface for close contact.
Page 568
CHART 24
Page 214
Engine Control Module: Specifications
Terminals Of ECU - Connector Pinouts (Part 2)
Page 5579
Terminal Retainer
Push the terminal retainer down to the temporary lock position.
c. Release the locking lug from terminal and pull the terminal out from rear.
4. INSTALL TERMINAL TO CONNECTOR
a. Insert the terminal.
HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug
locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position.
Brakes - Vibration From Front Brakes
Technical Service Bulletin # BR004R-02 Date: 040924
Brakes - Vibration From Front Brakes
BRAKES BR004-02 REVISED
Title: FRONT BRAKE VIBRATION
Models: '00 - '03 Tundra
September 16, 2002
TSB REVISION NOTICE:
^ September 24, 2004: A note has been added, step 26.
^ March 5, 2004: A torque speification, step 24, was changed.
^ September 8, 2003: A torque specification, step 28, was changed.
Previous versions of this TSB should be discarded.
Introduction
Under certain usage conditions, some Tundra trucks may exhibit front brake vibration. Improved
brake caliper assemblies have been introduced to correct this condition.
Applicable Vehicles
2000 - 2003 model year Tundra trucks built before the VIN shown below.
Production Change Information
Warranty Information
Applicable Warranty*:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36
months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Page 2347
Engine Control Module: Connector Views
Terminals Of ECM - Connector View
Terminals Of ECU - Connector Pinouts (Part 1)
Page 614
CHART 2
CHART 3
CHART 4
Page 4749
Glossary Of Terms And Symbols (Part 1)
Page 523
A/F and 02 Sensor Identification
Page 465
Mass Air Flow Meter: Testing and Inspection
MASS AIR FLOW (MAF) METER
INSPECTION
1. DISCONNECT MAF METER CONNECTOR
2. REMOVE MAF METER
Remove the 2 screws and MAF meter.
3. INSPECT MAF METER
a. Using an ohmmeter, measure the resistance between terminals THA and E2.
If the resistance is not as specified, replace the MAF meter.
b. Inspect for operation.
1. Connect the MAF meter connector. 2. Connect the negative (-) terminal cable to the battery. 3.
Turn the ignition switch ON. 4. Using a voltmeter, connect the positive (+) tester probe to terminal
VG, and negative (-) tester probe to terminal E2G. 5. Blow air into the MAF meter, and check that
the voltage fluctuates.
Page 4803
The ground points circuit diagram shows the connections from all major parts to the respective
ground points. When troubleshooting a faulty ground point, checking the system circuits which use
a common ground may help you identify the problem ground quickly. The relationship between
ground points (EA, IB and IC) can also be checked this way.
How to Read Power Source
HOW TO READ POWER SOURCE
Page 3011
- Be careful not to drop the injectors when removing the delivery pipes.
- Pay attention to put any hung load on the injector to and from the side direction.
a. Remove the bolt holding the clamp on the fuel return pipe to the LH delivery pipe. b. Remove the
bolt, 2 union bolts, 4 gaskets and front fuel pipe. c. Disconnect the 8 injector connectors. d.
Remove the 4 nuts holding the delivery pipes to the lower intake manifold. e. Remove the 2
delivery pipes, 8 injectors, 4 spacers and 8 insulators. f.
Remove the O-ring and grommet from each injector.
INSTALLATION
1. INSTALL INJECTORS AND DELIVERY PIPES
NOTE: Be careful not to drop the injectors when installing the delivery pipes.
- Pay attention to put any hung load on the injector to and from the side direction.
a. Install a new grommet to each injector. b. Apply a light coat of gasoline to a new O-rings and
install it to each injector.
c. While turning the injector clockwise and counterclockwise, push it to the delivery pipes. Install
the 8 injectors. d. Position injector connector outward. e. Place the 4 spacers and 8 new insulators
on the intake manifold. f.
Place the 2 delivery pipes and injectors assemblies on the lower intake manifold.
g. Temporarily install the 4 nuts. h. Install the front fuel pipe with the bolt, 4 new gaskets and 2
union bolts.
Torque:
Engine Controls - ECU Reprogramming Procedure
Technical Service Bulletin # SS002R-01 Date: 030922
Engine Controls - ECU Reprogramming Procedure
SPECIAL SERVICE TOOLS SS002-01 REVISED
March 9, 2001
Title: ECU FLASH REPROGRAMMING PROCESS
Models: Applicable Models
TSB REVISION NOTICE:
^ September 22, 2003: Models added - 2002 (and later) Solara, 2003 (and later) Corolla and
Matrix, and 2004 models; Operation Procedures updated for CAN Interface Module with the latest
Diagnostic Tester software (v. 10.1a and 10.2a), Calibration Update Wizard (v.6.0), and calibration
files.
^ June 20, 2003: Camry and Tacoma models added; Special Service Tools table updated. The
previous TSB should be discarded.
Introduction
Electronic Control Unit (ECU) is a Toyota term used to describe integrated computerized devices
responsible for managing the operation of a system or sub-system. For the purposes of this
bulletin, the term "ECU" is used as a generic label for the following SAE J1930 standard
references:
^ Powertrain Control Module (PCM)
^ Engine Control Module (ECM)
^ Transmission Control Module (TCM)
^ or any other Toyota specific control unit
Flash reprogramming allows the ECU software to be updated for changes in vehicle calibrations
without removing the ECU from the vehicle. Flash calibration updates for specific vehicle
models/ECUs will be released as field fix procedures described in individual service bulletins. This
bulletin details the ECU flash reprogramming process and the applications within the Technical
Information System (TIS) and the Toyota Diagnostic Tester used for reprogramming.
Flash calibration updates can only be applied to the vehicle/ECU combination for which they are
intended. ECUs have internal security that will not allow them to be programmed with another
ECU's information.
Applicable Vehicles ^
2001 (and later) model year 4Runner, Highlander, Land Cruiser, RAV4, Sequoia and Tundra
vehicles.
^ 2002 (and later) model year Camry, Solara and Tacoma vehicles.
^ 2003 (and later) model year Corolla and Matrix vehicles.
^ All 2004 (and later) model year Toyota vehicles except Celica, MR2 Spyder, Avalon, and Tacoma
(3RZ-FE engine)
Warranty Information
Parts Information
NOTE:
Authorized Modifications Labels may be ordered in packages of 25 from the Materials Distribution
Center (MDC) through the TDN Dealer Support
Page 1453
Timing Belt Tensioner: Service and Repair
For further information regarding this component and the system that it is a part of, please refer to
Timing Belt; Service and Repair.
Page 2946
Evaporative Vapor Pressure Sensor: Testing and Inspection
VAPOR PRESSURE SENSOR
INSPECTION
1. INSPECT POWER SOURCE VOLTAGE OF VAPOR PRESSURE SENSOR
a. Disconnect the vapor pressure sensor connector. b. Turn the ignition switch ON. c. Using a
voltmeter, measure the voltage between connector terminals VC and E2 of the wiring harness side.
Voltage: 4.5 - 5.5 V
d. Turn the ignition switch OFF. e. Reconnect the vapor pressure sensor connector.
2. INSPECT POWER OUTPUT OF VAPOR PRESSURE SENSOR
a. Turn the ignition switch ON. b. Disconnect the vacuum hose from the vapor pressure sensor. c.
Connect a voltmeter to terminals PTNK and E2 of the ECM, and measure the output voltage under
these conditions:
1. Apply vacuum (2.0 kPa (15 mmHg, 0.59 in.Hg)) to the vapor pressure sensor.
Voltage: 1.3 - 2.1 V
2. Release the vacuum from the vapor pressure sensor.
Voltage: 3.0 - 3.6 V
3. Apply pressure (1.5 kPa (15 gf/sq.cm, 0.22 psi)) to the vapor pressure sensor.
Page 5056
Page 1510
Page 6987
c. Cut the adhesive by pulling the piano wire around it. d. Remove the glass.
NOTE: Leave as much of the adhesive on the body as possible when cutting off the glass.
INSTALLATION
1. CLEAN AND SHAPE CONTACT SURFACE OF BODY
a. Using a knife, cut away any rough areas on the body.
HINT: Leave as much of the adhesive on the body as possible.
b. Clean the cutting surface of the adhesive with a shop rag saturated in cleaner.
HINT: Even if all the adhesive has been removed, clean the body.
2. CLEAN REMOVED GLASS
a. Remove the damaged stoppers and dam. b. Using a scraper, remove the adhesive sticking to
the glass. c. Clean the glass with cleaner.
NOTE: Do not touch the glass after cleaning it.
Page 6592
Body
Connector Location (Access Cab)
BA1 Front Door LH Wire and Wire Harness (Connector Location)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel)
BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel)
BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel)
BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Page 4582
e. Install new terminal C kit parts.
1. Temporarily install a new terminal insulator (inside). 2. Temporarily install a new contact plate. 3.
Temporarily install a new terminal bolt. 4. Temporarily install a new O-ring. 5. Temporarily install a
new terminal insulator (outside). 6. Temporarily install a new wave washer. 7. Temporarily install a
new terminal nut.
NOTE: Be careful to install the terminal insulator (inside) and wave washer in the correct direction.
f. Temporarily tighten the terminal nuts.
g. Tighten terminal nuts.
1. Put a wooden block on the contact plate and press it down with a hand press.
Dimensions of wooden block: 20 x 37 x 40 mm (0.79 x 1.46 x 1.57 in.)
Press force: 981 N (100 kgf, 221 lbf)
NOTE:
Gauge Pressure
- Check the diameter of the hand press ram. Then calculate the gauge pressure of the press when
981 N (100 kgf, 221 lbf) of force is applied.
Page 5556
BJ Inside of Rear Door LH
BK Inside of Rear Door RH
BL Surrounding of the Front of the Fuel Tank
Connector Location
BA1 Front Door LH Wire and Wire Harness (Connector Location)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel)
BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel)
BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel)
BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Page 6473
Oil Pressure Sender: Testing and Inspection
INSPECT OIL PRESSURE SWITCH CONTINUITY a. Disconnect the connector from the switch. b.
Check that continuity exists between terminal and ground with the engine stopped. c. Check that
no continuity exists between terminal and ground with the engine running.
HINT: Oil pressure should be over 24.5 kPa (0.25 kgf/sq.cm, 3.55 psi).
If operation is not as specified, replace the switch.
5VZ-FE (Access cab) and 2UZ-FE: INSPECT OIL PRESSURE SENDER GAUGE CONTINUITY a.
Disconnect the connector from the sender gauge. b. Check that no continuity exists between the
terminal and ground with the engine stopped. c. Check that continuity exists between the terminal
and ground with the engine running.
HINT: The oil pressure should be over 29.0 kPa (0.3 kgf/cm2, 4.2 psi).
If the continuity is not as specified, replace the sender gauge.
Page 574
Page 887
d. Check the spark plug for thread damage and insulator damage.
If abnormal, replace the spark plug.
e. Adjust the spark plug electrode gap.
Electrode gap: 0.8 mm (0.031 in.)
f. Using a 16 mm plug wrench, install the spark plugs. Torque: 17.5 N.m (180 kgf.cm, 13 ft.lbf)
g. Reinstall the ignition coils (with igniter).
Page 3037
Fuel Pump Relay: Testing and Inspection Circuit Opening Relay
CIRCUIT OPENING RELAY
INSPECTION
1. REMOVE RELAY BOX COVER
2. REMOVE CIRCUIT OPENING RELAY (Marking: CIR OPN)
3. INSPECT CIRCUIT OPENING RELAY CONTINUITY
a. Using an ohmmeter, check that there is continuity between terminals 1 and 2.
If there is no continuity, replace the relay.
b. Check that there is no continuity between terminals 3 and 5.
If there is continuity, replace the relay.
4. INSPECT CIRCUIT OPENING RELAY OPERATION
a. Apply battery positive voltage across terminals 1 and 2. b. Using an ohmmeter, check that there
is continuity between terminals 3 and 5.
If there is no continuity, replace the relay.
5. REINSTALL CIRCUIT OPENING RELAY
6. REINSTALL RELAY BOX COVER
Page 4777
B: Junction Connector
Indicates a connector which is connected to a short terminal.
Junction connector in this include a short terminal which is connected to a number of wire
harnesses. Always perform inspection with the short terminal installed. (When installing the wire
harnesses, the harnesses can be connected to any position within the short terminal grouping.
Accordingly, in other vehicles, the same position in the short terminal may be connected to wire
harness from a different part.) Wire harness sharing the same short terminal grouping ha the same
color.
C: Parts Code
The first letter of the code is taken from the first letter of part, and the numbers indicates its order in
parts which start with the same letter.
D: Connector Color
Connectors not indicated are milky white in color.
How to Read Ground Points
HOW TO READ GROUND POINTS
Ground Locations
Trailer Connector: Ground Locations
Engine Compartment
Ground Location
EA Front Left Fender
EB Rear Bank of Right Cylinder
EC Rear Bank of Left Cylinder
Connector Location
EA1 Cowl Wire Harness and Wire Harness (Connector Location)
EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B)
EC1 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC2 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC3 Engine No. 2 Wire and Engine Wire (Near the Starter)
ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission)
Page 4551
a. Install the pulley to the rotor shaft by tightening the pulley nut by hand. b. Hold SST (A) with a
torque wrench, and tighten SST (B) clockwise to the specified torque.
SST 09820-63011
Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)
c. Check that SST (A) is secured to the pulley shaft.
d. Mount SST (C) in a vise. e. Insert SST (B) into SST (C), and attach the pulley nut to SST (C).
f. To torque the pulley nut, turn SST (A) in the direction shown in the illustration.
Torque: 110.5 N.m (1,125 kgf.cm, 81 ft.lbf)
g. Remove the generator from SST (C). h. Turn SST (B), and remove SST (A and B).
5. INSTALL RECTIFIER HOLDER
Page 1430
Timing Belt: Service and Repair
Page 2974
Mass Air Flow Meter: Testing and Inspection
MASS AIR FLOW (MAF) METER
INSPECTION
1. DISCONNECT MAF METER CONNECTOR
2. REMOVE MAF METER
Remove the 2 screws and MAF meter.
3. INSPECT MAF METER
a. Using an ohmmeter, measure the resistance between terminals THA and E2.
If the resistance is not as specified, replace the MAF meter.
b. Inspect for operation.
1. Connect the MAF meter connector. 2. Connect the negative (-) terminal cable to the battery. 3.
Turn the ignition switch ON. 4. Using a voltmeter, connect the positive (+) tester probe to terminal
VG, and negative (-) tester probe to terminal E2G. 5. Blow air into the MAF meter, and check that
the voltage fluctuates.
Page 4309
Parts Information
NOTE:
Refer to TSB No. BR004-02, "Front Brake Vibration," when installing new design caliper assembly.
Component Tests and General Diagnostics
Engine Control Module: Component Tests and General Diagnostics
Terminals Of ECM - Connector View
Terminals Of ECU - Connector Pinouts (Part 1)
Page 4919
Wiring Harness Connector
E: Indicates the wiring harness and wiring harness connector. The wiring harness with male
terminal is shown with arrows.
Outside numerals are pin numbers.
The first letter of the code for each wiring harness and wiring harness connector(s) indicates the
component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and
Surrounding area, and "B" for the Body and Surrounding area.
When more than one code has the first and second letters in common, followed by numbers (e.g,
IH1, IH2), this indicates the same type of wiring harness and wiring harness connector.
F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in
parts position.
G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside
it). Junction Blocks are shaded to clearly separate
them from other parts.
H: When 2 parts both use one connector in common, the parts connector name used in wire
routing is shown in square brackets [ ].
Wiring Color
I: Indicates the wiring color.
Wire colors are indicated by an alphabetical code.
B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR =
Brown SB = Sky Blue LG = Light Green GR = Gray
The first letter indicates the basic wire color and the second letter indicates the color of the stripe.
Diagram Information and Instructions
Relay Box: Diagram Information and Instructions
Key to Diagrams
A: System Title
B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to
distinguish it from the J/B
Example: 1 Indicates Relay Block No.1
C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type,
or specification is different.
D: Indicates related system.
Page 1329
Oil Filter: Service and Repair
For further information regarding this component and the system that it is a part of, please refer to
Oil; Service and Repair.
Page 2100
Knock Sensor: Service and Repair
1. REMOVE THROTTLE BODY COVER
2. REMOVE INTAKE AIR CONNECTOR
3. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS
4. REMOVE UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY
5. INSPECT KNOCK SENSOR 1,2
Disconnect the knock sensor connectors.
1. REPLACE THE SENSOR WITH SST.
SST 09816-30010
Torque: 45 N.m (450 kgf.cm, 33 ft.lbf)
Reconnect the knock sensor connectors.
2. REINSTALL UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY
3. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS
4. REINSTALL INTAKE AIR CONNECTOR
5. REINSTALL THROTTLE BODY COVER
Page 5953
Page 5720
Body
Connector Location (Access Cab)
BA1 Front Door LH Wire and Wire Harness (Connector Location)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel)
BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel)
BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel)
BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Page 4061
Required Tools & Material
Page 3231
B: Junction Connector
Indicates a connector which is connected to a short terminal.
Junction connector in this include a short terminal which is connected to a number of wire
harnesses. Always perform inspection with the short terminal installed. (When installing the wire
harnesses, the harnesses can be connected to any position within the short terminal grouping.
Accordingly, in other vehicles, the same position in the short terminal may be connected to wire
harness from a different part.) Wire harness sharing the same short terminal grouping ha the same
color.
C: Parts Code
The first letter of the code is taken from the first letter of part, and the numbers indicates its order in
parts which start with the same letter.
D: Connector Color
Connectors not indicated are milky white in color.
How to Read Ground Points
HOW TO READ GROUND POINTS
Page 2011
Oxygen Sensor: Testing and Inspection
HEATED OXYGEN SENSOR
INSPECTION
1. INSPECT HEATER RESISTANCE OF HEATED OXYGEN SENSORS
a. Disconnect the oxygen sensor connector.
Resistance
b. Using an ohmmeter, measure the resistance between terminals +B and HT.
If the resistance is not as specified, replace the sensor.
Torque: 44 N.m (450 kgf.cm, 32 ft.lbf) for sensor 1 20 N.m (200 kgf.cm, 14 ft.lbf) for sensor 2
c. Reconnect the oxygen sensor connector.
2. INSPECT OPERATION OF HEATED OXYGEN SENSORS
Testing and Inspection
Fuel Gauge Sender: Testing and Inspection
INSPECT FUEL SENDER GAUGE RESISTANCE
Measure the resistance between terminals 1 and 2 for each float position. If resistance value is not
as specified, replace the main sender gauge.
INSPECT FUEL LEVEL WARNING SWITCH
a. Apply battery positive voltage between terminal 1 and 3, and through a 3.4 W test bulb, and
check that the bulb lights up.
HINT: It will take a short time for bulb to light up.
b. Submerge the switch in fuel, and check that the bulb goes out.
If operation is not as specified, replace the sender gauge.
Page 5533
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 shown. The worksheet
will allow the proper fitting and selection of a Seat Belt Extender for the customer. The dealership
personnel should then determine the applicable part number and place an order through Dealer
Daily.
The dealership service department should complete the affixed Seat Belt Extender Customer
Information Label on the part and review the "Owner Instruction Sheet" with the customer. The
dealership should give a copy of the completed worksheet to the customer and keep the original in
the customer's file.
To assure utmost owner satisfaction, it is recommended that a dealership designate one person to
coordinate all activities related to the Seat Belt Extender issue.
It is recommended that dealerships do NOT stock Seat Belt Extenders due to the need for proper
fitting to individual customers.
Page 41
INSPECT DAYTIME RUNNING LIGHT RELAY NO.4 CONTINUITY If continuity is not as specified,
replace the relay.
Page 2722
Applicable Vehicles
Page 6347
B: Junction Connector
Indicates a connector which is connected to a short terminal.
Junction connector in this include a short terminal which is connected to a number of wire
harnesses. Always perform inspection with the short terminal installed. (When installing the wire
harnesses, the harnesses can be connected to any position within the short terminal grouping.
Accordingly, in other vehicles, the same position in the short terminal may be connected to wire
harness from a different part.) Wire harness sharing the same short terminal grouping ha the same
color.
C: Parts Code
The first letter of the code is taken from the first letter of part, and the numbers indicates its order in
parts which start with the same letter.
D: Connector Color
Connectors not indicated are milky white in color.
How to Read Ground Points
HOW TO READ GROUND POINTS
Page 6679
B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(Connect the Relay) and SW 2 OFF (or Disconnect SW 2)
D. Disconnect and reconnect the connectors while watching the test light.
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
E. Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION:
a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals
are touched, the IC may be destroyed by
static electricity.)
b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact
with the terminals of leads from the IC, etc. of the replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
Special Tool
1. PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown.
2. DISCONNECT CONNECTOR
3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
a. Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the
secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
A: For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
Page 3460
The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit
breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery
power is supplied to each system are explained. Since all System Circuit diagrams start from the
power source, the power source system must be fully understood.
Page 3817
5. INSPECT ACTUATOR OPERATION
a. 2WD 4HI shift: Connect lines via a relay, then check that the actuator fork shaft moves to 2WD
-> 4HI position.
b. 4HI -> 2WD shift: Connect lines via a relay, then check that the actuator fork shaft moves to 4HI
-> 2WD position.
Testing and Inspection
Headlamp Dimmer Switch: Testing and Inspection
INSPECT LIGHT CONTROL SWITCH CONTINUITY
If continuity is not as specified, replace the switch.
INSPECT HEADLIGHT DIMMER SWITCH CONTINUITY
If continuity is not as specified, replace the switch.
Page 2330
Engine Control Module (ECM)
Page 2301
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 1828
Mass Air Flow Meter: Description and Operation
Mass Air Flow Meter
The mass air flow meter uses a platinum hot wire. The hot wire air flow meter consists of a
platinum hot wire, thermistor and a control circuit installed in a plastic housing. The hot wire air flow
meter works in principle that the hot wire and thermistor located in the intake air bypass of the
housing detect any changes in the intake air temperature.
The hot wire is maintained at the set temperature by controlling the current flow through the hot
wire. This current flow is then measured as an output voltage of the mass air flow meter.
The circuit is constructed so that the platinum hot wire and thermistor provide a bridge circuit, with
the power transistor, and controlled so that the potential of A and B remains equal in order to
maintain the set temperature.
Page 1977
CHART 1
Page 2635
Engine Control Module: Diagnostic Aids
Voltage Check
Voltage Check
Voltage Check
A. Establish conditions in which voltage is present at the check point.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(SW 2 OFF)
B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or
component terminal. This check can be done with a test light instead of a voltmeter.
Continuity and Resistance Check
Continuity and Resistance Check
Continuity And Resistance Check
A. Disconnect the battery terminal or wire so there is no voltage between the check points. B.
Contact the two leads of an ohmmeter to each of the check points.
Page 4817
Driver Side J/B And Integration Relay Inner Circuit
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)
Testing and Inspection
Four Wheel Drive Indicator Lamp: Testing and Inspection
5VZ-FE: INSPECT "4Lo/4Hi", 4WD" INDICATOR LIGHT a. Disconnect the connectors from the
ADD actuator. b. "4WD" indicator: Ground terminal 3 on the wire harness side connector. c. Turn
the ignition switch ON, check that the warning light lights up.
If the warning light does not light up, inspect the bulb or wire harness.
2UZ-FE: INSPECT "4Lo/4Hi", "4WD" INDICATOR LIGHT a. Remove the center cluster finish
panel. b. Disconnect the connectors from the center cluster integration. c. "4Lo" indicator: Ground
terminal 3 on the wire harness side connector. d. "4Hi" indicator: Ground terminal 2 on the wire
harness side connector.
Front
Diagrams
Page 5110
Page 5028
2. DISCONNECT RH AND LH TIE ROD ENDS
a. Remove the cotter pin and nut. b. Using SST, disconnect the tie rod end from the lower ball joint.
SST 09610-20012
c. Employ the same manner described to the other side.
3. REMOVE POWER STEERING GEAR SET BOLTS AND NUTS
4. DISCONNECT STABILIZER BAR LINK FROM LOWER SUSPENSION ARM
Remove the nut and disconnect the stabilizer bar link from the lower suspension arm.
HINT: If the ball joint turns together with nut, use a hexagon (6 mm) wrench to hold the stud.
5. DISCONNECT SHOCK ABSORBER FROM LOWER SUSPENSION ARM
a. Remove the shock absorber lower side set nut and washer.
NOTE: Do not remove the bolt.
b. Wrap the bolt's head with vinyl tape to prevent the drive shaft boot from being damaged. c. Pry
down the lower suspension arm to remove the bolt and disconnect the shock absorber.
Page 416
Terminal Retainer
Push the terminal retainer down to the temporary lock position.
c. Release the locking lug from terminal and pull the terminal out from rear.
4. INSTALL TERMINAL TO CONNECTOR
a. Insert the terminal.
HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug
locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position.
Page 4541
a. Using an ohmmeter, connect one tester probe to the positive (+) terminal and the other to each
rectifier terminal. b. Reverse the polarity of the tester probes and repeat step (a). c. Check that one
shows continuity and the other shows no continuity.
If continuity is not as specified, replace the rectifier holder.
8. INSPECT NEGATIVE RECTIFIER
a. Using an ohmmeter, connect one tester probe to each negative (-) terminal and the other to each
rectifier terminal. b. Reverse the polarity of the tester probes and repeat step (a). c. Check that one
shows continuity and the other shows no continuity.
If continuity is not as specified, replace the rectifier holder.
9. INSPECT BEARING
Check that the bearing is not rough or worn. If necessary, replace the bearing.
Page 2569
E. Confirm the Diagnostic Tester has the appropriate software for the type of calibration file that
was downloaded.
NOTE:
The calibration type is specific to the software version loaded on your Diagnostic Tester. If you
selected the wrong version when downloading the calibration file, you will receive an error when
attempting to install the file on the Diagnostic Tester.
Page 5517
Seat Belt: Diagrams
Seat Belt
Page 2242
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.
Testing and Inspection
Control Module: Testing and Inspection
For further information regarding this component and the system that it is a part of, please refer to
Four Wheel Drive Selector Relay; Testing and Inspection; Procedures.
Page 68
Non-Waterproof Type Connector
"Case 1" Raise the terminal retainer up to the temporary lock position.
Non-Waterproof Type Connector
"Case 2" Open the secondary locking device.
Pressure Specification
Fuel Pressure: Specifications
Fuel Pressure No Vacuum 38 to 44 psi
Page 1969
2. Start the engine.
3. Perform the drive pattern to run and complete the Oxygen Sensor (O2S) Monitor.
HINT:
The 02S Monitor is completed when the following conditions are met:
^ Two (2) minutes or more passed after the engine start.
^ The Engine Coolant Temperature (ECT) is 167°F (75°C) or more.
^ Cumulative running time at 30 mph (48 km/h) or more exceeds 6 minutes.
^ Vehicle is in closed loop.
^ The fuel-cut is operated for 8 seconds or more (for Rear O2S Monitor).
A. Allow the engine to idle for two minutes.
B. Warm up the engine until the Engine Coolant Temperature (ECT) reaches 167°F (75°C).
C. Drive the vehicle over 30 mph (48 km/h) for more than 40 seconds.
D. Stop the vehicle and allow the engine to idle for more than 20 seconds.
E. Repeat steps C and D at least 8 times in one driving cycle. (Do not cycle the ignition key.)
In addition, perform the following steps for the Rear O2S Readiness Monitor:
A. Select second gear.
B. Allow the vehicle to run at 30 mph (48 km/h) or more.
C. Keep the accelerator pedal "off-idle" for more than 10 seconds.
D. Immediately after step C, release the accelerator pedal for at least 10 seconds without
depressing the brake pedal (to execute the fuel-cut).
E. Decelerate the vehicle until the vehicle speed reaches less than 6mph (10km/h).
F. Repeat steps B - E at least twice in one driving cycle.
Accessing O2S Test Results
1. On the Diagnostic Tester* screen, select the following menus:
^ DIAGNOSTICS
^ CARB OBD II
Page 4713
B: Junction Connector
Indicates a connector which is connected to a short terminal.
Junction connector in this include a short terminal which is connected to a number of wire
harnesses. Always perform inspection with the short terminal installed. (When installing the wire
harnesses, the harnesses can be connected to any position within the short terminal grouping.
Accordingly, in other vehicles, the same position in the short terminal may be connected to wire
harness from a different part.) Wire harness sharing the same short terminal grouping ha the same
color.
C: Parts Code
The first letter of the code is taken from the first letter of part, and the numbers indicates its order in
parts which start with the same letter.
D: Connector Color
Connectors not indicated are milky white in color.
How to Read Ground Points
HOW TO READ GROUND POINTS
Page 5768
Wiring Harness Connector
E: Indicates the wiring harness and wiring harness connector. The wiring harness with male
terminal is shown with arrows.
Outside numerals are pin numbers.
The first letter of the code for each wiring harness and wiring harness connector(s) indicates the
component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and
Surrounding area, and "B" for the Body and Surrounding area.
When more than one code has the first and second letters in common, followed by numbers (e.g,
IH1, IH2), this indicates the same type of wiring harness and wiring harness connector.
F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in
parts position.
G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside
it). Junction Blocks are shaded to clearly separate
them from other parts.
H: When 2 parts both use one connector in common, the parts connector name used in wire
routing is shown in square brackets [ ].
Wiring Color
I: Indicates the wiring color.
Wire colors are indicated by an alphabetical code.
B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR =
Brown SB = Sky Blue LG = Light Green GR = Gray
The first letter indicates the basic wire color and the second letter indicates the color of the stripe.
Service and Repair
Transmission Temperature Sensor/Switch: Service and Repair
ON-VEHICLE REPAIR
1. 5VZ-FE:
DISCONNECT OIL COOLER PIPE
a. Remove the 3 bolts and clamps.
b. Disconnect the oil cooler pipe. c. Remove the elbow from the transmission.
2. DISCONNECT ATF TEMPERATURE SENSOR CONNECTOR 3. REMOVE ATF
TEMPERATURE SENSOR
a. Remove the ATF temperature sensor. b. Remove the O-ring from the ATF temperature sensor.
4. INSTALL ATF TEMPERATURE SENSOR
a. Coat a new O-ring with ATF and install it to the ATF temperature sensor. b. Install the ATF
temperature sensor.
Torque: 15 Nm (150 kgf-cm, 11 ft. lbs.)
5. CONNECT ATF TEMPERATURE SENSOR CONNECTOR
NOTICE: Be careful not to twist the wire harness.
6. CONNECT OIL COOLER PIPE
a. Install the elbow to the transmission.
Page 2804
Instruments - Oil Pressure Gauge Reads Abnormally Low
Oil Pressure Gauge: All Technical Service Bulletins Instruments - Oil Pressure Gauge Reads
Abnormally Low
ELECTRICAL EL017-03
December 23, 2503
Title OIL PRESSURE GAUGE READS LOW
Models '01 - '04 Sequoia & '00 - '02 Tundra
TSB UPDATE NOTICE:
This TSB updates EL006-03. TSB EL006-03 is now obsolete and should be discarded.
Introduction
Some customers with Sequoia or Tundra vehicles may encounter an oil pressure gauge that reads
abnormally low at idle. An updated oil pressure sender has been created to address this condition.
Applicable Vehicles ^
2001 - 2004 model year Sequoia vehicles produced BEFORE the Production Change Effective
VINs shown below.
^ 2000 - 2002 model year Tundra vehicles produced BEFORE the Production Change Effective
VIN shown below.
Production Change Information
Parts Information
Repair Procedure
1. Replace the Oil Pressure Sender.
2. Verify proper operation of the Oil Pressure Gauge.
Warranty Information
Applicable Warranty*:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36
months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Page 1998
Electrical Specifications
Resistance
Page 74
Lamp Control Module: Description and Operation
LIGHT AUTO TURN OFF
SYSTEM OUTLINE
With the ignition SW turned on, the current flows to TERMINAL 9 of the integration relay through
ECU IG fuse.
Voltage is applied at all times to TERMINAL 6 of the integration relay through the TAIL fuse, and
through the HEAD relay coil side [w/o daytime running light] or through the daytime running light
relay (Main) [w/ daytime running light].
1. NORMAL LIGHTING OPERATION
With the light control SW turned to TAIL position, a signal is input into the integration relay. Due to
this signal, the current flowing to TERMINAL 6 of the relay flows to TERMINAL 14 of the light
control SW to TERMINAL 16 to GROUND, and taillights to turn on.
With the light control SW turned to HEAD position, a signal is input into the integration relay. Due to
this signal, the current flowing to the relay flows to TERMINAL 13 of the light control SW to
TERMINAL 16 to GROUND in the headlight circuit, and causes taillight and HEAD relay to turn the
lights on. The taillight circuit is same as above.
2. LIGHT AUTO TURN OFF OPERATION
With light on and ignition SW turned off (Input signal goes to TERMINAL 9 of the relay), when the
driver's door is opened (Input signal goes to TERMINAL 14 of the relay), the relay operates and the
current is cutoff which flows from TERMINAL 6 of the relay to taillight circuit and headlight circuit.
As a result, all lights are turned off automatically.
Page 5916
Page 2489
CHART 18
CHART 19
Locations
Engine Room R/B
Capacity Specifications
Coolant: Capacity Specifications Drain and Refill
Drain and Refill
With Manual Transmission 10.6 qt (US)
With Automatic Transmission 12.3 qt (US)
Page 6252
Splice Location
B11
Page 1894
Engine Bank Identification
Page 4518
8. Select the appropriate model and press the NEXT soft key.
9. Select OEM battery type and press the NEXT soft key.
10. Choose the correct battery (model number and CCA) and press the NEXT soft key.
11. Aim the infrared (IR) temperature measurement sensor at the negative (-) battery post and
press the NEXT soft key.
Page 1947
Required Tools & Material
NOTE:
Additional Diagnostic Tester Kits, Program Cards or SSTs may be ordered by calling SPX-OTC at
1-800-933-8335.
Repair Procedure
Using the chart, refer to the Diagnostic Section (DI-###) in the appropriate Repair Manual and
follow the diagnostic procedure for the specific DTC.
Page 4574
REMOVAL
1. REMOVE THROTTLE BODY COVER
2. DISCONNECT ACCELERATOR CABLE
3. REMOVE INTAKE AIR CONNECTOR
Page 4440
4. REMOVE PISTON STOPPER BOLT
Using a screwdriver, push the pistons in all the way and remove the piston stopper bolt and gasket.
HINT: Tape the screwdriver tip before use.
Torque: 10 Nm (100 kgf-cm, 7 ft. lbs.)
5. REMOVE 2 PISTONS AND SPRINGS
(a) Push in the piston with a screwdriver and remove the snap ring with snap ring pliers.
HINT: Tape the screwdriver tip before use.
(b) Remove the No. 1 piston and spring by hand, pulling straight out, not at an angle.
NOTICE: If pulled out and installed at an angle, there is a possibility that the cylinder bore could be
damaged.
- At the time of reassembly, be careful not to damage the rubber lips on the pistons.
(c) Place a rag and 2 wooden blocks on the work table, and lightly tap the cylinder flange against
the block edges until the No. 2 piston and spring
drop out of the cylinder.
HINT: Make sure the distance (A) from the rag to the top of the blocks is at least 100 mm (3.94
inch).
INSPECTION
HINT: Clean the disassembled parts with compressed air.
1. INSPECT CYLINDER BORE FOR RUST OR SCORING
If necessary, clean or replace the cylinder.
2. INSPECT CYLINDER FOR WEAR OR DAMAGE
If necessary, clean or replace the cylinder.
REASSEMBLY
Reassembly is in the reverse order of disassembly.
Page 2725
A/F and 02 Sensor Identification
Page 4615
Fuse: Application and ID
Engine Room R/B Fuse Applications (Part 1)
Page 676
Waterproof Type Connector
B: For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White
: Gray
Black or White : Dark Gray
Gray or White : Black
Waterproof Type Connector
"Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up
to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Waterproof Type Connector
"Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 3640
Fluid - Differential: Service and Repair Rear
FILL DIFFERENTIAL WITH HYPOID GEAR OIL
Testing and Inspection
Windshield Washer Switch: Testing and Inspection
INSPECT FRONT WIPER AND WASHER SWITCH CONTINUITY
w/ MIST
w/ INTERMITTENT
If continuity is not as specified, replace the switch.
Page 3001
Fuel Injector: Locations
Injector (Part 1)
Page 2183
Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
INSPECTION
1. DRAIN ENGINE COOLANT
2. REMOVE THROTTLE BODY COVER
3. REMOVE INTAKE AIR CONNECTOR
4. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS
a. Disconnect the accelerator cable from the throttle body. b. Remove the 2 bolts and 2 nuts, and
disconnect the throttle body from the intake manifold. c. Remove the gasket
5. REMOVE ECT SENSOR
a. Disconnect the ECT sensor connector. b. Remove the ECT sensor and gasket.
6. INSPECT ECT SENSOR
Using an ohmmeter, measure the resistance between the terminals.
Resistance: Refer to the graph
If the resistance is not as specified, replace the ECT sensor.
7. REINSTALL ECT SENSOR
a. Install a new gasket and the ECT sensor.
Page 6588
Body
Splice Location (Standard Cab)
B1 Speaker Tweeter Wire LH
B2 Front Door LH Wire
B3 Front Door LH Wire
B4 Roof Wire
B5 Speaker Tweeter Wire RH
B6 B7
Front Door RH Wire
B10 Frame Wire
Seat
Page 4600
Glossary Of Terms And Symbols (Part 2)
Testing and Inspection
Door Switch: Testing and Inspection
INSPECT DOOR COURTESY SWITCH CONTINUITY
a. Check that continuity exists between terminals and the switch body with the switch ON (switch
pin released: opened door). b. Check that no continuity exists between terminals and the switch
body with the switch OFF (switch pin pushed in: closed door).
If operation is not as specified, replace the switch.
Page 1056
Air Bag(s) Arming and Disarming: Service and Repair Release Method of Airbag Activation
Prevention Mechanism
RELEASE METHOD OF AIRBAG ACTIVATION PREVENTION MECHANISM
Page 1318
Engine Oil: Testing and Inspection
For further information regarding this component and the system that it is a part of, please refer to
Engine Lubrication; Testing and Inspection; Procedures.
Page 29
Audible Warning Device Control Module: Testing and Inspection
LIGHT AUTO TURN OFF
HEAD RELAY
2 - 1 : Closed with the light control SW at HEAD position or the dimmer SW at FLASH position.
Closed with the engine running and the parking brake lever released (w/ daytime running light)
C15 LIGHT CONTROL SW [COMB. SW]
13 - 16 : Closed with light control SW at HEAD position
14 - 16 : Closed with light control SW at TAIL or HEAD position
D16 DOOR COURTESY SW FRONT LH
1 - GROUND : Continuity with the front LH door open
INTEGRATION RELAY
9 - GROUND : Approx. 12 volts with the ignition SW at ON position
14 - GROUND : Continuity with the front LH door open
3, 6 - GROUND : Always approx. 12 volts
8 - GROUND : Always continuity
POWER WINDOW
D16, D17 DOOR COURTESY SW LH, RH
1 - GROUND : Continuity with door open
INTEGRATION RELAY
9 - GROUND : Approx. 12 volts with ignition SW at ON position
3 - GROUND : Always approx. 12 volts
14 - GROUND : Continuity with front LH door open (Standard cab)
14 - GROUND : Continuity with each LH door open (Access cab)
15 - GROUND : Continuity with front RH door open (Standard cab)
15 - GROUND : Continuity with each RH door open (Access cab)
P9 POWER WINDOW CONTROL SW RH
4 - GROUND : Approx. 12 volts with ignition SW on and stays at 12 volts for 41.5 - 44.5 seconds
after the ignition SW is turned off, but if a door is
open in the 45 seconds period, voltage will drop to 0 volts
P10 POWER WINDOW MASTER SW 1 - GROUND : Always continuity 9 - GROUND : Approx. 12
volts with ignition SW on and stays at 12 volts for 41.5 - 44.5 seconds after the ignition SW is
turned off, but if a door is
opened in this 41.5 - 44.5 seconds period, voltage will drop to 0 volts
3 - GROUND : Approx. 12 volts with ignition SW at ON position and master SW at UP position 4 GROUND : Approx. 12 volts with ignition SW at ON position and master SW at DOWN or AUTO
DOWN position
WINDOW LOCK SW
Open with window lock SW at LOCK position
DOOR LOCK CONTROL
INTEGRATION RELAY
8 - GROUND : Always continuity
3 - GROUND : Always approx. 12 volts
Page 798
Vehicle Speed Sensor NO.2
Page 5987
An airbag activation prevention mechanism is built into the connector for the squib circuit of the
SRS.
When release of the airbag activation prevention mechanism is directed in the troubleshooting
procedure, as shown in the illustration of the connectors, insert paper which has the same
thickness as the male terminal, between the terminal and the short spring.
CAUTION: Never release the airbag activation prevention mechanism on the steering wheel pad
connector.
NOTE:
Page 3991
Anti-Lock Brake System
Page 6883
Waterproof Type Connector
B: For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White
: Gray
Black or White : Dark Gray
Gray or White : Black
Waterproof Type Connector
"Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up
to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Waterproof Type Connector
"Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 6208
Waterproof Type Connector
B: For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White
: Gray
Black or White : Dark Gray
Gray or White : Black
Waterproof Type Connector
"Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up
to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Waterproof Type Connector
"Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 2440
CHART 25
Page 5082
Diagram Information and Instructions
Vehicle Speed Sensor: Diagram Information and Instructions
Key to Diagrams
A: System Title
B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to
distinguish it from the J/B
Example: 1 Indicates Relay Block No.1
C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type,
or specification is different.
D: Indicates related system.
Page 6010
Page 6317
The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit
breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery
power is supplied to each system are explained. Since all System Circuit diagrams start from the
power source, the power source system must be fully understood.
Page 225
Glossary Of Terms And Symbols (Part 1)
Page 5426
a. Install the front airbag sensors with the 4 bolts.
Torque: 20 N.m (205 kgf.cm, 15 ft.lbf)
HINT: Install the front airbag sensor with the arrow on the sensor facing toward the front of the
vehicle.
NOTE: Connection of the connector is done after the sensor has been installed.
- Make sure the sensor is installed with the specified torque.
- If the sensor has been dropped, or there are cracks, dents or other defects in the case, brackets
or connector, replace the removed sensor with a new one.
- The front sensor is equipped with an electrical connection check mechanism. Be sure to lock this
mechanism securely when connecting the connector. If the connector is not securely locked, a
malfunction code will be detected by the diagnostic system.
b. Connect the front airbag sensor connectors.
c. Install the air cleaner assembly.
d. 2UZ-FE engine:
Install the battery tray, battery and battery carrier.
Page 2419
O2S Application Table
O2S Failure Threshold Charts
Page 736
Knock Sensor: Service and Repair
1. REMOVE THROTTLE BODY COVER
2. REMOVE INTAKE AIR CONNECTOR
3. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS
4. REMOVE UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY
5. INSPECT KNOCK SENSOR 1,2
Disconnect the knock sensor connectors.
1. REPLACE THE SENSOR WITH SST.
SST 09816-30010
Torque: 45 N.m (450 kgf.cm, 33 ft.lbf)
Reconnect the knock sensor connectors.
2. REINSTALL UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY
3. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS
4. REINSTALL INTAKE AIR CONNECTOR
5. REINSTALL THROTTLE BODY COVER
Page 651
Throttle Position Sensor: Testing and Inspection
ON-VEHICLE INSPECTION
1. REMOVE THROTTLE BODY COVER
2. INSPECT SYSTEM OPERATION
a. Check that the throttle linkage moves smoothly.
b. Inspect the throttle control motor for operating sound.
1. Turn the ignition switch ON. 2. When turning the accelerator pedal position sensor lever, check
the running sound of the motor. Also, check that there is no friction sound.
If operation is not as specified, check the throttle control motor (See step 3), wiring and ECM.
c. Inspect the accelerator pedal position sensor.
1. Connect the TOYOTA hand-held tester to the DLC3. 2. Check that the MIL does not light up. 3.
When turning the accelerator pedal position sensor lever to the full-open position, check that the
throttle valve opening percentage
(THROTTLE POS) of the CURRENT DATA shows the standard value.
Standard throttle valve opening percentage: 60 % or more
If operation is not as specified, check that the accelerator pedal position sensor (See step 5), wiring
and ECM.
Page 3829
Fluid - Transfer Case: Fluid Type Specifications
Transfer Case
Grade ...................................................................................................................................................
............................................................ GL-4 or GL-5 Viscosity ...........................................................
................................................................................................................................................ SAE
75W-90
Page 5915
Diagram Information and Instructions
Trailer Connector: Diagram Information and Instructions
Key to Diagrams
A: System Title
B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to
distinguish it from the J/B
Example: 1 Indicates Relay Block No.1
C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type,
or specification is different.
D: Indicates related system.
Page 813
c. 4HI -> 4LO shift: Connect lines via a relay, then check that the actuator fork shaft moves to 4HI
-> 4LO position.
d. 4LO 4HI shift: Connect lines via a relay, then check that the actuator fork shaft moves to 4LO ->
4HI position.
HINT: When inspecting the operation described, use a heater main relay.
NOTICE: Connect the terminals being careful not to touch the neighboring terminals or metallic
parts of relay housing.
Page 4714
The ground points circuit diagram shows the connections from all major parts to the respective
ground points. When troubleshooting a faulty ground point, checking the system circuits which use
a common ground may help you identify the problem ground quickly. The relationship between
ground points (EA, IB and IC) can also be checked this way.
How to Read Power Source
HOW TO READ POWER SOURCE
Page 4690
Relay Box: Diagnostic Aids
Voltage Check
Voltage Check
Voltage Check
A. Establish conditions in which voltage is present at the check point.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(SW 2 OFF)
B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or
component terminal. This check can be done with a test light instead of a voltmeter.
Continuity and Resistance Check
Continuity and Resistance Check
Continuity And Resistance Check
A. Disconnect the battery terminal or wire so there is no voltage between the check points. B.
Contact the two leads of an ohmmeter to each of the check points.
Page 1739
^ 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 6415
Body
Connector Location (Standard Cab)
BA1 Front Door LH Wire and Speaker Tweeter Wire LH (Inside of Front Door LH)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Seat
Connector Location
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
BJ1 Seat No. 1 Wire and Seat No. 2 Wire (Under the Driver's Seat)
Page 6356
Waterproof Type Connector
B: For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White
: Gray
Black or White : Dark Gray
Gray or White : Black
Waterproof Type Connector
"Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up
to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Waterproof Type Connector
"Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 5139
2. DISCONNECT SHOCK ABSORBER FROM LOWER SUSPENSION ARM
a. Remove the shock absorber lower side set nut and washer.
NOTICE: Do not remove the bolt.
b. Wrap the bolt's head with vinyl tape to prevent the drive shaft boot from being damaged. c. Pry
down the lower suspension arm to remove the bolt and disconnect the shock absorber.
3. REMOVE SHOCK ABSORBER WITH COIL SPRING
Remove the 3 nuts and shock absorber with the coil spring.
DISASSEMBLY
REMOVE SUSPENSION SUPPORT AND COIL SPRING
a. Using Special Service Tool (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 the SST.
^ Do not make your position at the top side of the shock absorber.
b. Remove the suspension support center nut. c. Remove the 2 retainers, cushion, suspension
support and coil spring.
INSPECTION
INSPECT SHOCK ABSORBER
Page 2872
Waterproof Type Connector
B: For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White
: Gray
Black or White : Dark Gray
Gray or White : Black
Waterproof Type Connector
"Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up
to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Waterproof Type Connector
"Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 1722
memory, the CUW will ask you to select the calibration file(s) to delete from the Diagnostic Tester
Program Card to make room for the new calibration file.
If necessary, check the calibration file(s) to delete, as shown in Figure 11. Click DELETE.
NOTE:
If there is adequate memory to store the calibration file, skip to Step J.
I. The CUW will now delete the calibration file(s) selected (see Figure 12).
Description and Operation
Throttle Position Sensor: Description and Operation
Throttle Position Sensor
Throttle position sensor is mounted on the throttle body and it has 2 sensors to detect the throttle
opening angle and a malfunction of the throttle position sensor's own.
Voltage applied to the terminals VTA and VTA2 of the ECM changes between 0 V and 5 V in
proportion to the opening angle of the throttle valve.
The ECM judges the current opening angle of the throttle valve from these signals output from
terminals VTA and VTA2, and the ECM controls the throttle motor to make the throttle valve
opening angle properly in accordance with the driving condition.
If this DTC is stored, the ECM cuts down the power for the throttle motor and the electromagnetic
clutch, and the throttle valve is fully closed by the return spring. However, the opening angle of the
throttle valve can be controlled by the accelerator pedal through the throttle cable.
Page 6833
Glossary Of Terms And Symbols (Part 1)
Testing and Inspection
Brake Fluid Level Sensor/Switch: Testing and Inspection
INSPECT BRAKE FLUID LEVEL WARNING SWITCH CONTINUITY a. remove the reservoir tank
cap and strainer. b. Disconnect the connector. c. Check that no continuity exists between the
terminals with the switch OFF (float up). d. Use siphon, etc. to take fluid out of the reservoir tank. e.
Check that continuity exists between the terminals with the switch ON (float down) f.
Pour the fluid back in the reservoir tank. If operation is not as specified, replace switch.
Page 3555
Transmission Mode Indicator - A/T: Splice Locations
Engine Compartment
Splice Location
E1 Engine Room Main Wire
E2 Engine Room Main Wire
E3 Engine Room Main Wire
E4 Engine No. 2 Wire
E5 Engine Wire
E6 Engine Wire
E7 Engine Wire
E8 Engine Wire
Instrument Panel
Page 117
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 4419
DISASSEMBLY
1. DISCONNECT CONNECTOR
(a) Remove the screw and clamp from the ABS actuator.
Torque: 2.9 Nm (30 kgf-cm, 26 inch lbs.)
(b) Disconnect the connector.
2. REMOVE ABS ECU
Using a hexagon wrench (4 mm), remove the 4 bolts and ABS ECU. Torque: 4.4 Nm (45 kgf-cm,
39 inch lbs.)
NOTICE: Protect the actuator in order to prevent sealing surface from getting dirty and causing
damage on the valve body. If the dirt and the like is stuck to the sealing surface, use plastic tools or
soft objects to remove the dirt. Do not use chemical solvents.
REASSEMBLY
Reassembly is in the reverse order of disassembly.
Page 5534
This bulletin contains the following information:
Procedure and Sample Label Application Charts Pages Part Number Information Owner
Instructions Seat Belt Extender Worksheet
Applicable Vehicles ^
2001 through 2003 model year Toyota vehicles.
Warranty Information
Procedure
1. Customer requests a Seat Belt Extender from dealer.
2. Dealer verifies the need for a Seat Belt Extender and obtains a current copy of this TSB and
copies the Worksheet.
3. Dealer measures the customer and completes the Worksheet. Dealer determines the correct
part number and places an order for the part through Dealer Daily.
4. Dealer receives Seat Belt Extender and calls the customer to check the fit of the part.
5. If the Seat Belt Extender fit is good, dealership personnel completes the Customer Information
Label on the part, explains usage of the part, and gives the customer a copy of the completed
Worksheet.
6. Dealer places copy of the completed Worksheet in the customer's records.
Page 2329
Engine Control Module: Locations
Instrument Panel
ABS/TCS - Zero Point Calibration Information
Steering Angle Sensor: Technical Service Bulletins ABS/TCS - Zero Point Calibration Information
T-SB-0020-08
March 25, 2008
Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment
Service Category Brake
Section Brake Control/Dynamic Control System
Market USA
Applicability
Introduction
The purpose of this TSB is to provide information on when and how to perform the zero point
calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting
the battery is a necessary step for performing the zero point calibration.
Warranty Information
Required Tools & Equipment
^ Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE).
^ The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the
service procedures listed in this bulletin.
Preliminary Information
Perform this procedure if any of these repairs have been performed on the vehicle:
^ Wheel alignment has been adjusted.
^ Any chassis components have been removed/installed or replaced.
Page 5648
Air Bag Deactivation Switch: Testing and Inspection
PASSENGER AIRBAG MANUAL ON-OFF SWITCH INSPECTION
1. INSPECT PASSENGER AIRBAG MANUAL ON-OFF SWITCH
HINT: Release the airbag activation prevention mechanism of the passenger airbag manual on-off
switch connector on the airbag sensor assembly side.
If continuity is not as specified, replace the switch.
2. INSPECT PASSENGER AIRBAG MANUAL ON-OFF INDICATOR OPERATION
a. Using a service wire, connect B1 and B3. b. Connect the positive (+) lead from the battery to
terminal A13 and negative (-) lead to terminal A1. c. Check that the indicator light lights up.
If the operation is not as specified, replace the indicator.
Page 492
Crankshaft Position Sensor: Mechanical Specifications
Torque: ................................................................................................................................................
.................................. 6.5 N.m (65 kgf.cm, 58 in.lbf)
Page 899
g. Reinstall the camshafts. h. Reinstall the timing belt. i.
Recheck the valve clearance.
11. REINSTALL CYLINDER HEAD COVERS 12. REINSTALL IGNITION COILS 13. REINSTALL
NO.3 TIMING BELT COVERS 14. REINSTALL AIR CLEANER AND INTAKE AIR CONNECTOR
ASSEMBLY 15. REINSTALL THROTTLE BODY COVER 16. REINSTALL BATTERY CLAMP
COVER
Electrical Specifications
Resistance
Page 4930
Waterproof Type Connector
B: For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White
: Gray
Black or White : Dark Gray
Gray or White : Black
Waterproof Type Connector
"Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up
to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Waterproof Type Connector
"Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 4523
The charger starts charging upon completion of testing. The screen displays the status of charge.
13. Read or print the battery test results.
P 1/4: BATTERY RESULTS
P 2/4: STATE OF CHARGE (SOC)
P 3/4: STATE OF HEALTH (SOH)
P 4/4: WARRANTY CODE
To print: Align the Midtronics IR Printer (P/N 00002-A0870, component of P/N 00002-V8150-KIT) in
front of the IR port on the charger and select the PRINT soft key.
Battery Charging Results
Once the test completes, proceed with 1 of the 3 procedures below according to the BATTERY
CONDITION results.
1. Battery Condition: "GOOD BATTERY"
Return the battery to service.
2. Battery Condition: "REPLACE BATTERY"
Replace the battery. Print the RESULTS screen for WARRANTY CODE by pressing the PRINT
soft key.
NOTE:
A REPLACE BATTERY result may also mean a poor connection between the battery cables and
the battery. Retest the battery using the out-of-vehicle test before replacing it.
3. Battery Condition: "BAD CELL-REPLACE"
Replace the battery. The decision indicates a bad cell within the battery. Print the RESULTS
screen for WARRANTY CODE by pressing the PRINT soft key.
Page 4122
INSTALL NEW OIL SEAL (INSIDE)
A. Using the following SST and a plastic hammer, install a NEW oil seal (inside).
09527-17011
NOTE:
Lightly strike the SST on its circumference evenly.
B. Coat MP grease to the oil seal lip.
23. INSTALL STEERING KNUCKLE
A. 4WD:
Insert the drive shaft into the axle hub and temporarily tighten the nut.
NOTE:
Be careful not to damage the oil seal and drive shaft boot.
B. Connect the steering knuckle to the upper suspension arm.
C. Install the nut and a NEW cotter pin. If the holes for the cotter pin are not aligned, tighten the nut
further up to 600.
Torque: 105 N.m (1,100 kgf.cm, 77 ft.lbf)
24. CONNECT LOWER BALL JOINT
Connect the lower ball joint to the steering knuckle with 4 bolts.
Torque: 50 N.m (510 kgf.cm, 37 ft.lbf)
25. INSTALL SHOCK ABSORBER WITH COIL SPRING
A. Install the upper side of shock absorber to the chassis frame with the 3 nuts.
Torque: 64 N.m (650 kgf.cm, 47 ft.lbf)
B. Connect the lower side of shock absorber to the lower suspension arm with bolt, washer and
nut.
Torque: 135 N.m (1,400 kgf.cm, 100 ft.lbf)
26. INSPECT AND INSTALL THE BRAKE ROTOR AND INSTALL THE BRAKE CALIPER WITH
NEW MOUNTING BOLTS
A. Inspect the brake rotors, and machine using an on-the-car brake lathe. Replace the rotor if it is
below minimum thickness values
Minimum Thickness: 26.0 mm (1.024 in.)
NOTE:
It is necessary to turn the rotors using the on-the-car brake lathe to ensure even and uniform rotor
run out. DO NOT turn the rotor using an off-the-car brake lathe.
B. Install the disc, brake caliper and 2 NEW bolts.
Torque: 123 N.m (1,259 kgf.cm, 90 ft.lbf)
C. Install the brake line clamp to the steering knuckle with the bolt.
Torque: 28 N.m (285 kgf.cm, 21 ft.lbf)
27. INSTALL NEW BRAKE LINE
Using the SST, connect NEW brake line.
09023-00100
Electrode Gap Specification
Spark Plug: Specifications Electrode Gap Specification
Electrode Gap
Correct Gap .........................................................................................................................................
........................................................................ 0.8 mm
Page 3105
1. Insert the wave washer into the throttle control motor cover. 2. Align the pin holes of the throttle
control motor with the positioning pins of the throttle control motor cover. 3. Attach the grommet to
the throttle control motor cover. 4. Install the throttle control motor with the 3 screws.
Torque: 3.4 N.m (35 kgf.cm, 30 in.lbf)
5. Apply the grease thinly on the whole surface of the gear teeth.
NOTE: Do not apply the grease other than specified because grease has been already applied to
the component to be replaced.
6. Install the washer as shown in the illustration. 7. Align the pin hole of the throttle control motor
cover with the positioning pin of the throttle body. 8. Install the throttle control motor cover and
motor assembly with the 6 screws.
Torque: 3.4 N.m (35 kgf.cm, 30 in.lbf)
9. Connect the throttle control motor connector to the connector bracket.
d. Reinstall and adjust the throttle position sensor. (See step 1)
3. REPLACE ACCELERATOR PEDAL POSITION SENSOR
a. Remove the 3 set screws and accelerator pedal position sensor.
Page 3094
Throttle Body (Part 2)
Page 5008
A. Move the hub up and down by hand (most models with wishbone suspension):
a. Remove the tire.
b. Install the 2 lug nuts.
c. Inspect the free play while moving the lug nuts up and down at a force of 67 lbf (294 N, 30 kgf).
B. Move the lower arm using a lever (some models with double wishbone type suspension):
a. Lift up the vehicle.
b. Place the tip of the lever to the wheel and inspect the free play while moving the lower arm up
and down.
C. Move the lower arm by hand (all models with strut type suspension and some models with
wishbone type suspension):
a Lift up the vehicle.
b. Inspect the free play while moving the lower arm up and down at a force of 67 lbf (294 N, 30
kgf).
2. Inspect Upper Ball Joint Free Play
A. Move the upper arm by hand (models with the LOWER control arm linked by a torsion bar, and
all models using a coil spring).
a. Remove the front tire.
b. Inspect the free play while moving the upper arm up and down at a force of 67 lbf (294 N, 30
kgf).
B. Move the tire with a lever (models with the UPPER control arm linked by a torsion bar).
Page 680
An AC voltage is generated in the No.2 vehicle speed sensor coil as the rotor mounted on the
output shaft rotates, and this voltage is sent to the ECM.
The gear shift point and lock-up timing are controlled by the ECM based on the signals from this
vehicle speed sensor and the throttle position sensor signal.
If the No.2 vehicle speed sensor malfunctions, the ECM uses input signals from the No.1 vehicle
speed sensor as a back-up signal.
Page 6686
Electronically Controlled Transmission And A/T Indicator (Part 3)
Locations
Transmission Speed Sensor: Locations
Vehicle Speed Sensor NO.1
Vehicle Speed Sensor NO.2
Vehicle Speed Sensor NO.1
Page 647
Oxygen Sensor: Testing and Inspection
HEATED OXYGEN SENSOR
INSPECTION
1. INSPECT HEATER RESISTANCE OF HEATED OXYGEN SENSORS
a. Disconnect the oxygen sensor connector.
Resistance
b. Using an ohmmeter, measure the resistance between terminals +B and HT.
If the resistance is not as specified, replace the sensor.
Torque: 44 N.m (450 kgf.cm, 32 ft.lbf) for sensor 1 20 N.m (200 kgf.cm, 14 ft.lbf) for sensor 2
c. Reconnect the oxygen sensor connector.
2. INSPECT OPERATION OF HEATED OXYGEN SENSORS
Page 943
12. Install the NEW A/C compressor mounting bracket and hand tighten bolts 1 and 2 while holding
the bracket forward (refer to illustration).
13. While holding the bracket forward, tighten the A/C compressor mounting bolts in the following
sequence: bolt 2, bolt 1, bolt 3.
Torque: 47 N.m (475 kgf.cm, 34 ft.lbf)
14. Remove the accessory drive belt tensioner.
15. Install the NEW accessory drive belt tensioner.
16. Reassemble in the reverse order of disassembly.
17. Refill cooling system.
Testing and Inspection
Overdrive Indicator Lamp: Testing and Inspection
O/D Main Switch & O/D OFF Indicator Light Circuit
CIRCUIT DESCRIPTION
The O/D main switch contacts go open when the switch is pushed in and go closed when it is
pushed out.
If O/D main switch is at OFF position, the O/D OFF indicator light lights up, and the ECM prohibits
shifting O/D.
Wiring Diagram
INSPECTION PROCEDURE
Page 1763
D. The Calibration Update Wizard (CUW) launches automatically when a calibration file link is
selected (or clicked). Verify that the CUW version is 6.0 or higher. If not, refer to the Note below.
The CUW will guide you through the steps to download the calibration file to the Diagnostic Tester
Program Card. Click NEXT on the first screen (Figure 7).
NOTE:
If the CUW does not launch, or the version is older than 6.0, install Diagnostic Software (TIS
Diagnostic Applications Installer). Specific installation instructions (Reprogramming with CUW 6.0)
are located under Diagnostics ECU Flash Reprogramming (Figure 6).
Page 2385
Required Tools & Material
NOTE:
Additional Diagnostic Tester Kits, Program Cards or SSTs may be ordered by calling SPX-OTC at
1-800-933-8335.
Repair Procedure
Using the chart, refer to the Diagnostic Section (DI-###) in the appropriate Repair Manual and
follow the diagnostic procedure for the specific DTC.
Testing and Inspection
Wiper Switch: Testing and Inspection
INSPECT FRONT WIPER AND WASHER SWITCH CONTINUITY
w/ MIST
w/ INTERMITTENT
If continuity is not as specified, replace the switch.
Description and Operation
Brake Switch - TCC: Description and Operation
Stop Light Switch Signal
Engine
This signal is used to detect when the brakes have been applied. The STP signal voltage is the
same as the voltage supplied to the stop lights.
The STP signal is used mainly to control the fuel cut-off engine speed (The fuel cut-off engine
speed is reduced slightly when the vehicle is braking.).
Automatic Transaxle
The purpose of this circuit is to prevent the engine from stalling, while driving in lock-up condition,
when brakes are suddenly applied.
When the brake pedal is operated, this switch sends a signal to ECM. Then the ECM cancels
operation of the lock-up clutch while braking is in progress.
Page 2042
b. Push the secondary locking device or terminal retainer in to the full lock position.
5. CONNECT CONNECTOR
Disconnection of Male and Female Connectors
Disconnection of Male and Female Connectors
Disconnection Of Male And Female Connectors
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Page 3241
Terminal Retainer
Push the terminal retainer down to the temporary lock position.
c. Release the locking lug from terminal and pull the terminal out from rear.
4. INSTALL TERMINAL TO CONNECTOR
a. Insert the terminal.
HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug
locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position.
Component Tests and General Diagnostics
Brake Light Switch: Component Tests and General Diagnostics
w/o Cruise Control:
INSPECT STOP LIGHT SWITCH CONTINUITY
If continuity is not as specified, replace the switch.
w/ Cruise Control:
INSPECT STOP LIGHT SWITCH CONTINUITY
If continuity is not as specified, replace the switch.
Page 1744
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 4133
12. 2WD: REMOVE LOCK NUT AND ABS SPEED SENSOR ROTOR (W/ABS) OR SPACER (W/O
ABS)
Using a chisel and hammer, loosen the staked part of the lock nut.
NOTE:
Be careful not to damage the bushing.
A. Using the following SST, remove the lock nut.
^ 00002-00909 (09318-12010)
NOTE:
Do NOT use air wrench.
B. Remove the ABS speed sensor rotor or spacer.
NOTE:
Take care not to scratch the serration of the speed sensor rotor.
13. REMOVE AXLE HUB FROM STEERING KNUCKLE
A. Remove the 4 bolts and shift the dust cover toward the hub side (outside).
B. Using the following SSTs, remove the axle hub from the steering knuckle.
^ 09710-28012-01 (09710-07031)
^ 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04031,
09957-04010, 09958-04011)
HINT
If necessary, use a press to remove the axle hub from the steering knuckle.
C. Remove the dust cover from the steering knuckle.
D. 4WD: Remove the bearing spacer and ABS speed sensor rotor (W/ABS) or spacer (W/O ABS).
NOTE:
Take care not to scratch the serration of the speed sensor rotor.
Page 4023
3. BLEED BRAKE LINE
(a) Connect the vinyl tube to the caliper. (b) Depress the brake pedal several times, then loosen the
bleeder plug with the pedal held down.
SST 09751-36011
(c) At the point when fluid stops coming out, tighten the bleeder plug, then release the brake pedal.
(d) Repeat (b) and (c) until all the air in the fluid has been bled out.
Torque: (Bleeder plug) 11 Nm (110 kgf-cm, 8 ft. lbs.)
(e) Repeat the procedure on the previous page to bleed the air out of brake line for each wheel.
4. CHECK FLUID LEVEL IN RESERVOIR
Check the fluid level and add fluid if necessary. Fluid: SAE J1703 or FMVSS No. 116 DOT3
LOAD SENSING PROPORTIONING AND BY-PASS VALVE ON-VEHICLE INSPECTION
1. SET REAR AXLE LOAD
Rear axle load (includes vehicle weight): Standard cab: 950 kg (2,094 lbs.) Access cab:
5VZ-FE engine: 1,000 kg (2,205 lbs.) 2UZ-FE engine: 1,050 kg (2,315 lbs.)
2. INSTALL LSPV GAUGE (SST) AND BLEED AIR
SST 09709-29018
3. RAISE FRONT BRAKE PRESSURE TO 7,845 kPa (80 kgf/cm2, 1,138 psi) AND CHECK REAR
BRAKE PRESSURE
Rear brake pressure: 5,110 ± 490 kPa (52.1 ± 5 kgf/cm2, 741 ± 71 psi)
Component Locations
Ignition Switch And Key Unlock Warning Switch
Page 2321
J. The top half of the CUW screen displays the calibrations currently stored on the Diagnostic
Tester Program Card. The bottom half of the screen displays the new calibration to be loaded onto
the Diagnostic Tester Program Card (see Figure 13). Click NEXT to continue the process.
K. Confirm the calibration file to be sent to the Diagnostic Tester Program Card (Figure 14). Click
SEND.
Page 1787
Continuity And Resistance Check
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Continuity And Resistance Check
C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the
electrical circuit.
Finding A Short Circuit
Finding A Short Circuit
Finding A Short Circuit
A. Remove the blown fuse and disconnect all loads of the fuse.
Page 6530
Terminal Retainer
Push the terminal retainer down to the temporary lock position.
c. Release the locking lug from terminal and pull the terminal out from rear.
4. INSTALL TERMINAL TO CONNECTOR
a. Insert the terminal.
HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug
locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position.
Page 3305
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
Diagram Information and Instructions
Cigarette Lighter: Diagram Information and Instructions
Key to Diagrams
A: System Title
B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to
distinguish it from the J/B
Example: 1 Indicates Relay Block No.1
C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type,
or specification is different.
D: Indicates related system.
Page 2796
A/F and 02 Sensor Identification
Page 181
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 4879
a. Coat the valve with power steering fluid and check that it falls smoothly into the valve hole by its
own weight.
b. Check the flow control valve for leakage. Close one of the holes and apply compressed air - 490
kPa (4 - 5 kgf/cm2, 57 - 71 psi) into the
opposite side, and confirm that air does not come out from the end holes.
If necessary, replace the valve with one having the same letter as inscribed on the front housing.
Inscribed mark: A, B, C, D, E or F
4. INSPECT SPRING
Using vernier calipers, measure the free length of the spring. Minimum free length: 33.2 mm (1.307
inch) If it is not within the specification, replace the spring.
REPLACEMENT
NOTICE: When using a vise, do not overtighten it.
IF NECESSARY, REPLACE OIL SEAL
Engine Controls - MIL ON/DTC's P0135/P0155 Stored
Oxygen Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0135/P0155
Stored
ENGINE EG019-02 REVISED
October 3, 2002
Title M.I.L. "ON" P0135 AND/OR P0155
Models: '00 - '02 Tundra (2UZ-FE) & '01 - '02 Sequoia
TSB REVISION NOTICE:
January 14, 2004: A Previous Part Number in the Parts Information table and one OFP number in
the Warranty Information table has been changed. All previous versions of this TSB should be
discarded.
Introduction
Certain 2000 - 2002 model year Tundra trucks (2UZ-FE) and 2001 - 2002 model year Sequoia
vehicles may exhibit a M.I.L. ON" condition with Diagnostic Trouble Code P0135 and/or P0155 in
the Engine Control Module (ECM)/SAE equivalent (PCM). The oxygen sensors have been
improved to correct this condition.
Applicable Vehicles ^
2000 - 2002 model year Tundra trucks with 2UZ-FE engines produced BEFORE the Production
Change Effective VINs listed below.
^ 2001 - 2002 model year Sequoia vehicles produced BEFORE the Production Change Effective
VINs listed below.
Production Change Information
Parts Information
Warranty Information
Applicable Warranty*:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36
months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Page 5757
BJ Inside of Rear Door LH
BK Inside of Rear Door RH
BL Surrounding of the Front of the Fuel Tank
Connector Location
BA1 Front Door LH Wire and Wire Harness (Connector Location)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel)
BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel)
BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel)
BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Page 5559
Body
Splice Location (Standard Cab)
B1 Speaker Tweeter Wire LH
B2 Front Door LH Wire
B3 Front Door LH Wire
B4 Roof Wire
B5 Speaker Tweeter Wire RH
B6 B7
Front Door RH Wire
B10 Frame Wire
Seat
Page 2498
CHART 25
Testing and Inspection
Seat Belt Buckle Switch: Testing and Inspection
Bench Type and Passenger Side: INSPECT BUCKLE SWITCH CONTINUITY a. Check that
continuity exists between terminals 1 and 2 on the switch side connector with the switch ON (belt
fastened). b. Check that no continuity exists between terminal 1 an 2 on the switch side connector
with the switch OFF (belt unfastened).
If operation is not as specified, replace the seat belt inner.
(w/o Bench Type (Driver Side): INSPECT BUCKLE SWITCH CONTINUITY a. Check that continuity
exists between terminals 3 and 4 on the switch side connector with the switch ON (elt fastened). b.
Check that no continuity exists between terminal 3 an 4 on the switch side connector with the
switch OFF (belt unfastened).
If operation is not as specified, replace the seat belt inner.
Separate Type (w/ Power Seat): INSPECT BUCKLE SWITCH CONTINUITY a. Check that
continuity exists between terminals 1 and 2 on the switch side connector with the switch ON (belt
fastened). b. Check that no continuity exists between terminal 1 an 2 on the switch side connector
with the switch OFF (belt unfastened).
If operation is not as specified, replace the seat belt inner.
Page 1521
Coolant: Testing and Inspection
INSPECTION
HINT: Check the coolant level when the engine is cold.
1. CHECK ENGINE COOLANT LEVEL AT RADIATOR RESERVOIR
The engine coolant level should be between the "LOW" and "FULL" lines at normal temperature
(20°C (68°F)). If low, check for leaks and add "TOYOTA Long Life Coolant" or equivalent up to the
"FULL" line.
2. CHECK ENGINE COOLANT QUALITY
a. Remove the radiator cap.
CAUTION: To avoid the danger of being burned, do not remove the radiator cap while the engine
and radiator are still hot, as fluid and steam can be blown out under pressure.
b. There should not be any excessive deposits of rust or scale around the radiator cap or radiator
hole, and the coolant should be free from oil.
If excessively dirty, clean the coolant passages and replace the coolant.
c. Reinstall the radiator cap.
Page 3292
5. INSPECT ACTUATOR OPERATION
a. 2WD 4HI shift: Connect lines via a relay, then check that the actuator fork shaft moves to 2WD
-> 4HI position.
b. 4HI -> 2WD shift: Connect lines via a relay, then check that the actuator fork shaft moves to 4HI
-> 2WD position.
Page 626
Page 4168
4. With ABS:
Disconnect ABS speed sensor and wire harness clamp from steering knuckle.
Remove the 2 bolts and disconnect the ABS speed sensor and wire harness clamp from the
steering knuckle.
5. Disconnect brake line.
Using the following SST, disconnect the brake line. Use a container to catch the brake fluid.
SST P/N: 09023-00100
6. Remove brake caliper and disc.
A. Remove the bolt and brake line clamp from the steering knuckle.
B. Remove the 2 bolts, brake caliper, and disc.
7. Remove shock absorber.
Page 2755
CHART 8
CHART 9
Page 4568
17. DO HOLD-IN COIL OPEN CIRCUIT TEST
Using an ohmmeter, check that there is continuity between terminal 50 and the switch body. If
there is no continuity, replace the magnetic switch.
TEST
NOTE: These tests must be done within 3 to 5 seconds to avoid burning out the coil.
1. DO PULL-IN TEST
a. Disconnect the field coil lead wire from terminal C. b. Connect the battery to the magnetic switch
as shown.
Check that the pinion gear moves outward.
2. DO HOLD-IN TEST
While connected as above with the pinion gear out, disconnect the negative (-) lead from terminal
C. Check that the pinion gear remains out.
3. INSPECT CLUTCH PINION GEAR RETURN
Page 6812
The ground points circuit diagram shows the connections from all major parts to the respective
ground points. When troubleshooting a faulty ground point, checking the system circuits which use
a common ground may help you identify the problem ground quickly. The relationship between
ground points (EA, IB and IC) can also be checked this way.
How to Read Power Source
HOW TO READ POWER SOURCE
Page 5966
Page 65
Lamp Control Module: Diagnostic Aids
Voltage Check
Voltage Check
Voltage Check
A. Establish conditions in which voltage is present at the check point.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(SW 2 OFF)
B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or
component terminal. This check can be done with a test light instead of a voltmeter.
Continuity and Resistance Check
Continuity and Resistance Check
Continuity And Resistance Check
A. Disconnect the battery terminal or wire so there is no voltage between the check points. B.
Contact the two leads of an ohmmeter to each of the check points.
Testing and Inspection
Door Switch: Testing and Inspection
INSPECT DOOR COURTESY SWITCH CONTINUITY
a. Check that continuity exists between terminals and the switch body with the switch ON (switch
pin released: opened door). b. Check that no continuity exists between terminals and the switch
body with the switch OFF (switch pin pushed in: closed door).
If operation is not as specified, replace the switch.
Page 561
CHART 20
Page 621
CHART 14
Page 3593
An AC voltage is generated in the No.2 vehicle speed sensor coil as the rotor mounted on the
output shaft rotates, and this voltage is sent to the ECM.
The gear shift point and lock-up timing are controlled by the ECM based on the signals from this
vehicle speed sensor and the throttle position sensor signal.
If the No.2 vehicle speed sensor malfunctions, the ECM uses input signals from the No.1 vehicle
speed sensor as a back-up signal.
Page 6836
Continuity And Resistance Check
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Continuity And Resistance Check
C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the
electrical circuit.
Finding A Short Circuit
Finding A Short Circuit
Finding A Short Circuit
A. Remove the blown fuse and disconnect all loads of the fuse.
Page 3103
Throttle Body: Service and Repair Replacement
REPLACEMENT
NOTE:
- To prevent deterioration, do not shock the throttle position sensor and accelerator pedal position
sensor.
- Mixing of the foreign objects may cause the gear locking, so thoroughly check that there is no
stuck of any foreign objects and clean up if any.
1. REPLACE THROTTLE POSITION SENSOR
a. Disconnect the throttle position sensor connector on the lead wire. b. Remove the 2 set screws
and throttle position sensor.
c. Reinstall a new throttle position sensor.
1. Check that the throttle valve is under the condition of the opener opening angle (about 5.5 °).
2. Install the sensor to the place where is at 15 ° rotated to the right from the specified installation
position. 3. Gradually turn sensor counterclockwise until it touches the throttle valve shaft, and
temporarily tighten the 2 set screws.
d. Connect the throttle position sensor connector on the lead wire.
e. Adjust the throttle position sensor.
1. Connect the throttle position sensor connector.
NOTE: Do not connect the accelerator pedal position sensor connector.
2. Connect the TOYOTA hand-held tester or OBD II scan tool to the DLC3. 3. Turn the ignition
switch ON.
Page 2610
DOWNLOAD FILE TO TESTER
2. Download the calibration file to the Diagnostic Tester.
The Calibration Update Wizard (CUW) is a new application on TIS which downloads calibration
files from TIS onto the Diagnostic Tester Program Card.
NOTE:
Before you begin, ensure that the Diagnostic Tester is equipped with software version 8.0a, or
later. Only a 12 MB program card (P/N 01002593-005) may be used for this process.
A. Before downloading a new calibration file from TIS, check the current calibration files stored on
the Diagnostic Tester Program Card by following the screen flow shown (Figure 4).
NOTE:
^ Screen D may be blank if no calibrations are stored on the Diagnostic Tester Program Card.
^ If the desired calibration file is already on the Diagnostic Tester, proceed to Step 3 (Reprogram
ECU with Tester shown).
^ A maximum of two calibration files may be loaded on the tester at one time with Diagnostic Tester
software version 10.2a and later. Prior versions may store up to four calibration files.
Page 5249
8. INSTALL CENTER CLUSTER INTEGRATION PANEL
a. When replacing the heater control assembly:
Pull off the cover.
b. Install the center cluster integration panel, then connect the 2 connectors. c. Install the 5 screws.
d. Install the 3 heater control knobs.
Disassembly and Reassembly
HEATER CONTROL ASSEMBLY
DISASSEMBLY
1. REMOVE HEATER CONTROL CABLES
a. Using a screwdriver, spread the claw of the cable clamp and disconnect the outer cable.
HINT: Tape the screwdriver tip before use.
b. Remove the inner cable from the heater control assembly.
2. REMOVE BLOWER SPEED CONTROL SWITCH
a. Disconnect the connector. b. Remove the 2 screws. c. Remove the switch.
Page 2746
Page 2912
An AC voltage is generated in the No.2 vehicle speed sensor coil as the rotor mounted on the
output shaft rotates, and this voltage is sent to the ECM.
The gear shift point and lock-up timing are controlled by the ECM based on the signals from this
vehicle speed sensor and the throttle position sensor signal.
If the No.2 vehicle speed sensor malfunctions, the ECM uses input signals from the No.1 vehicle
speed sensor as a back-up signal.
Page 2623
Terminals Of ECU - Connector Pinouts (Part 1)
Page 5386
Air Bag Deactivation Switch: Testing and Inspection
PASSENGER AIRBAG MANUAL ON-OFF SWITCH INSPECTION
1. INSPECT PASSENGER AIRBAG MANUAL ON-OFF SWITCH
HINT: Release the airbag activation prevention mechanism of the passenger airbag manual on-off
switch connector on the airbag sensor assembly side.
If continuity is not as specified, replace the switch.
2. INSPECT PASSENGER AIRBAG MANUAL ON-OFF INDICATOR OPERATION
a. Using a service wire, connect B1 and B3. b. Connect the positive (+) lead from the battery to
terminal A13 and negative (-) lead to terminal A1. c. Check that the indicator light lights up.
If the operation is not as specified, replace the indicator.
Page 4216
A. Remove the bolt and brake line clamp from the steering knuckle.
B. Remove the 2 bolts, brake caliper and disc.
7. REMOVE SHOCK ABSORBER
A. Disconnect Shock Absorber from lower suspension arm.
B. Remove the shock absorber lower side set nut and washer.
NOTE:
Do not remove the bolt.
C. Wrap the bolt's head with vinyl tape to prevent the drive shaft boot from being damaged.
D. Pry down the lower suspension arm to remove the bolt and disconnect the shock absorber.
E. Remove the 3 nuts and shock absorber with the coil spring.
NOTE:
Do not damage the brake tube.
8. DISCONNECT LOWER BALL JOINT
Page 3192
Step 1
Page 2476
Page 5942
Page 1114
Relay Box: Diagnostic Aids
Voltage Check
Voltage Check
Voltage Check
A. Establish conditions in which voltage is present at the check point.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(SW 2 OFF)
B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or
component terminal. This check can be done with a test light instead of a voltmeter.
Continuity and Resistance Check
Continuity and Resistance Check
Continuity And Resistance Check
A. Disconnect the battery terminal or wire so there is no voltage between the check points. B.
Contact the two leads of an ohmmeter to each of the check points.
Page 4673
Driver Side J/B And Integration Relay
Page 1816
Page 2524
A. Test J1962 OBDIII CAN Interface Module (P/N 01002744) for continuity.
^ If there is continuity, the cable and CAN Interface Module are OK. Re-check Cable Tests 1, 2,
and 3 while wiggling and flexing the cables.
^ If there is no continuity, proceed to CABLE TEST 4.
CABLE TEST 4.
A. Disconnect the CAN Interface Module (P/N 01002744) from the J1962 OBDII cable using a
Phillips screwdriver.
B. Test J1962 OBDII cable (P/N 02003180) for continuity.
^ If there is no continuity, the cable needs to be replaced.
^ If there is continuity, proceed to CAN Interface Module Test 5.
CAN INTERFACE MODULE TEST 5.
Page 3916
Electronically Controlled Transmission And A/T Indicator (Part 2)
Page 5573
Glossary Of Terms And Symbols (Part 2)
Page 2633
Glossary Of Terms And Symbols (Part 1)
Specifications
Valve Clearance: Specifications
Valve Clearance (Cold)
Intake ...................................................................................................................................................
.......................................................... 0.15 - 0.25 mm Exhaust ...........................................................
............................................................................................................................................... 0.25 0.35 mm
Page 1836
Camshaft Position Sensor: Mechanical Specifications
Torque: ................................................................................................................................................
.................................. 7.5 N.m (80 kgf.cm, 66 in.lbf)
Testing and Inspection
Four Wheel Drive Selector Switch: Testing and Inspection
INSPECTION
1. INSPECT 2WD -> 4HI SHIFT
a. Ignition switch ON. b. Check that the 4HI indicator lights come on when the touch select 2-4
switch is in ON position. c. Check that the 4HI indicator lights go off when the touch select 2-4
switch is in OFF position.
HINT: If the light does not light up, even though the switch has been turned ON, the vehicle should be
moved back and forth.
- If switching is not completed after 3 seconds of shift operation, the 4HI indicator light will flash.
2. INSPECT 4HI -> 4LO SHIFT
Page 2660
Mass Air Flow Meter: Description and Operation
Mass Air Flow Meter
The mass air flow meter uses a platinum hot wire. The hot wire air flow meter consists of a
platinum hot wire, thermistor and a control circuit installed in a plastic housing. The hot wire air flow
meter works in principle that the hot wire and thermistor located in the intake air bypass of the
housing detect any changes in the intake air temperature.
The hot wire is maintained at the set temperature by controlling the current flow through the hot
wire. This current flow is then measured as an output voltage of the mass air flow meter.
The circuit is constructed so that the platinum hot wire and thermistor provide a bridge circuit, with
the power transistor, and controlled so that the potential of A and B remains equal in order to
maintain the set temperature.
Page 1934
Page 6328
Cigarette Lighter: Testing and Inspection
CIGARETTE LIGHTER AND POWER OUTLET
C7 CIGARETTE LIGHTER
2 - GROUND : Approx. 12 volts with ignition SW at ON or ACC position 1 - GROUND : Always
continuity
P6, P7 POWER OUTLET
2 - GROUND : Approx. 12 volts with the ignition SW at ON or ACC position 1 - GROUND : Always
continuity
Page 4184
A. Remove the bolt and brake line clamp from the steering knuckle.
B. Remove the 2 bolts, brake caliper and disc.
7. REMOVE SHOCK ABSORBER
A. Disconnect Shock Absorber from lower suspension arm.
B. Remove the shock absorber lower side set nut and washer.
NOTE:
Do not remove the bolt.
C. Wrap the bolt's head with vinyl tape to prevent the drive shaft boot from being damaged.
D. Pry down the lower suspension arm to remove the bolt and disconnect the shock absorber.
E. Remove the 3 nuts and shock absorber with the coil spring.
NOTE:
Do not damage the brake tube.
8. DISCONNECT LOWER BALL JOINT
Page 6988
3. INSTALL NEW STOPPERS
Attach new stoppers to the glass with the ceramic notches on the glass aligned with the stoppers
as shown in the illustration.
4. INSTALL NEW DAM
Install a new dam with double-stick tape as shown in the illustration.
A: 7.0 mm (0.276 in.)
NOTE: Do not touch the glass surface after cleaning it.
5. POSITION GLASS
a. Place the glass in the correct position. b. Check that all contacting parts of the glass rim are
perfectly even. c. Place reference marks between the glass and body. d. Remove the glass.
Specifications
Throttle Body (Part 1)
Page 6084
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 5583
Seat Belt Reminder Buzzer: Testing and Inspection
KEY REMINDER AND SEAT BELT WARNING
B7 (A), (B) BUCKLE SW LH
(A) 1 - (A) 2, (B) 2 - (B) 1 : Closed with driver's seat belt in use
D16 DOOR COURTESY SW FRONT LH
1 - GROUND : Closed with front LH door open
U1 UNLOCK WARNING SW
1 - 2 : Closed with ignition key in cylinder
C11 (A), C12 (B), C13 (C) COMBINATION METER
(A) 12, (B) 15 - GROUND : Always continuity (B) 10 - GROUND
: Continuity with the front LH door open (Standard cab) : Continuity with the each LH door open
(Access cab)
(C) 1 - GROUND : Continuity with the ignition key in cylinder
(B) 9 - GROUND : Continuity with the driver's seat belt in use
(B) 5 - GROUND : Always approx. 12 volts
(A) 7 - GROUND : Approx. 12 volts with the ignition SW at ON or ST position
Testing and Inspection
Turn Signal Switch: Testing and Inspection
INSPECT TURN SIGNAL SWITCH CONTINUITY If continuity is not as specified, replace the
switch.
Page 1840
Camshaft Position Sensor: Service and Repair
Camshaft Position Sensor
REMOVAL
1. DRAIN ENGINE COOLANT
2. REMOVE DRIVE BELT
3. REMOVE LH NO.3 TIMING BELT COVER
Page 2175
4. REMOVE CAMSHAFT POSITION SENSOR
Remove the bolt, stud bolt and camshaft position sensor.
INSTALLATION
1. INSTALL CAMSHAFT POSITION SENSOR
Install the camshaft position sensor with the bolt and stud bolt Torque: 7.5 N.m (80 kgf.cm, 66
in.lbf)
2. INSTALL LH NO.3 TIMING BELT COVER
3. INSTALL DRIVE BELT
4. FILL ENGINE COOLANT
5. CHECK ENGINE COOLANT FOR LEAKS
6. CHECK IGNITION TIMING
Specifications
Page 800
An AC voltage is generated in the No.2 vehicle speed sensor coil as the rotor mounted on the
output shaft rotates, and this voltage is sent to the ECM.
The gear shift point and lock-up timing are controlled by the ECM based on the signals from this
vehicle speed sensor and the throttle position sensor signal.
If the No.2 vehicle speed sensor malfunctions, the ECM uses input signals from the No.1 vehicle
speed sensor as a back-up signal.
Specifications
Compression Check: Specifications
Compression Pressure ........................................................................................................................
...................................................... 1,324 kPa or More Minimum Pressure .........................................
...........................................................................................................................................................
981 kPa Difference Between Each Cylinder ........................................................................................
......................................................................... 98 kPa or Less
Brakes - Rear Brakes Vibrate Upon Application
Brake Drum: All Technical Service Bulletins Brakes - Rear Brakes Vibrate Upon Application
BRAKES BR003-02 REVISED
Title: REAR BRAKE VIBRATION
Models" '00 - '05 Tundra
September 16, 2002
TSB REVISION NOTICE:
^ April 4, 2005: Applicable Vehicles has been updated to include 2003 - 2005 model years. Parts
Informations table has been updated. Required SSTs table has been added. The Warranty
Information has been updated. The Diagnosis Procedure and Repair Procedure have been
combined into one Repair Procedure section. The Repair Procedure section has been updated.
PLEASE READ ENTIRE TSB.
The previous TSB should be discarded.
Introduction
New brake drums have been introduced for use as service parts on 2000 - 2005 model year
Tundra trucks to reduce rear brake vibration. The new drum has increased mass and rigidity.
Applicable Vehicles
2000 - 2005 model year Tundra vehicles.
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.
Applicable Warranty*: The replacement of the Rear Axle Shaft 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 correction of a problem based upon a customer's specific
complaint.
Airbag(s) Arming and Disarming
Air Bag(s) Arming and Disarming: Service and Repair Airbag(s) Arming and Disarming
CAUTION: *
Work must be started 90 seconds after the ignition switch is turned to the "LOCK" position and the
negative (-) terminal cable is disconnected from the battery. (The SRS is equipped with a back-up
power source so that if work is started within 90 seconds of disconnecting the negative (-) terminal
cable of the battery, the SRS may be deployed.)
* When the negative (-) terminal cable is disconnected from the battery, the memory of the clock
and audio system will be canceled. So before starting work, make a record of the contents
memorized in the audio memory system. When work is finished, reset the audio systems as before
and adjust the clock. To avoid erasing the memory of each memory system, never use a backup
power supply from outside the vehicle.
* Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during
repairs.
* Do not expose the steering wheel pad, front passenger airbag assembly, airbag sensor assembly
or front airbag sensor directly to hot air or flames.
AIR BAG SYSTEM DISARMING
The Air Bag/Supplemental Restraint System (SRS) incorporates a backup energy source that
maintains sufficient deployment voltage for up to 90 seconds after the ignition is turned Off and the
battery has been disconnected. Before disconnecting battery, note radio station settings, since all
vehicle memory will be lost. Never use a backup power source from outside the vehicle.
1. Turn ignition to Lock, then disconnect battery ground cable. 2. Wait at least 90 seconds after
disconnection before beginning service or diagnostic procedures.
AIR BAG SYSTEM ARMING
1. Ensure ignition is in Lock position. 2. Connect battery ground cable. 3. Wait at least 10 seconds
before turning ignition from Lock position. 4. Turn ignition to ACC or On position and ensure SRS
lamp lights, then goes off after approximately six seconds. If lamp remains lit, an SRS
condition is indicated. Refer to Restraint Systems, Air Bag Systems, Testing And Inspection. See:
Air Bag Systems/Testing and Inspection
Page 5772
The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit
breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery
power is supplied to each system are explained. Since all System Circuit diagrams start from the
power source, the power source system must be fully understood.
Specifications
Piston: Specifications
Piston Diameter (STD) Mark 1 ............................................................................................................
........................................................................................ 93.902 - 93.912 mm Mark 2 .......................
..............................................................................................................................................................
.............. 93.912 - 93.920 mm Mark 3 .................................................................................................
................................................................................................... 93.920 - 93.930 mm O/S 0.50 .........
..............................................................................................................................................................
.......................... 94.402 - 94.430 mm
Standard Oil Clearance .......................................................................................................................
....................................................... 0.090 - 0.111 mm Maximum Oil Clearance .................................
.........................................................................................................................................................
0.13 mm
Page 3717
b. Check the spider bearing axial play.
Maximum bearing axial play: 4WD rear propeller shaft: 0 mm (0 inch) 2WD and 4WD front propeller
shaft: 0.05 mm (0.0020 inch)
HINT: Install new spider bearings on the flange side in the procedure described.
- When replacing the rear propeller shaft spider on 4WD vehicle, be sure that the grease fitting
assembly hole is facing in the direction shown.
Page 5610
Non-Waterproof Type Connector
"Case 1" Raise the terminal retainer up to the temporary lock position.
Non-Waterproof Type Connector
"Case 2" Open the secondary locking device.
Page 3464
Continuity And Resistance Check
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Continuity And Resistance Check
C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the
electrical circuit.
Finding A Short Circuit
Finding A Short Circuit
Finding A Short Circuit
A. Remove the blown fuse and disconnect all loads of the fuse.
Page 5695
Page 5545
Warranty Information
Procedure and Sample Label
1. Owner requests a Seat Belt Extender from dealer.
2. Dealer verifies the need for a Seat Belt Extender and obtains a current copy of this TSB and
copies the Worksheet.
3. Dealer measures the customer and completes the Worksheet. Dealer determines the correct
part number and places a Critical Order for the part through the IDN Parts Network.
4. Dealer receives Seat Belt Extender and calls the customer in to check fit of the part.
5. If the Seat Belt Extender fit is good, dealership personnel completes the Customer Information
Label on the part, explains usage of the part, and gives the customer a copy of the completed
Worksheet.
6. Dealer places copy of the completed Worksheet in the customer's records.
Application Charts
Sample Seat Belt Extender Customer Information Label
Page 2915
Install the No.1 vehicle speed sensor with the bolt.
Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.)
6. CONNECT NO. I VEHICLE SPEED SENSOR CONNECTOR
Vehicle Speed Sensor NO.2
Vehicle speed Sensor NO.2 on-vehicle repair
1. DISCONNECT NO. 2 VEHICLE SPEED SENSOR CONNECTOR
2. REMOVE NO. 2 VEHICLE SPEED SENSOR
a. Remove the bolt and No. 2 vehicle speed sensor. b. Remove the O-ring from the No. 2 vehicle
speed sensor.
3. INSTALL NO. 2 VEHICLE SPEED SENSOR
a. Coat a new O-ring with ATF and install it to the No. 2 vehicle speed sensor. b. Install the No. 2
vehicle speed sensor with the bolt.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
4. CONNECT NO. 2 VEHICLE SPEED SENSOR CONNECTOR
Page 4321
B. Using Snap ring pliers, install a NEW snap ring.
17. INSTALL NEW OIL SEAL (OUTSIDE)
A. Using the following SSTs and a plastic hammer, install a NEW oil seal (outside).
^ 09223-15030
^ 09527-17011
B. Coat MP grease to the oil seal lip.
18. INSTALL NEW DUST COVER AND AXLE HUB TO STEERING KNUCKLE
A. Install the NEW dust cover to the steering knuckle with the 4 bolts.
Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)
B. Using the following SST and a press, install the axle hub to the steering knuckle.
09649-17010
19. INSTALL ABS SPEED SENSOR
ROTOR (W/ABS) OR SPACER (W/O ABS)
NOTE:
Take care not to scratch the serration of the speed sensor rotor.
Page 5588
Instrument Panel
Ground Location
IE Left Kick Panel
IF Left Kick Panel
IG Instrument Panel Brace RH
IH Right Kick Panel
II Right Kick Panel
Body
Ground Location (Access Cab)
Page 4424
Adjustment range: 112 - 128 mm (4.41 - 5.04 inch)
HINT: One turn of the nut changes the fluid pressure as shown in the following specification.
7.4 kPa (0.76 kgf/cm, 11 psi)
(c) Torque the lock nut.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)
(d) If the pressure cannot be adjusted by the shackle No. 2, raise or lower the valve body.
Low pressure-Lower body High pressure-Raise body
(e) Torque the nuts.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.) Adjust the length of the shackle No. 2 again. If it cannot be
adjusted, inspect the valve body.
5. IF NECESSARY, CHECK VALVE BODY
(a) Assemble the valve body in the uppermost position.
HINT: When the brakes are applied, the piston will move down about 0.8 mm (0.03 inch). Even at
this time, the piston should not make contact with the load sensing spring or move it.
(b) In this position. check the rear brake pressure
If the measured value is not within the standard, replace the valve body.
Page 6660
Transmission Mode Indicator - A/T: Splice Locations
Engine Compartment
Splice Location
E1 Engine Room Main Wire
E2 Engine Room Main Wire
E3 Engine Room Main Wire
E4 Engine No. 2 Wire
E5 Engine Wire
E6 Engine Wire
E7 Engine Wire
E8 Engine Wire
Instrument Panel
Page 2786
Page 231
Waterproof Type Connector
B: For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White
: Gray
Black or White : Dark Gray
Gray or White : Black
Waterproof Type Connector
"Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up
to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Waterproof Type Connector
"Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
ABS/TCS - Zero Point Calibration Information
Steering Angle Sensor: Technical Service Bulletins ABS/TCS - Zero Point Calibration Information
T-SB-0020-08
March 25, 2008
Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment
Service Category Brake
Section Brake Control/Dynamic Control System
Market USA
Applicability
Introduction
The purpose of this TSB is to provide information on when and how to perform the zero point
calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting
the battery is a necessary step for performing the zero point calibration.
Warranty Information
Required Tools & Equipment
^ Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE).
^ The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the
service procedures listed in this bulletin.
Preliminary Information
Perform this procedure if any of these repairs have been performed on the vehicle:
^ Wheel alignment has been adjusted.
^ Any chassis components have been removed/installed or replaced.
Page 916
3. TEMPORARILY INSTALL TIMING BELT
NOTICE: The engine should be cold.
a. Remove any oil or water on the crankshaft pulley, oil pump pulley, water pump pulley, No.1 idler
pulley and No.2 idler pulley, and keep them
clean.
NOTICE: Only wipe the pulleys; do not use any cleansing agent.
b. Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley.
c. Install the timing belt on the crankshaft timing pulley, No.1 idler pulley and No.2 idler pulley.
4. INSTALL TIMING BELT COVER SPACER
a. Install the gasket to the cover spacer. b. Install the cover spacer.
5. INSTALL TIMING BELT GUIDE
Install the belt guide, facing the cup side outward.
6. INSTALL NO.1TIMING BELT COVER
Install the timing belt cover with the 4 bolts.
7. INSTALL CRANKSHAFT PULLEY
a. Align the pulley set key with the key groove of the crankshaft pulley. b. Using SST and a
hammer, tap in the crankshaft pulley.
SST 09223-46011
8. INSTALL DRIVE BELT TENSIONER
Install the belt tensioner with the bolt and 2 nuts. Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.)
HINT: Use a bolt 106 mm (4.18 inch) in length.
9. INSTALL GENERATOR
Page 6821
Terminal Retainer
Push the terminal retainer down to the temporary lock position.
c. Release the locking lug from terminal and pull the terminal out from rear.
4. INSTALL TERMINAL TO CONNECTOR
a. Insert the terminal.
HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug
locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position.
Specifications
Axle Nut: Specifications
Front Drive Shaft Lock Nut 235 Nm (173 ft.lb)
Page 4081
12. 2WD: REMOVE LOCK NUT AND ABS SPEED SENSOR ROTOR (W/ABS) OR SPACER (W/O
ABS)
Using a chisel and hammer, loosen the staked part of the lock nut.
NOTE:
Be careful not to damage the bushing.
A. Using the following SST, remove the lock nut.
^ 00002-00909 (09318-12010)
NOTE:
Do NOT use air wrench.
B. Remove the ABS speed sensor rotor or spacer.
NOTE:
Take care not to scratch the serration of the speed sensor rotor.
13. REMOVE AXLE HUB FROM STEERING KNUCKLE
A. Remove the 4 bolts and shift the dust cover toward the hub side (outside).
B. Using the following SSTs, remove the axle hub from the steering knuckle.
^ 09710-28012-01 (09710-07031)
^ 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04031,
09957-04010, 09958-04011)
HINT
If necessary, use a press to remove the axle hub from the steering knuckle.
C. Remove the dust cover from the steering knuckle.
D. 4WD: Remove the bearing spacer and ABS speed sensor rotor (W/ABS) or spacer (W/O ABS).
NOTE:
Take care not to scratch the serration of the speed sensor rotor.
Page 4048
4. With ABS:
Disconnect ABS speed sensor and wire harness clamp from steering knuckle.
Remove the 2 bolts and disconnect the ABS speed sensor and wire harness clamp from the
steering knuckle.
5. Disconnect brake line.
Using the following SST, disconnect the brake line. Use a container to catch the brake fluid.
SST P/N: 09023-00100
6. Remove brake caliper and disc.
A. Remove the bolt and brake line clamp from the steering knuckle.
B. Remove the 2 bolts, brake caliper, and disc.
7. Remove shock absorber.
Page 3701
Drive/Propeller Shaft: Specifications
PROPELLER SHAFT ASSEMBLY
Specifications
Camshaft Gear/Sprocket: Specifications
Tightening Torque
Crankshaft Pulley ................................................................................................................................
...................................................................... 245 Nm LH, RH Camshaft Timing Pulleys ...................
..........................................................................................................................................................
108 Nm
Page 5824
Front Bumper Cover / Fascia: Technical Service Bulletins Paint - Refinishing Bumper Cover
PAINT PA003-02 REVISED
June 4, 2002
Title REFINISHING REPLACEMENT BUMPER COVERS
Models All '83 - '05 Models
TSB REVISION NOTICE: ^ February 14, 2005: Applicable Vehicles now includes 2004 - 2005
model years. Previous versions of this TSB should be discarded.
Introduction In cases where a bumper cover is being replaced a special preparation process is
necessary to assure the refinish is customer acceptable. This bulletin provides the recommended
refinishing procedure for new bumper covers.
Applicable Vehicles ^ All 1983 - 2005 model year Toyota vehicles.
Required Tools & Material
Note:Please visit www.3m.comlautomotive to find the nearest store that sells 3M automotive
products.
Warranty Information
Refinishing Procedure
1. Mix a solution of mild soap (car wash soap with no wax additives) and clean water.
Note: Carefully follow mixing instructions on the soap container. Too much soap or too much water
may cause surface contamination or rinsing difficulty.
Page 6421
The ground points circuit diagram shows the connections from all major parts to the respective
ground points. When troubleshooting a faulty ground point, checking the system circuits which use
a common ground may help you identify the problem ground quickly. The relationship between
ground points (EA, IB and IC) can also be checked this way.
How to Read Power Source
HOW TO READ POWER SOURCE
Page 4423
Load Compensator: Testing and Inspection
ON-VEHICLE INSPECTION
1. SET REAR AXLE LOAD
Rear axle load (includes vehicle weight): Standard cab: 950 kg (2,094 lbs.) Access cab:
5VZ-FE engine: 1,000 kg (2,205 lbs.) 2UZ-FE engine: 1,050 kg (2,315 lbs.)
2. INSTALL LSPV GAUGE (SST) AND BLEED AIR
SST 09709-29018
3. RAISE FRONT BRAKE PRESSURE TO 7,845 kPa (80 kgf/cm2, 1,138 psi) AND CHECK REAR
BRAKE PRESSURE
Rear brake pressure: 5,110 ± 490 kPa (52.1 ± 5 kgf/cm2, 741 ± 71 psi)
HINT: The brake pedal should not be depressed twice and/or returned while setting to the specified
pressure. Read the value of rear brake pressure after holding the specified fluid pressure for 2
seconds. If the brake pressure is incorrect, adjust the fluid pressure.
4. IF NECESSARY, ADJUST FLUID PRESSURE
(a) Loosen the lock nut.
(b) Adjust the length of the shackle No. 2.
Low pressure: Lengthen A High pressure: Shorten A Initial set: 120 mm (4.72 inch)
Diagrams
Power Steering Pump: Diagrams
POWER STEERING VANE PUMP REPLACEMENT AND OVERHAUL W/ RELATED
COMPONENTS
Part 1 of 2
Page 1913
CHART 1
Page 4164
Warranty Information
Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This
warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's
in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Page 2551
3. Start the engine and warm it up to normal operating temperatures before test-driving.
4. Perform a thorough test drive with several accelerations from a stop with "light throttle"
application until proper transmission shifting is verified.
Reset Procedure 2
1. Disconnect the negative battery cable for 5 minutes.
2. Reconnect battery cable.
3. Start the engine and warm it up to normal operating temperatures before test-driving.
4. Perform a thorough test drive with several accelerations from a stop with "light throttle"
application until proper transmission shifting is verified.
Page 5103
II. Identification of Affected Vehicles
Page 6684
Transmission Mode Indicator - A/T: Electrical Diagrams
Electronically Controlled Transmission And A/T Indicator (Part 1)
Engine Controls - ECU Reprogramming Procedure
Technical Service Bulletin # SS002R-01 Date: 030922
Engine Controls - ECU Reprogramming Procedure
SPECIAL SERVICE TOOLS SS002-01 REVISED
March 9, 2001
Title: ECU FLASH REPROGRAMMING PROCESS
Models: Applicable Models
TSB REVISION NOTICE:
^ September 22, 2003: Models added - 2002 (and later) Solara, 2003 (and later) Corolla and
Matrix, and 2004 models; Operation Procedures updated for CAN Interface Module with the latest
Diagnostic Tester software (v. 10.1a and 10.2a), Calibration Update Wizard (v.6.0), and calibration
files.
^ June 20, 2003: Camry and Tacoma models added; Special Service Tools table updated. The
previous TSB should be discarded.
Introduction
Electronic Control Unit (ECU) is a Toyota term used to describe integrated computerized devices
responsible for managing the operation of a system or sub-system. For the purposes of this
bulletin, the term "ECU" is used as a generic label for the following SAE J1930 standard
references:
^ Powertrain Control Module (PCM)
^ Engine Control Module (ECM)
^ Transmission Control Module (TCM)
^ or any other Toyota specific control unit
Flash reprogramming allows the ECU software to be updated for changes in vehicle calibrations
without removing the ECU from the vehicle. Flash calibration updates for specific vehicle
models/ECUs will be released as field fix procedures described in individual service bulletins. This
bulletin details the ECU flash reprogramming process and the applications within the Technical
Information System (TIS) and the Toyota Diagnostic Tester used for reprogramming.
Flash calibration updates can only be applied to the vehicle/ECU combination for which they are
intended. ECUs have internal security that will not allow them to be programmed with another
ECU's information.
Applicable Vehicles ^
2001 (and later) model year 4Runner, Highlander, Land Cruiser, RAV4, Sequoia and Tundra
vehicles.
^ 2002 (and later) model year Camry, Solara and Tacoma vehicles.
^ 2003 (and later) model year Corolla and Matrix vehicles.
^ All 2004 (and later) model year Toyota vehicles except Celica, MR2 Spyder, Avalon, and Tacoma
(3RZ-FE engine)
Warranty Information
Parts Information
NOTE:
Authorized Modifications Labels may be ordered in packages of 25 from the Materials Distribution
Center (MDC) through the TDN Dealer Support
Page 89
The ground points circuit diagram shows the connections from all major parts to the respective
ground points. When troubleshooting a faulty ground point, checking the system circuits which use
a common ground may help you identify the problem ground quickly. The relationship between
ground points (EA, IB and IC) can also be checked this way.
How to Read Power Source
HOW TO READ POWER SOURCE
Page 1915
CHART 5
CHART 6
Page 23
Body
Splice Location (Standard Cab)
B1 Speaker Tweeter Wire LH
B2 Front Door LH Wire
B3 Front Door LH Wire
B4 Roof Wire
B5 Speaker Tweeter Wire RH
B6 B7
Front Door RH Wire
B10 Frame Wire
Seat
Page 5015
Ball Joint: Testing and Inspection
ON-VEHICLE INSPECTION
INSPECT LOWER BALL JOINT EXCESSIVE PLAY ON-VEHICLE
a. Remove the front wheel and install the hub nuts to the disc.
b. Using a dial indicator, check the lower ball joint for excessive play when you push the hub nuts
up and down with a force of 294 N (30 kgf, 66
ft. lbs.). Maximum: 0.5 mm (0.020 inch)
Page 552
CHART 7
Page 6519
Splice Point
J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel,
and "B" for the Body).
The Location of splice Point I5 is shaded.
K: Indicates a shielded cable.
L: Indicates the pin number of the connector.
The numbering system is different for female and male connectors.
M: Indicates a ground point.
The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for
the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body
and Surrounding area.
How to Read Connector List
HOW TO READ CONNECTOR LIST
A: Indicates connector to be connected to a part. (The numeral indicates the pin No.)
Page 5874
Wheel Arch Moulding
Engine Controls - MIL ON/DTC's P0135/P0155 Stored
Oxygen Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0135/P0155
Stored
ENGINE EG019-02 REVISED
October 3, 2002
Title M.I.L. "ON" P0135 AND/OR P0155
Models: '00 - '02 Tundra (2UZ-FE) & '01 - '02 Sequoia
TSB REVISION NOTICE:
January 14, 2004: A Previous Part Number in the Parts Information table and one OFP number in
the Warranty Information table has been changed. All previous versions of this TSB should be
discarded.
Introduction
Certain 2000 - 2002 model year Tundra trucks (2UZ-FE) and 2001 - 2002 model year Sequoia
vehicles may exhibit a M.I.L. ON" condition with Diagnostic Trouble Code P0135 and/or P0155 in
the Engine Control Module (ECM)/SAE equivalent (PCM). The oxygen sensors have been
improved to correct this condition.
Applicable Vehicles ^
2000 - 2002 model year Tundra trucks with 2UZ-FE engines produced BEFORE the Production
Change Effective VINs listed below.
^ 2001 - 2002 model year Sequoia vehicles produced BEFORE the Production Change Effective
VINs listed below.
Production Change Information
Parts Information
Warranty Information
Applicable Warranty*:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36
months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Page 3385
L. The calibration file will now be downloaded to the Diagnostic Tester Program Card. This process
takes approximately 2-6 minutes (see Figure 15).
M. The CUW will prompt when the calibration file is completely downloaded. Click OK to close the
CUW (Figure 16).
NOTE:
With the calibration file loaded on the Diagnostic Tester Program Card, it is not necessary to repeat
the above steps to reprogram a different vehicle needing the same calibration file. The steps above
are only required when a new calibration file must be loaded onto the Diagnostic Tester Program
Card.
The Diagnostic Tester now has the calibration file stored and you may proceed to the next step to
reprogram the vehicle ECU.
REPROGRAM ECU WITH TESTER
3. Reprogram the vehicle ECU with the Diagnostic Tester.
NOTICE:
Errors during the flash reprogramming process can permanently damage the vehicle ECU.
Minimize the risks by following the steps below.
^ Battery voltage MUST NOT FALL BELOW 11.4 volts during reprogramming.
^ Confirm battery voltage is higher than 11.4 volts, but be sure voltage DOES NOT RISE ABOVE
16.0 volts during reprogramming.
^ Turn off all electrical accessories (e.g. Audio system, A/C, interior lights, DRL, etc.).
^ Do not add to or significantly change the vehicle's electrical load while reprogramming.
^ Confirm the hood is open and ensure under hood temperatures do not exceed 158°F.
Testing and Inspection
Cargo Lamp Switch: Testing and Inspection
INSPECT CARGO LIGHT SWITCH CONTINUITY
a. Remove the center cluster finish panel. b. Disconnect the connector from the center cluster
integration. c. Check the continuity exists between terminal 12 and terminal 1, with the switch ON.
d. Check that no continuity exists between terminal 12 and terminal 1, with the switch OFF.
If continuity is not as specified, replace the switch.
Page 4629
B: Junction Connector
Indicates a connector which is connected to a short terminal.
Junction connector in this include a short terminal which is connected to a number of wire
harnesses. Always perform inspection with the short terminal installed. (When installing the wire
harnesses, the harnesses can be connected to any position within the short terminal grouping.
Accordingly, in other vehicles, the same position in the short terminal may be connected to wire
harness from a different part.) Wire harness sharing the same short terminal grouping ha the same
color.
C: Parts Code
The first letter of the code is taken from the first letter of part, and the numbers indicates its order in
parts which start with the same letter.
D: Connector Color
Connectors not indicated are milky white in color.
How to Read Ground Points
HOW TO READ GROUND POINTS
Page 2239
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 2884
If you have no TOYOTA hand-held tester, measure voltage between terminals VPA and E2 of the
ECM connector.
d. Inspect the air assist system.
1. Start the engine and check that the MIL does not light up. 2. Allow the engine to warm up to
normal operating temperature. 3. Turn the A/C compressor ON to OFF, and check the idle speed.
Idle speed (Transmission in neutral): 700 ± 50 rpm
NOTE: Perform inspection under condition without electrical load.
e. After checking the above (b) to (d), perform the driving test and check that there is no sense of
incongruity.
3. INSPECT THROTTLE CONTROL MOTOR
a. Disconnect the throttle control motor connector. b. Using an ohmmeter, measure the motor
resistance between terminal 1 (M+) and 2 (M-).
Motor resistance: 0.3 - 100 ohms at 20 °C (68 °F)
If the resistance is not as specified, replace the throttle control motor.
c. Using an ohmmeter, measure the clutch resistance between terminal 3 (CL-) and 4 (CL+).
Clutch resistance: 4.2 - 5.2 ohms at 20 °C (68 °F)
If the resistance is not as specified, replace the throttle control motor.
d. Reconnect the throttle control motor connector.
Page 2795
Engine Bank Identification
Airbag(s) Arming and Disarming
Air Bag(s) Arming and Disarming: Service and Repair Airbag(s) Arming and Disarming
CAUTION: *
Work must be started 90 seconds after the ignition switch is turned to the "LOCK" position and the
negative (-) terminal cable is disconnected from the battery. (The SRS is equipped with a back-up
power source so that if work is started within 90 seconds of disconnecting the negative (-) terminal
cable of the battery, the SRS may be deployed.)
* When the negative (-) terminal cable is disconnected from the battery, the memory of the clock
and audio system will be canceled. So before starting work, make a record of the contents
memorized in the audio memory system. When work is finished, reset the audio systems as before
and adjust the clock. To avoid erasing the memory of each memory system, never use a backup
power supply from outside the vehicle.
* Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during
repairs.
* Do not expose the steering wheel pad, front passenger airbag assembly, airbag sensor assembly
or front airbag sensor directly to hot air or flames.
AIR BAG SYSTEM DISARMING
The Air Bag/Supplemental Restraint System (SRS) incorporates a backup energy source that
maintains sufficient deployment voltage for up to 90 seconds after the ignition is turned Off and the
battery has been disconnected. Before disconnecting battery, note radio station settings, since all
vehicle memory will be lost. Never use a backup power source from outside the vehicle.
1. Turn ignition to Lock, then disconnect battery ground cable. 2. Wait at least 90 seconds after
disconnection before beginning service or diagnostic procedures.
AIR BAG SYSTEM ARMING
1. Ensure ignition is in Lock position. 2. Connect battery ground cable. 3. Wait at least 10 seconds
before turning ignition from Lock position. 4. Turn ignition to ACC or On position and ensure SRS
lamp lights, then goes off after approximately six seconds. If lamp remains lit, an SRS
condition is indicated. Refer to Restraint Systems, Air Bag Systems, Testing And Inspection. See:
Restraint Systems/Air Bag Systems/Testing and Inspection
Locations
Fusible Link: Locations
Driver Side J/B And Integration Relay
Page 3381
E. Confirm the Diagnostic Tester has the appropriate software for the type of calibration file that
was downloaded.
NOTE:
The calibration type is specific to the software version loaded on your Diagnostic Tester. If you
selected the wrong version when downloading the calibration file, you will receive an error when
attempting to install the file on the Diagnostic Tester.
Testing and Inspection
Door/Trunk Ajar Indicator/Lamp: Testing and Inspection
INSPECT OPEN DOOR WARNING LIGHT a. Disconnect the connector from the door courtesy
switch and ground terminal on the wire harness side connector. b. Turn the ignition switch ON,
check that the warning light lights up.
If the warning light does not light up, test the bulb.
Page 3776
^ If there are 2 alignment pins present the transmissionltransaxle assembly may be installed
following the applicable Repair Manual procedure.
NOTE:
A missing alignment pin may result in failure of the transmissionltransaxle assembly.
2. Install the missing alignment pin(s).
^ Refer to the applicable Repair Manual procedure for location of the cylinder block rear side
alignment pins.
NOTE
In the Repair Manual, the alignment pin is referred to as a "straight pin."
Front
Wheel Fastener: Service and Repair Front
REPLACEMENT
1. REMOVE FRONT WHEEL
2. REMOVE BRAKE CALIPER AND DISC
a. Remove the bolt and brake line clamp from the steering knuckle. b. Remove the 2 bolts, brake
caliper and disc. c. Support the brake caliper securely.
3. REMOVE HUB BOLT
Using Special Service Tool (SST) and a screwdriver or an equivalent, remove the hub bolt. SST
09650-17011
4. INSTALL HUB BOLT
a. Install a washer and nut to a new hub bolt as shown in the illustration. b. Using a screwdriver or
an equivalent to hold, install the hub bolt by torquing the nut. c. Remove the nut and washer.
5. INSTALL BRAKE DISC AND CALIPER
a. Install the brake disc, caliper and 2 bolts.
Torque: 123 Nm (1,250 kgf-cm, 90 ft. lbs.)
b. Install the brake line clamp to the steering knuckle with bolt.
Torque: 28 Nm (285 kgf-cm, 21 ft. lbs.)
6. INSTALL FRONT WHEEL
Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.)
7. DEPRESS BRAKE PEDAL SEVERAL TIMES
Page 2431
CHART 18
CHART 19
Page 569
CHART 25
Page 4304
32. Depress brake pedal several times.
33. Fill the brake reservoir with brake fluid and bleed brake system.
34. Check ABS Speed Sensor Signal (refer to the Technical Information System (TIS):
2000 - 2005 model year Tundra Repair Manual: Diagnostics: Anti-lock Brake System: Pre-Check).
Repair Procedure No. 2
1. Resurface the disc rotors with the "On-Car Lathe" to within serviceable limits.
NOTE:
It is necessary to turn the rotors using only an on-the-car brake lathe to ensure even and uniform
rotor run out. DO NOT turn the rotor using an off-the-car brake lathe.
2. If the disc rotors are unserviceable or below minimum thickness (per specification stamped on
the rotor), replace the rotors using the service parts from the Parts Information table.
3. Check any new disc rotor for runout.
4. If the disc rotor runout is over 0.03 mm (0.0012 in.), perform a phase matching procedure.
5. Replace the front brake caliper LH and RH assemblies using the service parts from the Parts
Information table.
6. Perform a road test.
Service and Repair
Transmission Temperature Sensor/Switch: Service and Repair
ON-VEHICLE REPAIR
1. 5VZ-FE:
DISCONNECT OIL COOLER PIPE
a. Remove the 3 bolts and clamps.
b. Disconnect the oil cooler pipe. c. Remove the elbow from the transmission.
2. DISCONNECT ATF TEMPERATURE SENSOR CONNECTOR 3. REMOVE ATF
TEMPERATURE SENSOR
a. Remove the ATF temperature sensor. b. Remove the O-ring from the ATF temperature sensor.
4. INSTALL ATF TEMPERATURE SENSOR
a. Coat a new O-ring with ATF and install it to the ATF temperature sensor. b. Install the ATF
temperature sensor.
Torque: 15 Nm (150 kgf-cm, 11 ft. lbs.)
5. CONNECT ATF TEMPERATURE SENSOR CONNECTOR
NOTICE: Be careful not to twist the wire harness.
6. CONNECT OIL COOLER PIPE
a. Install the elbow to the transmission.
Page 4694
Waterproof Type Connector
B: For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White
: Gray
Black or White : Dark Gray
Gray or White : Black
Waterproof Type Connector
"Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up
to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Waterproof Type Connector
"Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 1771
B. Continue to update the ECU calibration file following the screen flow (Figure 18). Details for
selected screens are shown in Figure 19.
NOTE:
^ Each flash calibration update will take approximately 15 to 45 minutes.
^ Screens E through J (Figure 18) will need to be repeated for each flash calibration update
(calibration ID number).
^ All updates must display "YES" to complete the entire calibration file update for the vehicle ECU.
^ Failure to complete all updates may result in PERMANENT ECU DAMAGE!
CONFIRM UPDATE
4. Confirm successful flash calibration update and affix calibration update sticker.
Follow these steps to confirm the calibration was reprogrammed to the ECU.
Page 1640
Water Pump: Service and Repair
Page 2583
^ 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 2668
Camshaft Position Sensor: Mechanical Specifications
Torque: ................................................................................................................................................
.................................. 7.5 N.m (80 kgf.cm, 66 in.lbf)
Page 3723
Flex Plate: Specifications
Drive Plate Runout Maximum Runout 0.20 mm
New Drive Plate Bolts Torque 83 Nm
Page 6805
Body
Connector Location (Access Cab)
BA1 Front Door LH Wire and Wire Harness (Connector Location)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel)
BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel)
BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel)
BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Locations
Supplemental Restraint System
Page 463
Mass Air Flow (MAF) Meter
Page 627
CHART 21
Service and Repair
Planetary Gears: Service and Repair
For further information regarding this component and the system that it is a part of, please refer to
Automatic Transmission/Transaxle; Service and Repair.
Page 2059
Mass Air Flow Meter: Description and Operation
Mass Air Flow Meter
The mass air flow meter uses a platinum hot wire. The hot wire air flow meter consists of a
platinum hot wire, thermistor and a control circuit installed in a plastic housing. The hot wire air flow
meter works in principle that the hot wire and thermistor located in the intake air bypass of the
housing detect any changes in the intake air temperature.
The hot wire is maintained at the set temperature by controlling the current flow through the hot
wire. This current flow is then measured as an output voltage of the mass air flow meter.
The circuit is constructed so that the platinum hot wire and thermistor provide a bridge circuit, with
the power transistor, and controlled so that the potential of A and B remains equal in order to
maintain the set temperature.
Specifications
Harmonic Balancer - Crankshaft Pulley: Specifications
Crankshaft Pulley Bolt Torque .............................................................................................................
.................................................... 245 Nm (181 ft.lb)
Page 35
Backup Lamp Relay: Testing and Inspection
INSPECT BACK-UP LIGHT RELAY CONTINUITY If continuity is not as specified, replace the
relay.
Page 609
Locations
Hose/Line HVAC: Locations
Refrigerant Line (Part 1)
Page 3017
Fuel Pressure Regulator
Page 3766
Transmission Mode Indicator - A/T: Description and Operation
ELECTRONICALLY CONTROLLED TRANSMISSION AND A/T INDICATOR
SYSTEM OUTLINE
The electronically controlled transmission electrically controls the, throttle pressure, lock-up
pressure, and accumulator pressure etc. through the solenoid valve.
The electronically controlled transmission is a system which precisely controls the gear shift timing
and lock-up timing in response to the vehicle's driving conditions and the engine condition detected
by various sensors. It makes smooth driving possible by shift selection of the gear which is the
most appropriate to the driving conditions at that time, and by preventing downing, squat and gear
shift shock when starting off.
1. GEAR SHIFT OPERATION
When driving, the engine warm up condition is input as a control signal from the engine coolant
temperature sensor to TERMINAL THW of the engine control module, and the vehicle speed is
input to TERMINAL SP2+ of the engine control module from the vehicle speed sensor. At the same
time, the throttle valve opening signal from the throttle position sensor is input to TERMINALS VTA,
VTA2 of the engine control module as a throttle angle signal. Based on these signals, the engine
control module selects the best shift position for the driving conditions and sends current to the
electronically controlled transmission solenoid.
2. LOCK-UP OPERATION
When the engine control module decides based on each signal that the lock-up condition has been
met, the current flows from the engine control module TERMINAL SL to TERMINAL 7 of the
electronically controlled transmission solenoid to GROUND.
3. STOP LIGHT SW CIRCUIT
If the brake pedal is depressed (Stop light SW on) when driving in lock-up position, a signal is input
to TERMINAL STP of the engine control module. As a result, the engine control module cuts the
current to the solenoid to release the lock-up.
4. OVERDRIVE CIRCUIT
- O/D main SW on When the O/D main SW is switched to ON position, a signal is input to
TERMINAL ODMS of the engine control module, and enables shift change to the overdrive range,
through the control of the engine control module.
- O/D main SW off When the O/D main SW is switched to OFF position, a signal is input to
TERMINAL ODMS of the engine control module, and prohibits shift change to the overdrive range
through the control of the engine control module. When in the overdrive range already, shift down
is made.
Page 64
Glossary Of Terms And Symbols (Part 2)
Engine Controls - ECU Reprogramming Procedure
Technical Service Bulletin # SS002R-01 Date: 030922
Engine Controls - ECU Reprogramming Procedure
SPECIAL SERVICE TOOLS SS002-01 REVISED
March 9, 2001
Title: ECU FLASH REPROGRAMMING PROCESS
Models: Applicable Models
TSB REVISION NOTICE:
^ September 22, 2003: Models added - 2002 (and later) Solara, 2003 (and later) Corolla and
Matrix, and 2004 models; Operation Procedures updated for CAN Interface Module with the latest
Diagnostic Tester software (v. 10.1a and 10.2a), Calibration Update Wizard (v.6.0), and calibration
files.
^ June 20, 2003: Camry and Tacoma models added; Special Service Tools table updated. The
previous TSB should be discarded.
Introduction
Electronic Control Unit (ECU) is a Toyota term used to describe integrated computerized devices
responsible for managing the operation of a system or sub-system. For the purposes of this
bulletin, the term "ECU" is used as a generic label for the following SAE J1930 standard
references:
^ Powertrain Control Module (PCM)
^ Engine Control Module (ECM)
^ Transmission Control Module (TCM)
^ or any other Toyota specific control unit
Flash reprogramming allows the ECU software to be updated for changes in vehicle calibrations
without removing the ECU from the vehicle. Flash calibration updates for specific vehicle
models/ECUs will be released as field fix procedures described in individual service bulletins. This
bulletin details the ECU flash reprogramming process and the applications within the Technical
Information System (TIS) and the Toyota Diagnostic Tester used for reprogramming.
Flash calibration updates can only be applied to the vehicle/ECU combination for which they are
intended. ECUs have internal security that will not allow them to be programmed with another
ECU's information.
Applicable Vehicles ^
2001 (and later) model year 4Runner, Highlander, Land Cruiser, RAV4, Sequoia and Tundra
vehicles.
^ 2002 (and later) model year Camry, Solara and Tacoma vehicles.
^ 2003 (and later) model year Corolla and Matrix vehicles.
^ All 2004 (and later) model year Toyota vehicles except Celica, MR2 Spyder, Avalon, and Tacoma
(3RZ-FE engine)
Warranty Information
Parts Information
NOTE:
Authorized Modifications Labels may be ordered in packages of 25 from the Materials Distribution
Center (MDC) through the TDN Dealer Support
Page 629
Page 4766
Engine Compartment
Instrument Panel
Locations
Page 4686
The ground points circuit diagram shows the connections from all major parts to the respective
ground points. When troubleshooting a faulty ground point, checking the system circuits which use
a common ground may help you identify the problem ground quickly. The relationship between
ground points (EA, IB and IC) can also be checked this way.
How to Read Power Source
HOW TO READ POWER SOURCE
Page 1121
Relay Box: Connector Views
Engine Room R/B
Pressure Specification
Fuel Pressure: Specifications
Fuel Pressure No Vacuum 38 to 44 psi
Bleeding the Brake System
Brake Bleeding: Service and Repair Bleeding the Brake System
BRAKE FLUID BLEEDING
HINT: If any work is done on the brake system or if air is suspected in the brake lines, bleed the air
from the system.
NOTICE: Do not let brake fluid remain on a painted surface. Wash it off immediately.
1. FILL BRAKE RESERVOIR WITH BRAKE FLUID
Check the fluid level in the reservoir after bleeding each wheel. Add fluid, if necessary. Fluid: SAE
J1703 or FMVSS No. 116 DOT3
2. BLEED MASTER CYLINDER
HINT: If the master cylinder was disassembled or if the reservoir becomes empty, bleed the air
from the master cylinder.
(a) Disconnect the brake lines from the master cylinder.
SST 09023-00100
(b) Slowly depress the brake pedal and hold it.
(c) Block off the outlet plug with your finger, and release the brake pedal. (d) Repeat (b) and (c) 3
or 4 times.
Diagrams
Shifter A/T: Diagrams
COLUMN SHIFT ASSEMBLY OVERHAUL W/ RELATED COMPONENTS
Part 1 of 2
Page 2008
Oxygen Sensor: Mechanical Specifications
Torque: Sensor 1 .................................................................................................................................
...............................................
44 N.m (450 kgf.cm, 32 ft.lbf)
Sensor 2 ..............................................................................................................................................
.................................. 20 N.m (200 kgf.cm, 14 ft.lbf)
Page 1113
Glossary Of Terms And Symbols (Part 2)
Brakes - Vibration From Rear
Brake Drum: All Technical Service Bulletins Brakes - Vibration From Rear
BRAKES BR001-01
January 12, 2001
Title: REAR BRAKE VIBRATION
Models: '00 - '01 Tundra
TSB Update Notice:
The information contained in this TSB updates BR006-00, dated November 17, 2000.
Revised text is underlined.
New parking brake struts (star wheel adjusters) have been developed to reduce the possibility of
rear brake vibration on 2000 and 2001 model year Tundra vehicles. The number of teeth on the
star wheel adjuster has been reduced from 30 to 26 teeth.
Applicable Vehicles ^
2000 - 2001 model year Tundra vehicles.
Production Change Information
Parts Information
Repair Procedure
1. Grind rear brake drums with brake lathe to within serviceable limits.
2. If the drums are unserviceable or above maximum inside diameter, replace the drums.
3. If there is uneven wear on the lining, replace the left and right brake shoes.
4. Replace the parking brake shoe strut sets.
5. Adjust the parking brake to specifications.
6. Reinstall the rear wheels, and torque wheel nuts to:
Torque: 113 Nm (1,150 kgf cm, 83 ft.lbf)
7. Road test.
Warranty Information
Page 5928
Page 5781
b. Push the secondary locking device or terminal retainer in to the full lock position.
5. CONNECT CONNECTOR
Disconnection of Male and Female Connectors
Disconnection of Male and Female Connectors
Disconnection Of Male And Female Connectors
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Page 3871
a. Ignition switch ON. b. Shift the transmission shift lever in N position. c. Turn the touch select 2-4
switch ON. d. Check that the 4LO indicator lights come on and the 4HI indicator lights go off when
the touch select high-low switch is in ON position. e. Check that the 4LO indicator lights go off and
the 4HI indicator lights come on when the touch select high-low switch is in OFF position.
HINT: Inspection should be performed with the vehicle stopped, and transmission shift lever in N position.
- If switching is not completed after 3 seconds of shift operation, the 4LO indicator light will flash.
3. INSPECT TOUCH SELECT 2 - 4 AND HIGH-LOW SWITCH CONTINUITY
a. Remove center integration panel assembly. b. Inspect the continuity between the each terminals.
Touch select 2-4 switch
Touch select high-low switch:
If continuity is not as specified, replace the center integration panel assembly.
4. INSPECT ACTUATOR RESISTANCE
a. Using an ohmmeter, measure the resistance between terminals 1 and 2.
Standard resistance: 0.3 - 100 Ohms
b. Using an ohmmeter, measure the resistance between terminals 1 or 2 and body ground.
Standard resistance: More than 0.5 M Ohms If resistance value is not as specified, replace the
actuator assembly.
Page 4000
Hydraulic Control Assembly - Antilock Brakes: Service and Repair Disassembly and Assembly
Page 3446
Transmission Mode Indicator - A/T: Splice Locations
Engine Compartment
Splice Location
E1 Engine Room Main Wire
E2 Engine Room Main Wire
E3 Engine Room Main Wire
E4 Engine No. 2 Wire
E5 Engine Wire
E6 Engine Wire
E7 Engine Wire
E8 Engine Wire
Instrument Panel
Page 5524
D. Check to be sure that the male pin of the tongue plate stopper has become deformed evenly in
the hole of the female part and is firmly held to
the belt webbing.
Service Precautions
Air Bag(s) Arming and Disarming: Service Precautions
SRS AIRBAG PRECAUTION
CAUTION: TOYOTA trucks are equipped with SRS, which comprises a driver airbag, front
passenger airbag and failure to carry out service operations in the correct sequence could cause
the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Further, if
a mistake is made in servicing the SRS, it is possible that the SRS may fail to operate when
required. Before performing servicing (including removal or installation of parts, inspection or
replacement), be sure to read the following items carefully, then follow the correct procedures
described.
Work must be started 90 seconds after the ignition switch is turned to the "LOCK" position and the
negative (-) terminal cable is disconnected from the battery.
The SRS is equipped with a back-up power source so that if work is started within 90 seconds from
disconnecting the negative (-) terminal cable of the battery, the SRS may be deployed.)
Do not expose the steering wheel pad, front passenger airbag assembly, airbag sensor assembly
or front airbag sensor directly to hot air or flames.
NOTE: Malfunction symptoms of the SRS are difficult to confirm, so the DTCs become the most
important source of information when troubleshooting. When troubleshooting the SRS, always
inspect the DTCs before disconnecting the battery.
Even in cases of a minor collision where the SRS does not deploy, the steering wheel pad, front
passenger airbag assembly, airbag sensor assembly and front airbag sensor should be inspected.
Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during
repairs.
Never use SRS parts from another vehicle. When replacing parts, replace them with new parts.
Never disassemble and repair the steering wheel pad, front passenger airbag assembly, airbag
sensor assembly or front airbag sensor, in order to reuse it.
If the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag
sensor, has been dropped, or if there are cracks, dents or other defects in the case, bracket or
connector, replace it with new one.
Use a volt/ohmmeter with high impedance (10 Kohms/V minimum) for troubleshooting the system's
electrical circuits.
Information labels are attached to the periphery of the SRS components. Follow the instructions on
the notices.
After work on the SRS is completed, check the SRS warning light check.
When the negative (-) terminal cable is disconnected from the battery, the memory of the clock and
audio system will be canceled. So before starting work, make a record of the contents memorized
in the audio memory system. When work is finished, reset the audio systems as they were before
and adjust the clock. To avoid erasing the memory in each memory system, never use a back-up
power supply from outside the vehicle.
If the vehicle is equipped with a mobile communication system, refer to the precaution.
Page 73
Light Auto Turn Off
Page 2136
Spark Plug: Testing and Inspection
ON-VEHICLE INSPECTION
NOTE: "Cold" and "Hot" in these sentences express the temperature of the coils themselves.
"Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F).
INSPECT SPARK PLUGS
a. Remove the ignition coils (with igniter).
b. Using a 16 mm plug wrench, remove the spark plugs.
c. Clean the spark plugs.
If the electrode has traces of wet carbon, allow it to dry and then clean with a spark plug cleaner.
Air pressure: Below 588 kPa (6 kgf/sq.cm, 85 psi)
Duration: 20 seconds or less
HINT: If there are traces of oil, remove it with gasoline before using the spark plug cleaner.
Recommended Spark Plug
Page 4717
Glossary Of Terms And Symbols (Part 2)
Paint - Paint Codes - All
Paint: Technical Service Bulletins Paint - Paint Codes - All
COLLISION REPAIR INFORMATION CRIB107
TITLE: 2001 PAINT AND REFINISH FORMULAS CODES
SECTION: REFINISH BULLETIN #107
MODELS: ALL
DATE: OCTOBER 2000
Attached for your reference is a list of all 2001 Toyota paint codes and the refinish formula codes
for the following paint manufacturers:
BASF, DuPont, PPG, Sherwin-Williams, Akzo Nobel, Spies-Hecker, ICI Autocolor and Standox.
NOTE: The vehicle paint code is on the certification label which can be located on the driver side
door jamb or the lower section of the "B" pillar.
Please contact your local paint representative for the actual paint mixing formulas or if you need
help in color matching.
2001 TOYOTA PAINT CODES AND COLOR NAMES
Page 6093
Page 4683
Wiring Harness Connector
E: Indicates the wiring harness and wiring harness connector. The wiring harness with male
terminal is shown with arrows.
Outside numerals are pin numbers.
The first letter of the code for each wiring harness and wiring harness connector(s) indicates the
component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and
Surrounding area, and "B" for the Body and Surrounding area.
When more than one code has the first and second letters in common, followed by numbers (e.g,
IH1, IH2), this indicates the same type of wiring harness and wiring harness connector.
F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in
parts position.
G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside
it). Junction Blocks are shaded to clearly separate
them from other parts.
H: When 2 parts both use one connector in common, the parts connector name used in wire
routing is shown in square brackets [ ].
Wiring Color
I: Indicates the wiring color.
Wire colors are indicated by an alphabetical code.
B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR =
Brown SB = Sky Blue LG = Light Green GR = Gray
The first letter indicates the basic wire color and the second letter indicates the color of the stripe.
Page 4215
1. REMOVE FRONT WHEEL
2. 4WD: REMOVE GREASE CAP
Using a screwdriver and hammer remove the grease cap.
3. 4WD: DISCONNECT DRIVE SHAFT
A. Remove the cotter pin and lock cap.
B. While applying the brakes, remove the lock nut.
4. W/ABS DISCONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP FROM
STEERING KNUCKLE
Remove the 2 bolts and disconnect the ABS speed sensor and wire harness clamp from the
steering knuckle.
5. DISCONNECT BRAKE LINE
Using the SST, disconnect the brake line. Use a container to catch the brake fluid.
^ 09023-00100
6. REMOVE BRAKE,CALIPER AND DISC
Testing and Inspection
Four Wheel Drive Selector Switch: Testing and Inspection
INSPECTION
1. INSPECT 2WD -> 4HI SHIFT
a. Ignition switch ON. b. Check that the 4HI indicator lights come on when the touch select 2-4
switch is in ON position. c. Check that the 4HI indicator lights go off when the touch select 2-4
switch is in OFF position.
HINT: If the light does not light up, even though the switch has been turned ON, the vehicle should be
moved back and forth.
- If switching is not completed after 3 seconds of shift operation, the 4HI indicator light will flash.
2. INSPECT 4HI -> 4LO SHIFT
Testing and Inspection
Temperature Sensor (Gauge): Testing and Inspection
INSPECT ENGINE COOLANT TEMPERATURE SENDER GAUGE RESISTANCE Connect the
wire harness as shown in the illustration, and adjust the ammeter pointer to indicate "0" using the
slide rheostat, then read the rheostat indication.
If resistance value is not as specified, replace the engine coolant sender gauge.
Page 6527
B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(Connect the Relay) and SW 2 OFF (or Disconnect SW 2)
D. Disconnect and reconnect the connectors while watching the test light.
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
E. Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION:
a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals
are touched, the IC may be destroyed by
static electricity.)
b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact
with the terminals of leads from the IC, etc. of the replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
Special Tool
1. PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown.
2. DISCONNECT CONNECTOR
3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
a. Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the
secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
A: For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
Page 2861
Wiring Harness Connector
E: Indicates the wiring harness and wiring harness connector. The wiring harness with male
terminal is shown with arrows.
Outside numerals are pin numbers.
The first letter of the code for each wiring harness and wiring harness connector(s) indicates the
component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and
Surrounding area, and "B" for the Body and Surrounding area.
When more than one code has the first and second letters in common, followed by numbers (e.g,
IH1, IH2), this indicates the same type of wiring harness and wiring harness connector.
F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in
parts position.
G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside
it). Junction Blocks are shaded to clearly separate
them from other parts.
H: When 2 parts both use one connector in common, the parts connector name used in wire
routing is shown in square brackets [ ].
Wiring Color
I: Indicates the wiring color.
Wire colors are indicated by an alphabetical code.
B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR =
Brown SB = Sky Blue LG = Light Green GR = Gray
The first letter indicates the basic wire color and the second letter indicates the color of the stripe.
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 5998
Insert a screwdriver between the back panel upper garnish and body panel to remove the back
panel upper garnish.
15. REMOVE QUARTER TRIM
a. Standard cab:
Remove the bolt and front seat outer belt floor anchor.
Torque: 42 N.m (430 kgf.cm, 31 ft.lbf)
b. Access cab:
Remove the bolt and rear seat outer belt floor anchor.
Torque: 42 N.m (430 kgf.cm, 31 ft.lbf)
c. Using a screwdriver, remove the quarter trim belt hole cover.
d. Standard cab:
Using a screwdriver, remove the cap.
e. Standard cab:
Unfasten the bolt and remove front seat outer belt shoulder anchor.
Torque: 42 N.m (430 kgf.cm, 31 ft.lbf)
Page 3819
6. INSPECT LIMIT SWITCH CONTINUITY
a. Start the engine and raise the vehicle. b. With the actuator connector connected, shift the
transfer shift lever and after checking the operating sound, disconnect the connector and
inspect the continuity between each terminal.
HINT: When shifting the actuator fork shaft, connect the connectors.
7. INSPECT VEHICLE SPEED SENSOR 8. INSPECT 4HI AND 4LO INDICATOR LIGHT Check
the combination meter.
9. INSPECT 4WD CONTROL ECU
Connect the wire harness side connector to the 4WD control ECU and inspect wire harness side
connector from the back side.
Page 2909
Terminal Retainer
Push the terminal retainer down to the temporary lock position.
c. Release the locking lug from terminal and pull the terminal out from rear.
4. INSTALL TERMINAL TO CONNECTOR
a. Insert the terminal.
HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug
locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position.
Page 3609
1. POSITION NEW NO. 1 GASKET ON UPPER VALVE BODY
Align a new No. 1 gasket with each bolt hole.
2. POSITION VALVE BODY PLATE ON NO. 1 GASKET
Align the plate with each bolt hole.
3. POSITION NEW NO. 2 GASKET ON PLATE
Align a new No. 2 gasket with each bolt hole.
4. INSTALL 10 CHECK BALLS
5. INSTALL SPRING AND CHECK VALVE
6. INSTALL OIL STRAINER
Install the 3 oil strainers to the plate.
7. PLACE UPPER VALVE BODY WITH PLATE AND GASKETS ON TOP OF LOWER VALVE
BODY
Align each bolt hole with the gasket in the valve body.
NOTICE: Be careful that the check ball and strainer do not fall out.
Page 1084
Fuse Block: Diagnostic Aids
Voltage Check
Voltage Check
Voltage Check
A. Establish conditions in which voltage is present at the check point.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(SW 2 OFF)
B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or
component terminal. This check can be done with a test light instead of a voltmeter.
Continuity and Resistance Check
Continuity and Resistance Check
Continuity And Resistance Check
A. Disconnect the battery terminal or wire so there is no voltage between the check points. B.
Contact the two leads of an ohmmeter to each of the check points.
Page 3380
D. The Calibration Update Wizard (CUW) launches automatically when a calibration file link is
selected (or clicked). Verify that the CUW version is 6.0 or higher. If not, refer to the Note below.
The CUW will guide you through the steps to download the calibration file to the Diagnostic Tester
Program Card. Click NEXT on the first screen (Figure 7).
NOTE:
If the CUW does not launch, or the version is older than 6.0, install Diagnostic Software (TIS
Diagnostic Applications Installer). Specific installation instructions (Reprogramming with CUW 6.0)
are located under Diagnostics ECU Flash Reprogramming (Figure 6).
Page 871
4. Match the axis of the connector with axis of the pipe, and push in the connector until the
connector makes a "click" sound. In case that the
connections is tight, apply small amount of fresh engine oil on the tip of the pipe.
5. After having finished the connection, check if the pipe and the connector are securely connected
by pulling them. 6. Check if there is any fuel leakage.
h. Observe these precautions when handling nylon tube.
1. Pay attention not to turn the connected part of the nylon tube and the quick connector by force
when connecting them. 2. Pay attention not to kink the nylon tube. 3. Do not remove the EPDM
protector from the outside of the nylon tube. 4. Must not close the piping with the nylon tube by
bending it.
i. Check that there is any fuel leak after maintenance anywhere on the fuel system. 1. Connect a
TOYOTA hand-held tester to the DLC3. 2. Turn the ignition switch ON and push the TOYOTA
hand-held tester main switch ON.
NOTE: Do not start the engine.
3. Select the ACTIVE TEST mode on the TOYOTA hand-held tester. 4. Please refer to the
TOYOTA hand-held tester operator's manual for further details.
Page 122
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 5151
3. 4WD: DISCONNECT DRIVE SHAFT
a. Remove the cotter pin and lock cap. b. While applying the brakes, remove the lock nut.
4. w/ABS: DISCONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP FROM
STEERING KNUCKLE
Remove the 2 bolts and disconnect the ABS speed sensor and wire harness clamp from the
steering knuckle.
5. REMOVE BRAKE CALIPER AND DISC
a. Remove the bolt and brake line clamp from the steering knuckle. b. Remove the 2 bolts, brake
caliper and disc.
NOTICE: Do not damage the brake tube.
c. Support the brake caliper securely.
6. REMOVE SHOCK ABSORBER
7. DISCONNECT LOWER BALL JOINT
Remove the 4 bolts and disconnect the lower ball joint.
Page 4320
^ 09710-28012-01 (09710-07031) 09950-40011 (09951-04020, 09952-04010, 09953-04020,
09954-04010, 09955-04031, 09957-04010, 09958-04011)
HINT:
If necessary, use a press to remove the axle hub from the steering knuckle.
C. Remove the dust cover from the steering knuckle.
D. 4WD:
Remove the bearing spacer and ABS speed sensor rotor (W/ABS) or spacer (W/O ABS).
NOTE:
Take care not to scratch the serration of the speed sensor rotor.
14. REMOVE OIL SEAL (OUTSIDE)
Using a screwdriver, remove the oil seal (outside) from the steering knuckle.
15. REMOVE BEARING FROM STEERING KNUCKLE
A. Using snap ring pliers, remove the snap ring.
B. Using the following SSTs and a press, remove the bearing from the steering knuckle.
^ 09950-60020 (09951-00810)
^ 09950-70010 (09951-07150)
16. INSTALL NEW BEARING
A. Using the following SSTs and a press, install a NEW bearing to the steering knuckle.
^ 09527-17011
^ 09950-60020 (09951-00910)
Page 4587
Starter Relay: Testing and Inspection
INSPECTION
1. REMOVE STARTER RELAY
Remove the relay box cover and starter relay.
2. INSPECT STARTER RELAY CONTINUITY
a. Using an ohmmeter, check that there is continuity between terminals 1 and 2.
If there is no continuity, replace the relay.
b. Check that there is no continuity between terminals 3 and 5.
If there is continuity, replace the relay.
3. INSPECT STARTER RELAY OPERATION
a. Apply battery positive voltage across terminals 1 and 2. b. Using an ohmmeter, check that there
is continuity between terminals 3 and 5.
If there is no continuity, replace the relay.
4. REINSTALL STARTER RELAY
Page 3743
Transmission Mode Indicator - A/T: Harness Locations
Engine Compartment
Connector Location
EA1 Cowl Wire Harness and Wire Harness (Connector Location)
EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B)
EC1 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC2 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC3 Engine No. 2 Wire and Engine Wire (Near the Starter)
ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission)
Page 2573
L. The calibration file will now be downloaded to the Diagnostic Tester Program Card. This process
takes approximately 2-6 minutes (see Figure 15).
M. The CUW will prompt when the calibration file is completely downloaded. Click OK to close the
CUW (Figure 16).
NOTE:
With the calibration file loaded on the Diagnostic Tester Program Card, it is not necessary to repeat
the above steps to reprogram a different vehicle needing the same calibration file. The steps above
are only required when a new calibration file must be loaded onto the Diagnostic Tester Program
Card.
The Diagnostic Tester now has the calibration file stored and you may proceed to the next step to
reprogram the vehicle ECU.
REPROGRAM ECU WITH TESTER
3. Reprogram the vehicle ECU with the Diagnostic Tester.
NOTICE:
Errors during the flash reprogramming process can permanently damage the vehicle ECU.
Minimize the risks by following the steps below.
^ Battery voltage MUST NOT FALL BELOW 11.4 volts during reprogramming.
^ Confirm battery voltage is higher than 11.4 volts, but be sure voltage DOES NOT RISE ABOVE
16.0 volts during reprogramming.
^ Turn off all electrical accessories (e.g. Audio system, A/C, interior lights, DRL, etc.).
^ Do not add to or significantly change the vehicle's electrical load while reprogramming.
^ Confirm the hood is open and ensure under hood temperatures do not exceed 158°F.
Page 3909
Continuity And Resistance Check
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Continuity And Resistance Check
C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the
electrical circuit.
Finding A Short Circuit
Finding A Short Circuit
Finding A Short Circuit
A. Remove the blown fuse and disconnect all loads of the fuse.
Page 522
Engine Bank Identification
Page 961
4. Match the axis of the connector with axis of the pipe, and push in the connector until the
connector makes a "click" sound. In case that the
connections is tight, apply small amount of fresh engine oil on the tip of the pipe.
5. After having finished the connection, check if the pipe and the connector are securely connected
by pulling them. 6. Check if there is any fuel leakage.
h. Observe these precautions when handling nylon tube.
1. Pay attention not to turn the connected part of the nylon tube and the quick connector by force
when connecting them. 2. Pay attention not to kink the nylon tube. 3. Do not remove the EPDM
protector from the outside of the nylon tube. 4. Must not close the piping with the nylon tube by
bending it.
i. Check that there is any fuel leak after maintenance anywhere on the fuel system. 1. Connect a
TOYOTA hand-held tester to the DLC3. 2. Turn the ignition switch ON and push the TOYOTA
hand-held tester main switch ON.
NOTE: Do not start the engine.
3. Select the ACTIVE TEST mode on the TOYOTA hand-held tester. 4. Please refer to the
TOYOTA hand-held tester operator's manual for further details.
Page 5632
e. Dispose of front seat outer belt (with seat belt pretensioner).
CAUTION: The front seat outer belt is very hot when the seat belt pretensioner is activated, so leave it alone
for at least 30 minutes after activation.
- Use gloves and safety glasses when handling a front seat outer belt with activated seat belt
pretensioner.
- Always wash your hands with water after completing the operation.
- Do not apply water, etc. to a front seat outer belt with activated seat belt pretensioner.
1. Remove the disc wheel and SST. 2. Place the front seat outer belt in a vinyl bag, tie the end
tightly and dispose of it in the same way as other general parts.
Page 1686
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 909
6. REMOVE DRIVE BELT, FAN, FLUID COUPLING AND FAN PULLEY
a. Loosen the 4 nuts holding the fluid coupling to the fan bracket. b. Remove the drive belt. c.
Remove the 4 nuts, the fan, fluid coupling assembly and fan pulley.
7. DISCONNECT PS PUMP
Remove the 3 bolts, and disconnect the PS pump from the engine.
HINT: Suspend the PS pump securely.
8. REMOVE DRIVE BELT IDLER PULLEY
Remove the pulley bolt, cover plate and idler pulley.
9. REMOVE RH NO.3 TIMING BELT COVER
Remove the 3 bolts, nut and RH No.3 timing belt cover.
10. REMOVE LH NO.3 TIMING BELT COVER
a. Disconnect the engine wire from the 2 wire clamps. b. Remove the 4 bolts and nut. c. Disconnect
the camshaft position sensor wire from the wire clamp on the LH No.3 timing belt cover. d.
Disconnect the camshaft position sensor connector from the connector bracket. e. Disconnect the
camshaft position sensor connector. f.
Remove the wire grommet from the LH No.3 timing belt cover.
g. Remove the LH No.3 timing belt cover. h. Remove the bolt, nut and oil cooler pipe
Page 982
Brake Fluid: Testing and Inspection
Check for fluid leakage from actuator or hydraulic lines.
Page 2339
Glossary Of Terms And Symbols (Part 2)
Service and Repair
Planetary Gears: Service and Repair
For further information regarding this component and the system that it is a part of, please refer to
Transfer Case; Service and Repair.
Audio System - CD Player Skip Verification
CD Changer: Technical Service Bulletins Audio System - CD Player Skip Verification
SPECIAL SERVICE TOOLS SS003-05
Title: CD SKIP VERIFICATION USING TOYOTA MASTER CD
Models: '01 - '06 All Toyota & '04 - '06 All Scion
November 28, 2005
Introduction
Toyota has developed a master CD to be used for customer complaints of the CD player skipping
or CD player cannot read disc. This disc has been specially manufactured to test the performance
of the Toyota CD players. Using this master CD will confirm that the radio exceeds Toyota's
specification for CD player performance.
Applicable Vehicles
^ 2001 - 2006 model year Toyota vehicles.
^ 2004 - 2006 model year Scion vehicles.
Test Disc Specifications
Warranty Information
Page 5405
e. Install the SST.
CAUTION: Place the disc wheel on the level ground.
1. Connect the connectors of SST to the steering wheel pad connector.
SST 09082-00700, 09082-00760
NOTE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of
the twin lock. Also, secure some slack for the SST wire harness inside the disc wheel.
2. Move the SST to at least 10 m (33 ft) away from the steering wheel pad tied down on the disc
wheel.
f. Cover the steering wheel pad with a cardboard box or tires.
- Covering method using a cardboard box: Cover the steering wheel pad with the cardboard box
and weight the cardboard box down in 4 places with at least 190 N (20 kg, 44 lb).
Size of cardboard box: Must exceed the following dimensions: X = 460 mm (18.11 in.) Y = 650 mm
(25.59 in.)
NOTE: When dimension Y of the cardboard box exceeds the diameter of the disc wheel with tire to which
the steering wheel pad is tied, X should be the following size. X = 460 mm (18.11 in.) + width of tire
- If a cardboard box smaller than the specified size is used, the cardboard box will be broken by the
shock from the airbag deployment.
- Covering method using tires: Place at least 3 tires without disc wheel on top of the disc wheel with
tire to which the steering wheel pad is tied.
Tire size : Must exceed the following dimensions- Width : 185 mm (7.87 in.) Inner diameter : 360
mm (14.17 in.)
CAUTION: Do not use tires with disc wheels.
NOTE: The tires may be marked by the airbag deployment, so use the redundant tires.
Page 2809
CHART 1
Page 2037
Continuity And Resistance Check
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Continuity And Resistance Check
C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the
electrical circuit.
Finding A Short Circuit
Finding A Short Circuit
Finding A Short Circuit
A. Remove the blown fuse and disconnect all loads of the fuse.
Page 3013
4. CONNECT VSV FOR EVAP TO UPPER INTAKE MANIFOLD
a. Install the accelerator cable clamp and VSV for the EVAP to the upper intake manifold. b.
Connect the EVAP hose. c. Connect the VSV connector for the EVAP.
5. INSTALL THROTTLE BODY COVER BRACKET
Install the throttle body cover bracket with the bolt.
6. INSTALL ACCELERATOR CABLE BRACKET
a. Install the accelerator cable bracket with the 2 nuts.
Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)
b. Connect the accelerator cable to the engine.
7. INSTALL FUEL PRESSURE PULSATION DAMPER
8. INSTALL INTAKE AIR CONNECTOR
9. INSTALL THROTTLE BODY COVER
Page 1008
Fluid - Differential: Fluid Type Specifications
Differential Fluid
Front Grade .........................................................................................................................................
.............................................................. GL-5 or equivalent Viscosity .................................................
..........................................................................................................................................................
SAE 75W-90 Rear Grade ....................................................................................................................
................................................................................... GL-5 or equivalent Above -18° C (0° F) ..........
..............................................................................................................................................................
........................... SAE 90 Below -18° C (0° F) ....................................................................................
......................................................................................... SAE 85W-90 or 80W
Page 1676
A. Test the CAN Interface Module (P/N 01002744) for continuity.
^ If there is no continuity, the CAN Interface Module needs to be replaced.
^ If there is continuity, the CAN Interface Module is OK. Re-check Cable Tests 1, 2, 3, and 4 while
wiggling and flexing the cables.
Page 2611
B. You have the option to delete calibrations off the tester before downloading a new calibration.
The CUW also provides this option if there is not enough memory for the new calibration. To delete
one or all of the calibrations, follow the screen flow shown (Figure 5).
C. If this is the first time you have downloaded a calibration file from TIS to the Diagnostic Tester
Program Card, you MUST first install the latest version of the Calibration Update Wizard (CUW)
onto your TIS workstation PC, as shown in Figure 6.
This step is also required if you are using a version of CUW earlier than version 6.0. CUW 6.0 is
the only version compatible with Diagnostic Tester software version 10.2a and later. If necessary,
select the link to the TIS Diagnostic Applications Installer and follow the on-screen prompts to
install or reinstall CUW.
Page 6798
BJ Inside of Rear Door LH
BK Inside of Rear Door RH
BL Surrounding of the Front of the Fuel Tank
Connector Location
BA1 Front Door LH Wire and Wire Harness (Connector Location)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel)
BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel)
BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel)
BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Page 1865
Intake Air Temperature Sensor: Description and Operation
Intake Air Temperature Sensor
The intake air temperature sensor is built into the air cleaner cap and senses the intake air
temperature. A thermistor built in the sensor changes the resistance value according to the intake
air temperature.
The lower the intake air temperature, the greater the thermistor resistance value, and the higher
the intake air temperature, the lower the thermistor resistance value.
The intake air temperature sensor is connected to the ECM. The 5 V power source voltage in the
ECM is applied to the intake air temperature sensor from the terminal THA via a resistor R.
That is, the resistor R and the intake air temperature sensor are connected in series. When the
resistance value of the intake air temperature sensor changes in accordance with changes in the
intake air temperature, the potential at terminal THA also changes. Based on this signal, the ECM
increases the fuel injection volume to improve driveability during cold engine operation.
Page 6488
Driver Side J/B And Integration Relay
Page 3604
Width 5.0 mm
Thickness 3.2 mm
1-2 Shift Valve Height 16.5 mm
Width 6.0 mm
Thickness 3.2 mm
Valve Body Check Ball Upper Valve Body Rubber Ball (A) Diameter 6.35 mm
Rubber Ball (B) Diameter 5.45 mm
Lower Valve Body Steel Diameter 6.35 mm
Rubber Ball Diameter 5.45 mm
Upper Valve Body x Lower Valve Body 6.45 Nm
Detent Spring x Valve Body 10 Nm
Valve Body x Transmission Case 10 Nm
Oil Strainer x Valve Body 10 Nm
Shift Solenoid Valve x Valve Body 10 Nm
Spring Seat x Lower Valve Body 6.9 Nm
Page 4183
1. REMOVE FRONT WHEEL
2. 4WD: REMOVE GREASE CAP
Using a screwdriver and hammer remove the grease cap.
3. 4WD: DISCONNECT DRIVE SHAFT
A. Remove the cotter pin and lock cap.
B. While applying the brakes, remove the lock nut.
4. W/ABS DISCONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP FROM
STEERING KNUCKLE
Remove the 2 bolts and disconnect the ABS speed sensor and wire harness clamp from the
steering knuckle.
5. DISCONNECT BRAKE LINE
Using the SST, disconnect the brake line. Use a container to catch the brake fluid.
^ 09023-00100
6. REMOVE BRAKE,CALIPER AND DISC
Page 1429
Part 4 of 4
Page 4435
Speed Sensor, Front
Wheel Speed Sensor: Service and Repair Speed Sensor, Front
REMOVAL
1. REMOVE FRONT WHEEL
Torque: 113 Nm (1,150 kgf-cm, 83 ft. lbs.)
2. DISCONNECT SPEED SENSOR CONNECTOR
3. REMOVE SPEED SENSOR
(a) Remove the clips and 3 clamp bolts holding the sensor harness from the frame, upper arm and
steering knuckle.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
(b) Remove the bolt and speed sensor from the steering knuckle.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
INSTALLATION
Installation is in the reverse order of removal.
HINT: After installation, check speed sensor signal.
Locations
Engine Room R/B
Page 6863
Headlamp Dimmer Relay: Testing and Inspection
INSPECT HEADLIGHT CONTROL RELAY CONTINUITY If continuity is not as specified, replace
the relay.
Page 536
Required Tools & Material
NOTE:
Additional Diagnostic Tester Kits, Program Cards or SSTs may be ordered by calling SPX-OTC at
1-800-933-8335.
Repair Procedure
Using the chart, refer to the Diagnostic Section (DI-###) in the appropriate Repair Manual and
follow the diagnostic procedure for the specific DTC.
Page 1579
Radiator: Service and Repair Removal and Installation
Page 2761
CHART 16
CHART 17
Specifications
Suspension And Axle - Lubricant
Page 1918
CHART 10
Page 3364
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 4491
Wheel Speed Sensor: Diagrams
Page 5884
a. Apply protective tape to the outer surface as shown in illustration, to keep the surface from being
scratched. b. Using a heat light, heat the moulding to 20 - 30 °C (68- 86 °F).
NOTE: Do not heat the moulding excessively.
c. Using a scraper, pull off the roof drip side finish moulding from front end and rear end.
HINT: Tape the scraper tip before use.
2. REMOVE MOULDING AND ADHESIVE
a. Pull off the moulding by cutting the adhesive with a knife. b. Remove the moulding
NOTE: Do not damage the body with the knife.
INSTALLATION
1. CLEAN CONTACT SURFACE OF BODY
a. Using a heat light, heat the body surface 40 - 60 °C (104 - 140 °F).
NOTE: Do not heat the body excessively.
b. Using a knife, cut away any rough areas on the body.
NOTE: Be careful not to damage the body.
c. Wipe off stains with cleaner.
Page 2873
Terminal Retainer
Push the terminal retainer down to the temporary lock position.
c. Release the locking lug from terminal and pull the terminal out from rear.
4. INSTALL TERMINAL TO CONNECTOR
a. Insert the terminal.
HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug
locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position.
Page 5905
Page 2261
During ECU flash reprogramming, the Error screen shown may be displayed on the Diagnostic
Tester for one of the following reasons:
1. Immobilizer key not properly registered or auto-registration mode left open.
2. Ignition ON/OFF cycling not followed correctly during the flash reprogramming procedure.
3. The Diagnostic Tester cable is damaged, causing an open communication circuit.
NOTE:
The Diagnostic Tester may operate properly in other modes such as OBD, OBDII, or CARB, with a
damaged cable.
To eliminate the possibility of the first 2 reasons causing the error message, do the following:
1. Confirm the Immobilizer Transponder Master Key is properly registered and auto registration
mode is closed. Follow the appropriate Repair Manual procedure and consult TSB SS001-99,
"Scan tool Immobilizer key Code Utility
2. Conduct the ECU flash reprogramming process explicitly following key operation instructions.
Refer to TSB SS002-01, "ECU Flash Reprogramming Process, "for more details.
To determine if the Diagnostic Tester cable is damaged, follow the test procedures below to check
the electrical integrity of the cable. Conduct all continuity tests with an Ohm meter. For all five test
procedures, the resistance values must be below 6.0 ohms to pass.
Test CABLE TEST 1.
Testing and Inspection
Tachometer: Testing and Inspection
INSPECT TACHOMETER/ON-VEHICLE
a. Connect a tune-up test tachometer, and start the engine.
NOTE: -
Reversing the connection of the tachometer will damage the transistors and diodes inside.
- When removing or installing the tachometer, be careful not to drop or subject it to heavy shocks.
b. Compare the tester and tachometer indications.
DC 13.5 V 20°C at (77°F)
INSPECT TACHOMETER RESISTANCE Measure the resistance between terminals with fixing
pointer to the stopper. If resistance value is not as specified, replace the meter.
Locations
Engine Room R/B
Engine Controls - Error When Reprogramming ECU
Engine Control Module: All Technical Service Bulletins Engine Controls - Error When
Reprogramming ECU
SPECIAL SERVICE TOOLS SS004-01 REVISED
May 25, 2001
Title: ECU FLASH REPROGRAMMING ERROR MESSAGE
Models: Applicable Models
TSB REVISION NOTICE:
September 23, 2003: Models added - 2002 (and later) Solara, 2003 (and later) Corolla and Matrix,
and 2004 models; Test Procedures updated for new CAN Interface Module. The previous TSB
should be discarded.
Introduction
During ECU flash reprogramming, an error message may be displayed on the Diagnostic Tester
that will not allow ECU flash reprogramming to complete. This bulletin provides test procedures to
determine the cause for the error message.
Applicable Vehicles ^
2001 (and later) model year 4Runner, Highlander, Land Cruiser, RAV4, Sequoia and Tundra
vehicles.
^ 2002 (and later) model year Camry, Solara and Tacoma vehicles.
^ 2003 (and later) model year Corolla and Matrix vehicles.
^ All 2004 (and later) model year Toyota vehicles except Celica, MR2 Spyder, Avalon, and Tacoma
(3RZ-FE engine)
Required SSTs
NOTE:
Additional Diagnostic Tester Kits, CAN Interface Modules, Program Cards or other SSTs may be
ordered by calling SPX/OTC at 1-800-933-8335.
Warranty Information
Test Procedure
Diagram Information and Instructions
Engine Control Module: Diagram Information and Instructions
Key to Diagrams
A: System Title
B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to
distinguish it from the J/B
Example: 1 Indicates Relay Block No.1
C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type,
or specification is different.
D: Indicates related system.
Page 1123
Driver Side J/B And Integration Relay
Page 6797
Instrument Panel
Ground Location
IE Left Kick Panel
IF Left Kick Panel
IG Instrument Panel Brace RH
IH Right Kick Panel
II Right Kick Panel
Body
Ground Location (Access Cab)
Page 4171
11. 4WD: Remove oil seal (inside).
A. Mount the axle hub in a soft jaw vise.
HINT: Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further
(refer to the illustration above).
B. Using a screwdriver, remove the oil seal (inside).
12. 2WD: Remove lock nut and ABS speed sensor rotor (with ABS) or spacer (without ABS). Using
a chisel and hammer, loosen the staked part of the lock nut.
NOTE:
Be careful not to damage the bushing.
A. Using the following SST, remove the lock nut. SST P/N: 00002-00909 (09318-12010)
NOTE:
Do NOT use air wrench.
B. Remove the ABS speed sensor rotor or spacer.
NOTE:
Take care not to scratch the serration of the speed sensor rotor.
13. Remove axle hub from steering knuckle.
A. Remove the 4 bolts and shift the dust cover toward the hub side (outside).
B. Using the following SSTs, remove the axle hub from the steering knuckle.
SST P/N: 09710-28012-01 (09710-07031)
SST P/N: 09950-40011(09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04031,
09957-04010, 09958-04011)
HINT: If necessary, use a press to remove the axle hub from the steering knuckle.
C. Remove the dust cover from the steering knuckle.
D. 4WD: Remove the bearing spacer and ABS speed sensor rotor (with/ABS) or spacer (without
ABS).
NOTE:
Take care not to scratch the serration of the speed sensor rotor.
14. Remove oil seal (outside). Using a screwdriver, remove the oil seal (outside) from the steering
knuckle.
15. Remove bearing from steering knuckle.
Page 3892
Splice Location
I1 Cowl Wire
I2 Cowl Wire
I3 Cowl Wire
I4 Cowl Wire
I5 Cowl Wire
I6 Cowl Wire
I7 Engine Wire
I8 Engine Wire
I9 Engine Wire
I10 Engine Wire
I11 Engine Wire
I12 Engine Wire
I13 Engine Wire
I14 Engine Wire
I15 Engine Wire
I16 Cowl Wire
Body
Splice Location (Access Cab)
B1 Speaker Tweeter Wire LH
B2 Front Door LH Wire
B3 Front Door LH Wire
B4 Roof Wire
B5 Speaker Tweeter Wire RH
B6 B7
Front Door RH Wire
B8 Front Door RH Wire
B9 Rear Door No. 1 Wire RH
B10 Frame Wire
Page 30
12 - GROUND : Approx. 12 volts for 0.2 seconds with following operations
- Door lock control SW unlocked - Door lock control SW looked with ignition key in cylinder and LH
door open (Ignition key reminder function) - Door lock knob locked with ignition key in cylinder and
LH door open. (Ignition key reminder function) - Unlocking the LH, RH door cylinder with key
13 - GROUND : Approx. 12 volts for 0.2 seconds with following operations
- Door lock control SW locked - Locking the LH, RH door cylinder with key
14 - GROUND : Continuity with front LH door open (Standard cab)
14 - GROUND : Continuity with each LH door open (Access cab)
15 - GROUND : Continuity with front RH door open (Standard cab)
15 - GROUND : Continuity with each RH door open (Access cab)
D16, D17 DOOR COURTESY SW FRONT LH, RH
1 - GROUND : Closed with door open
D22, D23 DOOR KEY LOCK AND UNLOCK SW LH, RH
1 - 2 : Closed with door lock cylinder locked with key 3 - 2 : Closed with door lock cylinder unlocked
with key
D25, D26 DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW LH, RH
4 - 1 : Closed with door lock knob UNLOCK position
U1 UNLOCK WARNING SW
1 - 2 : Closed with key in cylinder
Locations
Hydraulic Control Assembly - Antilock Brakes: Locations
Engine Compartment
Ground Locations
Transmission Mode Indicator - A/T: Ground Locations
Engine Compartment
Ground Location
EA Front Left Fender
EB Rear Bank of Right Cylinder
EC Rear Bank of Left Cylinder
Connector Location
EA1 Cowl Wire Harness and Wire Harness (Connector Location)
EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B)
EC1 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC2 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC3 Engine No. 2 Wire and Engine Wire (Near the Starter)
ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission)
Page 6875
The ground points circuit diagram shows the connections from all major parts to the respective
ground points. When troubleshooting a faulty ground point, checking the system circuits which use
a common ground may help you identify the problem ground quickly. The relationship between
ground points (EA, IB and IC) can also be checked this way.
How to Read Power Source
HOW TO READ POWER SOURCE
Page 497
2. REMOVE CRANKSHAFT POSITION SENSOR
a. Disconnect the crankshaft position sensor connector. b. Remove the bolt and crankshaft position
sensor.
INSTALLATION
1. INSTALL CRANKSHAFT POSITION SENSOR
a. Install the crankshaft position sensor with the bolt.
Torque: 6.5 N.m (65 kgf.cm, 58 in.lbf)
b. Connect the crankshaft position sensor connector.
2. INSTALL ENGINE UNDER COVER
Page 5778
Non-Waterproof Type Connector
"Case 1" Raise the terminal retainer up to the temporary lock position.
Non-Waterproof Type Connector
"Case 2" Open the secondary locking device.
Page 3941
Step 3
Page 6089
Paint: Locations
BODY PANEL ANTI-CHIPPING PAINT APPLICATION AREAS
HINT:
1. Anti-chipping paint should be applied to some areas before the second coat and to others after
the top coat. 2. If other areas are accidentally coated, wipe of the paint immediately with a rag
soaked in grease, wax and silicone remover.
Page 3906
Glossary Of Terms And Symbols (Part 1)
Page 4275
Wheel Cylinder: Service and Repair
For information regarding the service and repair of this component and the system that it is a part
of, please refer to Drum Brake System; Service and Repair.
Specifications
Knock Sensor: Specifications
SST 09816-30010
Torque: ................................................................................................................................................
................................. 45 N.m (450 kgf.cm, 33 ft.lbf)
Page 5908
Information
PRELIMINARY INSPECTION INSTRUCTIONS
Page 5156
6. 4WD: INSTALL BEARING SPACER
Using SST and a press, install the bearing spacer. SST 09950-60010 (09951-00650), 09950-70010
(09951-07150)
7. 2WD: INSTALL GREASE CAP
8. 4WD: INSTALL NEW OIL SEAL (INSIDE)
a. Using SST and a plastic hammer, install a new oil seal (inside).
SST 09527-17011
HINT: Lightly strike the SST on its circumference evenly.
b. Coat MP grease to the oil seal lip.
Diagram Information and Instructions
Data Link Connector: Diagram Information and Instructions
Key to Diagrams
A: System Title
B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to
distinguish it from the J/B
Example: 1 Indicates Relay Block No.1
C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type,
or specification is different.
D: Indicates related system.
Page 936
A. Using a breaker bar or ratchet with a 14 mm socket, apply counterclockwise force on the
accessory drive belt tensioner to release tension and remove the accessory drive belt.
HINT:
The pulley bolt for the belt tensioner has a left hand thread.
B. Using the accessory drive belt routing label located on the passenger side of the radiator core
support as a guide, install the new accessory drive belt.
2. Check belt tensioner operation.
A. Check that the belt tensioner moves downward when the drive belt is pressed down at the points
indicated in the illustration with approximately 98 N (10 kgf, 22.0 lbf) of force.
B. Ensure proper alignment of the belt with the ribbed grooves of each pulley.
C. Check by hand to ensure that the belt has not slipped out of the groove on the bottom of each
pulley.
D. Check that the arrow mark on the belt tensioner falls within area "A" of the scale (see
illustration).
E. If the arrow mark falls outside area "A," the drive belt is incorrect.
HINT:
When a new belt is installed, it should lie within area "B." If not, the drive belt is incorrect.
Page 3542
Torque Converter: Testing and Inspection
INSPECTION
1. INSPECT ONE-WAY CLUTCH
a. Install SST in the inner race of one-way clutch.
SST 09350-30020 (09351-32010)
b. Install SST so that it fits in the notch of the converter hub and outer race of the one-way clutch.
SST 09350-30020 (09351-32020)
c. With the torque converter clutch standing on its side, check that the clutch locks when turned
counterclockwise, and rotates freely and
smoothly clockwise. If necessary, clean the converter and retest the clutch. Replace the converter
if the clutch still fails the test.
2. MEASURE DRIVE PLATE RUNOUT AND INSPECT RING GEAR
Set up a dial indicator, measure the drive plate runout. Maximum runout: 0.20 mm (0.0079 inch) If
runout is not within the specification or if the ring gear is dam- aged, replace the drive plate. If
installing a new drive plate, note the orientation of spacers and tighten the bolts. Torque: 83 Nm
(850 kgf-cm, 61 ft. lbs.)
Page 3901
Wiring Harness Connector
E: Indicates the wiring harness and wiring harness connector. The wiring harness with male
terminal is shown with arrows.
Outside numerals are pin numbers.
The first letter of the code for each wiring harness and wiring harness connector(s) indicates the
component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and
Surrounding area, and "B" for the Body and Surrounding area.
When more than one code has the first and second letters in common, followed by numbers (e.g,
IH1, IH2), this indicates the same type of wiring harness and wiring harness connector.
F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in
parts position.
G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside
it). Junction Blocks are shaded to clearly separate
them from other parts.
H: When 2 parts both use one connector in common, the parts connector name used in wire
routing is shown in square brackets [ ].
Wiring Color
I: Indicates the wiring color.
Wire colors are indicated by an alphabetical code.
B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR =
Brown SB = Sky Blue LG = Light Green GR = Gray
The first letter indicates the basic wire color and the second letter indicates the color of the stripe.
Page 3217
Instrument Panel
Ground Location
IE Left Kick Panel
IF Left Kick Panel
IG Instrument Panel Brace RH
IH Right Kick Panel
II Right Kick Panel
Body
Ground Location (Access Cab)
Page 2975
If operation is not as specified, replace the MAF meter.
6. Turn the ignition switch OFF. 7. Disconnect the negative (-) terminal cable from the battery. 8.
Disconnect the MAF meter connector.
4. REINSTALL MAF METER
Install the MAF meter with the 2 screws.
5. RECONNECT MAF METER CONNECTOR
Page 2439
CHART 24
Page 1962
Page 4635
Continuity And Resistance Check
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Continuity And Resistance Check
C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the
electrical circuit.
Finding A Short Circuit
Finding A Short Circuit
Finding A Short Circuit
A. Remove the blown fuse and disconnect all loads of the fuse.
Removal and Installation
Brake Master Cylinder: Service and Repair Removal and Installation
REMOVAL
1. DISCONNECT LEVEL WARNING SWITCH CONNECTOR 2. TAKE OUT FLUID WITH
SYRINGE
NOTICE: Do not let brake fluid remain on a painted surface. Wash it off immediately.
Page 848
5. As shown in the example chart, read the distance from the measured value to the standard
value, and adjust the front and/or rear adjusting
cams accordingly. Amount to turn adjusting cams (by graduation): Example:
Front cam: 1.3 + Direction Rear cam: 3.3 + Direction
d. Torque the front and/or rear adjusting cam set bolts.
Torque: 130 Nm (1,325 kgf-cm, 96 ft. lbs.)
Page 2613
E. Confirm the Diagnostic Tester has the appropriate software for the type of calibration file that
was downloaded.
NOTE:
The calibration type is specific to the software version loaded on your Diagnostic Tester. If you
selected the wrong version when downloading the calibration file, you will receive an error when
attempting to install the file on the Diagnostic Tester.
Locations
Page 4925
Glossary Of Terms And Symbols (Part 2)
Page 3000
Fuel Injector: Pressure, Vacuum and Temperature Specifications Pressure Drop
Pressure Drop
Pressure Drop 1 Drop per 12 Minutes
Page 3308
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 3529
Part 2 of 2
Page 6220
Cruise Control: Reading and Clearing Diagnostic Trouble Codes
Clearing Diagnostic Trouble Codes
NOTE: This is the only information provided by the manufacturer for Clearing Diagnostic Trouble
Codes for this system.
DTC CLEARANCE
a. The following actions will erase DTCs and freeze frame data.
1. Operating the OBD II scan tool (complying with SAE J1978) or TOYOTA hand-held tester to
erase codes. (See the OBD II scan tool's
instruction book for operating instructions.)
2. Disconnecting the battery terminals or EFI fuse.
b. After completing repairs, the DTC retained in the memory can be cleared by removing the
ECU-B fuse for 10 seconds or more with the ignition
switch OFF.
c. Check that the normal code is displayed after connecting the fuse.
Displaying & Reading Trouble Codes
NOTE: This is the only information provided by the manufacturer for reading diagnostic trouble
codes for this system.
1. DIAGNOSIS SYSTEM
a. Check the indicator.
1. Turn the ignition switch to ON. 2. Check that the CRUISE MAIN indicator light comes on when
the cruise control main switch is turned ON, and that the indicator light goes
off when the main switch is turned OFF.
HINT: If the indicator check result is not normal, proceed to troubleshooting for the combination
meter section.
b. Check the DTC.
HINT: If a malfunction occurs in the speed sensor or actuator, etc. during cruise control driving, the
ECU actuates AUTO CANCEL of the cruise control and turns ON and OFF the CRUISE MAIN
indicator light to inform the driver of a malfunction. At the same time, the malfunction is stored in
memory as a diagnostic trouble code.
Page 541
2. Start the engine.
3. Perform the drive pattern to run and complete the Oxygen Sensor (O2S) Monitor.
HINT:
The 02S Monitor is completed when the following conditions are met:
^ Two (2) minutes or more passed after the engine start.
^ The Engine Coolant Temperature (ECT) is 167°F (75°C) or more.
^ Cumulative running time at 30 mph (48 km/h) or more exceeds 6 minutes.
^ Vehicle is in closed loop.
^ The fuel-cut is operated for 8 seconds or more (for Rear O2S Monitor).
A. Allow the engine to idle for two minutes.
B. Warm up the engine until the Engine Coolant Temperature (ECT) reaches 167°F (75°C).
C. Drive the vehicle over 30 mph (48 km/h) for more than 40 seconds.
D. Stop the vehicle and allow the engine to idle for more than 20 seconds.
E. Repeat steps C and D at least 8 times in one driving cycle. (Do not cycle the ignition key.)
In addition, perform the following steps for the Rear O2S Readiness Monitor:
A. Select second gear.
B. Allow the vehicle to run at 30 mph (48 km/h) or more.
C. Keep the accelerator pedal "off-idle" for more than 10 seconds.
D. Immediately after step C, release the accelerator pedal for at least 10 seconds without
depressing the brake pedal (to execute the fuel-cut).
E. Decelerate the vehicle until the vehicle speed reaches less than 6mph (10km/h).
F. Repeat steps B - E at least twice in one driving cycle.
Accessing O2S Test Results
1. On the Diagnostic Tester* screen, select the following menus:
^ DIAGNOSTICS
^ CARB OBD II
Page 5495
Inspect the entire length of webbing for damage and replace the assembly if needed. Be careful
NOT to damage the webbing during repair.
3. Install the NEW tongue plate stopper
A. Install a NEW tongue plate stopper in the hole of the webbing.
NOTE
Be sure to install the stopper in the correct direction as shown in the illustration.
B. Pinch the tongue plate stopper into the webbing using the tool shown in Figure 3 or use a small
"C" clamp.
NOTE
To prevent damage to the plastic tongue plate stopper when using a "C" clamp device, use light to
moderate clamping force when crimping the two halves of the tongue plate stopper together.
HINT
Press the adjustment screw locating the male and female parts of the tongue plate stopper parallel
to each other.
Page 5408
Clockspring Assembly / Spiral Cable: Service and Repair Removal and Installation
Steering Wheel Pad And Spiral Cable
REMOVAL
1. REMOVE STEERING WHEEL PAD
2. REMOVE STEERING WHEEL
3. REMOVE UPPER AND LOWER COLUMN COVERS
4. REMOVE SPIRAL CABLE
INSTALLATION
Page 2060
Mass Air Flow Meter: Testing and Inspection
MASS AIR FLOW (MAF) METER
INSPECTION
1. DISCONNECT MAF METER CONNECTOR
2. REMOVE MAF METER
Remove the 2 screws and MAF meter.
3. INSPECT MAF METER
a. Using an ohmmeter, measure the resistance between terminals THA and E2.
If the resistance is not as specified, replace the MAF meter.
b. Inspect for operation.
1. Connect the MAF meter connector. 2. Connect the negative (-) terminal cable to the battery. 3.
Turn the ignition switch ON. 4. Using a voltmeter, connect the positive (+) tester probe to terminal
VG, and negative (-) tester probe to terminal E2G. 5. Blow air into the MAF meter, and check that
the voltage fluctuates.
Page 549
CHART 1
Page 1785
Glossary Of Terms And Symbols (Part 2)
Collision / Non-Collision Inspections
Airbag Sensor Assembly: Testing and Inspection Collision / Non-Collision Inspections
VEHICLE NOT INVOLVED IN COLLISION
Check a diagnostic system.
VEHICLE INVOLVED IN COLLISION WITH AIRBAG NOT DEPLOYED
Check a diagnostic system. *
VEHICLE INVOLVED IN COLLISION WITH AIRBAG DEPLOYED
Replace the airbag sensor assembly. *
* Refer to SRS Warning Light Check, and How to Display and Read Diagnostic Trouble Codes.
See: Air Bag Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble
Codes/Displaying & Reading Trouble Codes
Page 395
Splice Location
I1 Cowl Wire
I2 Cowl Wire
I3 Cowl Wire
I4 Cowl Wire
I5 Cowl Wire
I6 Cowl Wire
I7 Engine Wire
I8 Engine Wire
I9 Engine Wire
I10 Engine Wire
I11 Engine Wire
I12 Engine Wire
I13 Engine Wire
I14 Engine Wire
I15 Engine Wire
I16 Cowl Wire
Body
Splice Location (Access Cab)
B1 Speaker Tweeter Wire LH
B2 Front Door LH Wire
B3 Front Door LH Wire
B4 Roof Wire
B5 Speaker Tweeter Wire RH
B6 B7
Front Door RH Wire
B8 Front Door RH Wire
B9 Rear Door No. 1 Wire RH
B10 Frame Wire
Page 2191
Crankshaft Position Sensor
Page 223
The ground points circuit diagram shows the connections from all major parts to the respective
ground points. When troubleshooting a faulty ground point, checking the system circuits which use
a common ground may help you identify the problem ground quickly. The relationship between
ground points (EA, IB and IC) can also be checked this way.
How to Read Power Source
HOW TO READ POWER SOURCE
Page 4066
11. 4WD:
REMOVE OIL SEAL (INSIDE)
A. Mount the axle hub in a soft jaw vise.
HINT:
Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further.
B. Using a screwdriver, remove the oil seal (inside).
12. 2WD:
REMOVE LOCK NUT AND ABS
SPEED SENSOR ROTOR (W/ABS) OR SPACER (W/O ABS) Using a chisel and hammer, loosen
the staked part of the lock nut.
NOTE:
Be careful not to damage the bushing.
A. Using the following SST, remove the lock nut. 00002-00909 (09318-12010)
NOTE:
Do NOT use air wrench.
B. Remove the ABS speed sensor rotor or spacer.
NOTE:
Take care not to scratch the serration of the speed sensor rotor.
13. REMOVE AXLE HUB FROM STEERING KNUCKLE
A. Remove the 4 bolts and shift the dust cover toward the hub side (outside).
B. Using the following SSTs, remove the axle hub from the steering knuckle.
Page 6712
Brake Lamp: Harness Locations
Engine Compartment
Connector Location
EA1 Cowl Wire Harness and Wire Harness (Connector Location)
EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B)
EC1 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC2 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC3 Engine No. 2 Wire and Engine Wire (Near the Starter)
ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission)
Page 4697
Relay Box: Connector Views
Engine Room R/B
Page 864
Idle Speed: Testing and Inspection
INSPECTION
1. INITIAL CONDITIONS
a. Engine at normal operating temperature b. Air cleaner installed c. All pipes and hoses of air
induction system connected d. All accessories switched OFF e. All vacuum lines properly
connected f.
SFI system wiring connectors fully plugged
g. Ignition timing checked correctly h. Transmission in neutral position i.
Air conditioning switched OFF
2. CONNECT TOYOTA HAND-HELD TESTER OR OBD II SCAN TOOL 3. INSPECT IDLE SPEED
a. Race the engine speed at 2,500 rpm for approximately 90 seconds. b. Check the idle speed.
Idle speed: 700 ± 50 rpm If the idle speed is not as specified, check the air intake system.
4. DISCONNECT TOYOTA HAND-HELD TESTER OR OBD II SCAN TOOL
Page 3359
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
Electrical Specifications
Resistance
Testing and Inspection
Parking Brake Warning Switch: Testing and Inspection
INSPECT PARKING BRAKE SWITCH CONTINUITY a. Check that there is continuity terminals
with the switch ON (switch pin released). b. Check that there is no continuity between terminals
with the switch OFF (switch pin pushed in).
If operation is not as specified, replace the switch.
Page 2559
A. Test the CAN Interface Module (P/N 01002744) for continuity.
^ If there is no continuity, the CAN Interface Module needs to be replaced.
^ If there is continuity, the CAN Interface Module is OK. Re-check Cable Tests 1, 2, 3, and 4 while
wiggling and flexing the cables.
Page 1089
Terminal Retainer
Push the terminal retainer down to the temporary lock position.
c. Release the locking lug from terminal and pull the terminal out from rear.
4. INSTALL TERMINAL TO CONNECTOR
a. Insert the terminal.
HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug
locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position.
Page 1227
Intake: N = T + (A - 0.20 mm (0.008 inch))
Page 1908
Page 4223
Brake Rotor/Disc: Specifications
FRONT BRAKE
Standard thickness ..............................................................................................................................
................................................ 28.0 mm (1.102 in.) Minimum thickness .............................................
............................................................................................................................... 26.0 mm (1.024
in.)
Maximum disc runout ..........................................................................................................................
............................................. 0.07 mm (0.0028 in.)
Page 6088
be used during this type of repair due to the higher potential of damaging the paint surface.
Remember no broken paint.
Page 3225
Body
Connector Location (Access Cab)
BA1 Front Door LH Wire and Wire Harness (Connector Location)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel)
BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel)
BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel)
BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Diagrams
Front Door Window Glass: Diagrams
Front Door (Part 1)
Page 4169
A. Disconnect shock absorber from lower suspension arm.
B. Remove the shock absorber lower side set nut and washer.
NOTE:
Do not remove the
C. Wrap the bolt's head with vinyl tape to prevent the drive shaft boot from being damaged.
D. Pry down the lower suspension arm to remove the bolt and disconnect the shock absorber.
E. Remove the 3 nuts and shock absorber with the coil spring.
NOTE:
Do not damage the
8. Disconnect lower ball joint. Remove the 4 bolts and disconnect the lower ball joint.
Specifications
Wheel Cylinder: Specifications
Wheel Cylinder Mounting Bolts 10 Nm
Hydraulic Brake Line 15 Nm
Page 1581
8. REMOVE RADIATOR ASSEMBLY
Remove the 4 bolts and radiator assembly.
9. REMOVE NO.1 FAN SHROUD
Remove the 4 bolts and No.1 fan shroud.
DISASSEMBLY
1. REMOVE RADIATOR SUPPORTS
Remove the 4 bolts, 2 pipes, 2 bushings and 2 radiator supports.
2. REMOVE RADIATOR CAP 3. REMOVE DRAIN PLUG
4. ASSEMBLE SST
SST 09230-01010 a. Install the claw to the overhaul handle, inserting it in the hole in part "A" as
shown in the diagram. b. While gripping the handle, adjust the stopper bolt so that dimension "B"
shown in the diagram is 0.2 - 0.3 mm (0.008 - 0.012 inch).
NOTICE: If this adjustment is not done, the claw may be damaged.
5. UNCAULK LOCK PLATES
Using SST to release the caulking, squeeze the handle until stopped by the stopper bolt. SST
09230-01010
6. REMOVE TANKS AND O-RINGS
Page 2365
Steps 2 - 3
INSPECTION PROCEDURE
HINT:
- DTC P0325 is for the left bank knock sensor circuit.
- DTC P0330 is for the right bank knock sensor circuit.
- Read freeze frame data using TOYOTA hand-held tester or OBD II scan tool, as freeze frame
data records the engine conditions when a malfunction is detected. When troubleshooting it is
useful for determining whether the vehicle was running or stopped, the engine was warmed up or
not, the air-fuel ratio was lean or rich, etc. at the time of the malfunction.
Page 3737
Instrument Panel
Ground Location
IE Left Kick Panel
IF Left Kick Panel
IG Instrument Panel Brace RH
IH Right Kick Panel
II Right Kick Panel
Body
Ground Location (Access Cab)
Page 159
B. Continue to update the ECU calibration file following the screen flow (Figure 18). Details for
selected screens are shown in Figure 19.
NOTE:
^ Each flash calibration update will take approximately 15 to 45 minutes.
^ Screens E through J (Figure 18) will need to be repeated for each flash calibration update
(calibration ID number).
^ All updates must display "YES" to complete the entire calibration file update for the vehicle ECU.
^ Failure to complete all updates may result in PERMANENT ECU DAMAGE!
CONFIRM UPDATE
4. Confirm successful flash calibration update and affix calibration update sticker.
Follow these steps to confirm the calibration was reprogrammed to the ECU.
Testing and Inspection
Overdrive Switch: Testing and Inspection
O/D Main Switch & O/D OFF Indicator Light Circuit
CIRCUIT DESCRIPTION
The O/D main switch contacts go open when the switch is pushed in and go closed when it is
pushed out.
If O/D main switch is at OFF position, the O/D OFF indicator light lights up, and the ECM prohibits
shifting O/D.
Wiring Diagram
INSPECTION PROCEDURE
Page 949
Page 2904
Vehicle Speed Sensor: Diagnostic Aids
Voltage Check
Voltage Check
Voltage Check
A. Establish conditions in which voltage is present at the check point.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(SW 2 OFF)
B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or
component terminal. This check can be done with a test light instead of a voltmeter.
Continuity and Resistance Check
Continuity and Resistance Check
Continuity And Resistance Check
A. Disconnect the battery terminal or wire so there is no voltage between the check points. B.
Contact the two leads of an ohmmeter to each of the check points.
Page 2298
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 5541
Rear Seat Belt Extender Applications
Page 2213
Non-Waterproof Type Connector
"Case 1" Raise the terminal retainer up to the temporary lock position.
Non-Waterproof Type Connector
"Case 2" Open the secondary locking device.
Page 4208
32. Depress brake pedal several times.
33. Fill the brake reservoir with brake fluid and bleed brake system.
34. Check ABS Speed Sensor Signal (refer to the Technical Information System (TIS):
2000 - 2005 model year Tundra Repair Manual: Diagnostics: Anti-lock Brake System: Pre-Check).
Repair Procedure No. 2
1. Resurface the disc rotors with the "On-Car Lathe" to within serviceable limits.
NOTE:
It is necessary to turn the rotors using only an on-the-car brake lathe to ensure even and uniform
rotor run out. DO NOT turn the rotor using an off-the-car brake lathe.
2. If the disc rotors are unserviceable or below minimum thickness (per specification stamped on
the rotor), replace the rotors using the service parts from the Parts Information table.
3. Check any new disc rotor for runout.
4. If the disc rotor runout is over 0.03 mm (0.0012 in.), perform a phase matching procedure.
5. Replace the front brake caliper LH and RH assemblies using the service parts from the Parts
Information table.
6. Perform a road test.
Page 6968
a. Cut off the tip of the cartridge nozzle.
Part No. 08850-00801 or equivalent
HINT: After cutting off the tip, use all adhesive within the time described in the table.
b. Load the cartridge into the sealer gun. c. Coat the glass with adhesive as shown in the
illustration.
A: 8.0 mm (0.314 in.) B: 12.0 mm (0.472 in.)
8. INSTALL BACK WINDOW GLASS
a. Position the glass so that the reference marks are lined up, and press in gently along the rim. b.
Using a spatula, apply adhesive on the glass rim. c. Use a scraper to remove any excess or
protruding adhesive.
HINT: Confirm that the moulding is attached to the body panel as shown in the illustration.
Page 688
Evaporative Vapor Pressure Sensor: Testing and Inspection
VAPOR PRESSURE SENSOR
INSPECTION
1. INSPECT POWER SOURCE VOLTAGE OF VAPOR PRESSURE SENSOR
a. Disconnect the vapor pressure sensor connector. b. Turn the ignition switch ON. c. Using a
voltmeter, measure the voltage between connector terminals VC and E2 of the wiring harness side.
Voltage: 4.5 - 5.5 V
d. Turn the ignition switch OFF. e. Reconnect the vapor pressure sensor connector.
2. INSPECT POWER OUTPUT OF VAPOR PRESSURE SENSOR
a. Turn the ignition switch ON. b. Disconnect the vacuum hose from the vapor pressure sensor. c.
Connect a voltmeter to terminals PTNK and E2 of the ECM, and measure the output voltage under
these conditions:
1. Apply vacuum (2.0 kPa (15 mmHg, 0.59 in.Hg)) to the vapor pressure sensor.
Voltage: 1.3 - 2.1 V
2. Release the vacuum from the vapor pressure sensor.
Voltage: 3.0 - 3.6 V
3. Apply pressure (1.5 kPa (15 gf/sq.cm, 0.22 psi)) to the vapor pressure sensor.
Page 2770
CHART 24
Page 6091
Page 5033
3. DISCONNECT UPPER BALL JOINT
a. Remove the cotter pin and loosen the nut. b. Using Special Service Tool (SST), disconnect the
upper ball joint.
SST 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04031,
09958-04011)
c. Support the steering knuckle securely. d. Remove the nut.
4. REMOVE REAR FENDER APRON SEAL
Remove the 4 clips and rear fender apron seal.
5. REMOVE BRAKE AND FUEL LINE CLAMP
Disengage the 2 brake lines and fuel line, and remove the nut and brake line clamp.
6. REMOVE UPPER SUSPENSION ARM
Remove the nut, bolt, 2 washers and upper suspension arm.
REPLACEMENT
1. REMOVE BUSHING
a. Using a chisel and hammer, pry up the flange of the bushing. b. Using Special Service Tool
(SST) and a press, remove the bushing.
SST 09613-26010, 09631-20060, 09950-00020
Page 157
^ Confirm cable connections between the vehicle and Diagnostic Tester are secure. (Reference
TSB No. SS004-01, "ECU Flash Reprogramming Error Message.")
^ Do not disconnect or turn off the Diagnostic Tester or the vehicle ignition during reprogramming.
^ Set the parking brake.
^ Complete ALL flash calibration updates provided for each ECU.
If the battery's state of charge or capacity are in question, test with SST No. 00002-MP815-T,
"Midtronics Battery Tester," and follow TSB No. PG017-02, "Battery Maintenance for In-Stock
Vehicles & Pre-Delivery."
To ensure stable battery voltage, a battery charger may be connected during reprogramming if:
^ Voltage does not fall below 11.4 volts.
^ Voltage does not rise above 16.0 volts.
^ Setting is on SLOW charge and not BOOST.
A. Connect the Diagnostic Tester to the vehicle and select CURRENT ECU CAL from the ECU
REPROGRAM MAIN MENU. Determine the vehicle's current ECU calibration. (See Figure 17.)
NOTE:
The vehicle may contain up to 3 separate calibration ID numbers. In the example shown, the
vehicle ECU contains only 2 calibration IDs.
Page 4658
Wiring Harness Connector
E: Indicates the wiring harness and wiring harness connector. The wiring harness with male
terminal is shown with arrows.
Outside numerals are pin numbers.
The first letter of the code for each wiring harness and wiring harness connector(s) indicates the
component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and
Surrounding area, and "B" for the Body and Surrounding area.
When more than one code has the first and second letters in common, followed by numbers (e.g,
IH1, IH2), this indicates the same type of wiring harness and wiring harness connector.
F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in
parts position.
G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside
it). Junction Blocks are shaded to clearly separate
them from other parts.
H: When 2 parts both use one connector in common, the parts connector name used in wire
routing is shown in square brackets [ ].
Wiring Color
I: Indicates the wiring color.
Wire colors are indicated by an alphabetical code.
B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR =
Brown SB = Sky Blue LG = Light Green GR = Gray
The first letter indicates the basic wire color and the second letter indicates the color of the stripe.
Page 2095
Knock Sensor (Part 2)
Page 4517
4. Press the NEXT soft key (if applicable) when the HELLO screen appears to proceed to the Main
Menu.
5. Choose BATTERY TEST and press the SELECT soft key.
6. Select IN VEHICLE and press the NEXT soft key.
7. Select MODEL and press the NEXT soft key.
NOTE:
^ "MODEL" or "STOCK # " MUST be used to receive a warranty code if the tester determines that
the battery is bad.
^ "MODEL" and "STOCK#" are linked to custom algorithms and are the most accurate testing
procedures.
Page 2291
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.
Locations
Vapor Pressure Sensor
Page 3432
Fluid Pump: Service and Repair
For further information regarding this component and the system that it is a part of, please refer to
Automatic Transmission/Transaxle; Service and Repair.
Page 5142
Suspension Strut / Shock Absorber: Service and Repair Rear Shock Absorber
REMOVAL
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 3. REMOVE REAR SHOCK ABSORBER
a. Remove the bolt and nut on the lower side of the shock absorber. b. While holding the piston
rod, remove the nut, retainer, cushion and shock absorber. c. Remove the 2 retainers and cushion
from the shock absorber.
INSPECTION
INSPECT SHOCK ABSORBER
Page 4832
Page 6989
6. CLEAN CONTACT SURFACE OF GLASS
Using a cleaner, clean the contact surface which is black-colored area around the entire glass rim.
NOTE: Do not touch the glass face after cleaning it.
7. COAT CONTACT SURFACE OF BODY WITH PRIMER "M"
Using a brush, coat Primer M to the exposed part of body on the vehicle side.
NOTE: Let the primer coating dry for 3 minutes or more.
- Do not coat Primer M to the adhesive.
- Do not keep any of the opened Primer M for later use.
8. COAT CONTACT SURFACE OF GLASS WITH PRIMER "G"
a. Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G. b.
When the primer is coated wrongly to the area other than the specified, wipe it off with a clean shop
rag before the primer dries.
NOTE:
Page 3193
Steps 2 - 3
INSPECTION PROCEDURE
HINT:
- DTC P0325 is for the left bank knock sensor circuit.
- DTC P0330 is for the right bank knock sensor circuit.
- Read freeze frame data using TOYOTA hand-held tester or OBD II scan tool, as freeze frame
data records the engine conditions when a malfunction is detected. When troubleshooting it is
useful for determining whether the vehicle was running or stopped, the engine was warmed up or
not, the air-fuel ratio was lean or rich, etc. at the time of the malfunction.
Page 906
Timing Belt: Service and Repair
Testing and Inspection
Refrigerant Pressure Sensor / Switch: Testing and Inspection
ON-VEHICLE INSPECTION
1. SET ON MANIFOLD GAUGE SET
2. DISCONNECT CONNECTOR
3. RUN ENGINE AT APPROX. 2,000 rpm
4. SET BLOWER SPEED CONTROL SWITCH TO "HI" POSITION
5. SET TEMPERATURE CONTROL LEVER TO "MAX. COOL" POSITION
6. A/C SWITCH ON
7. INSPECT PRESSURE SWITCH OPERATION
a. Connect the positive (+) lead from the ohmmeter to terminal 1 and negative (-) lead to terminal 2.
b. Check continuity between terminals when refrigerant pressure is changed, as shown in the
illustration.
If operation is not as specified, replace the pressure switch.
Page 4350
9. Remove steering knuckle.
A. Remove the cotter pin and loosen the nut.
B. Using the following SSTs, disconnect the steering knuckle.
SST P/N: 09950-40011 (09951-04010, 09952-04010, 09553-04020, 09554-04010 09955-04031,
09958-04011)
C. Remove the nut and steering knuckle.
NOTE:
4WD: Be careful not to damage the oil seal and drive shaft boot.
HINT: 4WD: When it is difficult to disconnect the drive shaft, tap the tip of the drive shaft with a
plastic hammer.
10. 2WD: Remove grease cap.
A. Mount the axle hub in a soft jaw vise.
NOTE:
Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further (refer to
the illustration).
HINT: Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further
(refer to the illustration).
B. Using a screwdriver, remove the grease cap.
NOTE:
Be careful not to damage the grease cap.
Page 3325
A. Test the CAN Interface Module (P/N 01002744) for continuity.
^ If there is no continuity, the CAN Interface Module needs to be replaced.
^ If there is continuity, the CAN Interface Module is OK. Re-check Cable Tests 1, 2, 3, and 4 while
wiggling and flexing the cables.
Page 4092
Parts Information
Page 5597
Body
Connector Location (Standard Cab)
BA1 Front Door LH Wire and Speaker Tweeter Wire LH (Inside of Front Door LH)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Seat
Connector Location
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
BJ1 Seat No. 1 Wire and Seat No. 2 Wire (Under the Driver's Seat)
Page 2642
Engine Control Module: Connector Views
Terminals Of ECM - Connector View
Terminals Of ECU - Connector Pinouts (Part 1)
Page 4397
(b) Place the plate between the pistons and insert a pad at one side. (c) Use compressed air to
remove the pistons alternately from the cylinder.
CAUTION: Do not place your fingers in front of the pistons when using compressed air.
3. REMOVE PISTON SEALS
Using a screwdriver, remove the 4 piston seals from the cylinder.
INSPECTION
1. MEASURE PAD LINING THICKNESS
Using a ruler, measure the pad lining thickness. Standard thickness: 11.5 mm (0.453 inch)
Minimum thickness: 1.0 mm (0.039 inch) Replace the pad if the thickness is less than the minimum
(the 1.0 mm slit is no longer visible), or if it shows signs of uneven wear.
2. MEASURE DISC THICKNESS
Using a micrometer, measure the disc thickness. Standard thickness: 28.0 mm (1.102 inch)
Minimum thickness: 26.0 mm (1.024 inch) Replace the disc if the thickness of the disc is at the
minimum or less. Replace the disc or grind it on a lathe if it is scored or worn unevenly.
Service and Repair
Front Fender Liner: Service and Repair
FRONT FENDER APRON (ASSEMBLY)
REMOVAL (WITH THE RADIATOR SUPPORT, COWL TOP SIDE PANEL (REMOVED.)
Page 6083
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 415
Waterproof Type Connector
B: For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White
: Gray
Black or White : Dark Gray
Gray or White : Black
Waterproof Type Connector
"Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up
to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Waterproof Type Connector
"Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 1435
a. Turn the crankshaft pulley and align its groove with timing mark "0" of the No.1 timing belt cover.
b. Check that the timing marks of the camshaft timing pulleys and timing belt rear plates aligned. If
not, turn the crankshaft 1 revolution (360°). c. Remove the crankshaft pulley bolt.
NOTICE: Do not turn the crankshaft pulley.
17. REMOVE TIMING BELT TENSIONER
HINT:
- When re-using timing belt: If the installation marks have disappeared, before remove the timing
belt, place 2 new installation marks on the timing belt to match the timing marks of the camshaft
timing pulleys.
- When replacing timing belt tensioner only: To avoid meshing of the timing pulley and timing belt,
secure one of them with string. And place matchmarks on the timing belt and RH camshaft timing
pulley.
Page 5993
Headliner: Diagrams
Roof Headlining
Component Locations
Audible Warning Device Control Module: Component Locations
Instrument Panel
Page 4079
A. Remove the bolt and brake line clamp from the steering knuckle.
B. Remove the 2 bolts, brake caliper and disc.
7. REMOVE SHOCK ABSORBER
A. Disconnect Shock Absorber from lower suspension arm.
B. Remove the shock absorber lower side set nut and washer.
NOTE:
Do not remove the bolt.
C. Wrap the bolt's head with vinyl tape to prevent the drive shaft boot from being damaged.
D. Pry down the lower suspension arm to remove the bolt and disconnect the shock absorber.
E. Remove the 3 nuts and shock absorber with the coil spring.
NOTE:
Do not damage the brake tube.
8. DISCONNECT LOWER BALL JOINT
Page 3907
Glossary Of Terms And Symbols (Part 2)
Page 1841
4. REMOVE CAMSHAFT POSITION SENSOR
Remove the bolt, stud bolt and camshaft position sensor.
INSTALLATION
1. INSTALL CAMSHAFT POSITION SENSOR
Install the camshaft position sensor with the bolt and stud bolt Torque: 7.5 N.m (80 kgf.cm, 66
in.lbf)
2. INSTALL LH NO.3 TIMING BELT COVER
3. INSTALL DRIVE BELT
4. FILL ENGINE COOLANT
5. CHECK ENGINE COOLANT FOR LEAKS
6. CHECK IGNITION TIMING
Page 5087
Page 1437
24. REMOVE TIMING BELT GUIDE 25. REMOVE TIMING BELT COVER SPACER
26. REMOVE TIMING BELT
HINT: If re-using the belt and the installation mark has disappeared from it, place a new installation
mark on the timing belt to the match the dot mark of the crankshaft timing pulley.
27. REMOVE NO.1 IDLER PULLEY AND NO.2 IDLER PULLEY
a. Using a 10 mm hexagon wrench, remove the bolt, No.1 idler pulley and plate washer. b. Remove
the bolt and No.2 idler pulley.
28. REMOVE CRANKSHAFT TIMING PULLEY
Using SST, remove the timing pulley. SST 09950-50012 (09951-05010, 09952-05010,
09953-05010, 09953-05020, 09954-05010)
NOTICE: Do not turn the timing pulley.
INSPECTION
Instruments - Oil Pressure Gauge Reads Abnormally Low
Oil Pressure Gauge: Customer Interest Instruments - Oil Pressure Gauge Reads Abnormally Low
ELECTRICAL EL017-03
December 23, 2503
Title OIL PRESSURE GAUGE READS LOW
Models '01 - '04 Sequoia & '00 - '02 Tundra
TSB UPDATE NOTICE:
This TSB updates EL006-03. TSB EL006-03 is now obsolete and should be discarded.
Introduction
Some customers with Sequoia or Tundra vehicles may encounter an oil pressure gauge that reads
abnormally low at idle. An updated oil pressure sender has been created to address this condition.
Applicable Vehicles ^
2001 - 2004 model year Sequoia vehicles produced BEFORE the Production Change Effective
VINs shown below.
^ 2000 - 2002 model year Tundra vehicles produced BEFORE the Production Change Effective
VIN shown below.
Production Change Information
Parts Information
Repair Procedure
1. Replace the Oil Pressure Sender.
2. Verify proper operation of the Oil Pressure Gauge.
Warranty Information
Applicable Warranty*:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36
months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Engine Controls - ECU Reprogramming Procedure
Technical Service Bulletin # SS002R-01 Date: 030922
Engine Controls - ECU Reprogramming Procedure
SPECIAL SERVICE TOOLS SS002-01 REVISED
March 9, 2001
Title: ECU FLASH REPROGRAMMING PROCESS
Models: Applicable Models
TSB REVISION NOTICE:
^ September 22, 2003: Models added - 2002 (and later) Solara, 2003 (and later) Corolla and
Matrix, and 2004 models; Operation Procedures updated for CAN Interface Module with the latest
Diagnostic Tester software (v. 10.1a and 10.2a), Calibration Update Wizard (v.6.0), and calibration
files.
^ June 20, 2003: Camry and Tacoma models added; Special Service Tools table updated. The
previous TSB should be discarded.
Introduction
Electronic Control Unit (ECU) is a Toyota term used to describe integrated computerized devices
responsible for managing the operation of a system or sub-system. For the purposes of this
bulletin, the term "ECU" is used as a generic label for the following SAE J1930 standard
references:
^ Powertrain Control Module (PCM)
^ Engine Control Module (ECM)
^ Transmission Control Module (TCM)
^ or any other Toyota specific control unit
Flash reprogramming allows the ECU software to be updated for changes in vehicle calibrations
without removing the ECU from the vehicle. Flash calibration updates for specific vehicle
models/ECUs will be released as field fix procedures described in individual service bulletins. This
bulletin details the ECU flash reprogramming process and the applications within the Technical
Information System (TIS) and the Toyota Diagnostic Tester used for reprogramming.
Flash calibration updates can only be applied to the vehicle/ECU combination for which they are
intended. ECUs have internal security that will not allow them to be programmed with another
ECU's information.
Applicable Vehicles ^
2001 (and later) model year 4Runner, Highlander, Land Cruiser, RAV4, Sequoia and Tundra
vehicles.
^ 2002 (and later) model year Camry, Solara and Tacoma vehicles.
^ 2003 (and later) model year Corolla and Matrix vehicles.
^ All 2004 (and later) model year Toyota vehicles except Celica, MR2 Spyder, Avalon, and Tacoma
(3RZ-FE engine)
Warranty Information
Parts Information
NOTE:
Authorized Modifications Labels may be ordered in packages of 25 from the Materials Distribution
Center (MDC) through the TDN Dealer Support
Component Locations
Stop Light System
Page 908
REMOVAL
1. REMOVE ENGINE UNDER COVER 2. DRAIN ENGINE COOLANT 3. REMOVE RADIATOR
ASSEMBLY 4. REMOVE THROTTLE BODY COVER 5. REMOVE INTAKE AIR CONNECTOR
ASSEMBLY
Page 4354
21. 4WD:
Using the following SSTs and a press, install the bearing spacer.
SST P/N: 09950-60010 (09951-00650)
SST P/N: 09950-70010 (09951-07150)
22. 4WD:
Install new oil seal (inside).
A. Using the following SST and a plastic hammer, install a NEW oil seal (inside).
SST P/N: 09527-17011
NOTE:
Lightly strike the SST on its circumference evenly.
B. Coat MP grease to the oil seal lip.
23. Install steering knuckle.
A. 4WD:
Insert the drive shaft into the axle hub and temporarily tighten the nut.
NOTE:
Be careful not to damage the oil seal and drive shaft boot.
B. Connect the steering knuckle to the upper suspension arm.
C. Install the nut and a NEW cotter pin. If the holes for the cotter pin are not aligned, tighten the nut
further up to 600.
Torque: 105 N.m (1,100 kgf.cm, 77 ft.lbf)
24. Connect the lower ball joint to the steering knuckle with 4 bolts.
Electrical Specifications
Resistance
Service and Repair
Tape Player: Service and Repair
Tape player/head cleaning
MAINTENANCE a. Raise the cassette door with your finger.
Next, using a pencil or similar object, push in the guide.
b. Using a cleaning pen or cotton applicator soaked in cleaner, clean the head surface, pinch
rollers and capstans.
Testing and Inspection
Power Window Circuit Breaker: Testing and Inspection
Driver's Door
INSPECT POWER WINDOW MOTOR CIRCUIT BREAKER OPERATION
a. Disconnect the connector from the master switch. b. Connect the positive (+) lead from the
battery to terminal 3 and the negative (-) lead to terminal 4 on the wire harness side connector and
raise the
window to fully closed position.
c. Continue to apply voltage, check that a circuit breaker operation noise is heard within
approximately 4 to 40 seconds. d. Reverse the polarity, check that the window begins to descend
within approximately 60 seconds.
If operation is not as specified, replace the motor.
Passenger's Door
INSPECT POWER WINDOW MOTOR CIRCUIT BREAKER OPERATION
a. Disconnect the connector from the power window switch. b. Connect the positive (+) lead from
the battery to terminal 3 and the negative (-) lead to terminal 1 on the wire harness side connector,
and raise the
window to fully closed position.
Page 7029
b. Connect terminals 1 and 5.
c. Connect the positive (+) lead from the battery to terminal 2 and the negative (-) lead from the
battery to the motor body or terminal 4, and
check that the motor stops running at the stop position after the motor operates again. If operation
is not as specified, replace the motor.
Page 1576
Part 2 of 2
Engine - Accessory Drive Belt Squealing Noise
Drive Belt: Customer Interest Engine - Accessory Drive Belt Squealing Noise
ENGINE EG026-06 REVISED
Title: 2UZ-FE ACCESSORY DRIVE BELT NOISE
Models: '00 - '06 Tundra
April 21, 2006
TSB REVISION NOTICE:
^ July 9, 2007: The Introduction has been updated. Production Change Effective VINs have been
updated in the Production Change Information table. In the Repair Procedure steps 12 and 13 and
the illustration below step 13 have been updated, and steps 14 - 17 have been renumbered.
Previous versions of this TSB should be discarded.
Introduction
Some customers may experience an abnormal squeal noise from the engine accessory drive belt
area, usually during cold start-up. An improved accessory drive belt tensioner, A/C compressor
bracket, and revised installation procedure have been developed to address this condition.
Applicable Vehicles
^ 2000 - 2006 model year Tundra vehicles produced BEFORE the Production Change Effective
VINs shown below.
Production Change Information
Parts Information
Warranty Information
Applicable Warranty* This repair is covered under the Toyota Comprehensive Warranty. This
warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's
in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Repair Procedure
Page 3447
Splice Location
I1 Cowl Wire
I2 Cowl Wire
I3 Cowl Wire
I4 Cowl Wire
I5 Cowl Wire
I6 Cowl Wire
I7 Engine Wire
I8 Engine Wire
I9 Engine Wire
I10 Engine Wire
I11 Engine Wire
I12 Engine Wire
I13 Engine Wire
I14 Engine Wire
I15 Engine Wire
I16 Cowl Wire
Body
Splice Location (Access Cab)
B1 Speaker Tweeter Wire LH
B2 Front Door LH Wire
B3 Front Door LH Wire
B4 Roof Wire
B5 Speaker Tweeter Wire RH
B6 B7
Front Door RH Wire
B8 Front Door RH Wire
B9 Rear Door No. 1 Wire RH
B10 Frame Wire
Page 155
J. The top half of the CUW screen displays the calibrations currently stored on the Diagnostic
Tester Program Card. The bottom half of the screen displays the new calibration to be loaded onto
the Diagnostic Tester Program Card (see Figure 13). Click NEXT to continue the process.
K. Confirm the calibration file to be sent to the Diagnostic Tester Program Card (Figure 14). Click
SEND.
Page 6345
Wiring Harness Connector
E: Indicates the wiring harness and wiring harness connector. The wiring harness with male
terminal is shown with arrows.
Outside numerals are pin numbers.
The first letter of the code for each wiring harness and wiring harness connector(s) indicates the
component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and
Surrounding area, and "B" for the Body and Surrounding area.
When more than one code has the first and second letters in common, followed by numbers (e.g,
IH1, IH2), this indicates the same type of wiring harness and wiring harness connector.
F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in
parts position.
G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside
it). Junction Blocks are shaded to clearly separate
them from other parts.
H: When 2 parts both use one connector in common, the parts connector name used in wire
routing is shown in square brackets [ ].
Wiring Color
I: Indicates the wiring color.
Wire colors are indicated by an alphabetical code.
B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR =
Brown SB = Sky Blue LG = Light Green GR = Gray
The first letter indicates the basic wire color and the second letter indicates the color of the stripe.
Locations
Transmission Speed Sensor: Locations
Vehicle Speed Sensor NO.1
Vehicle Speed Sensor NO.2
Vehicle Speed Sensor NO.1
Page 6773
Fog/Driving Lamp Relay: Testing and Inspection
INSPECT FOG LIGHT RELAY CONTINUITY If continuity is not as specified, replace the relay.
Page 4024
HINT: The brake pedal should not be depressed twice and/or returned while setting to the specified
pressure. Read the value of rear brake pressure after holding the specified fluid pressure for 2
seconds. If the brake pressure is incorrect, adjust the fluid pressure.
4. IF NECESSARY, ADJUST FLUID PRESSURE
(a) Loosen the lock nut.
(b) Adjust the length of the shackle No. 2.
Low pressure: Lengthen A High pressure: Shorten A Initial set: 120 mm (4.72 inch) Adjustment
range: 112 - 128 mm (4.41 - 5.04 inch)
HINT: One turn of the nut changes the fluid pressure as shown in the following specification.
7.4 kPa (0.76 kgf/cm, 11 psi)
(c) Torque the lock nut.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)
(d) If the pressure cannot be adjusted by the shackle No. 2, raise or lower the valve body.
Low pressure-Lower body High pressure-Raise body
(e) Torque the nuts.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.) Adjust the length of the shackle No. 2 again. If it cannot be
adjusted, inspect the valve body.
5. IF NECESSARY, CHECK VALVE BODY
(a) Assemble the valve body in the uppermost position.
HINT: When the brakes are applied, the piston will move down about 0.8 mm (0.03 inch). Even at
this time, the piston should not make contact with the load sensing spring or move it.
Page 3219
Transmission Mode Indicator - A/T: Splice Locations
Engine Compartment
Splice Location
E1 Engine Room Main Wire
E2 Engine Room Main Wire
E3 Engine Room Main Wire
E4 Engine No. 2 Wire
E5 Engine Wire
E6 Engine Wire
E7 Engine Wire
E8 Engine Wire
Instrument Panel
Page 5836
Rear Bumper Cover / Fascia: Technical Service Bulletins Paint - Refinishing Bumper Cover
PAINT PA003-02 REVISED
June 4, 2002
Title REFINISHING REPLACEMENT BUMPER COVERS
Models All '83 - '05 Models
TSB REVISION NOTICE: ^ February 14, 2005: Applicable Vehicles now includes 2004 - 2005
model years. Previous versions of this TSB should be discarded.
Introduction In cases where a bumper cover is being replaced a special preparation process is
necessary to assure the refinish is customer acceptable. This bulletin provides the recommended
refinishing procedure for new bumper covers.
Applicable Vehicles ^ All 1983 - 2005 model year Toyota vehicles.
Required Tools & Material
Note:Please visit www.3m.comlautomotive to find the nearest store that sells 3M automotive
products.
Warranty Information
Refinishing Procedure
1. Mix a solution of mild soap (car wash soap with no wax additives) and clean water.
Note: Carefully follow mixing instructions on the soap container. Too much soap or too much water
may cause surface contamination or rinsing difficulty.
Page 6256
Body
Connector Location (Standard Cab)
BA1 Front Door LH Wire and Speaker Tweeter Wire LH (Inside of Front Door LH)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Seat
Connector Location
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
BJ1 Seat No. 1 Wire and Seat No. 2 Wire (Under the Driver's Seat)
Page 4597
The ground points circuit diagram shows the connections from all major parts to the respective
ground points. When troubleshooting a faulty ground point, checking the system circuits which use
a common ground may help you identify the problem ground quickly. The relationship between
ground points (EA, IB and IC) can also be checked this way.
How to Read Power Source
HOW TO READ POWER SOURCE
Page 1031
2. CHECK STEERING FLUID PRESSURE
a. 5VZ-FE engine: Remove the air cleaner assembly. b. 2UZ-FE engine: Remove the air cleaner
assembly with air cleaner hose. c. Disconnect the pressure feed tube from the PS vane pump. d.
Connect Special Service Tool (SST), as shown in the illustration.
SST 09640-10010 (09641-01010, 09641-01030, 09641-01060)
NOTICE: Check that the valve of the SST is in the open position.
e. Bleed the power steering system. f.
Start the engine and run it at idle.
g. Turn the steering wheel from lock to lock several times to boost fluid temperature.
Fluid temperature: 80°C (176°F)
h. With the engine idling, close the valve of the SST and observe the reading on the SST.
Minimum fluid pressure: 8,336 kPa (85 kgf/cm2, 1,209 psi)
NOTICE: ^
Do not keep the valve closed for more than 10 seconds.
^ Do not let the fluid temperature become too high.
i. With the engine idling, open the valve fully.
Page 2443
Page 2218
Data Link Connector: Testing and Inspection
Check the DLC3.
The vehicle's ECM uses the ISO 9141-2 communication protocol. The terminal arrangement of the
DLC3 complies with SAE J1962 and matches the ISO 9141-2 format.
HINT: If your display shows UNABLE TO CONNECT TO VEHICLE when you have connected the
cable of the OBD II scan tool or TOYOTA hand-held tester to the DLC3, turn the ignition switch ON
and operate the scan tool, there is a problem on the vehicle side or tool side. If the communication is normal when the tool is connected to another vehicle, inspect the DLC3 on
the original vehicle.
- If the communication is still impossible when the tool is connected to another vehicle, the problem
is probably in the tool itself, so consult the Service Department listed in the tool's instruction
manual.
Electrical Specifications
Resistance
Testing and Inspection
Vanity Lamp: Testing and Inspection
INSPECT VANITY LIGHT CONTINUITY If continuity is not as specified, replace the bulb or vanity
light.
Page 5631
c. Install the SST.
1. Connect the 2 SST, then connect them to the seat belt pretensioner.
SST 09082-00700,09082-00740
NOTE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of
the twin lock.
2. Place the front seat outer belt on the ground and cover it with the disc wheel with tire.
NOTE: Place the front seat outer belt as shown in the illustration.
3. Move the SST at least 10 m (33 ft) away from the disc wheel.
NOTE: Take care not to damage the SST wire harness.
d. Activate the seat belt pretensioner.
1. Connect the SST red clip to the battery positive (+) terminal and black clip to the battery negative
(-) terminal.
2. Check that no one is within 10 m (33 ft) area around the disc wheel. 3. Press the SST activation
switch and activate the seat belt pretensioner.
HINT: The seat belt pretensioner operates simultaneously as the LED of the SST activation switch
lights up.
Locations
Relay Box: Locations
Driver Side J/B And Integration Relay
Page 856
Fuel Pressure: Specifications Volume Specification
Information not supplied by the manufacturer.
Page 258
EFI Main Relay: Testing and Inspection
EFI MAIN RELAY
INSPECTION
1. REMOVE RELAY BOX COVER
2. REMOVE EFI MAIN RELAY (Marking: EFI)
3. INSPECT EFI MAIN RELAY CONTINUITY
a. Using an ohmmeter, check that there is continuity between terminals 1 and 2.
If there is no continuity, replace the relay.
b. Check that there is no continuity between terminals 3 and 5.
If there is continuity, replace the relay.
4. INSPECT EFI MAIN RELAY OPERATION
a. Apply battery voltage across terminals 1 and 2. b. Using an ohmmeter, check that there is
continuity between terminals 3 and 5.
If there is no continuity, replace the relay.
5. REINSTALL EFI MAIN RELAY
6. REINSTALL RELAY BOX COVER
Page 6731
b. Push the secondary locking device or terminal retainer in to the full lock position.
5. CONNECT CONNECTOR
Disconnection of Male and Female Connectors
Disconnection of Male and Female Connectors
Disconnection Of Male And Female Connectors
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Page 257
Brakes - Front Brakes Vibrating
Technical Service Bulletin # BR004R-02 Date: 040305
Brakes - Front Brakes Vibrating
BRAKES BR004-02 REVISED
September 16, 2002
Title: FRONT BRAKE VIBRATION
Models: '00 - '03 Tundra
TSB REVISION NOTICE: ^
March 5, 2004: A torque specification in, step 24, was changed.
^ September 8, 2003: A torque specification in, step 28, was changed.
The previous TSB should be discarded.
Introduction
Under certain usage conditions, some Tundra trucks may exhibit front brake vibration. Improved
brake caliper assemblies have been introduced to correct this condition.
Applicable Vehicles ^
2000 - 2003 model year Tundra trucks built before the VIN shown below.
Production Change Information
Warranty Information
Applicable Warranty:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36
months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Page 6562
Waterproof Type Connector
B: For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White
: Gray
Black or White : Dark Gray
Gray or White : Black
Waterproof Type Connector
"Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up
to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Waterproof Type Connector
"Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 4989
c. Deploy the airbag.
1. Check that no one is inside the vehicle or within 10 m (33 ft) area around the vehicle. 2. Press
the SST activation switch and deploy the airbag.
HINT: The airbag deploys simultaneously as the LED of the SST activation switch lights up.
d. Dispose of steering wheel pad (with airbag).
CAUTION: The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30
minutes after deployment.
- Use gloves and safety glasses when handling a steering wheel pad with the deployed airbag.
- Always wash your hands with water after completing the operation.
- Do not apply water, etc. to a steering wheel pad with the deployed airbag.
1. When scrapping a vehicle, deploy the airbag and scrap the vehicle with the steering wheel pad
still installed. 2. When moving a vehicle for scrapping which has a steering wheel pad with
deployed airbag, use gloves and safety glasses.
Deployment When Disposing of Steering Wheel Pad
DISPOSAL
HINT: When scrapping vehicle equipped with an SRS or disposing of a front passenger airbag
assembly, always first deploy the airbag in accordance with the procedure described below. If any
abnormality occurs with the airbag deployment, contact the SERVICE DEPT. of the TOYOTA
MOTOR SALES, U.S.A., INC.
CAUTION:
- Never dispose of a front passenger airbag assembly which has an undeployed airbag.
- The airbag produces a sizeable exploding sound when it deploys, so perform the operation
out-of-doors and where it will not create a nuisance to nearby residents.
- When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool).
Perform the operation in a place away from electrical noise.
- When deploying an airbag, perform the operation at least 10 m (33 ft) away from the front
passenger airbag assembly.
- The front passenger airbag assembly is very hot when the airbag is deployed, so leave it alone for
at least 30 minutes after deployment.
- Use gloves and safety glasses when handling a front passenger airbag assembly with the
deployed airbag.
- Always wash your hands with water after completing the operation.
- Do not apply water, etc. to a front passenger airbag assembly with the deployed airbag.
DISPOSE HORN BUTTON ASSY(WHEN DISPOSING OF AIRBAG ASSEMBLY DEPLOYMENT
METHOD)[45130/ 98-75]
NOTE:
- When disposing of the steering wheel pad (with air- bag) only, never use the customers vehicle to
deploy the airbag.
- Be sure to follow the procedure given below when deploying the airbag.
Testing and Inspection
Overdrive Indicator Lamp: Testing and Inspection
O/D Main Switch & O/D OFF Indicator Light Circuit
CIRCUIT DESCRIPTION
The O/D main switch contacts go open when the switch is pushed in and go closed when it is
pushed out.
If O/D main switch is at OFF position, the O/D OFF indicator light lights up, and the ECM prohibits
shifting O/D.
Wiring Diagram
INSPECTION PROCEDURE
Page 2182
Coolant Temperature Sensor/Switch (For Computer): Description and Operation
Engine Coolant Temperature Sensor
A thermistor that is built into the engine coolant temperature sensor changes the resistance value
according to the engine coolant temperature.
The lower the engine coolant temperature sensor, the greater the thermistor resistance value, and
the higher the engine coolant temperature sensor temperature, the lower the thermistor resistance
value.
The engine coolant temperature sensor is connected to the ECM. The 5 V power source voltage in
the ECM is applied to the engine coolant temperature sensor from the terminal THA via a resistor
R. That is, the resistor R and the engine coolant temperature sensor are connected in series.
When the resistance value of the engine coolant temperature sensor changes in accordance with
changes in the engine coolant temperature, the potential at terminal THA also changes. Based on
this signal, the ECM increases the fuel injection volume to improve driveability during cold engine
operation.
Page 1963
Engine Bank Identification
Page 70
Terminal Retainer
Push the terminal retainer down to the temporary lock position.
c. Release the locking lug from terminal and pull the terminal out from rear.
4. INSTALL TERMINAL TO CONNECTOR
a. Insert the terminal.
HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug
locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position.
Engine Controls - Error When Reprogramming ECU
Engine Control Module: Customer Interest Engine Controls - Error When Reprogramming ECU
SPECIAL SERVICE TOOLS SS004-01 REVISED
May 25, 2001
Title: ECU FLASH REPROGRAMMING ERROR MESSAGE
Models: Applicable Models
TSB REVISION NOTICE:
September 23, 2003: Models added - 2002 (and later) Solara, 2003 (and later) Corolla and Matrix,
and 2004 models; Test Procedures updated for new CAN Interface Module. The previous TSB
should be discarded.
Introduction
During ECU flash reprogramming, an error message may be displayed on the Diagnostic Tester
that will not allow ECU flash reprogramming to complete. This bulletin provides test procedures to
determine the cause for the error message.
Applicable Vehicles ^
2001 (and later) model year 4Runner, Highlander, Land Cruiser, RAV4, Sequoia and Tundra
vehicles.
^ 2002 (and later) model year Camry, Solara and Tacoma vehicles.
^ 2003 (and later) model year Corolla and Matrix vehicles.
^ All 2004 (and later) model year Toyota vehicles except Celica, MR2 Spyder, Avalon, and Tacoma
(3RZ-FE engine)
Required SSTs
NOTE:
Additional Diagnostic Tester Kits, CAN Interface Modules, Program Cards or other SSTs may be
ordered by calling SPX/OTC at 1-800-933-8335.
Warranty Information
Test Procedure
Service Data
Connecting Rod: Specifications Service Data
Connecting Rod Thrust Clearance Standard .......................................................................................
.............................................................................................................. 0.160 - 0.290 mm Maximum .
..............................................................................................................................................................
.................................................. 0.35 mm
Connecting Rod Thickness ..................................................................................................................
.................................................. 22.880 - 22.920 mm
Connecting Rod Big End Inside Diameter Mark 1 ...............................................................................
..................................................................................................................... 55.000 - 55.006 mm
Mark 2 ..................................................................................................................................................
.................................................. 55.006 - 55.012 mm Mark 3 .............................................................
....................................................................................................................................... 55.012 55.018 mm Mark 4 ...............................................................................................................................
..................................................................... 55.018 - 55.024 mm
Connecting Rod Alignment Maximum Bend ........................................................................................
............................................................................................ 0.05 mm per 100 mm Maximum Twist ...
..............................................................................................................................................................
................. 0.15 mm per 100 mm
Connecting Rod Bolt Standard Diameter ............................................................................................
......................................................................................... 7.200 - 7.300 mm Minimum Diameter .......
..............................................................................................................................................................
............................. 7.00 mm
Connecting Rod Cap Bolts Torque ......................................................................................................
................................................................................................................ 24.5 Nm
Page 5558
Splice Location
I1 Cowl Wire
I2 Cowl Wire
I3 Cowl Wire
I4 Cowl Wire
I5 Cowl Wire
I6 Cowl Wire
I7 Engine Wire
I8 Engine Wire
I9 Engine Wire
I10 Engine Wire
I11 Engine Wire
I12 Engine Wire
I13 Engine Wire
I14 Engine Wire
I15 Engine Wire
I16 Cowl Wire
Body
Splice Location (Access Cab)
B1 Speaker Tweeter Wire LH
B2 Front Door LH Wire
B3 Front Door LH Wire
B4 Roof Wire
B5 Speaker Tweeter Wire RH
B6 B7
Front Door RH Wire
B8 Front Door RH Wire
B9 Rear Door No. 1 Wire RH
B10 Frame Wire
Page 4083
^ 09527-17011
B. Coat MP grease to the oil seal lip.
18. INSTALL NEW DUST COVER AND AXLE HUB TO STEERING KNUCKLE
A. Install the NEW dust cover to the steering knuckle with the 4 bolts.
Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)
B. Using the following SST and a press, install the axle hub to the steering knuckle.
^ 09649-17010
19. INSTALL ABS SPEED SENSOR ROTOR (W/ABS) OR SPACER (W/O ABS)
NOTE:
Take care not to scratch the serration of the speed sensor rotor.
20. 2WD: INSTALL NEW LOCK NUT
A. Using the following SST, install and torque a NEW lock nut to the axle hub.
^ 00002-00909 (09318-12010)
Torque: 274 N.m (2,800 kgf.cm, 203 ft.lbf)
NOTE:
Do NOT use air wrench.
B. Using a chisel and hammer, stake the lock nut.
21. 4WD: INSTALL BEARING SPACER
Page 6334
BJ Inside of Rear Door LH
BK Inside of Rear Door RH
BL Surrounding of the Front of the Fuel Tank
Connector Location
BA1 Front Door LH Wire and Wire Harness (Connector Location)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel)
BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel)
BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel)
BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Page 5072
Page 2473
Engine Controls - Error When Reprogramming ECU
Engine Control Module: All Technical Service Bulletins Engine Controls - Error When
Reprogramming ECU
SPECIAL SERVICE TOOLS SS004-01 REVISED
May 25, 2001
Title: ECU FLASH REPROGRAMMING ERROR MESSAGE
Models: Applicable Models
TSB REVISION NOTICE:
September 23, 2003: Models added - 2002 (and later) Solara, 2003 (and later) Corolla and Matrix,
and 2004 models; Test Procedures updated for new CAN Interface Module. The previous TSB
should be discarded.
Introduction
During ECU flash reprogramming, an error message may be displayed on the Diagnostic Tester
that will not allow ECU flash reprogramming to complete. This bulletin provides test procedures to
determine the cause for the error message.
Applicable Vehicles ^
2001 (and later) model year 4Runner, Highlander, Land Cruiser, RAV4, Sequoia and Tundra
vehicles.
^ 2002 (and later) model year Camry, Solara and Tacoma vehicles.
^ 2003 (and later) model year Corolla and Matrix vehicles.
^ All 2004 (and later) model year Toyota vehicles except Celica, MR2 Spyder, Avalon, and Tacoma
(3RZ-FE engine)
Required SSTs
NOTE:
Additional Diagnostic Tester Kits, CAN Interface Modules, Program Cards or other SSTs may be
ordered by calling SPX/OTC at 1-800-933-8335.
Warranty Information
Test Procedure
Page 5986
Air Bag(s) Arming and Disarming: Service and Repair Release Method of Airbag Activation
Prevention Mechanism
RELEASE METHOD OF AIRBAG ACTIVATION PREVENTION MECHANISM
Page 2069
Throttle Position Sensor: Service and Repair
Refer to Fuel Delivery and Air Induction / Throttle Body / Service and Repair, for removal and
installation of this component.
Page 5917
Page 5354
Air Bag(s) Arming and Disarming: Service and Repair Release Method of Airbag Activation
Prevention Mechanism
RELEASE METHOD OF AIRBAG ACTIVATION PREVENTION MECHANISM
Ground Locations
Transmission Mode Indicator - A/T: Ground Locations
Engine Compartment
Ground Location
EA Front Left Fender
EB Rear Bank of Right Cylinder
EC Rear Bank of Left Cylinder
Connector Location
EA1 Cowl Wire Harness and Wire Harness (Connector Location)
EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B)
EC1 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC2 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC3 Engine No. 2 Wire and Engine Wire (Near the Starter)
ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission)
Page 1746
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 6309
Body
Connector Location (Access Cab)
BA1 Front Door LH Wire and Wire Harness (Connector Location)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel)
BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel)
BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel)
BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Page 2362
Knock Sensor (Part 2)
Page 2849
4. INSPECT THROTTLE POSITION SENSOR
a. Disconnect the throttle position sensor connector. b. Using an ohmmeter, measure the
resistance between terminals VC and E2.
Resistance: 1.25 - 2.35 kohms at 20 °C (68 °F)
If the resistance is not as specified, replace the throttle position sensor.
c. Reconnect the throttle position sensor connector.
5. INSPECT ACCELERATOR PEDAL POSITION SENSOR
a. Disconnect the pedal position sensor connector. b. Using an ohmmeter, measure the resistance
between terminals VC and E2.
Resistance: 1.64 - 3.28 kohms at 20 °C (68 °F)
If the resistance is not as specified, replace the accelerator pedal position sensor.
c. Reconnect the pedal position sensor connector.
6. REINSTALL THROTTLE BODY COVER
Page 548
O2S Application Table
O2S Failure Threshold Charts
Page 5369
Supplemental Restraint System
Page 2034
Glossary Of Terms And Symbols (Part 1)
Page 3613
HINT: During reassembly please refer to the spring specifications to help you to discriminate
between the different springs.
Spring
Retainer
3. CHECK BALL
Page 5284
4. Cycle the temperature control knob several times and confirm proper water control valve
adjustment.
Page 6951
c. Continue to apply voltage, check that circuit breaker operation noise is heard within
approximately 4 to 40 seconds. d. Reverse the polarity, check that the window begins to descend
within approximately 60 seconds.
If operation is not as specified, replace the motor.
Page 773
Repair Procedure
1. Disconnect the cable from the negative (-) battery terminal for MORE THAN two (2) seconds.
2. Reconnect the cable to the negative (-) battery terminal.
3. Perform the applicable zero point calibration of the yaw rate sensor and/or the steering angle
sensor.
HINT Refer to the applicable TSB or Repair Manual for the zero point calibration procedure.
4. Re-initialize all applicable systems available on the vehicle (power window sunroof power lift
door etc.).
Page 849
Measuring Point Reference
5. INSPECT TOE-IN
If the toe-in is not within the specified value, adjust the rack ends.
6. ADJUST TOE-IN AND WHEEL ANGLE
a. Remove the 2 clips.
b. Loosen the tie rod end lock nuts. c. Turn the right and left rack ends by an equal amount to
adjust the toe-in.
HINT: Try to adjust the toe-in to the center of the specified value.
d. Make sure that the lengths of the right and left rack ends are the same.
Rack end length difference: 1.5 mm (0.059 inch) or less
e. Tighten the tie rod end lock nuts.
Torque: 55 Nm (560 kgf-cm, 41 ft. lbs.)
f. Place the boots on the seats and install the clips.
HINT: Make sure that the boots are not twisted.
g. Inspect the wheel angle.
Turn the steering wheel fully and measure the turning angle.
Removal and Installation
Heater Core Case: Service and Repair Removal and Installation
Heater Unit
REMOVAL
1. REMOVE COOLING UNIT
2. DRAIN ENGINE COOLANT FROM RADIATOR
HINT: It is not necessary to drain out all the coolant.
Page 6565
Seat Belt Reminder Lamp: Electrical Diagrams
Key Reminder And Seat Belt Warning
Service Hints
KEY REMINDER AND SEAT BELT WARNING
Page 6673
The ground points circuit diagram shows the connections from all major parts to the respective
ground points. When troubleshooting a faulty ground point, checking the system circuits which use
a common ground may help you identify the problem ground quickly. The relationship between
ground points (EA, IB and IC) can also be checked this way.
How to Read Power Source
HOW TO READ POWER SOURCE
Front Differential
Seals and Gaskets: Service and Repair Front Differential
REPLACEMENT
1. REMOVE ENGINE UNDER COVER 2. DRAIN DIFFERENTIAL OIL 3. REMOVE FRONT
PROPELLER SHAFT 4. REMOVE COMPANION FLANGE
a. Using a chisel and hammer, loosen the staked part of the nut. b. Using Special Service Tool
(SST) to hold the flange, remove the nut.
SST 09330-00021
c. Using SST, remove the companion flange.
SST 09950-30011 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020)
Page 1129
Malfunction Indicator Lamp: Description and Operation
Malfunction Indicator Lamp (MIL)
OBD II regulations require that the vehicle's on-board computer lights up the Malfunction Indicator
Lamp (MIL) on the instrument panel when the computer detects a malfunction in the emission
control system/components or in the powertrain control components which affect vehicle
emissions, or a malfunction in the computer. In addition to the MIL lighting up when a malfunction is
detected, the applicable Diagnostic Trouble Codes (DTCs) prescribed by SAE J2012 are recorded
in the ECM memory.
If the malfunction does not reoccur in 3 consecutive trips, the MIL goes off automatically but the
DTCs remain recorded in the ECM memory.
Page 4601
Auxiliary Power Outlet: Diagnostic Aids
Voltage Check
Voltage Check
Voltage Check
A. Establish conditions in which voltage is present at the check point.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(SW 2 OFF)
B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or
component terminal. This check can be done with a test light instead of a voltmeter.
Continuity and Resistance Check
Continuity and Resistance Check
Continuity And Resistance Check
A. Disconnect the battery terminal or wire so there is no voltage between the check points. B.
Contact the two leads of an ohmmeter to each of the check points.
Page 4674
Driver Side J/B And Integration Relay
Page 3358
^ 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 1780
Splice Point
J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel,
and "B" for the Body).
The Location of splice Point I5 is shaded.
K: Indicates a shielded cable.
L: Indicates the pin number of the connector.
The numbering system is different for female and male connectors.
M: Indicates a ground point.
The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for
the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body
and Surrounding area.
How to Read Connector List
HOW TO READ CONNECTOR LIST
A: Indicates connector to be connected to a part. (The numeral indicates the pin No.)
Front Seat Cover - Damaged
Seat Cover: All Technical Service Bulletins Front Seat Cover - Damaged
BODY
BO006-02
Title: FRONT SEAT COVER DAMAGE
Models: '00 - '02 Tundra & '01 - '02 Sequoia Equipped with Power Seats
March 1, 2002
Introduction
Due to the unique curvature of the front seat frames' outboard edge, the driver or passenger could
potentially wear a hole into the seat cover material during entry and exit of the vehicle. This
condition has been addressed and corrected in production. The instructions below will illustrate
how to properly repair vehicles with this condition.
Applicable Vehicles
2000 - 2002 model year Tundra vehicles equipped with power seats produced before the VIN
shown below.
2001 - 2002 model year Sequoia vehicles equipped with power seats produced before the VIN
shown below.
Production Change 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.
Page 5525
Seat Belt
Page 1790
Waterproof Type Connector
B: For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White
: Gray
Black or White : Dark Gray
Gray or White : Black
Waterproof Type Connector
"Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up
to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Waterproof Type Connector
"Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 5395
Clockspring Assembly / Spiral Cable: Testing and Inspection Replacement Requirements
REPLACEMENT REQUIREMENTS
CAUTION: Be sure to follow the correct procedure, for removal and installation of the steering
wheel pad.
Page 2750
O2S Application Table
O2S Failure Threshold Charts
Page 3281
Transmission Speed Sensor: Service and Repair
Vehicle Speed Sensor NO.1
1. DISCONNECT NO. 1 VEHICLE SPEED SENSOR CONNECTOR
2. REMOVE NO. 1 VEHICLE SPEED SENSOR
Remove the bolt and No.1 vehicle speed sensor.
3. DISASSEMBLE NO. 1 VEHICLE SPEED SENSOR
a. Remove the O-ring from the speedometer driven gear assembly. b. Remove the clip and
speedometer driven gear from the speedometer driven gear sleeve.
4. ASSEMBLE NO. 1 VEHICLE SPEED SENSOR
a. Install the speedometer driven gear and clip to the speedometer driven gear sleeve. b. Coat a
new O-ring with ATF. c. Install the O-ring to the speedometer driven gear assembly.
5. INSTALL NO. 1 VEHICLE SPEED SENSOR
Page 6531
b. Push the secondary locking device or terminal retainer in to the full lock position.
5. CONNECT CONNECTOR
Disconnection of Male and Female Connectors
Disconnection of Male and Female Connectors
Disconnection Of Male And Female Connectors
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Page 5390
Supplemental Restraint System
Page 2810
CHART 2
CHART 3
CHART 4
Page 731
Knock Sensor (Part 2)
Page 5577
Non-Waterproof Type Connector
"Case 1" Raise the terminal retainer up to the temporary lock position.
Non-Waterproof Type Connector
"Case 2" Open the secondary locking device.
Page 1364
Engine Oil Pressure: Testing and Inspection
INSPECTION
1. CHECK ENGINE OIL QUALITY
Check the oil for deterioration, entry of water, discoloring or thinning. If the quality is visibly poor,
replace the oil. Oil grade: Use API SJ, Energy-Conserving or ILSAC multi-grade engine oil. SAE
5W-30 is the best choice for your vehicle, for good fuel economy, and good starting in cold
weather.
2. CHECK ENGINE OIL LEVEL
The oil level should be between the "L" and "F" marks on the dipstick. If low, check for leakage and
add oil up to the "F" mark.
NOTICE: Do not fill with engine oil above the "F" mark.
3. REMOVE ENGINE UNDER COVER
4. REMOVE OIL PRESSURE SWITCH 5. INSTALL OIL PRESSURE GAUGE 6. WARM UP
ENGINE
Allow the engine to warm up to normal operating temperature.
7. CHECK OIL PRESSURE
Oil pressure:
8. REMOVE OIL PRESSURE GAUGE
9. REINSTALL OIL PRESSURE SWITCH
a. Apply adhesive to 2 or 3 threads of the oil pressure switch.
Adhesive: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
b. Reinstall the oil pressure switch.
10. START ENGINE, AND CHECK FOR ENGINE OIL LEAKS
Page 4564
Using vernier calipers, measure the commutator diameter.
Standard diameter
Minimum diameter
If the diameter is less than minimum, replace the armature.
6. INSPECT UNDERCUT DEPTH
Check that the undercut depth is clean and free of foreign materials. Smooth out the edge.
Standard undercut depth
Minimum undercut depth: 0.2 mm (0.008 in.)
If the undercut depth is less than minimum, correct it with a hacksaw blade.
Diagram Information and Instructions
Seat Belt Reminder Buzzer: Diagram Information and Instructions
Key to Diagrams
A: System Title
B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to
distinguish it from the J/B
Example: 1 Indicates Relay Block No.1
C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type,
or specification is different.
D: Indicates related system.
Locations
Relay Box: Locations
Driver Side J/B And Integration Relay
ABS/TCS - Zero Point Calibration Information
Steering Angle Sensor: Technical Service Bulletins ABS/TCS - Zero Point Calibration Information
T-SB-0020-08
March 25, 2008
Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment
Service Category Brake
Section Brake Control/Dynamic Control System
Market USA
Applicability
Introduction
The purpose of this TSB is to provide information on when and how to perform the zero point
calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting
the battery is a necessary step for performing the zero point calibration.
Warranty Information
Required Tools & Equipment
^ Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE).
^ The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the
service procedures listed in this bulletin.
Preliminary Information
Perform this procedure if any of these repairs have been performed on the vehicle:
^ Wheel alignment has been adjusted.
^ Any chassis components have been removed/installed or replaced.
Page 2732
Engine Bank Identification
Page 4911
Body
Splice Location (Standard Cab)
B1 Speaker Tweeter Wire LH
B2 Front Door LH Wire
B3 Front Door LH Wire
B4 Roof Wire
B5 Speaker Tweeter Wire RH
B6 B7
Front Door RH Wire
B10 Frame Wire
Seat
Page 3682
Page 4836
Page 5055
- Length: 6 in.
^ Ratcheting tie down strap (quantity 1)
- Minimum Width & Length: 1 in. x 6 ft.
^ Bicycle Cable Lock (quantity 1)
- Minimum Width & Length: 3/8 in. x 5 ft.
- Built-in lock with key
- Bell: P/N 1002107, Master Lock: P/N 8126D, Kryptonite: P/N 999782 or equivalent
IV. Background
On certain 2000 through 2003 model year Tundra vehicles operated in cold climate areas with high
road salt use (Severe Cold Climate States) excessive corrosion may be exhibited on the rear frame
cross-member. In the worst case the spare tire stowed under the truck bed may become separated
from the rear cross-member. Eventually excessive corrosion of the rear cross-member may also
affect the functionality of the brake system Load Sensing Proportioning & By-Pass Valve and/or
associated brake lines.
Page 3313
^ 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 2041
Terminal Retainer
Push the terminal retainer down to the temporary lock position.
c. Release the locking lug from terminal and pull the terminal out from rear.
4. INSTALL TERMINAL TO CONNECTOR
a. Insert the terminal.
HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug
locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position.
Page 2475
Page 6323
Non-Waterproof Type Connector
"Case 1" Raise the terminal retainer up to the temporary lock position.
Non-Waterproof Type Connector
"Case 2" Open the secondary locking device.
Page 2076
Camshaft Position Sensor
Instruments - Oil Pressure Gauge Reads Abnormally Low
Oil Pressure Sender: All Technical Service Bulletins Instruments - Oil Pressure Gauge Reads
Abnormally Low
ELECTRICAL EL017-03
December 23, 2503
Title OIL PRESSURE GAUGE READS LOW
Models '01 - '04 Sequoia & '00 - '02 Tundra
TSB UPDATE NOTICE:
This TSB updates EL006-03. TSB EL006-03 is now obsolete and should be discarded.
Introduction
Some customers with Sequoia or Tundra vehicles may encounter an oil pressure gauge that reads
abnormally low at idle. An updated oil pressure sender has been created to address this condition.
Applicable Vehicles ^
2001 - 2004 model year Sequoia vehicles produced BEFORE the Production Change Effective
VINs shown below.
^ 2000 - 2002 model year Tundra vehicles produced BEFORE the Production Change Effective
VIN shown below.
Production Change Information
Parts Information
Repair Procedure
1. Replace the Oil Pressure Sender.
2. Verify proper operation of the Oil Pressure Gauge.
Warranty Information
Applicable Warranty*:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36
months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Page 5442
SRS Warning Light: Description and Operation
SRS WARNING LIGHT
The SRS warning light is located on the combination meter. It goes on to alert the driver of trouble
in the system when a malfunction is detected in the airbag sensor assembly self-diagnosis. In
normal operation conditions when the ignition switch is turned to the ACC or ON position, the light
goes on for about 6 seconds and then goes off.
Page 5647
Air Bag Deactivation Switch: Description and Operation
PASSENGER AIRBAG MANUAL ON-OFF SWITCH
Passenger airbag manual on-off switch is mounted on the center cluster finish panel. By turning the
passenger airbag manual on-0ff switch to OFF with the ignition key, the passenger airbag system
can be disabled. Also, in order to notify the passenger that the front passenger airbag is disabled,
OFF indicator inside the switch will light up.
Page 4638
Waterproof Type Connector
B: For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White
: Gray
Black or White : Dark Gray
Gray or White : Black
Waterproof Type Connector
"Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up
to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Waterproof Type Connector
"Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 5230
7. DISCONNECT LIQUID TUBE AND DISCHARGE HOSE
Remove the 2 bolts and disconnect the both tube and hose.
Torque: 10 N.m (100 kgf.cm, 7 ft.lbf)
NOTE: Cap open the fittings immediately to keep moisture or dirt out of the system.
HINT: At the time of installation, please refer to the following item. Lubricate 2 new O-rings with
compressor oil and install them to the tubes.
8. REMOVE CONDENSER
a. Remove the 2 bolts and 2 lower brackets. b. Remove the 4 bolts and 2 upper brackets. c. Pull
the condenser forward and pull it upward.
HINT: At the time of installation, please refer to the following item. If condenser is replaced, add
compressor oil to the compressor.
Add 40 - 50 cc (1.4 - 1.7 fl.oz.) Compressor oil: ND-OIL 8 or equivalent
INSTALLATION
Installation is in the reverse order of removal.
Testing and Inspection
Power Door Lock Actuator: Testing and Inspection
INSPECT DOOR KEY LOCK MOTOR OPERATION
a. Connect the positive (+) lead from the battery to terminal 3 and the negative (-) lead to terminal
2, and check that the door lock link moves to
UNLOCK position.
b. Reverse the polarity and check that the door lock link moves to LOCK position.
If operation is not as specified, replace the door lock assembly.
Diagram Information and Instructions
Relay Box: Diagram Information and Instructions
Key to Diagrams
A: System Title
B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to
distinguish it from the J/B
Example: 1 Indicates Relay Block No.1
C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type,
or specification is different.
D: Indicates related system.
Page 5407
- When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool)
Perform the operation in a place away from electrical noise. SST 09082-00700
- When deploying an airbag, perform the operation at least 10 m (33 ft) away from the steering
wheel pad.
- The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30
minutes after deployment.
- Use gloves and safety glasses when handling a steering wheel pad with the deployed airbag.
- Always wash your hands with water after completing the operation.
- Do not apply water, etc. to a steering wheel pad with the deployed airbag.
DEPLOYMENT WHEN DISPOSING OF STEERING WHEEL PAD WITH AIRBAG DEPLOYED IN
COLLISION
Dispose of the steering wheel pad (with airbag).
CAUTION:
- The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30
minutes after deployment.
- When moving a vehicle for scrapping which has a steering wheel pad with the deployed airbag,
use gloves and safety glasses
- Use gloves and safety glasses when handling a steering wheel pad with deployed airbag.
- Always wash your hands with water after completing the operation.
- Do not apply water, etc. to a steering wheel pad with deployed airbag.
1. Remove the steering wheel pad from the steering wheel. 2. Place the steering wheel pad in a
vinyl bag, tie the end tightly and dispose of it in the same way as other general parts disposal.
Description and Operation
Brake Fluid Solenoid Valve Relay: Description and Operation
ABS Solenoid Relay
This relay supplies power to each ABS solenoid. After the ignition switch is turned ON, if the initial
check is OK, the relay goes on.
Page 547
Page 3799
Transmission Position Switch/Sensor: Service and Repair
ON-VEHICLE REPAIR
1. DISCONNECT OIL COOLER PIPE 2. REMOVE PARK/NEUTRAL POSITION SWITCH
a. Disconnect the connector. b. Pry off the lock washer and remove the nut. c. Remove the bolt and
park/neutral position switch.
3. INSTALL PARK/NEUTRAL POSITION SWITCH
a. Install the park/neutral position switch and bolt.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)
b. Install a new lock plate and the nut.
Torque: 3.9 Nm (40 kgf-cm, 35 inch lbs.)
c. Bend claws on the lock plate to fix the nut. d. Connect the connector. e. Check that the engine
can be started with the shift lever only in the N or P position, but not in other positions. If not as
stated, carry out the
adjustment procedure. See: Automatic Transmission/Transaxle/Testing and Inspection/Initial
Inspection and Diagnostic Overview
4. CONNECT OIL COOLER PIPE 5. FILL ATF AND CHECK FLUID LEVEL 6. TEST DRIVE
VEHICLE
Page 2823
CHART 21
Page 2819
CHART 16
CHART 17
Page 4316
Repair Procedure
1. REMOVE FRONT WHEEL
2. 4WD:
REMOVE GREASE CAP
Using a screwdriver and hammer, remove the grease cap.
3. 4WD:
DISCONNECT DRIVE SHAFT
A. Remove the cotter pin and lock cap.
B. While applying the brakes, remove the lock nut.
4. W/ABS DISCONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP FROM
STEERING KNUCKLE
Remove the 2 bolts and disconnect the ABS speed sensor and wire harness clamp from the
steering knuckle.
5. DISCONNECT BRAKE LINE
Using the SST, disconnect the brake line. Use a container to catch the brake fluid.
Page 152
E. Confirm the Diagnostic Tester has the appropriate software for the type of calibration file that
was downloaded.
NOTE:
The calibration type is specific to the software version loaded on your Diagnostic Tester. If you
selected the wrong version when downloading the calibration file, you will receive an error when
attempting to install the file on the Diagnostic Tester.
Page 577
CHART 30
Page 4595
Splice Point
J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel,
and "B" for the Body).
The Location of splice Point I5 is shaded.
K: Indicates a shielded cable.
L: Indicates the pin number of the connector.
The numbering system is different for female and male connectors.
M: Indicates a ground point.
The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for
the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body
and Surrounding area.
How to Read Connector List
HOW TO READ CONNECTOR LIST
A: Indicates connector to be connected to a part. (The numeral indicates the pin No.)
Page 211
Page 811
a. Ignition switch ON. b. Shift the transmission shift lever in N position. c. Turn the touch select 2-4
switch ON. d. Check that the 4LO indicator lights come on and the 4HI indicator lights go off when
the touch select high-low switch is in ON position. e. Check that the 4LO indicator lights go off and
the 4HI indicator lights come on when the touch select high-low switch is in OFF position.
HINT: Inspection should be performed with the vehicle stopped, and transmission shift lever in N position.
- If switching is not completed after 3 seconds of shift operation, the 4LO indicator light will flash.
3. INSPECT TOUCH SELECT 2 - 4 AND HIGH-LOW SWITCH CONTINUITY
a. Remove center integration panel assembly. b. Inspect the continuity between the each terminals.
Touch select 2-4 switch
Touch select high-low switch:
If continuity is not as specified, replace the center integration panel assembly.
4. INSPECT ACTUATOR RESISTANCE
a. Using an ohmmeter, measure the resistance between terminals 1 and 2.
Standard resistance: 0.3 - 100 Ohms
b. Using an ohmmeter, measure the resistance between terminals 1 or 2 and body ground.
Standard resistance: More than 0.5 M Ohms If resistance value is not as specified, replace the
actuator assembly.
Page 1593
1. Remove coolant and any foreign material on rubber points "A," "B," and "C."
2. Check that points "A" and "B" are not deformed, cracked, or swollen.
3. Check that points "B" and "C" are not stuck together.
4. Apply engine coolant to point "B" before using the radiator cap tester.
^ Radiator Cap Tester: Snap-On/Sun P/N SVTS262A (or equivalent)
5. Before installing the radiator cap tester, use the applicable radiator cap adaptor provided in the
following SST kits in conjunction with the radiator cap tester:
^ SST P/N 09230-00030-01 (09231-10080-01) or 09230-00020-01 (09231-10060-01) or
09230-00050-01(09231-10110-01
6. When using the radiator cap tester, tilt it more than 30 degrees.
7. Pump the radiator cap tester several times, and check the maximum pressure.
Pumping speed: 1 pump/second
HINT:
Stop pumping when the valve opens and read the gauge. The gauge must be within the standard
values listed below when the pressure valve opens. The cap is considered OK when the pressure
holds steady or falls very slowly, but holds within the standard values listed below for one minute.
Exhaust System - Sulfur Smell
Fuel: Technical Service Bulletins Exhaust System - Sulfur Smell
ENGINE EG003-03
February 24, 2003
Title: SULFUR ODOR FROM EXHAUST
Models: All Models
Introduction
Some owners of Toyota vehicles may experience a sulfur-like or "rotten egg" odor from the exhaust
system. Sulfur is a natural component of crude oil from which gasoline is refined and the amount of
sulfur can be decreased through the refining process. The amount of sulfur in fuel sold in California
is regulated, however gasoline sold in other states can have substantially higher sulfur content.
Sulfur content also varies considerably between gasoline brands and locations.
Applicable Vehicles
^ All Models.
Repair Procedure
A sulfur odor emitted from the vehicle's tailpipe does not necessarily indicate that there is an issue
with the engine's running condition, but is most likely directly related to the fuel.
^ If the vehicle is exhibiting an excessive sulfur odor, the following checks should be performed:
^ If the MIL light is ON, check for DTCs and repair as necessary.
If no trouble is found after performing the above check, recommend the customer try a different
source of fuel.
Replacement of oxygen sensors, air/fuel ratio sensors or catalytic converters will not reduce the
odor and will therefore not be considered warrantable.
Warranty Information
Page 6272
b. Push the secondary locking device or terminal retainer in to the full lock position.
5. CONNECT CONNECTOR
Disconnection of Male and Female Connectors
Disconnection of Male and Female Connectors
Disconnection Of Male And Female Connectors
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Page 1939
CHART 28
Page 6709
Splice Location
I1 Cowl Wire
I2 Cowl Wire
I3 Cowl Wire
I4 Cowl Wire
I5 Cowl Wire
I6 Cowl Wire
I7 Engine Wire
I8 Engine Wire
I9 Engine Wire
I10 Engine Wire
I11 Engine Wire
I12 Engine Wire
I13 Engine Wire
I14 Engine Wire
I15 Engine Wire
I16 Cowl Wire
Body
Splice Location (Access Cab)
B1 Speaker Tweeter Wire LH
B2 Front Door LH Wire
B3 Front Door LH Wire
B4 Roof Wire
B5 Speaker Tweeter Wire RH
B6 B7
Front Door RH Wire
B8 Front Door RH Wire
B9 Rear Door No. 1 Wire RH
B10 Frame Wire
Locations
Specifications
Fuel Tank And Line
Testing and Inspection
Seat Belt Buckle Switch: Testing and Inspection
Bench Type and Passenger Side: INSPECT BUCKLE SWITCH CONTINUITY a. Check that
continuity exists between terminals 1 and 2 on the switch side connector with the switch ON (belt
fastened). b. Check that no continuity exists between terminal 1 an 2 on the switch side connector
with the switch OFF (belt unfastened).
If operation is not as specified, replace the seat belt inner.
(w/o Bench Type (Driver Side): INSPECT BUCKLE SWITCH CONTINUITY a. Check that continuity
exists between terminals 3 and 4 on the switch side connector with the switch ON (elt fastened). b.
Check that no continuity exists between terminal 3 an 4 on the switch side connector with the
switch OFF (belt unfastened).
If operation is not as specified, replace the seat belt inner.
Separate Type (w/ Power Seat): INSPECT BUCKLE SWITCH CONTINUITY a. Check that
continuity exists between terminals 1 and 2 on the switch side connector with the switch ON (belt
fastened). b. Check that no continuity exists between terminal 1 an 2 on the switch side connector
with the switch OFF (belt unfastened).
If operation is not as specified, replace the seat belt inner.
Page 6586
Key Reminder Switch: Splice Locations
Engine Compartment
Splice Location
E1 Engine Room Main Wire
E2 Engine Room Main Wire
E3 Engine Room Main Wire
E4 Engine No. 2 Wire
E5 Engine Wire
E6 Engine Wire
E7 Engine Wire
E8 Engine Wire
Instrument Panel
Page 2277
J. The top half of the CUW screen displays the calibrations currently stored on the Diagnostic
Tester Program Card. The bottom half of the screen displays the new calibration to be loaded onto
the Diagnostic Tester Program Card (see Figure 13). Click NEXT to continue the process.
K. Confirm the calibration file to be sent to the Diagnostic Tester Program Card (Figure 14). Click
SEND.
Page 583
Required Tools & Material
NOTE:
Additional Diagnostic Tester Kits, Program Cards or SSTs may be ordered by calling SPX-OTC at
1-800-933-8335.
Repair Procedure
Using the chart, refer to the Diagnostic Section (DI-###) in the appropriate Repair Manual and
follow the diagnostic procedure for the specific DTC.
Page 3706
b. Using SST to hold the flange, remove the nut and spacer.
SST 09330-00021
c. Place matchmarks on the flange and shaft.
d. Using SST, remove the flange from the intermediate shaft.
SST 09950-30011 (09951-03010, 09953 -03010, 09954-03010, 09955-03030, 09956-03020)
e. Remove the spacer and center support bearing from the intermediate shaft.
INSPECTION
NOTICE: Be careful not to grip the propeller shaft tube too tightly in a vise as this will cause
deformation.
1. INSPECT PROPELLER SHAFT AND INTERMEDIATE SHAFT FOR DAMAGE OR RUNOUT
Using a dial indicator, check the runout of shafts. Maximum runout: 0.8 mm (0.031 inch) If shaft
runout is greater than the maximum, replace the shaft.
2. INSPECT SPIDER BEARING
a. Inspect the spider bearing for wear or damage. b. Using a dial indicator, check the spider
bearing axial play by turning the yoke of flange while holding the shaft tightly.
Maximum bearing axial play: Front propeller shaft: 0.05 mm (0.0020 inch) Rear propeller shaft: 0
mm (0 inch) If the spider bearing axial play exceeds the maximum, replace the spider bearing.
Page 4636
B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(Connect the Relay) and SW 2 OFF (or Disconnect SW 2)
D. Disconnect and reconnect the connectors while watching the test light.
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
E. Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION:
a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals
are touched, the IC may be destroyed by
static electricity.)
b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact
with the terminals of leads from the IC, etc. of the replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
Special Tool
1. PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown.
2. DISCONNECT CONNECTOR
3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
a. Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the
secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
A: For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
Replacement Requirements
Impact Sensor: Service and Repair Replacement Requirements
REPLACEMENT REQUIREMENTS
In the following cases, replace the front airbag sensor.
- If the SRS has been deployed in a collision. (Replace both the left and right airbag sensors.)
- If the front airbag sensor has been found to be faulty in troubleshooting.
- If the front airbag sensor has been found to be faulty during checking items.
- If the front airbag sensor has been dropped.
CAUTION: Be sure to follow the correct procedure for removal and installation of the front airbag
sensor.
Page 1571
Temperature Gauge: Testing and Inspection
INSPECT ENGINE COOLANT TEMPERATURE RECEIVER GAUGE OPERATION
a. Disconnect the connector from the sender gauge. b. Turn the ignition switch ON, check that the
receiver gauge needle indicates COOL.
c. Ground terminal on the wire harness side connector through a 3.4 W test bulb. d. Turn the
ignition switch ON, check that the bulb lights up and the receiver gauge needle moves to the hot
side.
If operation is as specified, replace the sender gauge. Then, recheck the system. If operation is not
as specified, measure the receiver gauge resistance.
INSPECT ENGINE COOLANT TEMPERATURE RECEIVER GAUGE RESISTANCE
Measure the resistance between terminals.
w/ Tachometer
Page 6322
B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(Connect the Relay) and SW 2 OFF (or Disconnect SW 2)
D. Disconnect and reconnect the connectors while watching the test light.
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
E. Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION:
a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals
are touched, the IC may be destroyed by
static electricity.)
b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact
with the terminals of leads from the IC, etc. of the replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
Special Tool
1. PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown.
2. DISCONNECT CONNECTOR
3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
a. Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the
secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
A: For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
Page 4974
Steering Wheel: Description and Operation
STEERING WHEEL PAD (with AIRBAG)
The inflater and bag of the SRS are stored in the steering wheel pad and cannot be disassembled.
The inflater contains a squib, igniter charge, gas generant, etc., and inflates the bag when
instructed by the airbag sensor assembly.
Page 4838
a. Loosen the front and/or rear adjusting cam set bolts. b. Adjust the camber and caster by front
and/or rear adjusting cams (See adjustment chart).
HINT: Try to adjust the camber and caster to the center of the specified values.
c. How to read adjustment chart (Example).
1. Find the applicable wheel alignment standard value for the particular model. 2. Mark the selected
standard value on the adjustment chart.
Example: Camber: 0°10'(0.17°) Caster: 3°00'
3. Measure the present wheel alignment value with the vehicle in non-loaded condition. 4. Mark the
measured present value on the adjustment chart.
Example: Camber: 0°30'(0.50°) Caster: 2°40'(2.67°)
Page 2814
CHART 10
Engine Controls - Error When Reprogramming ECU
Engine Control Module: Customer Interest Engine Controls - Error When Reprogramming ECU
SPECIAL SERVICE TOOLS SS004-01 REVISED
May 25, 2001
Title: ECU FLASH REPROGRAMMING ERROR MESSAGE
Models: Applicable Models
TSB REVISION NOTICE:
September 23, 2003: Models added - 2002 (and later) Solara, 2003 (and later) Corolla and Matrix,
and 2004 models; Test Procedures updated for new CAN Interface Module. The previous TSB
should be discarded.
Introduction
During ECU flash reprogramming, an error message may be displayed on the Diagnostic Tester
that will not allow ECU flash reprogramming to complete. This bulletin provides test procedures to
determine the cause for the error message.
Applicable Vehicles ^
2001 (and later) model year 4Runner, Highlander, Land Cruiser, RAV4, Sequoia and Tundra
vehicles.
^ 2002 (and later) model year Camry, Solara and Tacoma vehicles.
^ 2003 (and later) model year Corolla and Matrix vehicles.
^ All 2004 (and later) model year Toyota vehicles except Celica, MR2 Spyder, Avalon, and Tacoma
(3RZ-FE engine)
Required SSTs
NOTE:
Additional Diagnostic Tester Kits, CAN Interface Modules, Program Cards or other SSTs may be
ordered by calling SPX/OTC at 1-800-933-8335.
Warranty Information
Test Procedure
Page 1743
^ 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 6261
B: Junction Connector
Indicates a connector which is connected to a short terminal.
Junction connector in this include a short terminal which is connected to a number of wire
harnesses. Always perform inspection with the short terminal installed. (When installing the wire
harnesses, the harnesses can be connected to any position within the short terminal grouping.
Accordingly, in other vehicles, the same position in the short terminal may be connected to wire
harness from a different part.) Wire harness sharing the same short terminal grouping ha the same
color.
C: Parts Code
The first letter of the code is taken from the first letter of part, and the numbers indicates its order in
parts which start with the same letter.
D: Connector Color
Connectors not indicated are milky white in color.
How to Read Ground Points
HOW TO READ GROUND POINTS
Page 6315
B: Junction Connector
Indicates a connector which is connected to a short terminal.
Junction connector in this include a short terminal which is connected to a number of wire
harnesses. Always perform inspection with the short terminal installed. (When installing the wire
harnesses, the harnesses can be connected to any position within the short terminal grouping.
Accordingly, in other vehicles, the same position in the short terminal may be connected to wire
harness from a different part.) Wire harness sharing the same short terminal grouping ha the same
color.
C: Parts Code
The first letter of the code is taken from the first letter of part, and the numbers indicates its order in
parts which start with the same letter.
D: Connector Color
Connectors not indicated are milky white in color.
How to Read Ground Points
HOW TO READ GROUND POINTS
Page 3101
3. REMOVE INTAKE AIR CONNECTOR
4. DISCONNECT ACCELERATOR CABLE FROM THROTTLE BODY
5. REMOVE THROTTLE BODY
a. Disconnect the throttle position sensor connector. b. Disconnect the throttle control motor
connector. c. Disconnect the accelerator pedal position sensor connector. d. Disconnect the
accelerator pedal position sensor wire from the 2 clamps on the wire brackets.
e. Disconnect the PCV hose and water bypass hose from the throttle body. f.
Remove the ventilation cap.
g. Remove the 2 bolts and 2 nuts, and disconnect the throttle body from the intake manifold.
h. Disconnect the water bypass hose from the manifold thermostat on the throttle body, and
remove the throttle body. i.
Remove the gasket.
INSTALLATION
1. INSTALL THROTTLE BODY
a. Connect the water bypass hose to the manifold thermostat on the throttle body.
Page 4234
Required SSTs
Repair Procedure
1. Confirm the customer complaint.
2. Determine if vibration is from front or rear (while brakes are still warm from confirmation driving).
The following procedure will isolate the drum brakes from the rest of the hydraulic system by using
the parking brake (PKB).
NOTE:
Remember with a foot PKB (on an automatic transmission), the pedal must be pressed a second
time to disengage the parking brake.
HINT:
When diagnosing a Tundra with a foot PKB, slowly apply the PKB until the first "click" and then
press the PKB pedal a second time so it will disengage when it is released. At this time, the PKB
can be pressed to the desired level for continued diagnosis.
A. Drive the Tundra along a smooth, level section of road at approximately 40 - 50 mph.
B. Slowly apply the PKB while driving until the brake begins to engage and slow the vehicle. Do not
apply the PKB past this point of initial engagement.
C. Hold the PKB at this point of initial engagement for a few seconds to slowly reduce the vehicle
speed and allow adequate time to monitor the ride condition.
D. Disengage the PKB.
E. If brake vibration is felt during step C, then it indicates that the rear brake drums are one source
of brake vibration on this vehicle.
Proceed to the Repair Procedures that follow.
F. If no vibration is felt during step C, then the front brake assemblies are the cause of brake
vibration on this vehicle.
Refer to TSB No. BR004-02, "Front Brake Vibration," for parts and repair information relating to
Tundra front brake vibration.
3. Measure the rear axle shaft centering area diameter. If the measured value deviates from the
standard (105.946 - 106 mm [4.171 - 4.173 in.]), replace the rear axle shaft (Standard: Refer to
Figure 1).
Ground Locations
Audible Warning Device: Ground Locations
Engine Compartment
Ground Location
EA Front Left Fender
EB Rear Bank of Right Cylinder
EC Rear Bank of Left Cylinder
Connector Location
EA1 Cowl Wire Harness and Wire Harness (Connector Location)
EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B)
EC1 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC2 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC3 Engine No. 2 Wire and Engine Wire (Near the Starter)
ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission)
Page 5346
- Standard cab: Check for deformation of the quarter panel.
- Access cab: Check for deformation of the ELR bracket.
- Check for cuts and minute cracks in wire harness or marked discoloration on the front seat outer
belt.
CAUTION: Be sure to follow the correct procedure, for removal and installation of the front seat
outer belt.
2. PRETENSIONER IS ACTIVATED
a. Perform a diagnostic system check. *
Page 4599
Glossary Of Terms And Symbols (Part 1)
Page 846
Alignment: Service and Repair
NOTICE: For Zero Point Calibration information, please refer to: TSB T-SB-0020-8 (3/25/08).
INSPECTION
1. MEASURE VEHICLE HEIGHT
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 leaf spring front side bushing center D:
Ground clearance of the rear axle shaft center Vehicle height:
Front: A - B Rear: C - D
NOTICE: Before inspecting the wheel alignment, adjust the vehicle height to the specified value.
If the vehicle height is not the specified value, try to adjust it by pushing down on or lifting the body.
2. INSTALL CAMBER-CASTER-KING PIN GAUGE OR POSITION VEHICLE ON WHEEL
ALIGNMENT TESTER
Follow the specific instructions of the equipment manufacturer.
3. INSPECT CAMBER, CASTER AND STEERING AXIS INCLINATION
If the steering axis inclination is not within the specified value, after the camber and caster have
been correctly adjusted, recheck the steering knuckle and front wheel for bearing or looseness.
4. ADJUST CAMBER AND CASTER
Description and Operation
Brake Switch - TCC: Description and Operation
Stop Light Switch Signal
Engine
This signal is used to detect when the brakes have been applied. The STP signal voltage is the
same as the voltage supplied to the stop lights.
The STP signal is used mainly to control the fuel cut-off engine speed (The fuel cut-off engine
speed is reduced slightly when the vehicle is braking.).
Automatic Transaxle
The purpose of this circuit is to prevent the engine from stalling, while driving in lock-up condition,
when brakes are suddenly applied.
When the brake pedal is operated, this switch sends a signal to ECM. Then the ECM cancels
operation of the lock-up clutch while braking is in progress.
Specifications
Compression Check: Specifications
Compression Pressure ........................................................................................................................
...................................................... 1,324 kPa or More Minimum Pressure .........................................
...........................................................................................................................................................
981 kPa Difference Between Each Cylinder ........................................................................................
......................................................................... 98 kPa or Less
Page 1766
memory, the CUW will ask you to select the calibration file(s) to delete from the Diagnostic Tester
Program Card to make room for the new calibration file.
If necessary, check the calibration file(s) to delete, as shown in Figure 11. Click DELETE.
NOTE:
If there is adequate memory to store the calibration file, skip to Step J.
I. The CUW will now delete the calibration file(s) selected (see Figure 12).
Page 6589
Splice Location
B11
Page 1387
Oil Pressure Gauge: Testing and Inspection
INSPECT OIL PRESSURE GAUGE RESISTANCE Measure the resistance between terminals A
and B. If resistance value is not as specified, replace the receiver gauge.
Locations
Windshield Wiper Blade - Maintenance and Cleaning
Wiper Blade: Technical Service Bulletins Windshield Wiper Blade - Maintenance and Cleaning
BODY BO030-01
Title: WINDSHIELD WIPER BLADE MAINTENANCE AND CLEANING
Models: All Models
December 7, 2001
Introduction
The following procedures are recommended to maintain windshield wiper blade performance.
Applicable Vehicles ^
All models.
Warranty Information
Maintenance, Cleaning and Use Recommendations for Windshield Wiper Maintenance, Cleaning
and Use:
1. Scheduled Maintenance
^ Check wiper rubber blades every 4 - 6 months or 7,500 miles for wear, cracking and
contamination.
^ Clean glass and rubber wiper blades if blades are not clearing glass adequately. If this does not
correct the problem, then replace the rubber elements.
2. Cleaning Procedure
^ Wiper Rubber: Bugs, dirt, sap and road grime on blades will cause streaking.
^ Clean wiper rubber of road and environmental debris using cloth or paper towel soaked with
windshield washer fluid or mild detergent.
^8DO NOT USE fuel, kerosene, or petroleum based products to clean rubber wiper blades.
^ Windshield: Bugs, road grime, sap and car wash wax treatments decrease wiper performance.
^ Rinse windshield with water and apply non-abrasive cleaner, such as Bon-Ami
(www.faultless.com), with a sponge.
NOTE:
Make sure to use plenty of water with all powder based cleaners so the glass is not scratched.
3. Contributors to Poor Performance/Decreased Rubber Blade Life (require rubber replacement)
^ Dusty areas cause the rubber edge to wear quickly.
^ Sand and salt used for road conditioning during winter causes the edge to wear quickly, so areas
with significant snowfall require more frequent wiper replacement.
^ Heat and time cause the rubber to become excessively "permanent set," so the rubber does not
turn over, resulting in streaking and/or unwiped areas on the glass.
^ Rubber is easily cut or torn while using ice scrapers on the glass.
^ Rubber can be torn when pulling blades off a frozen windshield.
Page 4528
c. Measure the battery voltage between the negative (-) and positive (+) terminals of the battery.
Standard voltage: 12.5 - 12.9 V at 20 °C (68 °F)
If the voltage is less than specification, charge the battery.
HINT: Check the indicator as shown in the illustration.
4. CHECK BATTERY TERMINALS, FUSIBLE LINK AND FUSES
a. Check that the battery terminals are not loose or corroded. b. Check the fusible link and fuses for
continuity.
Page 6551
Wiring Harness Connector
E: Indicates the wiring harness and wiring harness connector. The wiring harness with male
terminal is shown with arrows.
Outside numerals are pin numbers.
The first letter of the code for each wiring harness and wiring harness connector(s) indicates the
component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and
Surrounding area, and "B" for the Body and Surrounding area.
When more than one code has the first and second letters in common, followed by numbers (e.g,
IH1, IH2), this indicates the same type of wiring harness and wiring harness connector.
F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in
parts position.
G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside
it). Junction Blocks are shaded to clearly separate
them from other parts.
H: When 2 parts both use one connector in common, the parts connector name used in wire
routing is shown in square brackets [ ].
Wiring Color
I: Indicates the wiring color.
Wire colors are indicated by an alphabetical code.
B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR =
Brown SB = Sky Blue LG = Light Green GR = Gray
The first letter indicates the basic wire color and the second letter indicates the color of the stripe.
Page 6284
Audible Warning Device Control Module: Splice Locations
Engine Compartment
Splice Location
E1 Engine Room Main Wire
E2 Engine Room Main Wire
E3 Engine Room Main Wire
E4 Engine No. 2 Wire
E5 Engine Wire
E6 Engine Wire
E7 Engine Wire
E8 Engine Wire
Instrument Panel
Page 4578
a. 1.4 kW type:
Remove the 2 bolts.
Torque: 5.9 N.m (60 kgf.cm, 52 in.lbf)
b. 2.0 kW type:
Remove the 2 screws.
Torque: 9.3 N.m (95 kgf.cm, 82 in.lbf)
c. Remove the starter housing, return spring, idler gear, bearing and starter clutch assembly.
HINT: At the time of assembly, please refer to the following item. Apply grease to the return spring
and insert the return spring into the clutch shaft hole.
4. REMOVE STEEL BALL
Using a magnetic finger, remove the steel ball from the clutch shaft hole.
HINT: At the time of assembly, please refer to the following item. Apply grease to the steel ball and
insert the steel ball into the clutch shaft hole.
5. REMOVE BRUSH HOLDER
a. Remove the 2 screws w/ O-ring and end cover from the field frame.
Torque: 1.4 kW type
: 1.5 N.m (15 kgf.cm, 13 in.lbf)
2.0 kW type : 3.8 N.m (39 kgf.cm, 34 in.lbf)
b. Remove the O-ring from the field frame.
Page 3240
Waterproof Type Connector
B: For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White
: Gray
Black or White : Dark Gray
Gray or White : Black
Waterproof Type Connector
"Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up
to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Waterproof Type Connector
"Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 3678
The design of the rear axle seal has been changed from a flat face to an angled face for part
number 90310-50006 and part number 90310-56002.
Installation Procedure
Sequoia
To properly install Rear Axle Oil Seal part number 90310-56002, use the following SSTs and a
hammer to install the new oil seal:
^ SST P/N 09950-60020-01 (09951-00730-01) - Replacer 73
^ SST P/N 09951-70010-01 (09951-07150-01) - Handle
Tacoma & Tundra
To properly install Rear Axle Oil Seal part number 90310-56006, use the following SSTs and a
hammer to install the new oil seal:
^ SST P/N 09950-60020-01 (09951-00710) - Replacer 71
^ SST P/N 09951-70010-01 (09951-07150-01) - Handle
Page 968
TOY 730 - 73mm Toyota Oil Filter Wrench
M 0219 - 74mm Oil Filter Wrench
Diagrams
Access Door
Page 1716
The calibration file contains the Calibration ID number(s) for a specific vehicle ECU (see Figure 1).
NOTE:
The total number of Calibration ID numbers corresponds to the number of reprogrammable
processors in the ECU (see Figure 2).
Operation Procedure
LOCATE CALIBRATION FILE
The following steps in this bulletin describe how to properly flash reprogram an ECU.
1. Locate calibration file on TIS.
Calibration files may be found in two areas (see Figure 3):
A. Search by model and year for a Technical Service Bulletin addressing a specific Product issue.
^ Within the TSB, click on the link for the calibration file.
B. Search by model under the ECU Flash Reprogramming Section.
^ Under the ECU Flash Reprogramming section on TIS, a drop-down list of the latest calibration
files will be displayed.
C. Proceed to step 2 for instructions on how to download the calibration file from TIS to the
Diagnostic Tester Program Card.
Page 6265
Glossary Of Terms And Symbols (Part 2)
Page 870
e. Install the injector to the delivery pipe and lower intake manifold as shown in the illustration.
Before installing the injector, must apply spindle oil or gasoline on the place where a delivery pipe
or an intake manifold touches an O-ring of the injector.
f. Observe these precautions when disconnecting the fuel tube connector (quick type): 1. Check
that there is any dirt or the like on the pipe and around the connector before disconnecting them
and clean the dirt away. 2. Be sure to disconnect by hands. 3. When the connector and the pipe
are stuck, turn and pull the connector to free to disconnect and pull it out. Do not use any tools at
this
time.
4. Inspect if there is any dirt or the like on the seal surface of the disconnected pipe and clean it
away.
5. Prevent the disconnected pipe and connector from being damaged or mixed with foreign objects
by covering them with a vinyl bag.
g. Observe these precautions when connecting the fuel tube connector (quick type):
1. Do not reuse the retainer removed from the pipe. 2. Must use hands to remove the retainer from
the pipe. 3. Check that there is any damage or foreign objects on the connected part of the pipe.
Page 6832
The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit
breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery
power is supplied to each system are explained. Since all System Circuit diagrams start from the
power source, the power source system must be fully understood.
Page 742
Air Bag Deactivation Switch: Testing and Inspection
PASSENGER AIRBAG MANUAL ON-OFF SWITCH INSPECTION
1. INSPECT PASSENGER AIRBAG MANUAL ON-OFF SWITCH
HINT: Release the airbag activation prevention mechanism of the passenger airbag manual on-off
switch connector on the airbag sensor assembly side.
If continuity is not as specified, replace the switch.
2. INSPECT PASSENGER AIRBAG MANUAL ON-OFF INDICATOR OPERATION
a. Using a service wire, connect B1 and B3. b. Connect the positive (+) lead from the battery to
terminal A13 and negative (-) lead to terminal A1. c. Check that the indicator light lights up.
If the operation is not as specified, replace the indicator.
Page 558
CHART 15
Page 1530
Coolant Temperature Sensor/Switch (For Computer): Description and Operation
Engine Coolant Temperature Sensor
A thermistor that is built into the engine coolant temperature sensor changes the resistance value
according to the engine coolant temperature.
The lower the engine coolant temperature sensor, the greater the thermistor resistance value, and
the higher the engine coolant temperature sensor temperature, the lower the thermistor resistance
value.
The engine coolant temperature sensor is connected to the ECM. The 5 V power source voltage in
the ECM is applied to the engine coolant temperature sensor from the terminal THA via a resistor
R. That is, the resistor R and the engine coolant temperature sensor are connected in series.
When the resistance value of the engine coolant temperature sensor changes in accordance with
changes in the engine coolant temperature, the potential at terminal THA also changes. Based on
this signal, the ECM increases the fuel injection volume to improve driveability during cold engine
operation.
Page 6523
Glossary Of Terms And Symbols (Part 1)
Page 6507
BJ Inside of Rear Door LH
BK Inside of Rear Door RH
BL Surrounding of the Front of the Fuel Tank
Connector Location
BA1 Front Door LH Wire and Wire Harness (Connector Location)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel)
BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel)
BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel)
BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Page 5247
8. REMOVE HEATER CONTROL ASSEMBLY
Remove the heater control assembly, then disconnect the connectors.
INSTALLATION
1. INSTALL HEATER CONTROL ASSEMBLY
a. Connect the connectors.
b. Pass the heater control as shown in the illustration.
c. When using the removed one:
Install the heater control assembly.
d. When using a new one:
Install the heater control assembly.
2. ADJUST HEATER CONTROL CABLES
a. Set the mode control dial at "FACE" position.
Page 6554
The ground points circuit diagram shows the connections from all major parts to the respective
ground points. When troubleshooting a faulty ground point, checking the system circuits which use
a common ground may help you identify the problem ground quickly. The relationship between
ground points (EA, IB and IC) can also be checked this way.
How to Read Power Source
HOW TO READ POWER SOURCE
Page 1016
Fluid - Transfer Case: Fluid Type Specifications
Transfer Case
Grade ...................................................................................................................................................
............................................................ GL-4 or GL-5 Viscosity ...........................................................
................................................................................................................................................ SAE
75W-90
Page 423
d. Disconnect the negative (-) lead from the body ground to terminal 1 or 10. e. Check that the
buzzer stops sounding.
If operation is not as specified, replace the combination meter.
4. INSPECT COMBINATION METER CIRCUIT
Page 3561
Body
Connector Location (Access Cab)
BA1 Front Door LH Wire and Wire Harness (Connector Location)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel)
BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel)
BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel)
BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Page 2454
Applicable Vehicles
Page 2617
L. The calibration file will now be downloaded to the Diagnostic Tester Program Card. This process
takes approximately 2-6 minutes (see Figure 15).
M. The CUW will prompt when the calibration file is completely downloaded. Click OK to close the
CUW (Figure 16).
NOTE:
With the calibration file loaded on the Diagnostic Tester Program Card, it is not necessary to repeat
the above steps to reprogram a different vehicle needing the same calibration file. The steps above
are only required when a new calibration file must be loaded onto the Diagnostic Tester Program
Card.
The Diagnostic Tester now has the calibration file stored and you may proceed to the next step to
reprogram the vehicle ECU.
REPROGRAM ECU WITH TESTER
3. Reprogram the vehicle ECU with the Diagnostic Tester.
NOTICE:
Errors during the flash reprogramming process can permanently damage the vehicle ECU.
Minimize the risks by following the steps below.
^ Battery voltage MUST NOT FALL BELOW 11.4 volts during reprogramming.
^ Confirm battery voltage is higher than 11.4 volts, but be sure voltage DOES NOT RISE ABOVE
16.0 volts during reprogramming.
^ Turn off all electrical accessories (e.g. Audio system, A/C, interior lights, DRL, etc.).
^ Do not add to or significantly change the vehicle's electrical load while reprogramming.
^ Confirm the hood is open and ensure under hood temperatures do not exceed 158°F.
Page 200
Materials System.
Required SSTs
NOTE:
Additional Diagnostic Tester Kits, CAN Interface Modules, Program Cards or SSTs may be ordered
by calling SPX/OTC at 1-800-933-8335.
Process Overview
ECU Flash Reprogramming is a 4-step process:
1. Locate the desired calibration file on TIS (Technical Information System).
Calibration files may be found in two areas:
a. Search by model and year for a Technical Service Bulletin addressing a specific product issue.
b. Search by model under the ECU Flash Reprogramming section.
2. Download the calibration file from TIS to the Diagnostic Tester.
The Calibration Update Wizard (CUW) is an application on TIS which downloads calibration files
from TIS to the Diagnostic Tester Program Card. This step is only required when the calibration file
is not currently stored on the Diagnostic Tester Program Card.
3. Reprogram the vehicle ECU with the Diagnostic Tester.
Diagnostic Tester Software now incorporates a function to update a vehicle's ECU calibration
through flash reprogramming.
4. Confirm successful flash update and affix calibration update sticker.
Modifications to ECU calibration files must be recorded and properly displayed on the vehicle using
the calibration update sticker.
NOTE:
Page 705
Throttle Position Sensor: Service and Repair
Refer to Fuel Delivery and Air Induction / Throttle Body / Service and Repair, for removal and
installation of this component.
Page 5811
Waterproof Type Connector
B: For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White
: Gray
Black or White : Dark Gray
Gray or White : Black
Waterproof Type Connector
"Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up
to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Waterproof Type Connector
"Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 5578
Waterproof Type Connector
B: For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White
: Gray
Black or White : Dark Gray
Gray or White : Black
Waterproof Type Connector
"Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up
to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Waterproof Type Connector
"Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 2343
Non-Waterproof Type Connector
"Case 1" Raise the terminal retainer up to the temporary lock position.
Non-Waterproof Type Connector
"Case 2" Open the secondary locking device.
Page 6683
b. Push the secondary locking device or terminal retainer in to the full lock position.
5. CONNECT CONNECTOR
Disconnection of Male and Female Connectors
Disconnection of Male and Female Connectors
Disconnection Of Male And Female Connectors
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Page 125
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.
Electrical - SRS And HV Wiring Repairs
Wiring Harness: Technical Service Bulletins Electrical - SRS And HV Wiring Repairs
TITLE: SRS & HV WIRING REPAIRS
SECTION: ELECTRICAL
BULLETIN # 156
MODELS: ALL TOYOTA LEXUS and SCION MODELS
DATE: AUGUST 2007
There are no approved repairs to Supplemental Restraint System (SRS) or High Voltage (HV)
wiring or connectors. SRS system wiring and connectors are color coded yellow and HV wiring is
orange however vehicle-specific wiring diagrams are the best source for identifying wiring in these
circuits. Wiring diagrams are available through the Technical Information System (TIS)
www.techinfo.toyota.com.
If SRS or HV wiring or connectors are suspected of damage they should be inspected thoroughly.
Damaged wiring and/or connectors require replacement of the affected harness. Follow all
precautions and procedures outlined in model-specific repair manuals for replacing SRS wiring or
components. Only Certified Hybrid Service Technicians are qualified to replace HV system wiring
and components.
Page 4190
Torque: 64 N.m (650 kgf.cm, 47 ft.lbf)
B. Connect the lower side of shock absorber to the lower suspension arm with bolt, washer and
nut.
Torque: 135 N.m (1,400 kgf.cm, 100 ft.lbf)
26. INSPECT AND INSTALL THE BRAKE ROTOR AND INSTALL THE BRAKE CALIPER WITH
NEW MOUNTING BOLTS
A. Inspect the brake rotors, and machine using an on-the-car brake lathe. Replace the rotor if it is
below minimum thickness values Minimum Thickness: 26.0 mm (1.024 in.)
B. Install the disc, brake caliper and 2 NEW bolts.
Torque: 123 N.m (1,259 kgf.cm, 90 ft.lbf)
C. Install the brake line clamp to the steering knuckle with the bolt.
Torque: 28 N.m (285 kgf.cm, 21 ft.lbf)
27. INSTALL NEW BRAKE LINE
Using the SST, connect NEW brake line.
^ 09023-00100
Torque: 15 N.m (155 kgf.cm, 11 ft.lbf)
28. W/ABS: CONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP
Connect the ABS speed sensor and wire harness clamp to the steering knuckle with the 2 bolts.
Torque: 8.0 N.m (82 kgf.cm, 71 in..lbf)
29. 4WD: INSTALL DRIVE SHAFT LOCK NUT
A. While applying the brakes, tighten the nut.
Torque: 235 N.m (2,400 kgf.cm, 173 ft.lbf)
B. Install the lock cap and a NEW cotter pin.
If the holes for the cotter pin are not aligned, tighten the nut further up to 60°.
30. 2WD: INSTALL GREASE CAP
31. INSTALL FRONT WHEEL
NOTE:
Do NOT use air wrench.
Torque: 110 N.m (1,150 kgf.cm, 83 ft.lbf)
32. DEPRESS BRAKE PEDAL SEVERAL TIMES
33. FILL THE BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM
34. CHECK ABS SPEED SENSOR SIGNAL (SEE REPAIR MANUAL)
Page 6293
12 - GROUND : Approx. 12 volts for 0.2 seconds with following operations
- Door lock control SW unlocked - Door lock control SW looked with ignition key in cylinder and LH
door open (Ignition key reminder function) - Door lock knob locked with ignition key in cylinder and
LH door open. (Ignition key reminder function) - Unlocking the LH, RH door cylinder with key
13 - GROUND : Approx. 12 volts for 0.2 seconds with following operations
- Door lock control SW locked - Locking the LH, RH door cylinder with key
14 - GROUND : Continuity with front LH door open (Standard cab)
14 - GROUND : Continuity with each LH door open (Access cab)
15 - GROUND : Continuity with front RH door open (Standard cab)
15 - GROUND : Continuity with each RH door open (Access cab)
D16, D17 DOOR COURTESY SW FRONT LH, RH
1 - GROUND : Closed with door open
D22, D23 DOOR KEY LOCK AND UNLOCK SW LH, RH
1 - 2 : Closed with door lock cylinder locked with key 3 - 2 : Closed with door lock cylinder unlocked
with key
D25, D26 DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW LH, RH
4 - 1 : Closed with door lock knob UNLOCK position
U1 UNLOCK WARNING SW
1 - 2 : Closed with key in cylinder
Page 2744
^ O2S TEST RESULTS
A list of the available oxygen sensors will be displayed.
2. Select the desired oxygen sensor and press Enter.
NOTE:
The monitor result of the A/F sensor will not be displayed. If you select "Bank 1-Sensor 1" or Bank
2-Sensor 1" for a vehicle equipped with an A/F sensor, the Diagnostic Tester will display "No
parameter to display."
3. Compare the test results with the values listed in the Failure Threshold Chart.
* Although this procedure references the Toyota Diagnostic Tester, the O2S test results can be
checked using a generic OBD II scantool. Refer to your OBD II scantool operator's manual for
specific procedures.
Comparing O2S Test Results to Failure Thresholds
1. Determine the correct O2S Failure Threshold Chart for your vehicle by looking in the "O2S
Application Table," in this bulletin.
2. Select appropriate year, model, and engine for specified O2S Failure Threshold Chart.
3. Compare O2S test results with the specified O2S Failure Threshold Chart. It may be necessary
to convert O2S test results to a specific measurement unit using the conversion factor that is
supplied in the specified table. See example.
Example:
Diagram Information and Instructions
Transmission Mode Indicator - A/T: Diagram Information and Instructions
Key to Diagrams
A: System Title
B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to
distinguish it from the J/B
Example: 1 Indicates Relay Block No.1
C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type,
or specification is different.
D: Indicates related system.
Page 5630
3. Move the SST to at least 10 m (33 ft) away from the front of the vehicle. 4. Close all the doors
and windows of the vehicle.
NOTE: Take care not to damage the SST wire harness.
5. Connect the SST red clip to the battery positive (+) terminal and the black clip to the negative (-)
terminal.
e. Activate the seat belt pretensioner.
1. Confirm that no one is inside the vehicle or within 10 m (33 ft) area around of the vehicle. 2.
Press the SST activation switch and activate the seat belt pretensioner.
HINT: The seat belt pretensioner operates simultaneously as the LED of the SST activation switch
lights up.
f. Dispose of front seat outer belt (with seat belt pretensioner).
CAUTION: The front seat outer belt is very hot when the seat belt pretensioner is activated, so leave it alone
for at least 30 minutes after activation.
- Use gloves and safety glasses when handling a front seat outer belt with activated seat belt
pretensioner.
- Always wash your hands with water after completing the operation.
- Do not apply water, etc. to a front seat outer belt with activated seat belt pretensioner.
HINT: When scrapping a vehicle, activate the seat belt pretensioner and scrap the vehicle with
activated front seat outer belt still installed.
2. ACTIVATION WHEN DISPOSING OF FRONT SEAT OUTER BELT ONLY
NOTE: When disposing of the front seat outer belt (with seat belt pretensioner) only, never use the
customer's vehicle to activate the seat belt pretensioner.
- Be sure to follow the procedure given when activating the seat belt pretensioner.
HINT: Have a battery ready as the power source when activating the seat belt pretensioner.
a. Remove the front seat outer belt.
HINT: Cut the belt near the seat belt retractor.
b. Check the functioning of SST. (See step 1-(a))
SST 09082-00700,09082-00740
Page 26
Instrument Panel
Connector Location
IA1 Engine Room Main and Cowl Wire (Left Kick Panel)
IA2 Engine Room Main and Cowl Wire (Left Kick Panel)
IA3 Engine Room Main and Cowl Wire (Left Kick Panel)
IA4 Engine Room Main and Cowl Wire (Left Kick Panel)
IB1 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IB2 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IB3 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IC1 Cowl Wire and Roof Wire (Left Side of Instrument Panel)
Instrument Panel
Connector Location
ID1 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH)
ID2 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH)
IE1 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IE2 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IE3 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IF1 Front Door RH Wire and Cowl Wire (Right Kick Panel)
IF2 Front Door RH Wire and Cowl Wire (Right Kick Panel)
IF3 Front Door RH Wire and Cowl Wire (Right Kick Panel)
Page 4751
Fuse Block: Diagnostic Aids
Voltage Check
Voltage Check
Voltage Check
A. Establish conditions in which voltage is present at the check point.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(SW 2 OFF)
B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or
component terminal. This check can be done with a test light instead of a voltmeter.
Continuity and Resistance Check
Continuity and Resistance Check
Continuity And Resistance Check
A. Disconnect the battery terminal or wire so there is no voltage between the check points. B.
Contact the two leads of an ohmmeter to each of the check points.
Page 6232
Terminals Of ECM - View/Pinouts
Page 5096
Seat Belts - Shoulder Belt Particle (Dirt) Buildup
Seat Belt: Customer Interest Seat Belts - Shoulder Belt Particle (Dirt) Buildup
BODY BO019-01
August 10, 2001
Title: SHOULDER BELT ANCHOR TAPE SET
Models: All Applicable Models
Introduction To assist customers in preventing particle buildup and preserve the appearance of the
shoulder belt anchor, the following procedure has been developed.
Applicable Vehicles ^
1996-2001 model year 4Runner*1 vehicles.
^ 1996-2001 model year Land Cruiser vehicles.
^ 1996-2001 model year RAV4*2 vehicles.
^ 2001 model year Sequoia vehicles.
^ 1996-1998 model year T100 trucks.
^ 1996-2001 model year Tacoma*1 trucks.
^ 2000-2001 model year Tundra trucks.
*1 Except rear seat belt. *2 Except rear seat belt of soft top models.
Parts Information
Warranty Information
Applicable Warranty*:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36
months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Installation Procedure
1. CLEAN SHOULDER BELT ANCHOR
NOTE:
^ Do not install the tape when the vehicle temperature is below the freezing point.
^ Do not re-use removed fluorocarbon resin tape.
Page 2209
Glossary Of Terms And Symbols (Part 2)
Page 2010
Oxygen Sensor: Description and Operation
Heated Oxygen Sensor
The ECM observes the waveform of the heated oxygen sensor located behind the catalyst to
determine whether the catalyst performance has deteriorated.
If the catalyst is functioning normally, the waveform of the heated oxygen sensor located behind
the catalyst switches back and forth between rich and lean much more slowly.
When the waveform of the heated oxygen sensor located behind the catalyst alternates flutteringly
between rich and lean, it indicates that catalyst performance has deteriorated.
Page 2134
Spark Plug: Specifications Torque Specification
Spark Plug x Cylinder Head ................................................................................................................
......................................................................... 18 Nm
Ground Locations
Seat Belt Reminder Lamp: Ground Locations
Engine Compartment
Ground Location
EA Front Left Fender
EB Rear Bank of Right Cylinder
EC Rear Bank of Left Cylinder
Connector Location
EA1 Cowl Wire Harness and Wire Harness (Connector Location)
EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B)
EC1 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC2 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC3 Engine No. 2 Wire and Engine Wire (Near the Starter)
ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission)
Page 2045
Vehicle Speed Sensor: Testing and Inspection
INSPECT VEHICLE SPEED SENSOR OPERATION
a. Connect the positive (+) lead from the battery to terminal 1 and negative (-) lead to terminal 2. b.
Connect the positive (+) lead from the tester to terminal 3 and the negative (-) lead to terminal 2. c.
Rotate the shaft. d. Check that there is voltage change from approx. 0 V to 11 V or more between
terminals 2 and 3.
HINT: The voltage change should be performed 4 times for every revolution of the speed sensor
shaft.
If operation is not as specified, replace the sensor.
Page 1987
CHART 16
CHART 17
Page 5180
ERROR: stackunderflow
OFFENDING COMMAND: ~
STACK:
Specifications
Idle Speed: Specifications
Idle Speed 700 +/- 50 rpm
Page 2522
During ECU flash reprogramming, the Error screen shown may be displayed on the Diagnostic
Tester for one of the following reasons:
1. Immobilizer key not properly registered or auto-registration mode left open.
2. Ignition ON/OFF cycling not followed correctly during the flash reprogramming procedure.
3. The Diagnostic Tester cable is damaged, causing an open communication circuit.
NOTE:
The Diagnostic Tester may operate properly in other modes such as OBD, OBDII, or CARB, with a
damaged cable.
To eliminate the possibility of the first 2 reasons causing the error message, do the following:
1. Confirm the Immobilizer Transponder Master Key is properly registered and auto registration
mode is closed. Follow the appropriate Repair Manual procedure and consult TSB SS001-99,
"Scan tool Immobilizer key Code Utility
2. Conduct the ECU flash reprogramming process explicitly following key operation instructions.
Refer to TSB SS002-01, "ECU Flash Reprogramming Process, "for more details.
To determine if the Diagnostic Tester cable is damaged, follow the test procedures below to check
the electrical integrity of the cable. Conduct all continuity tests with an Ohm meter. For all five test
procedures, the resistance values must be below 6.0 ohms to pass.
Test CABLE TEST 1.
Page 845
Page 4064
^ 09023-00100
6. REMOVE BRAKE CALIPER AND DISC
A. Remove the bolt and brake line clamp from the steering knuckle.
B. Remove the 2 bolts, brake caliper and disc.
7. REMOVE SHOCK ABSORBER
A. Disconnect Shock Absorber from lower suspension arm.
B. Remove the shock absorber lower side set nut and washer.
NOTE:
Do not remove the bolt.
C. Wrap the bolt's head with vinyl tape to prevent the drive shaft boot from being damaged.
D. Pry down the lower suspension arm to remove the bolt and disconnect the shock absorber.
E. Remove the 3 nuts and shock absorber with the coil spring.
NOTE:
Do not damage the brake tube.
Page 2241
^ 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 6803
Horn: Harness Locations
Engine Compartment
Connector Location
EA1 Cowl Wire Harness and Wire Harness (Connector Location)
EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B)
EC1 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC2 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC3 Engine No. 2 Wire and Engine Wire (Near the Starter)
ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission)
Page 6230
Wiring Diagram
Page 4337
Using the following SSTs and a press, install the bearing spacer.
^ 09950-60010 (09951-00650)
^ 09950-70010 (09951-07150)
22. 4WD: INSTALL NEW OIL SEAL (INSIDE)
A. Using the following SST and a plastic hammer, install a NEW oil seal (inside).
^ 09527-17011
NOTE:
Lightly strike the SST on its circumference evenly.
B. Coat MP grease to the oil seal lip.
23. INSTALL STEERING KNUCKLE
A. 4WD: Insert the drive shaft into the axle hub and temporarily tighten the nut.
NOTE:
Be careful not to damage the oil seal and drive shaft boot.
B. Connect the steering knuckle to the upper suspension arm.
C. Install the nut and a NEW cotter pin. If the holes for the cotter pin are not aligned, tighten the nut
further up to 60°.
Torque: 105 N.m (1,100 kgf.cm, 77 ft.lbf)
24. CONNECT LOWER BALL JOINT
Connect the lower ball joint to the steering knuckle with 4 bolts.
Torque: 50 N.m (510 kgf.cm, 37 ft.lbf)
25. INSTALL SHOCK ABSORBER WITH COIL SPRING
A. Install the upper side of shock absorber to the chassis frame with the 3 nuts.
Page 4861
Steering - Lubricant
Page 6353
Continuity And Resistance Check
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Continuity And Resistance Check
C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the
electrical circuit.
Finding A Short Circuit
Finding A Short Circuit
Finding A Short Circuit
A. Remove the blown fuse and disconnect all loads of the fuse.
Page 2620
B. Continue to update the ECU calibration file following the screen flow (Figure 18). Details for
selected screens are shown in Figure 19.
NOTE:
^ Each flash calibration update will take approximately 15 to 45 minutes.
^ Screens E through J (Figure 18) will need to be repeated for each flash calibration update
(calibration ID number).
^ All updates must display "YES" to complete the entire calibration file update for the vehicle ECU.
^ Failure to complete all updates may result in PERMANENT ECU DAMAGE!
CONFIRM UPDATE
4. Confirm successful flash calibration update and affix calibration update sticker.
Follow these steps to confirm the calibration was reprogrammed to the ECU.
A/C - Insufficient Cabin Cooling
Heater Control Valve: All Technical Service Bulletins A/C - Insufficient Cabin Cooling
HEATING & AIR CONDITIONING AC004-04
May 20, 2004
Title: POOR PERFORMANCE OF A/C SYSTEM
Models: '01 - '04 Sequoia & '00 - '04 Tundra
May 20, 2004
Introduction Some Sequoia and Tundra vehicles may exhibit a condition where the air conditioning
system does not sufficiently cool the cabin. Adjustment of the water control valve is necessary to
correct the condition.
Applicable ^
2001 - 2004 model year Sequoia vehicles produced BEFORE the Production Vehicles Change
Effective VINs shown below.
^ 2000 - 2004 model year Tundra vehicles produced BEFORE the Production Change Effective
VINs shown below.
Production Change Information
Warranty Information
Applicable Warranty*:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36
months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Repair Procedure
Page 3875
STANDARD VALUE OF ECU TERMINAL
Page 6270
Waterproof Type Connector
B: For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White
: Gray
Black or White : Dark Gray
Gray or White : Black
Waterproof Type Connector
"Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up
to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Waterproof Type Connector
"Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Brakes - Vibration From Front Brakes
Technical Service Bulletin # BR004R-02 Date: 040924
Brakes - Vibration From Front Brakes
BRAKES BR004-02 REVISED
Title: FRONT BRAKE VIBRATION
Models: '00 - '03 Tundra
September 16, 2002
TSB REVISION NOTICE:
^ September 24, 2004: A note has been added, step 26.
^ March 5, 2004: A torque speification, step 24, was changed.
^ September 8, 2003: A torque specification, step 28, was changed.
Previous versions of this TSB should be discarded.
Introduction
Under certain usage conditions, some Tundra trucks may exhibit front brake vibration. Improved
brake caliper assemblies have been introduced to correct this condition.
Applicable Vehicles
2000 - 2003 model year Tundra trucks built before the VIN shown below.
Production Change Information
Warranty Information
Applicable Warranty*:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36
months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Page 5603
The ground points circuit diagram shows the connections from all major parts to the respective
ground points. When troubleshooting a faulty ground point, checking the system circuits which use
a common ground may help you identify the problem ground quickly. The relationship between
ground points (EA, IB and IC) can also be checked this way.
How to Read Power Source
HOW TO READ POWER SOURCE
Testing and Inspection
Door Switch: Testing and Inspection
INSPECT DOOR COURTESY SWITCH CONTINUITY
a. Check that continuity exists between terminals and the switch body with the switch ON (switch
pin released: opened door). b. Check that no continuity exists between terminals and the switch
body with the switch OFF (switch pin pushed in: closed door).
If operation is not as specified, replace the switch.
Page 71
b. Push the secondary locking device or terminal retainer in to the full lock position.
5. CONNECT CONNECTOR
Disconnection of Male and Female Connectors
Disconnection of Male and Female Connectors
Disconnection Of Male And Female Connectors
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Page 2842
Oxygen Sensor: Description and Operation
Heated Oxygen Sensor
The ECM observes the waveform of the heated oxygen sensor located behind the catalyst to
determine whether the catalyst performance has deteriorated.
If the catalyst is functioning normally, the waveform of the heated oxygen sensor located behind
the catalyst switches back and forth between rich and lean much more slowly.
When the waveform of the heated oxygen sensor located behind the catalyst alternates flutteringly
between rich and lean, it indicates that catalyst performance has deteriorated.
Specifications
Crankshaft Main Bearing: Specifications
Main Bearing Cap Bolt Standard Diameter .........................................................................................
........................................................................................ 10.760 - 10.970 mm Minimum Diameter ....
..............................................................................................................................................................
.............................. 10.40 mm
Tightening Torque Step 1 ....................................................................................................................
...................................................................................................... 27 Nm Step 2 ................................
..............................................................................................................................................................
... Additional 90 degrees
Page 1093
Driver Side J/B And Integration Relay
Page 551
CHART 5
CHART 6
Page 6178
b. Using a torx socket wrench (T40), remove the 4 screws and 2 tailgate hinges from the tailgate.
INSTALLATION
1. INSTALL TAILGATE
a. Using a torx socket wrench, install the tailgate hinges with the 4 torx screws to the tailgate.
Torque: 17 N.m (178 kgf.cm, 13 ft.lbf)
b. Install the tailgate with the 2 bolts to the body.
Torque: 17 N.m (178 kgf.cm, 13 ft.lbf)
NOTE: Be careful not to drop the tailgate.
2. INSTALL TAILGATE CABLE
a. Install the tailgate cable and gate side shaft to the tailgate.
Torque: 26 N.m (270 kgf.cm, 20 ft.lbf)
b. Install the tailgate cable and deck side shaft to the body.
Torque: 26 N.m (270 kgf.cm, 20 ft.lbf)
c. Employ the same manner described above to the other side.
3. INSTALL TAILGATE LOCK STRIKER
Using a torx socket wrench, install the 2 tailgate lock strikers with the 4 torx screws.
Page 3158
Steps 2 - 3
INSPECTION PROCEDURE
HINT:
- DTC P0325 is for the left bank knock sensor circuit.
- DTC P0330 is for the right bank knock sensor circuit.
- Read freeze frame data using TOYOTA hand-held tester or OBD II scan tool, as freeze frame
data records the engine conditions when a malfunction is detected. When troubleshooting it is
useful for determining whether the vehicle was running or stopped, the engine was warmed up or
not, the air-fuel ratio was lean or rich, etc. at the time of the malfunction.
Specifications
Thermostat: Specifications
Valve Opening Temperature 80 - 84 deg C
Valve Lift 10 mm at 95 deg C
or More
Page 6012
Wireless Transmitter Identification
Page 3603
Total No. Of Coils 10.83
1-2 Shift Valve Purple Free Length 30.77 mm
Coil Outer Diameter 9.7 mm
Total No. Of Coils 8.5
Check Valve Free Length 20.45 mm
Coil Outer Diameter 6.6 mm
Total No. Of Coils 8.73
Valve Body Key Upper Valve Body Lock-Up Valve Height 14.00 mm
Width 5.00 mm
Thickness 3.2 mm
Secondary Regulator Valve Height 10.0 mm
Width 5.00 mm
Thickness 3.2 mm
3-4 Shift Valve Height 16.5 mm
Width 6.00 mm
Thickness 3.2 mm
2-3 Shift Valve Height 14.00 mm
Width 5.00 mm
Thickness 3.2 mm
2nd Coast Modulator Valve Height 16.5 mm
Width 6.00 mm
Thickness 3.2 mm
Low Coast Modulator Valve Height 25.0 mm
Width 4.0 mm
Lower Valve Body Primary Regulator Valve Height 14.5 mm
Thickness 3.2 mm
Cut Back Valve Height 6.0 mm
Width 6.0 mm
Thickness 3.2 mm
Solenoid Modulator Valve Height 25.0 mm
Width 4.0 mm
Accumulator Control Valve Height 12.5 mm
Page 2636
Continuity And Resistance Check
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Continuity And Resistance Check
C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the
electrical circuit.
Finding A Short Circuit
Finding A Short Circuit
Finding A Short Circuit
A. Remove the blown fuse and disconnect all loads of the fuse.
Page 4721
Non-Waterproof Type Connector
"Case 1" Raise the terminal retainer up to the temporary lock position.
Non-Waterproof Type Connector
"Case 2" Open the secondary locking device.
Page 4735
Driver Side J/B And Integration Relay Fuse Applications (Part 2)
Driver Side J/B And Integration Relay Fuse Applications (Part 3)
Testing and Inspection
Igniter: Testing and Inspection
ON-VEHICLE INSPECTION
NOTE: "Cold" and "Hot" in these sentences express the temperature of the coils themselves.
"Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F).
INSPECT IGNITION COIL (WITH IGNITER) AND SPARK TEST
Check that the spark occurs.
1. Remove the ignition coils (with igniter). 2. Remove the spark plugs. 3. Install the spark plugs to
each ignition coil (with igniter), and connect the ignition coil (with igniter) connector. 4. Disconnect
the 8 injector connectors. 5. Ground the spark plug. 6. Check that spark occurs while engine is
being cranked.
NOTE: To prevent gasoline from being injected out of injectors during this test, crank the engine for
no more than 5 - 10 seconds at a time.
If the spark does not occur, do the test as per the given flow chart.
7. Using a 16 mm plug wrench, install the spark plugs.
Torque: 17.5 N.m (180 kgf.cm, 13 ft.lbf)
8. Reinstall the ignition coils (with igniter).
Page 3632
Maximum clearance: 0.35 mm (0.0138 inch) If the clearance exceeds the maximum, replace the
fork or sleeve.
Brakes - Vibration From Rear
Brake Drum: Customer Interest Brakes - Vibration From Rear
BRAKES BR001-01
January 12, 2001
Title: REAR BRAKE VIBRATION
Models: '00 - '01 Tundra
TSB Update Notice:
The information contained in this TSB updates BR006-00, dated November 17, 2000.
Revised text is underlined.
New parking brake struts (star wheel adjusters) have been developed to reduce the possibility of
rear brake vibration on 2000 and 2001 model year Tundra vehicles. The number of teeth on the
star wheel adjuster has been reduced from 30 to 26 teeth.
Applicable Vehicles ^
2000 - 2001 model year Tundra vehicles.
Production Change Information
Parts Information
Repair Procedure
1. Grind rear brake drums with brake lathe to within serviceable limits.
2. If the drums are unserviceable or above maximum inside diameter, replace the drums.
3. If there is uneven wear on the lining, replace the left and right brake shoes.
4. Replace the parking brake shoe strut sets.
5. Adjust the parking brake to specifications.
6. Reinstall the rear wheels, and torque wheel nuts to:
Torque: 113 Nm (1,150 kgf cm, 83 ft.lbf)
7. Road test.
Warranty Information
Page 2762
CHART 18
CHART 19
Page 3660
8. REMOVE DRIVE SHAFT
a. Right-Hand drive shaft:
Using a brass bar and hammer, remove the Right-Hand drive shaft.
NOTICE: Be careful not to damage the dust cover and oil seal.
b. Left-Hand drive shaft:
Using SST, remove the Left-Hand drive shaft. SST 09520-01010, 09520-24010 (09520-32040)
NOTICE: Be careful not to damage the dust cover and oil seal.
c. Using a screwdriver, remove the snap ring from the inboard joint shaft.
INSTALLATION
1. INSTALL DRIVE SHAFT TO DIFFERENTIAL
a. Install a new snap ring to the inboard joint shaft. b. Coat the gear oil to the inboard joint shaft and
differential case sliding surface. c. Set the snap ring with opening side facing downward. d. Using a
brass bar and hammer, install the drive shaft.
NOTICE: Be careful not to damage the dust cover and oil seal.
HINT: Whether the inboard joint shaft is in contact with the pinion shaft or not can be known from
the sound or feeling when driving it in.
e. Check that there is 2 - 3 mm (0.08 - 0.12 inch) of play in the axial direction. f.
Check that the drive shaft cannot be removed by hand.
2. Left-Hand drive shaft: INSTALL LEFT-HAND SHOCK ABSORBER 3. CONNECT DRIVE SHAFT
TO STEERING KNUCKLE
NOTICE: Be careful not to damage the oil seal, boots and dust seal.
4. CONNECT LOWER SUSPENSION ARM TO LOWER BALL JOINT
a. Connect the lower suspension arm to the lower ball joint. b. Install the nut and a new cotter pin.
If the holes for the cotter pin are not aligned, tighten the nut further up to 60°.
HINT: Face the hole for the cotter pin forward.
Torque: 140 Nm (1,450 kgf-cm, 103 ft. lbs.)
5. INSTALL DRIVE SHAFT LOCK NUT
a. While applying brakes, install the nut.
Torque: 235 Nm (2,400 kgf-cm, 173 ft. lbs.)
b. Install the lock cap and a new cotter pin.
If the holes for the cotter pin are not aligned, tighten the nut further up to 60°.
Page 1531
Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
INSPECTION
1. DRAIN ENGINE COOLANT
2. REMOVE THROTTLE BODY COVER
3. REMOVE INTAKE AIR CONNECTOR
4. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS
a. Disconnect the accelerator cable from the throttle body. b. Remove the 2 bolts and 2 nuts, and
disconnect the throttle body from the intake manifold. c. Remove the gasket
5. REMOVE ECT SENSOR
a. Disconnect the ECT sensor connector. b. Remove the ECT sensor and gasket.
6. INSPECT ECT SENSOR
Using an ohmmeter, measure the resistance between the terminals.
Resistance: Refer to the graph
If the resistance is not as specified, replace the ECT sensor.
7. REINSTALL ECT SENSOR
a. Install a new gasket and the ECT sensor.
Page 2031
B: Junction Connector
Indicates a connector which is connected to a short terminal.
Junction connector in this include a short terminal which is connected to a number of wire
harnesses. Always perform inspection with the short terminal installed. (When installing the wire
harnesses, the harnesses can be connected to any position within the short terminal grouping.
Accordingly, in other vehicles, the same position in the short terminal may be connected to wire
harness from a different part.) Wire harness sharing the same short terminal grouping ha the same
color.
C: Parts Code
The first letter of the code is taken from the first letter of part, and the numbers indicates its order in
parts which start with the same letter.
D: Connector Color
Connectors not indicated are milky white in color.
How to Read Ground Points
HOW TO READ GROUND POINTS
Testing and Inspection
Overdrive Switch: Testing and Inspection
O/D Main Switch & O/D OFF Indicator Light Circuit
CIRCUIT DESCRIPTION
The O/D main switch contacts go open when the switch is pushed in and go closed when it is
pushed out.
If O/D main switch is at OFF position, the O/D OFF indicator light lights up, and the ECM prohibits
shifting O/D.
Wiring Diagram
INSPECTION PROCEDURE
Page 4581
Maximum wear: 0.9 mm (0.035 in.)
If the depth of wear is greater than the maximum, replace the contact plate.
c. Remove terminal kit parts.
1. Using SST, loosen the terminal nuts.
SST 09810-38140
2. Terminal C
Remove the terminal nut, wave washer, terminal insulator (outside), O-ring, terminal bolt, contact
plate and terminal insulator (inside).
3. Terminal 30
Remove the terminal nut, wave washer, terminal insulator (outside), O-ring, terminal bolt, contact
plate, terminal insulator (inside) and insulation paper.
d. Install new terminal 30 kit parts.
1. Temporarily install a new terminal insulator (inside). 2. Temporarily install a new contact plate. 3.
Temporarily install a new terminal bolt. 4. Temporarily install a new O-ring. 5. Temporarily install a
new packing and new terminal insulator (outside).
Install a new packing to a new terminal insulator, and install them.
HINT: Match the protrusion of the insulator with the indentation of the housing.
6. Temporarily install a new wave washer. 7. Temporarily install a new terminal nut.
NOTE: Be careful to install the terminal insulator (inside) and wave washer in the correct direction.
Page 959
2. Tighten the union bolt by hand.
3. Using SST, tighten the union bolt to the specified torque.
SST 09612-24014 (09617-24011)
Torque: 33 N.m (340 kgf.cm, 24 ft.lbf) for use with SST 39 N.m (400 kgf.cm, 29 ft.lbf)
HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
c. When connecting the flare nut on the high pressure pipe union, observe these procedures:
1. Apply a light coat of engine oil to the flare nut, and tighten the flare nut by hand. 2. Using SST,
tighten the flare nut to the specified torque.
SST 09023-38400
NOTE: Do not rotate the fuel filter outlet, when tightening the flare nut.
Torque: 28 N.m (285 kgf.cm, 21 ft.lbf) for use with SST 34.3 N.m (350 kgf.cm, 25 ft.lbf)
HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
d. Observe these precautions when removing and installing the injectors.
1. Never reuse the O-ring. 2. When placing a new O-ring on the injector, take care not to damage it
in any way. 3. Coat a new O-ring with spindle oil or gasoline before installing-never use engine,
gear or brake oil.
Page 3755
Glossary Of Terms And Symbols (Part 2)
Page 1085
Continuity And Resistance Check
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Continuity And Resistance Check
C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the
electrical circuit.
Finding A Short Circuit
Finding A Short Circuit
Finding A Short Circuit
A. Remove the blown fuse and disconnect all loads of the fuse.
Page 4988
SST.
b. Install the SST.
CAUTION: Check that there is no looseness in the steering wheel and steering wheel pad.
1. Remove the steering column lower cover. Remove the 3 screws and steering column lower
cover as shown in the illustration. 2. Disconnect the airbag connector of the spiral cable.
3. Connect the SST connector to the airbag connector of the spiral cable.
SST 09082-00700
4. Move the SST at least 10 m (33 ft) away from the front of the vehicle. 5. Close all the doors and
windows of the vehicle.
NOTE: Take care not to damage the SST wire harness.
6. Connect the SST red clip to the battery positive (+) terminal and the black clip to the negative (-)
terminal.
Page 2954
Fuel Pressure: Testing and Inspection
CHECK FUEL PRESSURE
a. Check the battery positive voltage is above 12 V. b. Disconnect the negative (-) terminal cable
from the battery. c. Remove the front fuel pipe from the LH delivery pipe.
d. Install the front fuel pipe and SST (pressure gauge) to the delivery pipe with 3 lower gaskets and
SST (adapter).
SST 09268-45014 (09268-1190, 90405-06167)
Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)
e. Wipe off any splattered gasoline. f.
Reconnect the negative (-) terminal cable to the battery.
g. Connect a TOYOTA hand-held tester to the DLC3. (See step 1 in check fuel pump operation (a)
to (e)) h. Measure the fuel pressure.
Fuel pressure: 265 - 304 kPa (2.7 - 3.1 kgf/sq.cm, 38 - 44 psi)
If pressure is high, replace the fuel pressure regulator. If pressure is low, check the fuel hoses and
connections, fuel pump, fuel filter and fuel pressure regulator.
i. Disconnect the TOYOTA hand-held tester from the DLC3.
j. Start the engine.
k. Measure the fuel pressure at idle.
Fuel pressure: 265 - 304 kPa (2.7 - 3.1 kgf/sq.cm, 38 - 44 psi)
l. Stop the engine.
m. Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped.
Fuel pressure: 147 kPa (1.5 kgf/sq.cm, 21 psi) or more
If pressure is not as specified, check the fuel pump, pressure regulator and/or injectors.
n. After checking fuel pressure, disconnect the negative (-) terminal cable from the battery and
carefully remove the SST to prevent gasoline from
splashing. SST 09268-45014
o. Reinstall the front fuel pipe to the LH delivery pipe. p. Reconnect the negative (-) terminal cable
to the battery. q. Check for fuel leaks.
Page 6320
Cigarette Lighter: Diagnostic Aids
Voltage Check
Voltage Check
Voltage Check
A. Establish conditions in which voltage is present at the check point.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(SW 2 OFF)
B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or
component terminal. This check can be done with a test light instead of a voltmeter.
Continuity and Resistance Check
Continuity and Resistance Check
Continuity And Resistance Check
A. Disconnect the battery terminal or wire so there is no voltage between the check points. B.
Contact the two leads of an ohmmeter to each of the check points.
Page 4572
Starter (Part 2)
Instruments - Oil Pressure Gauge Reads Abnormally Low
Oil Pressure Sender: Customer Interest Instruments - Oil Pressure Gauge Reads Abnormally Low
ELECTRICAL EL017-03
December 23, 2503
Title OIL PRESSURE GAUGE READS LOW
Models '01 - '04 Sequoia & '00 - '02 Tundra
TSB UPDATE NOTICE:
This TSB updates EL006-03. TSB EL006-03 is now obsolete and should be discarded.
Introduction
Some customers with Sequoia or Tundra vehicles may encounter an oil pressure gauge that reads
abnormally low at idle. An updated oil pressure sender has been created to address this condition.
Applicable Vehicles ^
2001 - 2004 model year Sequoia vehicles produced BEFORE the Production Change Effective
VINs shown below.
^ 2000 - 2002 model year Tundra vehicles produced BEFORE the Production Change Effective
VIN shown below.
Production Change Information
Parts Information
Repair Procedure
1. Replace the Oil Pressure Sender.
2. Verify proper operation of the Oil Pressure Gauge.
Warranty Information
Applicable Warranty*:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36
months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Page 140
A. Connect Diagnostic Tester cables DLC (P/N 02001637) and CAN Interface Module / J1962
OBDII together (P/N 01002744).
B. Test for continuity.
^ If there is continuity, the cable is OK. Check steps 1 and 2 above to complete the flash
reprogramming process.
^ If there is no continuity, proceed to CABLE TEST 2.
CABLE TEST 2.
A. Disconnect Diagnostic Tester cables DLC (P/N 02001637) and CAN Interface Module /J1962
OBDII (P/N 01002744).
B. Test DLC cable (P/N 02001637) for continuity.
^ If there is continuity, the cable is OK. Proceed to CABLE TEST 3.
^ If there is no continuity, the cable needs to be replaced.
CABLE TEST 3.
Page 1995
Page 2703
Knock Sensor: Description and Operation
P0325 - Knock Sensor 1 Circuit Malfunction (Bank 1) CIRCUIT DESCRIPTION
DTC Detection Condition
One of the knock sensors is fitted to the right bank and another to the left bank of the cylinder block
to detect the engine knocking. This sensor contains a piezoelectric element which generates
voltage when it becomes deformed. This occurs when the cylinder block vibrates due to knocking.
If the engine knocking occurs, ignition timing is retarded to suppress it.
Wiring Diagram
Page 5698
Page 600
A/F and 02 Sensor Identification
Locations
Page 572
Page 482
Coolant Temperature Sensor/Switch (For Computer): Mechanical Specifications
New gasket and the ECT sensor. Torque: ..........................................................................................
.................................................................................... 20.4 N.m (208 kgf.cm, 15 ft.lbf)
New gasket and the throttle body with the 2 bolts and 2 nuts. Torque: ...............................................
.................................................................................................................................. 18 N.m (185
kgf.cm, 13 ft.lbf)
Page 3082
Mass Air Flow Meter: Service and Repair
MASS AIR FLOW (MAF) METER
1. DISCONNECT MAF METER CONNECTOR
2. REMOVE MAF METER
Remove the 2 screws and MAF meter.
3. REINSTALL MAF METER
Install the MAF meter with the 2 screws.
4. RECONNECT MAF METER CONNECTOR
Page 2215
Terminal Retainer
Push the terminal retainer down to the temporary lock position.
c. Release the locking lug from terminal and pull the terminal out from rear.
4. INSTALL TERMINAL TO CONNECTOR
a. Insert the terminal.
HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug
locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position.
Page 1228
Exhaust: N = T + (A - 0.30 mm (0.012 inch))
3. Select a new shim with thickness as close as possible to the calculated value.
HINT: Shims are available in 41 increments of 0.020 mm (0.0008 inch), from 2.00 mm (0.0787
inch) to 2.80 mm (0.1102 inch).
e. Place a new adjusting shim on the valve. f.
Place the valve lifter.
Page 6615
d. Disconnect the negative (-) lead from the body ground to terminal 1 or 10. e. Check that the
buzzer stops sounding.
If operation is not as specified, replace the combination meter.
4. INSPECT COMBINATION METER CIRCUIT
Page 1753
Refer to Reset Procedure 2 for the vehicles with Electronically Controlled Automatic
Transmissions:
Reset Procedure 1
1. Connect the Toyota Diagnostic Tester to the vehicle.
2. Reset the ECM (PCM). Refer to the procedures below.
Page 4966
15. INSTALL RACK GUIDE SPRING CAP LOCK NUT
a. Apply sealant to 2 or 3 threads of the lock nut.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
b. Temporarily install the lock nut. c. Using a hexagon wrench to hold the rack guide spring cap,
and using SST, torque the lock nut.
SST 09922-10010 Torque: 51 Nm (520 kgf-cm, 38 ft. lbs.)
NOTICE: Use SST 09922-10010 in the direction shown in the illustration.
HINT: Use a torque wrench with a fulcrum length of 345 mm (13.58 inch).
d. Recheck the total preload.
Preload (turning): 1.0 - 1.45 Nm (10 - 14.5 kgf-cm, 8.7 - 12.6 inch lbs.)
e. Remove the Right-Hand and Left-Hand rack ends.
16. INSTALL RIGHT-HAND AND LEFT-HAND CLAW WASHERS AND RACK ENDS
a. Install a new claw washer, and temporarily install the rack end.
HINT: Align the claws of the claw washer with the steering rack grooves.
b. Using a spanner to hold the steering rack steady, and using SST, torque the rack end.
SST 09922-10010 Torque: 76 Nm (770 kgf-cm, 56 ft. lbs.)
NOTICE: Use SST 09922-10010 in the direction shown in the illustration.
HINT: Use a torque wrench with a fulcrum length of 345 mm (13.58 inch).
Page 4283
(b) In this position. check the rear brake pressure
If the measured value is not within the standard, replace the valve body.
Page 4730
Engine Room R/B
Details
Page 97
Waterproof Type Connector
B: For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White
: Gray
Black or White : Dark Gray
Gray or White : Black
Waterproof Type Connector
"Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up
to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Waterproof Type Connector
"Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 3895
Transmission Mode Indicator - A/T: Harness Locations
Engine Compartment
Connector Location
EA1 Cowl Wire Harness and Wire Harness (Connector Location)
EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B)
EC1 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC2 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC3 Engine No. 2 Wire and Engine Wire (Near the Starter)
ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission)
Page 5875
Wheel Opening Moulding
Page 3842
a. Ignition switch ON. b. Shift the transmission shift lever in N position. c. Turn the touch select 2-4
switch ON. d. Check that the 4LO indicator lights come on and the 4HI indicator lights go off when
the touch select high-low switch is in ON position. e. Check that the 4LO indicator lights go off and
the 4HI indicator lights come on when the touch select high-low switch is in OFF position.
HINT: Inspection should be performed with the vehicle stopped, and transmission shift lever in N position.
- If switching is not completed after 3 seconds of shift operation, the 4LO indicator light will flash.
3. INSPECT TOUCH SELECT 2 - 4 AND HIGH-LOW SWITCH CONTINUITY
a. Remove center integration panel assembly. b. Inspect the continuity between the each terminals.
Touch select 2-4 switch
Touch select high-low switch:
If continuity is not as specified, replace the center integration panel assembly.
4. INSPECT ACTUATOR RESISTANCE
a. Using an ohmmeter, measure the resistance between terminals 1 and 2.
Standard resistance: 0.3 - 100 Ohms
b. Using an ohmmeter, measure the resistance between terminals 1 or 2 and body ground.
Standard resistance: More than 0.5 M Ohms If resistance value is not as specified, replace the
actuator assembly.
Page 4959
NOTICE: Make sure to install the oil seal facing in the correct direction.
d. Coat a new bearing with molybdenum disulfide lithium base grease.
e. Using SST, press in the bearing.
SST 09950-60010 (09951-00340), 09950-70010 (09951-07150)
2. IF NECESSARY, REPLACE 2 BEARINGS
a. Using SST, press out the bearing.
SST 09950-60010 (09951-00260), 09950-70010 (09951-07150)
b. Using SST, press out the bearing from the rack housing.
SST 09950-60010 (09951-00260), 09950-70010 (09951-07200)
c. Coat a new bearing with molybdenum disulfide lithium base grease.
d. Using SST, press in the bearing.
SST 09950-60010 (09951-00310), 09950-70010 (09951-07150)
e. Coat a new bearing with molybdenum disulfide lithium base grease.
Page 6426
Continuity And Resistance Check
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Continuity And Resistance Check
C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the
electrical circuit.
Finding A Short Circuit
Finding A Short Circuit
Finding A Short Circuit
A. Remove the blown fuse and disconnect all loads of the fuse.
Page 5969
Page 5582
Seat Belt Reminder Buzzer: Description and Operation
KEY REMINDER AND SEAT BELT WARNING
SYSTEM OUTLINE
Current always flows to TERMINAL (B) 5 of the combination meter through the DOME fuse.
1. SEAT BELT WARNING SYSTEM
When the ignition SW is turned on, current flows from the GAUGE fuse to TERMINAL (A) 7 of the
combination meter. This current activates the combination meter and the current flowing through
the seat belt warning light flows from TERMINAL (A) 12 to GROUND, causing the warning light to
light up. A buckle SW off signal is input to TERMINAL (B) 9 of the combination meter to TERMINAL
(A) 12 to GROUND, causing the warning light to light up. A buckle SW off signal is input to
TERMINAL (B) 9 of the combination meter, the current flowing to TERMINAL (B) 5 of the
combination meter flows from TERMINAL (A) 12 to GROUND and the seat belt warning buzzer
sounds. However, if the seat belt is put on during this period (While the buzzer is sounding), signal
input to TERMINAL (B) 9 of the combination meter stops and the current flow from TERMINAL (B)
5 of the combination meter to TERMINAL (A) 12 to GROUND is cut, causing the buzzer to stop.
2. KEY REMINDER SYSTEM
With the ignition key inserted in the key cylinder (Unlock warning SW on), the ignition SW still off
and driver's door open (Door courtesy SW on), when a signal is input to TERMINAL (B) 10 of the
combination meter, the combination meter operates, current flows from TERMINAL (B) 5 of the
combination meter to TERMINAL (A) 12 to GROUND and key reminder buzzer sounds.
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 1920
CHART 12
CHART 13
Page 1038
Refrigerant: Fluid Type Specifications
Type R-134a
Page 2879
Install the No.1 vehicle speed sensor with the bolt.
Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.)
6. CONNECT NO. I VEHICLE SPEED SENSOR CONNECTOR
Vehicle Speed Sensor NO.2
Vehicle speed Sensor NO.2 on-vehicle repair
1. DISCONNECT NO. 2 VEHICLE SPEED SENSOR CONNECTOR
2. REMOVE NO. 2 VEHICLE SPEED SENSOR
a. Remove the bolt and No. 2 vehicle speed sensor. b. Remove the O-ring from the No. 2 vehicle
speed sensor.
3. INSTALL NO. 2 VEHICLE SPEED SENSOR
a. Coat a new O-ring with ATF and install it to the No. 2 vehicle speed sensor. b. Install the No. 2
vehicle speed sensor with the bolt.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
4. CONNECT NO. 2 VEHICLE SPEED SENSOR CONNECTOR
Description and Operation
Transmission Position Switch/Sensor: Description and Operation
PARK / NEUTRAL POSITION SWITCH
Engine Control System
The park/neutral position switch comes on when the shift lever is in the N or P position. When it
comes on, terminal NSW of the ECM is grounded to the body ground via the starter relay, thus the
terminal NSW voltage becomes 0 V. When the shift lever is in the D, 2, L or R position, the
park/neutral position switch goes off, so the voltage of the terminal NSW becomes battery voltage
and the voltage of the ECM internal power source. If the shift lever is moved from the N position to
the D position, this signal is used for air-fuel ratio correction and for idle speed control (estimated
control), etc.
Transmission Control System
The park/neutral position switch detects the shift lever position and sends signals to the ECM.
The ECM receives signals (NSW, R, D, 2 and L) from the park/neutral position switch.
Page 4123
Torque: 15 N.m (155 kgf.cm, 11 ft.lbf)
28. W/ABS:
CONNECTABS SPEED SENSOR AND WIRE HARNESS CLAMP
Connect the ABS speed sensor and wire harness clamp to the steering knuckle with the 2 bolts.
Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
29. 4WD:
INSTALL DRIVE SHAFT LOCK NUT
A. While applying the brakes, tighten the nut.
Torque: 235 N.m (2,400 kgf.cm, 173 ft.lbf)
B. Install the lock cap and a NEW cotter pin.
If the holes for the cotter pin are not aligned, tighten the nut further up to 600.
30. 2WD:
INSTALL GREASE CAP
31. INSTALL FRONT WHEEL
NOTE:
Do NOT use air wrench.
Torque: 110 N.m (1,150 kgf.cm, 83 ft.lbf)
32. DEPRESS BRAKE PEDAL SEVERAL TIMES
33. FILL THE BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM
34. CHECK ABS SPEED SENSOR SIGNAL (SEE REPAIR MANUAL)
Page 5959
FOR
SPECIAL SERVICE CAMPAIGN
REAR FRAME CROSS MEMBER &
LOAD SENSING PROPORTIONING & BY-PASS VALVE INSPECTION
2000-2003 MODEL YEAR TUNDRA
Page 6672
B: Junction Connector
Indicates a connector which is connected to a short terminal.
Junction connector in this include a short terminal which is connected to a number of wire
harnesses. Always perform inspection with the short terminal installed. (When installing the wire
harnesses, the harnesses can be connected to any position within the short terminal grouping.
Accordingly, in other vehicles, the same position in the short terminal may be connected to wire
harness from a different part.) Wire harness sharing the same short terminal grouping ha the same
color.
C: Parts Code
The first letter of the code is taken from the first letter of part, and the numbers indicates its order in
parts which start with the same letter.
D: Connector Color
Connectors not indicated are milky white in color.
How to Read Ground Points
HOW TO READ GROUND POINTS
Page 5190
Wheel Fastener: Service and Repair Rear
REPLACEMENT
1. REMOVE REAR WHEEL 2. REMOVE BRAKE DRUM AND GASKET
3. REMOVE REAR HUB BOLT
Using Special Service Tool (SST) and a brass bar or an equivalent, remove the hub bolt. SST
09650-17011
4. INSTALL HUB BOLT
a. Install a washer and nut to a new hub bolt as shown in the illustration. b. Using a brass bar or an
equivalent to hold, install the hub bolt by torquing the nut. c. Remove the nut and washer.
5. INSTALL NEW GASKET AND BRAKE DRUM 6. INSTALL REAR WHEEL
Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.)
Page 6313
Wiring Harness Connector
E: Indicates the wiring harness and wiring harness connector. The wiring harness with male
terminal is shown with arrows.
Outside numerals are pin numbers.
The first letter of the code for each wiring harness and wiring harness connector(s) indicates the
component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and
Surrounding area, and "B" for the Body and Surrounding area.
When more than one code has the first and second letters in common, followed by numbers (e.g,
IH1, IH2), this indicates the same type of wiring harness and wiring harness connector.
F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in
parts position.
G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside
it). Junction Blocks are shaded to clearly separate
them from other parts.
H: When 2 parts both use one connector in common, the parts connector name used in wire
routing is shown in square brackets [ ].
Wiring Color
I: Indicates the wiring color.
Wire colors are indicated by an alphabetical code.
B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR =
Brown SB = Sky Blue LG = Light Green GR = Gray
The first letter indicates the basic wire color and the second letter indicates the color of the stripe.
Page 4815
Driver Side J/B And Integration Relay
Page 4934
Key Reminder Switch: Description and Operation
KEY REMINDER AND SEAT BELT WARNING
SYSTEM OUTLINE
Current always flows to TERMINAL (B) 5 of the combination meter through the DOME fuse.
1. SEAT BELT WARNING SYSTEM
When the ignition SW is turned on, current flows from the GAUGE fuse to TERMINAL (A) 7 of the
combination meter. This current activates the combination meter and the current flowing through
the seat belt warning light flows from TERMINAL (A) 12 to GROUND, causing the warning light to
light up. A buckle SW off signal is input to TERMINAL (B) 9 of the combination meter to TERMINAL
(A) 12 to GROUND, causing the warning light to light up. A buckle SW off signal is input to
TERMINAL (B) 9 of the combination meter, the current flowing to TERMINAL (B) 5 of the
combination meter flows from TERMINAL (A) 12 to GROUND and the seat belt warning buzzer
sounds. However, if the seat belt is put on during this period (While the buzzer is sounding), signal
input to TERMINAL (B) 9 of the combination meter stops and the current flow from TERMINAL (B)
5 of the combination meter to TERMINAL (A) 12 to GROUND is cut, causing the buzzer to stop.
2. KEY REMINDER SYSTEM
With the ignition key inserted in the key cylinder (Unlock warning SW on), the ignition SW still off
and driver's door open (Door courtesy SW on), when a signal is input to TERMINAL (B) 10 of the
combination meter, the combination meter operates, current flows from TERMINAL (B) 5 of the
combination meter to TERMINAL (A) 12 to GROUND and key reminder buzzer sounds.
Page 725
Crankshaft Position Sensor: Service and Repair
Crankshaft Position Sensor
REMOVAL
1. REMOVE ENGINE UNDER COVER
Page 1546
4. Cycle the temperature control knob several times and confirm proper water control valve
adjustment.
Page 872
5. Pinch the fuel return hose.
The pressure in the high pressure line will rise to approx. 392 kPa (4 kgf/sq.cm, 57 psi). In this
state, check to see that there are no leaks from any part of the fuel system.
NOTE: Always pinch the hose. Avoid bending as it may cause the hose to crack.
6. Turn the ignition switch OFF. 7. Disconnect the TOYOTA hand-held tester from the DLC3.
Page 6829
Splice Point
J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel,
and "B" for the Body).
The Location of splice Point I5 is shaded.
K: Indicates a shielded cable.
L: Indicates the pin number of the connector.
The numbering system is different for female and male connectors.
M: Indicates a ground point.
The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for
the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body
and Surrounding area.
How to Read Connector List
HOW TO READ CONNECTOR LIST
A: Indicates connector to be connected to a part. (The numeral indicates the pin No.)
Page 3086
Throttle Position Sensor: Testing and Inspection
ON-VEHICLE INSPECTION
1. REMOVE THROTTLE BODY COVER
2. INSPECT SYSTEM OPERATION
a. Check that the throttle linkage moves smoothly.
b. Inspect the throttle control motor for operating sound.
1. Turn the ignition switch ON. 2. When turning the accelerator pedal position sensor lever, check
the running sound of the motor. Also, check that there is no friction sound.
If operation is not as specified, check the throttle control motor (See step 3), wiring and ECM.
c. Inspect the accelerator pedal position sensor.
1. Connect the TOYOTA hand-held tester to the DLC3. 2. Check that the MIL does not light up. 3.
When turning the accelerator pedal position sensor lever to the full-open position, check that the
throttle valve opening percentage
(THROTTLE POS) of the CURRENT DATA shows the standard value.
Standard throttle valve opening percentage: 60 % or more
If operation is not as specified, check that the accelerator pedal position sensor (See step 5), wiring
and ECM.
Page 4165
Parts Information
Page 4200
4. With ABS:
Disconnect ABS speed sensor and wire harness clamp from steering knuckle.
Remove the 2 bolts and disconnect the ABS speed sensor and wire harness clamp from the
steering knuckle.
5. Disconnect brake line.
Using the following SST, disconnect the brake line. Use a container to catch the brake fluid.
SST P/N: 09023-00100
6. Remove brake caliper and disc.
A. Remove the bolt and brake line clamp from the steering knuckle.
B. Remove the 2 bolts, brake caliper, and disc.
7. Remove shock absorber.
Page 2269
Materials System.
Required SSTs
NOTE:
Additional Diagnostic Tester Kits, CAN Interface Modules, Program Cards or SSTs may be ordered
by calling SPX/OTC at 1-800-933-8335.
Process Overview
ECU Flash Reprogramming is a 4-step process:
1. Locate the desired calibration file on TIS (Technical Information System).
Calibration files may be found in two areas:
a. Search by model and year for a Technical Service Bulletin addressing a specific product issue.
b. Search by model under the ECU Flash Reprogramming section.
2. Download the calibration file from TIS to the Diagnostic Tester.
The Calibration Update Wizard (CUW) is an application on TIS which downloads calibration files
from TIS to the Diagnostic Tester Program Card. This step is only required when the calibration file
is not currently stored on the Diagnostic Tester Program Card.
3. Reprogram the vehicle ECU with the Diagnostic Tester.
Diagnostic Tester Software now incorporates a function to update a vehicle's ECU calibration
through flash reprogramming.
4. Confirm successful flash update and affix calibration update sticker.
Modifications to ECU calibration files must be recorded and properly displayed on the vehicle using
the calibration update sticker.
NOTE:
Page 275
Airbag Sensor Assembly: Service and Repair Removal and Installation
Airbag Sensor Assembly
REMOVAL
NOTE: Do not open the cover or the case of the ECU and various electrical devices unless
absolutely necessary (If the IC terminals are touched, the IC may be destroyed by static
electricity.).
1. REMOVE LOWER CENTER COVER
Remove the 2 clips and lower center cover.
Page 5962
- Length: 6 in.
^ Ratcheting tie down strap (quantity 1)
- Minimum Width & Length: 1 in. x 6 ft.
^ Bicycle Cable Lock (quantity 1)
- Minimum Width & Length: 3/8 in. x 5 ft.
- Built-in lock with key
- Bell: P/N 1002107, Master Lock: P/N 8126D, Kryptonite: P/N 999782 or equivalent
IV. Background
On certain 2000 through 2003 model year Tundra vehicles operated in cold climate areas with high
road salt use (Severe Cold Climate States) excessive corrosion may be exhibited on the rear frame
cross-member. In the worst case the spare tire stowed under the truck bed may become separated
from the rear cross-member. Eventually excessive corrosion of the rear cross-member may also
affect the functionality of the brake system Load Sensing Proportioning & By-Pass Valve and/or
associated brake lines.
Testing and Inspection
Power Window Relay: Testing and Inspection
INSPECT POWER MAIN RELAY CONTINUITY If continuity is not as specified, replace the switch.
Page 2492
CHART 21
Bleeding the Brake System
Brake Bleeding: Service and Repair Bleeding the Brake System
BRAKE FLUID BLEEDING
HINT: If any work is done on the brake system or if air is suspected in the brake lines, bleed the air
from the system.
NOTICE: Do not let brake fluid remain on a painted surface. Wash it off immediately.
1. FILL BRAKE RESERVOIR WITH BRAKE FLUID
Check the fluid level in the reservoir after bleeding each wheel. Add fluid, if necessary. Fluid: SAE
J1703 or FMVSS No. 116 DOT3
2. BLEED MASTER CYLINDER
HINT: If the master cylinder was disassembled or if the reservoir becomes empty, bleed the air
from the master cylinder.
(a) Disconnect the brake lines from the master cylinder.
SST 09023-00100
(b) Slowly depress the brake pedal and hold it.
(c) Block off the outlet plug with your finger, and release the brake pedal. (d) Repeat (b) and (c) 3
or 4 times.
Page 4271
Brake Shoe: Service and Repair
For information regarding the service and repair of this component and the system that it is a part
of, please refer to Drum Brake System; Service and Repair.
Page 1858
Crankshaft Position Sensor: Description and Operation
Crankshaft Position Sensor
Crankshaft position sensor (NE signal) consists of a signal plate and pick up coil.
The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor
generates 34 signals of every engine revolution.
The ECM detects the standard crankshaft angle based on the G signals, and the actual crankshaft
angle the engine speed by the NE signals.
Page 391
Key Reminder Switch: Ground Locations
Engine Compartment
Ground Location
EA Front Left Fender
EB Rear Bank of Right Cylinder
EC Rear Bank of Left Cylinder
Connector Location
EA1 Cowl Wire Harness and Wire Harness (Connector Location)
EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B)
EC1 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC2 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC3 Engine No. 2 Wire and Engine Wire (Near the Starter)
ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission)
Page 2989
5. Pinch the fuel return hose.
The pressure in the high pressure line will rise to approx. 392 kPa (4 kgf/sq.cm, 57 psi). In this
state, check to see that there are no leaks from any part of the fuel system.
NOTE: Always pinch the hose. Avoid bending as it may cause the hose to crack.
6. Turn the ignition switch OFF. 7. Disconnect the TOYOTA hand-held tester from the DLC3.
Electrical Specifications
Fuel Injector: Electrical Specifications
Resistance Between Terminals 13.4 to 14.2 ohms at 68 deg F
Page 4648
Engine Room R/B
Details
Page 3715
6. INSTALL SNAP RINGS
a. Install 2 new snap rings of equal thickness which will allow 0 - 0.05 mm (0 - 0.0020 inch) axial
play.
HINT: Do not reuse the snap rings.
4WD rear Propeller shaft
Page 4786
Waterproof Type Connector
B: For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White
: Gray
Black or White : Dark Gray
Gray or White : Black
Waterproof Type Connector
"Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up
to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Waterproof Type Connector
"Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 5941
Page 4576
e. Connect the engine wire with the bolt.
f. Install the starter with the 2 bolts.
Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)
2. INSTALL INTAKE MANIFOLD ASSEMBLY
3. CONNECT THROTTLE BODY ASSEMBLY TO INTAKE MANIFOLD
4. INSTALL INTAKE AIR CONNECTOR
5. CONNECT ACCELERATOR CABLE
6. INSTALL THROTTLE BODY COVER
Page 3873
c. 4HI -> 4LO shift: Connect lines via a relay, then check that the actuator fork shaft moves to 4HI
-> 4LO position.
d. 4LO 4HI shift: Connect lines via a relay, then check that the actuator fork shaft moves to 4LO ->
4HI position.
HINT: When inspecting the operation described, use a heater main relay.
NOTICE: Connect the terminals being careful not to touch the neighboring terminals or metallic
parts of relay housing.
Locations
EFI Main Relay: Locations
Engine Room R/B
Page 5032
Control Arm: Service and Repair Upper
REMOVAL
1. REMOVE SHOCK ABSORBER WITH COIL SPRING 2. w/ ABS: DISCONNECT ABS SPEED
SENSOR WIRE HARNESS CLAMPS
Remove the 2 bolts and ABS speed sensor wire harness clamps from the steering knuckle and
upper suspension arm.
Page 96
Non-Waterproof Type Connector
"Case 1" Raise the terminal retainer up to the temporary lock position.
Non-Waterproof Type Connector
"Case 2" Open the secondary locking device.
Page 4828
Alignment: Specifications
Instruments - Oil Pressure Gauge Reads Abnormally Low
Oil Pressure Gauge: All Technical Service Bulletins Instruments - Oil Pressure Gauge Reads
Abnormally Low
ELECTRICAL EL017-03
December 23, 2503
Title OIL PRESSURE GAUGE READS LOW
Models '01 - '04 Sequoia & '00 - '02 Tundra
TSB UPDATE NOTICE:
This TSB updates EL006-03. TSB EL006-03 is now obsolete and should be discarded.
Introduction
Some customers with Sequoia or Tundra vehicles may encounter an oil pressure gauge that reads
abnormally low at idle. An updated oil pressure sender has been created to address this condition.
Applicable Vehicles ^
2001 - 2004 model year Sequoia vehicles produced BEFORE the Production Change Effective
VINs shown below.
^ 2000 - 2002 model year Tundra vehicles produced BEFORE the Production Change Effective
VIN shown below.
Production Change Information
Parts Information
Repair Procedure
1. Replace the Oil Pressure Sender.
2. Verify proper operation of the Oil Pressure Gauge.
Warranty Information
Applicable Warranty*:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36
months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Page 5885
2. COAT CONTACT SURFACE OF BODY WITH PRIMER "M"
Using a brush, coat the body surface except the front and rear end with Primer M as shown in the
illustration.
Front end: 23 mm (0.91 in.) + 8 mm (0.31 in.) or less Rear end: 70 mm (2.76 in.) + 12 mm (0.47 in.)
or less
NOTE: Let the primer coating dry for 3 minutes or more.
- Do not coat to the adhesive.
- Do not keep any of the opened Primer M for later use.
3. INSTALL NEW MOULDING
a. Using a heat light, heat the body and moulding.
Body: 40 - 60 °C (104 - 140 °F) Moulding: 20 - 30 °C (68 - 86 °F)
NOTE: Do not heat the moulding excessively.
b. Lift the moulding release sheet from face of the moulding.
NOTE: When the moulding release sheet is removed, make sure that no dirt or dust con get onto
the uncoated area.
c. Install the moulding.
Specifications
Knock Sensor: Specifications
SST 09816-30010
Torque: ................................................................................................................................................
................................. 45 N.m (450 kgf.cm, 33 ft.lbf)
Page 3043
Fuel Return Line: Testing and Inspection
INSPECTION
INSPECT FUEL TANK AND LINE
a. Check the fuel lines for cracks or leakage, and all connections for deformation. b. Check the fuel
tank vapor vent system hoses and connections for looseness, sharp bends or damage. c. Check
the fuel tank for deformation, cracks, fuel leakage or tank band looseness. d. Check the filler neck
for damage or fuel leakage.
e. Hose and pipe connections are as shown in the illustration.
If a problem is found, repair or replace the parts as necessary.
Page 565
Page 4880
a. Using a screwdriver with vinyl tape wound around its tip, remove the oil seal.
NOTICE: Be careful not to damage the front housing.
b. Coat a new oil seal lip with power steering fluid.
c. Using Special Service Tool (SST), press in the oil seal.
SST 09950-60010 (09951-00330), 09950-70010 (09951-07100)
NOTICE: Make sure to install the oil seal facing in the correct direction.
REASSEMBLY
NOTICE: When using a vise, do not overtighten it.
1. COAT PARTS INDICATED BY ARROWS WITH POWER STEERING FLUID 2. INSTALL VANE
PUMP SHAFT WITH VANE PUMP PULLEY 3. INSTALL STRAIGHT PINS
Using a plastic hammer, tap in 2 new pins to the front housing.
NOTICE: Be careful not to damage the pins.
4. INSTALL CAM RING
Install the cam ring with the inscribed mark facing outward.
HINT: Align the holes of the cam ring with the straight pins.
5. INSTALL VANE PUMP ROTOR
a. Install the vane pump rotor with the inscribed mark facing outward. b. Install a new snap ring to
the vane pump shaft.
Capacity Specifications
Refrigerant: Capacity Specifications
Charge Volume 600 +/- 50 g
Page 5109
Page 5866
Wheel Opening Moulding
Page 4030
Brake Pedal Assy: Testing and Inspection
ON-VEHICLE INSPECTION
1. CHECK PEDAL HEIGHT
Pedal height from dash panel: 164 - 174 mm (6.46 - 6.85 inch)
2. IF NECESSARY, ADJUST PEDAL HEIGHT
(a) Remove the scuff plate LH, cowl side trim LH, lower finish panel and No. 2 heater to register
duct. (b) Disconnect the connector from the stop light switch. (c) Loosen the stop light switch lock
nut and remove the stop light switch. (d) Loosen the push rod lock nut. (e) Adjust the pedal height
by turning the pedal push rod. (f) Tighten the push rod lock nut.
Torque: 25 Nm (260 kgf-cm, 19 ft. lbs.)
(g) Install the stop light switch and turn it until it lightly contacts the pedal stopper. (h) Connect the
connector to the stop light switch. (i) Push in the brake pedal 5 - 15 mm (0.20 - 0.59 inch), turn the
stop light switch to lock the nut in the position where the stop light goes off. (j) After installation,
push in the brake pedal 5 - 15 mm (0.20 - 0.59 inch), check that stop light lights up. (k) After
adjusting the pedal height, check the pedal free play. (l) Install the No. 2 heater to register duct,
lower finish panel, cowl side trim LH and scuff plate LH.
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 pedal by hand until the second point of resistance begins to be felt,
then measure the distance as shown in the illustration.
Pedal free play: 1 - 6 mm (0.04 - 0.24 inch) If incorrect, check the stop light switch clearance. If the
clearance is OK, then troubleshoot the brake system. Stop light switch clearance: 0.5 - 2.4 mm
(0.020 - 0.094 inch)
HINT: The free play to the first point of resistance is due to the play between the clevis and pin. It is
1 - 3 mm (0.04 - 0.12 inch) at the pedal.
Locations
Transmission Speed Sensor: Locations
Vehicle Speed Sensor NO.1
Vehicle Speed Sensor NO.2
Vehicle Speed Sensor NO.1
Page 3533
f. After installation, confirm the following items. 1 When the shift lever is at P position and the pedal
button is pushed by 7 mm (0.28 inch), shift lever should be locked by lock pin. 2 When the pedal
button is released, the shift lever should be able to be shifted from P position to other positions. 3
When the shift lever is at N or D position and the pedal button is pushed by 7 mm (0.28 inch), the
shift lever should be able to be shifted.
g. Install the cable No. 2 to column upper bracket with the clip. h. Install the cable end to the sliding
block of the column upper bracket with the screw.
Torque: 2.2 Nm (23 kgf-cm, 19 inch lbs.)
i. After installation, check the following items. 1 When the pedal button is pushed, shift lever should
be locked. 2 When the pedal button is released, shift lever should be unlocked.
4. INSTALL STEERING COLUMN ASSEMBLY
5. ADJUST CABLE HOUSING
a. Shift the shift lever to the P position. b. Turn the ignition key to LOCK. c. Loosen the 2 bolts and
adjust the cable housing.
HINT: Pedal button should touch the pedal plate cushion.
- Brake pedal should not be moved by the pedal button.
- Cable housing should not be toughed the brake pedal and the brake pedal plate cushion.
d. Torque the 2 bolts.
Torque: 10.5 Nm (110 kgf-cm, 8 ft. lbs.)
6. CONFIRM SHIFT LOCK SYSTEM OPERATION
a. Only when the brake pedal is engaged and the ignition key is not at LOCK, should the shift lever
be able to be shifted from P position to other
positions. When the shift lever is at P position and the brake pedal is released, the shift lever
should not be able to be shifted from P position to other positions.
b. When the shift lever is not at P position, the ignition key should not be able to be turned to
LOCK. Once when the shift lever is at P position,
should the ignition key be able to be removed.
c. Cable No. 1 and No. 2 should not be deformed by other parts located around the steering
column.
Page 4998
e. Draw a new line on the masking tape of the steering wheel as shown in the illustration. f.
Measure the distance between the 2 lines on the masking tape of the steering wheel.
g. Convert the measured distance to steering angle.
Measured distance 1 mm (0.04 inch) = Steering angle approximately 1°. HINT: Make a note of the
steering angle.
2. ADJUST STEERING ANGLE
a. Draw a line on the RH and LH tie rod and rack ends where it can easily be seen. b. Using a
paper gauge, measure the distance from RH and LH tie rod ends to the rack end screws.
HINT: ^
Measure the RH side and LH side.
^ Make a note of the measured values.
c. Remove the RH and LH boot clips from the rack boots. d. Loosen the RH and LH lock nuts. e.
Turn the RH and LH rack end by the same amount (but in different directions) according to the
steering angle.
1 turn 360° of rack end (1.5 mm ( 1.5mm ( 0.059 in.) horizontal movement ) = 12° of steering angle
f. Tighten the RH and LH lock nuts. Torque: 55 Nm (560 kgf-cm, 41 ft. lbs.)
NOTICE: Make sure that the difference in length between RH and LH tie rod ends and rack end
screws are within 1.5 mm (0.059 inch).
g. Install the RH and LH boot clips.
Page 4396
Brake Caliper: Service and Repair Disassembly and Assembly
DISASSEMBLY
1. REMOVE CYLINDER BOOT SET RINGS AND BOOTS
Using a screwdriver, remove the 4 cylinder boot set rings and boots.
2. REMOVE PISTONS FROM CYLINDER
(a) Prepare the wooden plate to hold the pistons.
Collision / Non-Collision Inspections
Impact Sensor: Testing and Inspection Collision / Non-Collision Inspections
INSPECTION
1. VEHICLES NOT INVOLVED IN COLLISION
Do a diagnostic system check. *
2. VEHICLES INVOLVED IN COLLISION
a. Do a diagnostic system check. *
b. If the front fender of the car or its periphery is damaged, do a visual check for damage to the
front airbag sensor, which includes the following
items even if the airbag was not deployed: Check the bracket deformation.
- Check the paint peeling off the bracket.
- Check the cracks, dents or chips in the case.
- Check the cracks, dents, chipping and scratches in the connector.
- Check the peeling off of the label or damage to the serial number.
* Refer to SRS Warning Light Check, and How to Display and Read Diagnostic Trouble Codes.
See: Air Bag Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble
Codes/Displaying & Reading Trouble Codes
Page 5307
Receiver Dryer: Service and Repair
REMOVAL
1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM
HINT: At the time of the installation, please refer to the following item. Evacuate air from
refrigeration system. Charge system with refrigerant and inspect for leakage of refrigerant.
Specified amount: 600 ± 50 g (21.16 ± 1.76 oz.)
2. DISCONNECT 2 LIQUID TUBES FROM RECEIVER
Remove the 2 bolts and disconnect the both tubes.
Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
NOTE: Cap the open fittings immediately to keep moisture or dirt out of the system.
HINT: At the time of the installation, please refer to the following item. Lubricate 2 new O-rings with
compressor oil and install them to the tubes.
3. REMOVE RECEIVER
a. Remove the holder bolt and pull receiver downward.
HINT: At the time of the installation, please refer to the following item. If receiver is replaced, add
compressor oil to compressor.
Add 20 cc (0.71 fl.oz.) Compressor oil: ND-OIL 8 or equivalent
b. Remove the bolt and holder.
INSTALLATION
Installation is in the reverse order of removal.
Page 5936
A. AFFECTED VIN RANGE
III. Preparation
A. PARTS
^ No parts are required for the inspection.
B. EQUIPMENT & MATERIALS
^ Protective eyewear
^ Standard heater core hose
Page 6542
Splice Location
I1 Cowl Wire
I2 Cowl Wire
I3 Cowl Wire
I4 Cowl Wire
I5 Cowl Wire
I6 Cowl Wire
I7 Engine Wire
I8 Engine Wire
I9 Engine Wire
I10 Engine Wire
I11 Engine Wire
I12 Engine Wire
I13 Engine Wire
I14 Engine Wire
I15 Engine Wire
I16 Cowl Wire
Body
Splice Location (Access Cab)
B1 Speaker Tweeter Wire LH
B2 Front Door LH Wire
B3 Front Door LH Wire
B4 Roof Wire
B5 Speaker Tweeter Wire RH
B6 B7
Front Door RH Wire
B8 Front Door RH Wire
B9 Rear Door No. 1 Wire RH
B10 Frame Wire
Engine Controls - MIL ON/DTC's P0135/P0155 Stored
Oxygen Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0135/P0155
Stored
ENGINE EG019-02 REVISED
October 3, 2002
Title M.I.L. "ON" P0135 AND/OR P0155
Models: '00 - '02 Tundra (2UZ-FE) & '01 - '02 Sequoia
TSB REVISION NOTICE:
January 14, 2004: A Previous Part Number in the Parts Information table and one OFP number in
the Warranty Information table has been changed. All previous versions of this TSB should be
discarded.
Introduction
Certain 2000 - 2002 model year Tundra trucks (2UZ-FE) and 2001 - 2002 model year Sequoia
vehicles may exhibit a M.I.L. ON" condition with Diagnostic Trouble Code P0135 and/or P0155 in
the Engine Control Module (ECM)/SAE equivalent (PCM). The oxygen sensors have been
improved to correct this condition.
Applicable Vehicles ^
2000 - 2002 model year Tundra trucks with 2UZ-FE engines produced BEFORE the Production
Change Effective VINs listed below.
^ 2001 - 2002 model year Sequoia vehicles produced BEFORE the Production Change Effective
VINs listed below.
Production Change Information
Parts Information
Warranty Information
Applicable Warranty*:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36
months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Page 814
6. INSPECT LIMIT SWITCH CONTINUITY
a. Start the engine and raise the vehicle. b. With the actuator connector connected, shift the
transfer shift lever and after checking the operating sound, disconnect the connector and
inspect the continuity between each terminal.
HINT: When shifting the actuator fork shaft, connect the connectors.
7. INSPECT VEHICLE SPEED SENSOR 8. INSPECT 4HI AND 4LO INDICATOR LIGHT Check
the combination meter.
9. INSPECT 4WD CONTROL ECU
Connect the wire harness side connector to the 4WD control ECU and inspect wire harness side
connector from the back side.
Capacity Specifications
Fluid - A/T: Capacity Specifications
Automatic Transmission Capacity (Drain & Refill)
........................................................................................................................... up to 2.0L (2.1 US
qt.)
Page 1688
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 2927
2. Apply battery positive voltage across the terminals. 3. Check that air flows from ports.
If operation is not as specified, replace the VSV.
3. REINSTALL VSV
Page 2089
Crankshaft Position Sensor: Service and Repair
Crankshaft Position Sensor
REMOVAL
1. REMOVE ENGINE UNDER COVER
Page 5060
Page 682
Vehicle Speed Sensor: Service and Repair
Vehicle Speed Sensor NO.1
1. DISCONNECT NO. 1 VEHICLE SPEED SENSOR CONNECTOR
2. REMOVE NO. 1 VEHICLE SPEED SENSOR
Remove the bolt and No.1 vehicle speed sensor.
3. DISASSEMBLE NO. 1 VEHICLE SPEED SENSOR
a. Remove the O-ring from the speedometer driven gear assembly. b. Remove the clip and
speedometer driven gear from the speedometer driven gear sleeve.
4. ASSEMBLE NO. 1 VEHICLE SPEED SENSOR
a. Install the speedometer driven gear and clip to the speedometer driven gear sleeve. b. Coat a
new O-ring with ATF. c. Install the O-ring to the speedometer driven gear assembly.
5. INSTALL NO. 1 VEHICLE SPEED SENSOR
System Diagnosis
Air/Fuel Mixture: Testing and Inspection
INSPECTION
HINT: This check is used only to determine whether or not the idle CO/HC complies with
regulations.
1. INITIAL CONDITIONS
a. Engine at normal operating temperature b. Air cleaner installed c. All pipes and hoses of air
induction system connected d. All accessories switched OFF e. All vacuum lines properly
connected f.
SFI system wiring connectors fully plugged
g. Ignition timing checked correctly h. Transmission in neutral position i.
Tachometer and CO/HC meter calibrated by hand
2. START ENGINE 3. RACE ENGINE AT 2,500 RPM FOR APPROXIMATELY 180 SECONDS
4. INSERT CO/HC METER TESTING PROBE AT LEAST 40 cm (1.3 ft) INTO TAILPIPE DURING
IDLING 5. IMMEDIATELY CHECK CO/HC CONCENTRATION AT IDLE AND/OR 2,500 RPM
HINT: When performing the 2 mode (2,500 rpm and idle) test, follow the measurement orders are
prescribed by the applicable local regulations.
If the CO/HC concentration does not comply with regulations, perform troubleshooting in the order
given. a. Check the heated oxygen sensors operation.
b. See the table for possible causes, and then inspect and correct the applicable causes if
necessary.
Page 4349
A. Disconnect shock absorber from lower suspension arm.
B. Remove the shock absorber lower side set nut and washer.
NOTE:
Do not remove the
C. Wrap the bolt's head with vinyl tape to prevent the drive shaft boot from being damaged.
D. Pry down the lower suspension arm to remove the bolt and disconnect the shock absorber.
E. Remove the 3 nuts and shock absorber with the coil spring.
NOTE:
Do not damage the
8. Disconnect lower ball joint. Remove the 4 bolts and disconnect the lower ball joint.
SRS/Interior - Seat Cover Replacement Caution
Side Air Bag: Technical Service Bulletins SRS/Interior - Seat Cover Replacement Caution
BODY BO014-05
Title: SEAT COVER REPLACEMENT FOR SIDE AIRBAG EQUIPPED VEHICLES
Models: '98 - '06 All Models
November 10, 2005
TSB UPDATE NOTICE:
The information contained in this TSB supercedes TSB No. B0025-97. TSB No. B0025-97 is now
obsolete and should be discarded.
Introduction
Beginning in 1998, Toyota introduced side airbags as optional equipment.
Toyota does NOT recommend replacement of original seat covers* with non-Toyota leather or
other seat cover materials on vehicles due to the following:
^ Seat covers NOT recommended by Toyota may affect side airbag performance, in general or in
part, during an accident.
^ Modifications that negatively affect side airbag performance can result in severe occupant
injuries.
^ Seat covers are an integral part of this safety system. Replacing fabric seat covers* with
non-Toyota leather or other seat cover materials may compromise the effectiveness of this safety
system.
^ The design of the seat is complex, integrating safety and strength with comfort and luxury.
*NOTE:
Toyota original seat covers that were NOT designed for side airbag equipped seats cannot be used
due to the effect on proper airbag performance.
Toyota strongly discourages modifying original equipment seats that have optional side airbags.
Additionally, Toyota strongly advises against the installation or use of aftermarket seat covers,
which could impair the performance of the side airbags in the event of an accident.
Applicable Vehicles
^ All 1998 - 2006 model year Toyota and Scion vehicles equipped with side airbags.
Warranty Information
Page 1857
Crankshaft Position Sensor
Page 2173
Camshaft Position Sensor: Testing and Inspection
ON-VEHICLE INSPECTION
NOTE: "Cold" and "Hot" in these sentences express the temperature of the coils themselves.
"Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F).
INSPECT CAMSHAFT POSITION SENSOR
a. Disconnect the camshaft position sensor connector.
Resistance
b. Using an ohmmeter, measure the resistance between terminals.
If the resistance is not as specified, replace the camshaft position sensor.
c. Reconnect the camshaft position sensor connector.
Testing and Inspection
Overdrive Switch: Testing and Inspection
O/D Main Switch & O/D OFF Indicator Light Circuit
CIRCUIT DESCRIPTION
The O/D main switch contacts go open when the switch is pushed in and go closed when it is
pushed out.
If O/D main switch is at OFF position, the O/D OFF indicator light lights up, and the ECM prohibits
shifting O/D.
Wiring Diagram
INSPECTION PROCEDURE
Page 3914
b. Push the secondary locking device or terminal retainer in to the full lock position.
5. CONNECT CONNECTOR
Disconnection of Male and Female Connectors
Disconnection of Male and Female Connectors
Disconnection Of Male And Female Connectors
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Page 3917
Electronically Controlled Transmission And A/T Indicator (Part 3)
Page 6697
Backup Lamp Relay: Testing and Inspection
INSPECT BACK-UP LIGHT RELAY CONTINUITY If continuity is not as specified, replace the
relay.
Page 6993
a. Install the front pillar garnish. b. Employ the same manner described above to the other side.
22. INSTALL ASSIST GRIPS
a. Driver's side:
Using a torx socket wrench, install the assist grip with the 2 torx screws.
Torx driver: T30 (Part No. 09041-00030 or locally manufactured tool)
b. Passenger's side:
Using a torx socket wrench, install the 2 assist grips with the 4 torx screws.
Torx driver: T30 (Part No. 09041-00030 or locally manufactured tool)
c. Install the caps.
23. INSTALL INNER REAR VIEW MIRROR
Install the inner rear view mirror as shown in the illustration.
Page 4745
Splice Point
J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel,
and "B" for the Body).
The Location of splice Point I5 is shaded.
K: Indicates a shielded cable.
L: Indicates the pin number of the connector.
The numbering system is different for female and male connectors.
M: Indicates a ground point.
The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for
the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body
and Surrounding area.
How to Read Connector List
HOW TO READ CONNECTOR LIST
A: Indicates connector to be connected to a part. (The numeral indicates the pin No.)
Page 153
F. Confirm the Diagnostic Tester software version and connections to the TIS workstation are
correct.
* NOTE:
This screen displays the required version of Diagnostic Tester software that is compatible with the
selected calibration file, and the other required steps to properly connect the Diagnostic Tester to
your PC.
^ Type I calibration files are only compatible with software version 10.1a and older versions.
^ Type II calibration files are only compatible with software version 10.2a and newer versions.
G. Place the Diagnostic Tester in the "GET CAL FROM PC" mode to receive the calibration file
(Figure 10).
Click NEXT on the TIS workstation. Once communications begin between the PC and the
Diagnostic Tester, the Diagnostic Tester display will flash CONNECTED.
H. The CUW determines if there is enough memory to store the calibration file on the Diagnostic
Tester Program Card. If there is insufficient
Page 5013
Ball Joint: Diagrams
Page 4914
Instrument Panel
Connector Location
IA1 Engine Room Main and Cowl Wire (Left Kick Panel)
IA2 Engine Room Main and Cowl Wire (Left Kick Panel)
IA3 Engine Room Main and Cowl Wire (Left Kick Panel)
IA4 Engine Room Main and Cowl Wire (Left Kick Panel)
IB1 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IB2 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IB3 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IC1 Cowl Wire and Roof Wire (Left Side of Instrument Panel)
Instrument Panel
Connector Location
ID1 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH)
ID2 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH)
IE1 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IE2 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IE3 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IF1 Front Door RH Wire and Cowl Wire (Right Kick Panel)
IF2 Front Door RH Wire and Cowl Wire (Right Kick Panel)
IF3 Front Door RH Wire and Cowl Wire (Right Kick Panel)
Page 4051
11. 4WD: Remove oil seal (inside).
A. Mount the axle hub in a soft jaw vise.
HINT: Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further
(refer to the illustration above).
B. Using a screwdriver, remove the oil seal (inside).
12. 2WD: Remove lock nut and ABS speed sensor rotor (with ABS) or spacer (without ABS). Using
a chisel and hammer, loosen the staked part of the lock nut.
NOTE:
Be careful not to damage the bushing.
A. Using the following SST, remove the lock nut. SST P/N: 00002-00909 (09318-12010)
NOTE:
Do NOT use air wrench.
B. Remove the ABS speed sensor rotor or spacer.
NOTE:
Take care not to scratch the serration of the speed sensor rotor.
13. Remove axle hub from steering knuckle.
A. Remove the 4 bolts and shift the dust cover toward the hub side (outside).
B. Using the following SSTs, remove the axle hub from the steering knuckle.
SST P/N: 09710-28012-01 (09710-07031)
SST P/N: 09950-40011(09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04031,
09957-04010, 09958-04011)
HINT: If necessary, use a press to remove the axle hub from the steering knuckle.
C. Remove the dust cover from the steering knuckle.
D. 4WD: Remove the bearing spacer and ABS speed sensor rotor (with/ABS) or spacer (without
ABS).
NOTE:
Take care not to scratch the serration of the speed sensor rotor.
14. Remove oil seal (outside). Using a screwdriver, remove the oil seal (outside) from the steering
knuckle.
15. Remove bearing from steering knuckle.
Page 973
Refrigerant Line (Part 2)
Page 4758
Fuse Block: Connector Views
Engine Room R/B
Capacity Specifications
Steering - Lubricant
Locations
Transmission Speed Sensor: Locations
Vehicle Speed Sensor NO.1
Vehicle Speed Sensor NO.2
Vehicle Speed Sensor NO.1
Page 5570
The ground points circuit diagram shows the connections from all major parts to the respective
ground points. When troubleshooting a faulty ground point, checking the system circuits which use
a common ground may help you identify the problem ground quickly. The relationship between
ground points (EA, IB and IC) can also be checked this way.
How to Read Power Source
HOW TO READ POWER SOURCE
Page 1773
Engine Control Module: Specifications
Terminals Of ECU - Connector Pinouts (Part 2)
Page 6707
BJ Inside of Rear Door LH
BK Inside of Rear Door RH
BL Surrounding of the Front of the Fuel Tank
Connector Location
BA1 Front Door LH Wire and Wire Harness (Connector Location)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel)
BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel)
BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel)
BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Page 2062
Mass Air Flow Meter: Service and Repair
MASS AIR FLOW (MAF) METER
1. DISCONNECT MAF METER CONNECTOR
2. REMOVE MAF METER
Remove the 2 screws and MAF meter.
3. REINSTALL MAF METER
Install the MAF meter with the 2 screws.
4. RECONNECT MAF METER CONNECTOR
Page 6688
Transmission Mode Indicator - A/T: Testing and Inspection
ELECTRONICALLY CONTROLLED TRANSMISSION AND A/T INDICATOR
E1 ELECTRONICALLY CONTROLLED TRANSMISSION SOLENOID
4, 7, 8 - GROUND : Approx. 13 Ohms
O4 O/D MAIN SW
3 - 1 : Open with O/D main SW at ON position
Closed with O/D main SW at OFF position
S4 STOP LIGHT SW
1 - 2 : Closed with brake pedal depressed
E3 (A) E4 (B), E5 (C), E6 (D), E7 (E) ENGINE CONTROL MODULE
S1 - E1 : 9 - 14 volts with vehicle not move and shift lever in D position
S2, SL - E1 : 0 - 1.5 volts with vehicle not move
STP - E1 : 7.5 - 14 volts with brake pedal depressed 0 - 1.5 volts with brake pedal released
THW - E1 : 0.2 - 1.0 volts with idling, engine coolant temperature 60 °C (140 °F) -120 °C (248 °F)
OIL - E1 : Below 1.0 volts with fluid temperature 110 °C (230 °F)
VTA - E1 : 0.4 - 1.0 volts with ignition SW on and throttle valve fully closed : 3.2 - 4.8 volts with
ignition SW on and throttle valve fully open
VC - E1 : 4.5 - 5.5 volts with ignition SW at ON or ST position
ODMS - E1 : 9 - 14 volts with O/D main SW turned on : 0 - 3 volts with 0/D main SW turned off
SPD - E1 : Pulse generation with vehicle moving
2 - E1 : 7.5 - 14 volts with shift lever at 2 position : 0 - 1.5 volts with shift lever at except 2 position
L - E1 : 7.5 - 14 volts with shift lever at L position : 0 - 1.5 volts with shift lever at except L position
+B - E1 : 9 - 14 volts with ignition SW at ON or ST position
BATT - E1 : Always 9 - 14 volts
P1 A/T INDICATOR SW [PARK/NEUTRAL POSITION SW]
3 - 1 : Closed with shift lever in P position 3 - 2 : Closed with shift lever in R position 3 - 5 : Closed
with shift lever in N position 3 - 7 : Closed with shift lever in D position 3 - 4 : Closed with shift lever
in 2 position 3 - 8 : Closed with shift lever in L position
Page 1441
10. CHECK CRANKSHAFT PULLEY POSITION
Check that the timing mark of the crankshaft pulley is aligned with timing mark "0" of the No.1
timing belt cover.
11. INSTALL RH, LH CAMSHAFT TIMING PULLEYS
a. Align the camshaft knock pin with the knock pin groove of the timing pulley, and slide on the
timing pulley. b. Using SST, install the pulley bolt.
SST 09960-10010 (09962-01000, 09963-01000) Torque: 108 Nm (1,100 kgf-cm, 80 ft. lbs.)
12. CONNECT TIMING BELT TO LH CAMSHAFT TIMING PULLEY
a. Remove any oil or water on the LH camshaft timing pulley, and keep it clean.
NOTICE: Only wipe the pulleys; do not use any cleansing agent.
b. Turn the LH camshaft timing pulley. Align the installation mark on the timing belt with the timing
mark of the camshaft timing pulley, and
hang the timing belt on the LH camshaft timing pulley.
c. Turn the LH camshaft timing pulley counterclockwise until there is tension between the
crankshaft timing pulley and LH camshaft timing
pulley.
Page 6966
a. Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G as
shown in the illustration. b. When the primer is coated wrongly to the area other than the specified,
wipe it off with a clean shop rag before the primer dries.
NOTE: Let the primer coating dry for 3 minutes or more.
- Do not keep any of the opened Primer G for later use.
5. Slide type:
COAT CONTACT SURFACE OF GLASS WITH PRIMER "G"
a. Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G as
shown in the illustration. b. When the primer is coated wrongly to the area other than the specified,
wipe it off with a clean shop rag before the primer dries.
NOTE: Let the primer coating dry for 3 minutes or more.
- Do not keep any of the opened Primer G for later use.
6. Fixed type:
APPLY ADHESIVE
Ground Locations
Transmission Mode Indicator - A/T: Ground Locations
Engine Compartment
Ground Location
EA Front Left Fender
EB Rear Bank of Right Cylinder
EC Rear Bank of Left Cylinder
Connector Location
EA1 Cowl Wire Harness and Wire Harness (Connector Location)
EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B)
EC1 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC2 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC3 Engine No. 2 Wire and Engine Wire (Near the Starter)
ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission)
Page 559
CHART 16
CHART 17
Testing and Inspection
Turn Signal Switch: Testing and Inspection
INSPECT TURN SIGNAL SWITCH CONTINUITY If continuity is not as specified, replace the
switch.
Page 3616
HINT: During reassembly please refer to the spring specifications to help you to discriminate
between the different springs.
Spring
Retainer and clip
Specifications
Water Pump: Specifications
Water Pump W/ Bolts, Stud Bolts, and Nut Bolt 21 Nm
Stud Bolt and Nut 18 Nm
Page 3805
An AC voltage is generated in the No.2 vehicle speed sensor coil as the rotor mounted on the
output shaft rotates, and this voltage is sent to the ECM.
The gear shift point and lock-up timing are controlled by the ECM based on the signals from this
vehicle speed sensor and the throttle position sensor signal.
If the No.2 vehicle speed sensor malfunctions, the ECM uses input signals from the No.1 vehicle
speed sensor as a back-up signal.
Page 6843
Light Auto Turn Off
Page 678
b. Push the secondary locking device or terminal retainer in to the full lock position.
5. CONNECT CONNECTOR
Disconnection of Male and Female Connectors
Disconnection of Male and Female Connectors
Disconnection Of Male And Female Connectors
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Page 3811
b. Connect the oil cooler pipe.
Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.)
c. Install the 3 clamps with the 3 bolts.
7. FILL ATF AND CHECK FLUID LEVEL
Page 1774
Terminals Of ECU - Connector Pinouts (Part 1)
Page 3316
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
Transmission Speed Sensor: Locations
Vehicle Speed Sensor NO.1
Vehicle Speed Sensor NO.2
Vehicle Speed Sensor NO.1
Locations
Page 3649
10. INSTALL COMPANION FLANGE
a. Place the companion flange on the drive pinion. b. Coat the threads of a new nut with hypoid
gear oil. c. Using SST to hold the flange, torque the nut.
SST 09330-00021 Torque: 147 Nm (1,500 kgf-cm, 109 ft. lbs.)
11. ADJUST DRIVE PINION PRELOAD 12. STAKE DRIVE PINION NUT 13. CONNECT REAR
PROPELLER SHAFT
2WD: See Propeller Shaft; Service and Repair. 4WD: See Propeller Shaft; Service and Repair.
14. FILL DIFFERENTIAL WITH HYPOID GEAR OIL
Torque: 49 Nm (500 kgf-cm, 39 ft. lbs.) Oil type: Hypoid gear oil API GL-5 Recommended oil
viscosity:
Above 18°C (0°F): SAE 90 Below -18°C (0°F): SAE 80W or 8OW-90
Capacity:
2WD: 3.15 liters (3.33 US qts., 2.77 Imp. qts.) 4WD: 2.95 liters (3.12 US qts., 2.60 Imp. qts.)
Page 5773
Glossary Of Terms And Symbols (Part 1)
Diagram Information and Instructions
Lamp Control Module: Diagram Information and Instructions
Key to Diagrams
A: System Title
B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to
distinguish it from the J/B
Example: 1 Indicates Relay Block No.1
C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type,
or specification is different.
D: Indicates related system.
Page 6759
INSPECT DAYTIME RUNNING LIGHT RELAY NO.4 CONTINUITY If continuity is not as specified,
replace the relay.
Page 4076
Required Tools & Material
NOTE:
Additional Diagnostic Tester Kits, Program Cards or SSTs may be ordered by calling SPX-OTC at
1-800-933-8335.
Page 3360
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 341
Repair Procedure
1. Disconnect the cable from the negative (-) battery terminal for MORE THAN two (2) seconds.
2. Reconnect the cable to the negative (-) battery terminal.
3. Perform the applicable zero point calibration of the yaw rate sensor and/or the steering angle
sensor.
HINT Refer to the applicable TSB or Repair Manual for the zero point calibration procedure.
4. Re-initialize all applicable systems available on the vehicle (power window sunroof power lift
door etc.).
Page 3448
Body
Splice Location (Standard Cab)
B1 Speaker Tweeter Wire LH
B2 Front Door LH Wire
B3 Front Door LH Wire
B4 Roof Wire
B5 Speaker Tweeter Wire RH
B6 B7
Front Door RH Wire
B10 Frame Wire
Seat
Locations
Impact Sensor: Locations
Front Airbag Sensor
Page 4128
Required Tools & Material
NOTE:
Additional Diagnostic Tester Kits, Program Cards or SSTs may be ordered by calling SPX-OTC at
1-800-933-8335.
Page 6371
An airbag activation prevention mechanism is built into the connector for the squib circuit of the
SRS.
When release of the airbag activation prevention mechanism is directed in the troubleshooting
procedure, as shown in the illustration of the connectors, insert paper which has the same
thickness as the male terminal, between the terminal and the short spring.
CAUTION: Never release the airbag activation prevention mechanism on the steering wheel pad
connector.
NOTE:
Page 303
INSPECT DOOR KEY LOCK AND UNLOCK SWITCH CONTINUITY
If continuity is not as specified, replace the switch.
INSPECT DOOR UNLOCK DETECTION SWITCH CONTINUITY
If continuity is not as specified, replace the switch.
Page 311
b. Inspect the connector on the wire harness side.
If circuit is not as specified, inspect the circuits connected to other parts.
Page 528
Applicable Vehicles
Page 2495
CHART 23
Page 1507
Part 2 of 3
Page 4520
Battery Charging Procedure
If the battery requires charging, follow the procedures below using the GR8 Battery Diagnostic
Station (P/N 00002-MCGR8).
1. Connect the charger cables to the positive (+) and negative (-) battery terminals.
2. Plug the charger into the 110V outlet and turn the switch to the ON position.
3. Select appropriate USER ID (if applicable) and press the NEXT soft key.
4. Enter USER PIN (if applicable) and press the NEXT soft key.
NOTE:
For details on defining USER ID or PIN, refer to the GR8 Instruction Manual.
5. Press the NEXT soft key when the HELLO screen appears to proceed to the Main Menu.
Page 3389
A. The new calibration file should be displayed as the current ECU calibration file.
B. Using a permanent marker or ball point pen, enter the required information on the Authorized
Modifications Label (Figures 21 and 22).
C. Affix this label under the hood in the location determined by the specific vehicle TSB or
Campaign.
NOTE:
Wait 60-90 seconds for ink to set before handling.
Specifications
Page 3006
j. Connect a TOYOTA hand-held tester to the DLC3.
k. Connect the battery negative (-) cable to the battery. l.
Turn the ignition switch ON, and push the TOYOTA hand-held tester main switch ON.
NOTE: Do not start the engine.
m. Select the ACTIVE TEST mode on the TOYOTA hand-held tester. n. Please refer to the
TOYOTA hand-held tester operator's manual for further details.
o. Connect SST (wire) to the injector and battery for 15 seconds, and measure the injection volume
with a graduated cylinder. Test each injector
2 or 3 times. SST 09842-30070
Volume: 56 - 69 cu.cm (3.4 - 4.2 cu in.) per 15 seconds
Difference between each injector: 13 cu.cm (0.8 cu in.) or less
If the injection volume is not as specified, replace the injector.
2. INSPECT LEAKAGE
a. In the condition above, disconnect the tester probes of SST (wire) from the battery and check the
fuel leakage from the injector.
SST 09842-30070
Fuel drop: 1 drop or less per 12 minutes
b. Turn the ignition switch OFF.
Page 3010
3. REMOVE FUEL PRESSURE PULSATION DAMPER
Remove the pulsation damper, upper gasket, fuel main hose and lower gasket.
CAUTION: Put a shop towel under the delivery pipe.
- Slowly loosen the pulsation damper.
4. REMOVE ACCELERATOR CABLE BRACKET
a. Disconnect the accelerator cable from the engine. b. Remove the 2 nuts and accelerator cable
bracket.
5. DISCONNECT PCV HOSE FROM PCV VALVE
6. DISCONNECT VSV FOR EVAP
a. Disconnect the VSV connector for EVAP. b. Disconnect the EVAP hose. c. Remove the
accelerator cable clamp and VSV for EVAP from the intake manifold.
7. REMOVE THROTTLE BODY COVER BRACKET
Remove the bolt and throttle body cover bracket.
8. DISCONNECT ENGINE WIRES
a. Disconnect the engine wire clamps from the No.1 engine hanger and engine wire bracket. b.
Disconnect the 2 wire clamps on the engine wire from the brackets on the RH delivery pipe.
9. REMOVE DELIVERY PIPES AND INJECTORS
NOTE:
Page 4539
Alternator: Testing and Inspection
INSPECTION
1. INSPECT ROTOR FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity between the slip rings.
Standard resistance: 2.1 - 2.5 ohms at 20 °C (68 °F).
If there is no continuity, replace the rotor.
2. INSPECT ROTOR FOR GROUND
Using an ohmmeter, check that there is no continuity between the slip ring and rotor. If there is
continuity, replace the rotor.
3. INSPECT SLIP RINGS
a. Check that the slip rings are not rough or scored.
If rough or scored, replace the rotor.
b. Using vernier calipers, measure the slip ring diameters.
If the diameter is less than minimum, replace the rotor.
Page 631
Page 4174
21. 4WD:
Using the following SSTs and a press, install the bearing spacer.
SST P/N: 09950-60010 (09951-00650)
SST P/N: 09950-70010 (09951-07150)
22. 4WD:
Install new oil seal (inside).
A. Using the following SST and a plastic hammer, install a NEW oil seal (inside).
SST P/N: 09527-17011
NOTE:
Lightly strike the SST on its circumference evenly.
B. Coat MP grease to the oil seal lip.
23. Install steering knuckle.
A. 4WD:
Insert the drive shaft into the axle hub and temporarily tighten the nut.
NOTE:
Be careful not to damage the oil seal and drive shaft boot.
B. Connect the steering knuckle to the upper suspension arm.
C. Install the nut and a NEW cotter pin. If the holes for the cotter pin are not aligned, tighten the nut
further up to 600.
Torque: 105 N.m (1,100 kgf.cm, 77 ft.lbf)
24. Connect the lower ball joint to the steering knuckle with 4 bolts.
Page 1286
Drive Belt: Testing and Inspection
INSPECTION
INSPECT DRIVE BELT
a. Visually check the belt for excessive wear, frayed cords, etc.
If any defect has been found, replace the drive belt.
HINT: Cracks on the rib side of a belt are considered acceptable. If the missing chunks from the
ribs are found on the belt, it should be replaced.
b. 5VZ-FE engine:
Belt tension gauge: DENSO BTG-20 (95506-00020) Borroughs No. BT-33-73F Drive belt tension:
New belt: 135 - 180 lbs. Used belt: 85 - 120 lbs. If the belt tension is not as specified, adjust it.
HINT: "New belt" refers to a belt which has been used less than 5 minutes on a running engine.
- "Used belt" refers to a belt which has been used on a running engine for 5 minutes or more.
- After installing a belt, check that it fits properly in the ribbed grooves.
- Check with your hand to confirm that the belt has not slipped out of the groove on the bottom of
the pulley.
- After installing a new belt, run the engine for about 5 minutes and recheck the belt tension.
Page 1971
A. The Diagnostic Tester displays 17" as a value of the Time $81" (see illustration).
B. Find the Conversion Factor value of Time $81" in the O2S Failure Threshold chart. 0.3906 is
specified for Time $81 in this chart.
C. Multiply "17" in step "A" by 0.3906 (Conversion Factor) in step "B."
17 x 0.3906 = 6.6%
D. If the answer is within the Standard Value of TEST LIMIT, the Time $81" can be confirmed to be
normal.
NOTE:
^ "LOW SW V" indicates the O2S voltage when the O2S status changes from rich to lean.
^ "HIGH SW V" indicates the O2S voltage when the O2S status changes from lean to rich.
^ If the O2S voltage is lower than "LOW SW V," the O2S status is lean.
^ If the O2S voltage is higher than "HIGH SW V," the O2S status is rich.
NOTE:
Before the O2S Monitor completes or after the ignition switch is turned OFF, the Diagnostic Tester
displays the viewable upper limit or a lower limit of the test value (example: 0 V, 1.275 V, Os
[seconds], 10.2s, 0 and 255).
Page 3565
Wiring Harness Connector
E: Indicates the wiring harness and wiring harness connector. The wiring harness with male
terminal is shown with arrows.
Outside numerals are pin numbers.
The first letter of the code for each wiring harness and wiring harness connector(s) indicates the
component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and
Surrounding area, and "B" for the Body and Surrounding area.
When more than one code has the first and second letters in common, followed by numbers (e.g,
IH1, IH2), this indicates the same type of wiring harness and wiring harness connector.
F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in
parts position.
G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside
it). Junction Blocks are shaded to clearly separate
them from other parts.
H: When 2 parts both use one connector in common, the parts connector name used in wire
routing is shown in square brackets [ ].
Wiring Color
I: Indicates the wiring color.
Wire colors are indicated by an alphabetical code.
B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR =
Brown SB = Sky Blue LG = Light Green GR = Gray
The first letter indicates the basic wire color and the second letter indicates the color of the stripe.
Page 1285
Page 2612
D. The Calibration Update Wizard (CUW) launches automatically when a calibration file link is
selected (or clicked). Verify that the CUW version is 6.0 or higher. If not, refer to the Note below.
The CUW will guide you through the steps to download the calibration file to the Diagnostic Tester
Program Card. Click NEXT on the first screen (Figure 7).
NOTE:
If the CUW does not launch, or the version is older than 6.0, install Diagnostic Software (TIS
Diagnostic Applications Installer). Specific installation instructions (Reprogramming with CUW 6.0)
are located under Diagnostics ECU Flash Reprogramming (Figure 6).
Page 2418
Page 4219
14. REMOVE OIL SEAL (OUTSIDE)
Using a screwdriver, remove the oil seal (outside) from the steering knuckle.
15. REMOVE BEARING FROM STEERING KNUCKLE
A. Using snap ring pliers, remove the snap ring.
B. Using the following SSTs and a press, remove the bearing from the steering knuckle.
^ 09950-60020 (09951-00810)
^ 09950-70010 (09951-07150)
16. INSTALL NEW BEARING
A. Using the following SSTs and a press, install a NEW bearing to the steering knuckle.
^ 09527-17011
^ 09950-60020 (09951-00910)
B. Using Snap ring pliers, install a NEW snap ring.
17. INSTALL NEW OIL SEAL (OUTSIDE)
A. Using the following SSTs and a plastic hammer, install a NEW oil seal (outside).
^ 09223-15030
Page 4753
B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(Connect the Relay) and SW 2 OFF (or Disconnect SW 2)
D. Disconnect and reconnect the connectors while watching the test light.
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
E. Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION:
a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals
are touched, the IC may be destroyed by
static electricity.)
b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact
with the terminals of leads from the IC, etc. of the replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
Special Tool
1. PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown.
2. DISCONNECT CONNECTOR
3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
a. Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the
secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
A: For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
Page 3141
2. REMOVE CRANKSHAFT POSITION SENSOR
a. Disconnect the crankshaft position sensor connector. b. Remove the bolt and crankshaft position
sensor.
INSTALLATION
1. INSTALL CRANKSHAFT POSITION SENSOR
a. Install the crankshaft position sensor with the bolt.
Torque: 6.5 N.m (65 kgf.cm, 58 in.lbf)
b. Connect the crankshaft position sensor connector.
2. INSTALL ENGINE UNDER COVER
Page 6792
Headlamp Relay: Testing and Inspection
POWER SOURCE
HEATER RELAY
1 - 2 : Closed with ignition SW on and heater blower SW on
HEAD RELAY
2 - 1 : Closed with light control SW at HEAD position or dimmer SW at FLASH position Closed with
engine running and parking brake lever released
(w/ daytime running light)
I23 IGNITION SW
2 - 3 : Closed with ignition key at ACC or ON position 2 - 4 : Closed with ignition key at ON or ST
position 7 - 6 : Closed with ignition key at ON or ST position
DIMMER RELAY (w/ DAYTIME RUNNING LIGHT)
4 - 3 : Closed with HEAD relay on and dimmer SW at HIGH or FLASH position
Fuel Pump Relay
Fuel Pump Relay: Testing and Inspection Fuel Pump Relay
INSPECTION
1. REMOVE RELAY BOX COVER
2. REMOVE FUEL PUMP RELAY (Marking: FUEL PUMP)
3. INSPECT FUEL PUMP RELAY CONTINUITY
a. Using an ohmmeter, check that there is continuity between terminals 1 and 2.
If there is no continuity, replace the relay.
b. Check that there is continuity between terminals 3 and 4.
If there is no continuity, replace the relay.
4. INSPECT FUEL PUMP RELAY OPERATION
a. Apply battery positive voltage across terminals 1 and 2. b. Using an ohmmeter, check that there
is no continuity between terminals 3 and 4.
If there is continuity, replace the relay.
5. REINSTALL FUEL PUMP RELAY
6. REINSTALL RELAY BOX COVER
Page 3710
Drive/Propeller Shaft: Tools and Equipment
Propeller Shaft - SST (Special Service Tools)
Propeller Shaft - Equipment
Testing and Inspection
Fog/Driving Lamp Switch: Testing and Inspection
INSPECT FOG LIGHT SWITCH CONTINUITY If continuity is not as specified, replace the switch.
Page 4672
Relay Box: Connector Views
Engine Room R/B
Page 3581
Electronically Controlled Transmission And A/T Indicator (Part 3)
Removal and Installation
Load Compensator: Service and Repair Removal and Installation
REMOVAL
1. DISCONNECT SHACKLE NO. 2 FROM BRACKET
(a) Remove the nut and cushion retainer, and disconnect the shackle No. 2. (b) Remove the 2
bushings and collar. (c) Remove the 2 bolts and shackle bracket.
2. REMOVE LSP & BV ASSEMBLY
(a) Using SST, disconnect the 3 brake lines from the valve body.
SST 09751-36011
(b) Remove the 2 valve bracket mounting bolts and the LSP & BV assembly.
INSTALLATION
Ground Locations
Transmission Mode Indicator - A/T: Ground Locations
Engine Compartment
Ground Location
EA Front Left Fender
EB Rear Bank of Right Cylinder
EC Rear Bank of Left Cylinder
Connector Location
EA1 Cowl Wire Harness and Wire Harness (Connector Location)
EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B)
EC1 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC2 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC3 Engine No. 2 Wire and Engine Wire (Near the Starter)
ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission)
Page 6009
Application Chart
Engine Controls - Error When Reprogramming ECU
Engine Control Module: All Technical Service Bulletins Engine Controls - Error When
Reprogramming ECU
SPECIAL SERVICE TOOLS SS004-01 REVISED
May 25, 2001
Title: ECU FLASH REPROGRAMMING ERROR MESSAGE
Models: Applicable Models
TSB REVISION NOTICE:
September 23, 2003: Models added - 2002 (and later) Solara, 2003 (and later) Corolla and Matrix,
and 2004 models; Test Procedures updated for new CAN Interface Module. The previous TSB
should be discarded.
Introduction
During ECU flash reprogramming, an error message may be displayed on the Diagnostic Tester
that will not allow ECU flash reprogramming to complete. This bulletin provides test procedures to
determine the cause for the error message.
Applicable Vehicles ^
2001 (and later) model year 4Runner, Highlander, Land Cruiser, RAV4, Sequoia and Tundra
vehicles.
^ 2002 (and later) model year Camry, Solara and Tacoma vehicles.
^ 2003 (and later) model year Corolla and Matrix vehicles.
^ All 2004 (and later) model year Toyota vehicles except Celica, MR2 Spyder, Avalon, and Tacoma
(3RZ-FE engine)
Required SSTs
NOTE:
Additional Diagnostic Tester Kits, CAN Interface Modules, Program Cards or other SSTs may be
ordered by calling SPX/OTC at 1-800-933-8335.
Warranty Information
Test Procedure
Page 4298
9. Remove steering knuckle.
A. Remove the cotter pin and loosen the nut.
B. Using the following SSTs, disconnect the steering knuckle.
SST P/N: 09950-40011 (09951-04010, 09952-04010, 09553-04020, 09554-04010 09955-04031,
09958-04011)
C. Remove the nut and steering knuckle.
NOTE:
4WD: Be careful not to damage the oil seal and drive shaft boot.
HINT: 4WD: When it is difficult to disconnect the drive shaft, tap the tip of the drive shaft with a
plastic hammer.
10. 2WD: Remove grease cap.
A. Mount the axle hub in a soft jaw vise.
NOTE:
Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further (refer to
the illustration).
HINT: Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further
(refer to the illustration).
B. Using a screwdriver, remove the grease cap.
NOTE:
Be careful not to damage the grease cap.
Page 591
Engine Bank Identification
Page 2902
Glossary Of Terms And Symbols (Part 1)
Testing and Inspection
Cargo Lamp Switch: Testing and Inspection
INSPECT CARGO LIGHT SWITCH CONTINUITY
a. Remove the center cluster finish panel. b. Disconnect the connector from the center cluster
integration. c. Check the continuity exists between terminal 12 and terminal 1, with the switch ON.
d. Check that no continuity exists between terminal 12 and terminal 1, with the switch OFF.
If continuity is not as specified, replace the switch.
Testing and Inspection
Power Mirror Switch: Testing and Inspection
Left side
INSPECT MIRROR SWITCH INSPECTION
Right side
INSPECT MIRROR SWITCH INSPECTION
If continuity is not as specified, replace the switch.
Page 571
CHART 26
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)
Body Outside Moulding
Lower Side Moulding / Trim: Service and Repair Body Outside Moulding
Body Outside Moulding
REMOVAL
1. HEAT MOULDING
Using a heat light, heat the moulding to 20 - 30 °C (68 - 86 °F).
NOTE: Do not heat the moulding excessively.
2. REMOVE MOULDING
Page 2931
Evaporative Vapor Pressure Sensor: Testing and Inspection
VAPOR PRESSURE SENSOR
INSPECTION
1. INSPECT POWER SOURCE VOLTAGE OF VAPOR PRESSURE SENSOR
a. Disconnect the vapor pressure sensor connector. b. Turn the ignition switch ON. c. Using a
voltmeter, measure the voltage between connector terminals VC and E2 of the wiring harness side.
Voltage: 4.5 - 5.5 V
d. Turn the ignition switch OFF. e. Reconnect the vapor pressure sensor connector.
2. INSPECT POWER OUTPUT OF VAPOR PRESSURE SENSOR
a. Turn the ignition switch ON. b. Disconnect the vacuum hose from the vapor pressure sensor. c.
Connect a voltmeter to terminals PTNK and E2 of the ECM, and measure the output voltage under
these conditions:
1. Apply vacuum (2.0 kPa (15 mmHg, 0.59 in.Hg)) to the vapor pressure sensor.
Voltage: 1.3 - 2.1 V
2. Release the vacuum from the vapor pressure sensor.
Voltage: 3.0 - 3.6 V
3. Apply pressure (1.5 kPa (15 gf/sq.cm, 0.22 psi)) to the vapor pressure sensor.
Page 3595
Install the No.1 vehicle speed sensor with the bolt.
Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.)
6. CONNECT NO. I VEHICLE SPEED SENSOR CONNECTOR
Vehicle Speed Sensor NO.2
Vehicle speed Sensor NO.2 on-vehicle repair
1. DISCONNECT NO. 2 VEHICLE SPEED SENSOR CONNECTOR
2. REMOVE NO. 2 VEHICLE SPEED SENSOR
a. Remove the bolt and No. 2 vehicle speed sensor. b. Remove the O-ring from the No. 2 vehicle
speed sensor.
3. INSTALL NO. 2 VEHICLE SPEED SENSOR
a. Coat a new O-ring with ATF and install it to the No. 2 vehicle speed sensor. b. Install the No. 2
vehicle speed sensor with the bolt.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
4. CONNECT NO. 2 VEHICLE SPEED SENSOR CONNECTOR
Page 6521
The ground points circuit diagram shows the connections from all major parts to the respective
ground points. When troubleshooting a faulty ground point, checking the system circuits which use
a common ground may help you identify the problem ground quickly. The relationship between
ground points (EA, IB and IC) can also be checked this way.
How to Read Power Source
HOW TO READ POWER SOURCE
Page 3992
Hydraulic Control Assembly - Antilock Brakes: Diagrams
ABS ACTUATOR REPLACEMENT AND OVERHAUL W/ RELATED COMPONENTS
Part 1 of 2
Page 1080
The ground points circuit diagram shows the connections from all major parts to the respective
ground points. When troubleshooting a faulty ground point, checking the system circuits which use
a common ground may help you identify the problem ground quickly. The relationship between
ground points (EA, IB and IC) can also be checked this way.
How to Read Power Source
HOW TO READ POWER SOURCE
Page 160
A. The new calibration file should be displayed as the current ECU calibration file.
B. Using a permanent marker or ball point pen, enter the required information on the Authorized
Modifications Label (Figures 21 and 22).
C. Affix this label under the hood in the location determined by the specific vehicle TSB or
Campaign.
NOTE:
Wait 60-90 seconds for ink to set before handling.
Page 3661
6. FILL DIFFERENTIAL WITH HYPOID GEAR OIL 7. INSTALL ENGINE UNDER COVER 8.
INSTALL FRONT WHEEL
Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.)
Disassembly and Reassembly
DISASSEMBLY
Page 2778
CHART 29
Page 5048
Page 2274
E. Confirm the Diagnostic Tester has the appropriate software for the type of calibration file that
was downloaded.
NOTE:
The calibration type is specific to the software version loaded on your Diagnostic Tester. If you
selected the wrong version when downloading the calibration file, you will receive an error when
attempting to install the file on the Diagnostic Tester.
Page 5927
Page 3570
Glossary Of Terms And Symbols (Part 1)
Page 6285
Splice Location
I1 Cowl Wire
I2 Cowl Wire
I3 Cowl Wire
I4 Cowl Wire
I5 Cowl Wire
I6 Cowl Wire
I7 Engine Wire
I8 Engine Wire
I9 Engine Wire
I10 Engine Wire
I11 Engine Wire
I12 Engine Wire
I13 Engine Wire
I14 Engine Wire
I15 Engine Wire
I16 Cowl Wire
Body
Splice Location (Access Cab)
B1 Speaker Tweeter Wire LH
B2 Front Door LH Wire
B3 Front Door LH Wire
B4 Roof Wire
B5 Speaker Tweeter Wire RH
B6 B7
Front Door RH Wire
B8 Front Door RH Wire
B9 Rear Door No. 1 Wire RH
B10 Frame Wire
Page 6540
BJ Inside of Rear Door LH
BK Inside of Rear Door RH
BL Surrounding of the Front of the Fuel Tank
Connector Location
BA1 Front Door LH Wire and Wire Harness (Connector Location)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel)
BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel)
BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel)
BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Page 6318
Glossary Of Terms And Symbols (Part 1)
Specifications
Three-Way Catalytic Converter (TWC) System
Page 2638
Non-Waterproof Type Connector
"Case 1" Raise the terminal retainer up to the temporary lock position.
Non-Waterproof Type Connector
"Case 2" Open the secondary locking device.
Page 1299
12. Install the NEW A/C compressor mounting bracket and hand tighten bolts 1 and 2 while holding
the bracket forward (refer to illustration).
13. While holding the bracket forward, tighten the A/C compressor mounting bolts in the following
sequence: bolt 2, bolt 1, bolt 3.
Torque: 47 N.m (475 kgf.cm, 34 ft.lbf)
14. Remove the accessory drive belt tensioner.
15. Install the NEW accessory drive belt tensioner.
16. Reassemble in the reverse order of disassembly.
17. Refill cooling system.
Page 6723
Glossary Of Terms And Symbols (Part 1)
Page 6715
Body
Connector Location (Standard Cab)
BA1 Front Door LH Wire and Speaker Tweeter Wire LH (Inside of Front Door LH)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Seat
Connector Location
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
BJ1 Seat No. 1 Wire and Seat No. 2 Wire (Under the Driver's Seat)
Page 1923
CHART 16
CHART 17
Front
Wheel Bearing: Service and Repair Front
Removal and Installation
REMOVAL
1. REMOVE FRONT WHEEL 2. REMOVE GREASE CAP
Using a screwdriver and hammer, remove the grease cap.
Page 4417
Installation is in the reverse order of removal.
HINT: After installation, fill brake reservoir with brake fluid and bleed brake system.
- Check for leaks.
Page 4439
Brake Master Cylinder: Service and Repair Disassembly and Assembly
DISASSEMBLY
1. REMOVE RESERVOIR
(a) Remove the set screw and pull out the reservoir.
Torque: 1.8 Nm (18 kgf-cm, 16 inch lbs.)
(b) Remove the cap and strainer from the reservoir.
2. REMOVE 2 GROMMETS 3. PLACE CYLINDER IN VISE
Page 5771
The ground points circuit diagram shows the connections from all major parts to the respective
ground points. When troubleshooting a faulty ground point, checking the system circuits which use
a common ground may help you identify the problem ground quickly. The relationship between
ground points (EA, IB and IC) can also be checked this way.
How to Read Power Source
HOW TO READ POWER SOURCE
Page 2009
Heated Oxygen Sensor
Page 3184
Crankshaft Position Sensor: Service and Repair
Crankshaft Position Sensor
REMOVAL
1. REMOVE ENGINE UNDER COVER
Testing and Inspection
Backup Lamp Switch: Testing and Inspection
INSPECT BACK-UP LIGHT SWITCH CONTINUITY If continuity is not as specified, replace the
switch.
Page 139
During ECU flash reprogramming, the Error screen shown may be displayed on the Diagnostic
Tester for one of the following reasons:
1. Immobilizer key not properly registered or auto-registration mode left open.
2. Ignition ON/OFF cycling not followed correctly during the flash reprogramming procedure.
3. The Diagnostic Tester cable is damaged, causing an open communication circuit.
NOTE:
The Diagnostic Tester may operate properly in other modes such as OBD, OBDII, or CARB, with a
damaged cable.
To eliminate the possibility of the first 2 reasons causing the error message, do the following:
1. Confirm the Immobilizer Transponder Master Key is properly registered and auto registration
mode is closed. Follow the appropriate Repair Manual procedure and consult TSB SS001-99,
"Scan tool Immobilizer key Code Utility
2. Conduct the ECU flash reprogramming process explicitly following key operation instructions.
Refer to TSB SS002-01, "ECU Flash Reprogramming Process, "for more details.
To determine if the Diagnostic Tester cable is damaged, follow the test procedures below to check
the electrical integrity of the cable. Conduct all continuity tests with an Ohm meter. For all five test
procedures, the resistance values must be below 6.0 ohms to pass.
Test CABLE TEST 1.
Page 3577
Terminal Retainer
Push the terminal retainer down to the temporary lock position.
c. Release the locking lug from terminal and pull the terminal out from rear.
4. INSTALL TERMINAL TO CONNECTOR
a. Insert the terminal.
HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug
locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position.
Page 6888
Lamp Control Module: Description and Operation
LIGHT AUTO TURN OFF
SYSTEM OUTLINE
With the ignition SW turned on, the current flows to TERMINAL 9 of the integration relay through
ECU IG fuse.
Voltage is applied at all times to TERMINAL 6 of the integration relay through the TAIL fuse, and
through the HEAD relay coil side [w/o daytime running light] or through the daytime running light
relay (Main) [w/ daytime running light].
1. NORMAL LIGHTING OPERATION
With the light control SW turned to TAIL position, a signal is input into the integration relay. Due to
this signal, the current flowing to TERMINAL 6 of the relay flows to TERMINAL 14 of the light
control SW to TERMINAL 16 to GROUND, and taillights to turn on.
With the light control SW turned to HEAD position, a signal is input into the integration relay. Due to
this signal, the current flowing to the relay flows to TERMINAL 13 of the light control SW to
TERMINAL 16 to GROUND in the headlight circuit, and causes taillight and HEAD relay to turn the
lights on. The taillight circuit is same as above.
2. LIGHT AUTO TURN OFF OPERATION
With light on and ignition SW turned off (Input signal goes to TERMINAL 9 of the relay), when the
driver's door is opened (Input signal goes to TERMINAL 14 of the relay), the relay operates and the
current is cutoff which flows from TERMINAL 6 of the relay to taillight circuit and headlight circuit.
As a result, all lights are turned off automatically.
Page 126
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 4205
SST P/N: 09527-17011
B. Coat MP grease to the oil seal lip.
18. Install new dust cover and axle hub to steering knuckle.
A. Install the NEW dust cover to the steering knuckle with the 4 bolts.
Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)
B. Using the following SST and a press, install the axle hub to the steering knuckle.
SST P/N: 09649-17010
19. Install ABS speed sensor rotor (with ABS) or spacer (without ABS).
NOTE:
Take care not to scratch the serration of the speed sensor rotor and ensure the speed sensor is
installed completely.
20. 2WD:
Install new lock nut.
A. Using the following SST, install and torque a NEW lock nut to the axle hub.
SST P/N: 00002-00909 (09318-12010)
Torque: 274 N.m (2,800 kgf.cm, 203 ft.lbf)
NOTE:
Do NOT use air wrench.
B. Using a chisel and hammer, stake the lock nut.
Page 2575
Specifications
Page 233
b. Push the secondary locking device or terminal retainer in to the full lock position.
5. CONNECT CONNECTOR
Disconnection of Male and Female Connectors
Disconnection of Male and Female Connectors
Disconnection Of Male And Female Connectors
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Instruments - Oil Pressure Gauge Reads Abnormally Low
Oil Pressure Gauge: Customer Interest Instruments - Oil Pressure Gauge Reads Abnormally Low
ELECTRICAL EL017-03
December 23, 2503
Title OIL PRESSURE GAUGE READS LOW
Models '01 - '04 Sequoia & '00 - '02 Tundra
TSB UPDATE NOTICE:
This TSB updates EL006-03. TSB EL006-03 is now obsolete and should be discarded.
Introduction
Some customers with Sequoia or Tundra vehicles may encounter an oil pressure gauge that reads
abnormally low at idle. An updated oil pressure sender has been created to address this condition.
Applicable Vehicles ^
2001 - 2004 model year Sequoia vehicles produced BEFORE the Production Change Effective
VINs shown below.
^ 2000 - 2002 model year Tundra vehicles produced BEFORE the Production Change Effective
VIN shown below.
Production Change Information
Parts Information
Repair Procedure
1. Replace the Oil Pressure Sender.
2. Verify proper operation of the Oil Pressure Gauge.
Warranty Information
Applicable Warranty*:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36
months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Page 4137
Torque: 64 N.m (650 kgf.cm, 47 ft.lbf)
B. Connect the lower side of shock absorber to the lower suspension arm with bolt, washer and
nut.
Torque: 135 N.m (1,400 kgf.cm, 100 ft.lbf)
26. INSPECT AND INSTALL THE BRAKE ROTOR AND INSTALL THE BRAKE CALIPER WITH
NEW MOUNTING BOLTS
A. Inspect the brake rotors, and machine using an on-the-car brake lathe. Replace the rotor if it is
below minimum thickness values Minimum Thickness: 26.0 mm (1.024 in.)
B. Install the disc, brake caliper and 2 NEW bolts.
Torque: 123 N.m (1,259 kgf.cm, 90 ft.lbf)
C. Install the brake line clamp to the steering knuckle with the bolt.
Torque: 28 N.m (285 kgf.cm, 21 ft.lbf)
27. INSTALL NEW BRAKE LINE
Using the SST, connect NEW brake line.
^ 09023-00100
Torque: 15 N.m (155 kgf.cm, 11 ft.lbf)
28. W/ABS: CONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP
Connect the ABS speed sensor and wire harness clamp to the steering knuckle with the 2 bolts.
Torque: 8.0 N.m (82 kgf.cm, 71 in..lbf)
29. 4WD: INSTALL DRIVE SHAFT LOCK NUT
A. While applying the brakes, tighten the nut.
Torque: 235 N.m (2,400 kgf.cm, 173 ft.lbf)
B. Install the lock cap and a NEW cotter pin.
If the holes for the cotter pin are not aligned, tighten the nut further up to 60°.
30. 2WD: INSTALL GREASE CAP
31. INSTALL FRONT WHEEL
NOTE:
Do NOT use air wrench.
Torque: 110 N.m (1,150 kgf.cm, 83 ft.lbf)
32. DEPRESS BRAKE PEDAL SEVERAL TIMES
33. FILL THE BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM
34. CHECK ABS SPEED SENSOR SIGNAL (SEE REPAIR MANUAL)
Testing and Inspection
Overdrive Indicator Lamp: Testing and Inspection
O/D Main Switch & O/D OFF Indicator Light Circuit
CIRCUIT DESCRIPTION
The O/D main switch contacts go open when the switch is pushed in and go closed when it is
pushed out.
If O/D main switch is at OFF position, the O/D OFF indicator light lights up, and the ECM prohibits
shifting O/D.
Wiring Diagram
INSPECTION PROCEDURE
Testing and Inspection
Power Door Lock Switch: Testing and Inspection
Master switch
INSPECT DRIVER'S DOOR LOCK CONTROL SWITCH CONTINUITY
If continuity is not as specified, replace the switch.
INSPECT PASSENGER'S DOOR LOCK CONTROL SWITCH CONTINUITY
If continuity is not as specified, replace the switch.
Page 6520
B: Junction Connector
Indicates a connector which is connected to a short terminal.
Junction connector in this include a short terminal which is connected to a number of wire
harnesses. Always perform inspection with the short terminal installed. (When installing the wire
harnesses, the harnesses can be connected to any position within the short terminal grouping.
Accordingly, in other vehicles, the same position in the short terminal may be connected to wire
harness from a different part.) Wire harness sharing the same short terminal grouping ha the same
color.
C: Parts Code
The first letter of the code is taken from the first letter of part, and the numbers indicates its order in
parts which start with the same letter.
D: Connector Color
Connectors not indicated are milky white in color.
How to Read Ground Points
HOW TO READ GROUND POINTS
Page 952
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 4494
Wheel Speed Sensor: Service and Repair Speed Sensor, Rear
REMOVAL
1. DISCONNECT SPEED SENSOR CONNECTOR
2. REMOVE SPEED SENSOR
(a) Remove the 2 clamp bolts, clamp nut and 5 resin clips holding the sensor wire harness from the
axle and the fuel tank.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)
HINT: When installing the rear sensor wire harness, never use the removed resin clips, which are service
parts.
- When replacing clips, set up new resin clips at the same angle of the removed resin clips.
(b) Remove the bolt and speed sensor from the axle carrier.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
INSTALLATION
Installation is in the reverse order of removal.
HINT: After installation, check speed sensor signal.
Page 3221
Body
Splice Location (Standard Cab)
B1 Speaker Tweeter Wire LH
B2 Front Door LH Wire
B3 Front Door LH Wire
B4 Roof Wire
B5 Speaker Tweeter Wire RH
B6 B7
Front Door RH Wire
B10 Frame Wire
Seat
Service and Repair
Valve: Service and Repair
For further information regarding this component and the system that it is a part of, please refer to
Cylinder Head Assembly; Service and Repair.
Page 6489
Audible Warning Device Control Module: Ground Locations
Engine Compartment
Ground Location
EA Front Left Fender
EB Rear Bank of Right Cylinder
EC Rear Bank of Left Cylinder
Connector Location
EA1 Cowl Wire Harness and Wire Harness (Connector Location)
EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B)
EC1 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC2 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC3 Engine No. 2 Wire and Engine Wire (Near the Starter)
ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission)
Page 3361
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 6878
Glossary Of Terms And Symbols (Part 2)
Page 2603
3. Start the engine and warm it up to normal operating temperatures before test-driving.
4. Perform a thorough test drive with several accelerations from a stop with "light throttle"
application until proper transmission shifting is verified.
Reset Procedure 2
1. Disconnect the negative battery cable for 5 minutes.
2. Reconnect battery cable.
3. Start the engine and warm it up to normal operating temperatures before test-driving.
4. Perform a thorough test drive with several accelerations from a stop with "light throttle"
application until proper transmission shifting is verified.
Page 5229
Condenser HVAC: Service and Repair
REMOVAL
1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM
HINT: At the time of installation, please refer to the following item. Evacuate air from refrigeration
system. Charge system with refrigerant and inspect for leakage of refrigerant.
Specified amount: 600 ± 50 g (21.16 ± 1.76 oz.)
2. 2UZ-FE engine
REMOVE A/T OIL COOLER
3. REMOVE HORN
4. REMOVE HOOD LOCK
5. REMOVE CENTER BRACE
6. REMOVE RECEIVER AND HOLDER
Page 501
Intake Air Temperature Sensor: Description and Operation
Intake Air Temperature Sensor
The intake air temperature sensor is built into the air cleaner cap and senses the intake air
temperature. A thermistor built in the sensor changes the resistance value according to the intake
air temperature.
The lower the intake air temperature, the greater the thermistor resistance value, and the higher
the intake air temperature, the lower the thermistor resistance value.
The intake air temperature sensor is connected to the ECM. The 5 V power source voltage in the
ECM is applied to the intake air temperature sensor from the terminal THA via a resistor R.
That is, the resistor R and the intake air temperature sensor are connected in series. When the
resistance value of the intake air temperature sensor changes in accordance with changes in the
intake air temperature, the potential at terminal THA also changes. Based on this signal, the ECM
increases the fuel injection volume to improve driveability during cold engine operation.
Page 3999
Installation is in the reverse order of removal.
HINT: After installation, fill brake reservoir with brake fluid and bleed brake system.
- Check for leaks.
Page 2497
CHART 24
Page 3007
c. Disconnect the negative (-) terminal cable from the battery. d. Remove the SST and fuel tube
connector.
SST 09268-41047, 09842-30070
e. Disconnect the TOYOTA hand-held tester from the DLC3. f.
Reconnect the fuel inlet pipe to the fuel tube.
Page 3485
Step 3
Description and Operation
Brake Fluid Solenoid Valve Relay: Description and Operation
ABS Solenoid Relay
This relay supplies power to each ABS solenoid. After the ignition switch is turned ON, if the initial
check is OK, the relay goes on.
Page 1728
A. The new calibration file should be displayed as the current ECU calibration file.
B. Using a permanent marker or ball point pen, enter the required information on the Authorized
Modifications Label (Figures 21 and 22).
C. Affix this label under the hood in the location determined by the specific vehicle TSB or
Campaign.
NOTE:
Wait 60-90 seconds for ink to set before handling.
Page 496
Crankshaft Position Sensor: Service and Repair
Crankshaft Position Sensor
REMOVAL
1. REMOVE ENGINE UNDER COVER
Page 976
Hose/Line HVAC: Tools and Equipment
A/C Clamp Remover
AST tool# TOY 200
Locations
Engine Room R/B
Fuel Pump Relay
Fuel Pump Relay: Testing and Inspection Fuel Pump Relay
INSPECTION
1. REMOVE RELAY BOX COVER
2. REMOVE FUEL PUMP RELAY (Marking: FUEL PUMP)
3. INSPECT FUEL PUMP RELAY CONTINUITY
a. Using an ohmmeter, check that there is continuity between terminals 1 and 2.
If there is no continuity, replace the relay.
b. Check that there is continuity between terminals 3 and 4.
If there is no continuity, replace the relay.
4. INSPECT FUEL PUMP RELAY OPERATION
a. Apply battery positive voltage across terminals 1 and 2. b. Using an ohmmeter, check that there
is no continuity between terminals 3 and 4.
If there is continuity, replace the relay.
5. REINSTALL FUEL PUMP RELAY
6. REINSTALL RELAY BOX COVER
Page 3759
Non-Waterproof Type Connector
"Case 1" Raise the terminal retainer up to the temporary lock position.
Non-Waterproof Type Connector
"Case 2" Open the secondary locking device.
Page 2843
Oxygen Sensor: Testing and Inspection
HEATED OXYGEN SENSOR
INSPECTION
1. INSPECT HEATER RESISTANCE OF HEATED OXYGEN SENSORS
a. Disconnect the oxygen sensor connector.
Resistance
b. Using an ohmmeter, measure the resistance between terminals +B and HT.
If the resistance is not as specified, replace the sensor.
Torque: 44 N.m (450 kgf.cm, 32 ft.lbf) for sensor 1 20 N.m (200 kgf.cm, 14 ft.lbf) for sensor 2
c. Reconnect the oxygen sensor connector.
2. INSPECT OPERATION OF HEATED OXYGEN SENSORS
Page 4664
Glossary Of Terms And Symbols (Part 2)
Page 3350
A. Connect Diagnostic Tester cables DLC (P/N 02001637) and CAN Interface Module / J1962
OBDII together (P/N 01002744).
B. Test for continuity.
^ If there is continuity, the cable is OK. Check steps 1 and 2 above to complete the flash
reprogramming process.
^ If there is no continuity, proceed to CABLE TEST 2.
CABLE TEST 2.
A. Disconnect Diagnostic Tester cables DLC (P/N 02001637) and CAN Interface Module /J1962
OBDII (P/N 01002744).
B. Test DLC cable (P/N 02001637) for continuity.
^ If there is continuity, the cable is OK. Proceed to CABLE TEST 3.
^ If there is no continuity, the cable needs to be replaced.
CABLE TEST 3.
Page 4718
Auxiliary Power Outlet: Diagnostic Aids
Voltage Check
Voltage Check
Voltage Check
A. Establish conditions in which voltage is present at the check point.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(SW 2 OFF)
B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or
component terminal. This check can be done with a test light instead of a voltmeter.
Continuity and Resistance Check
Continuity and Resistance Check
Continuity And Resistance Check
A. Disconnect the battery terminal or wire so there is no voltage between the check points. B.
Contact the two leads of an ohmmeter to each of the check points.
Locations
Engine Room R/B
Page 4445
Wheel Cylinder: Service and Repair
For information regarding the service and repair of this component and the system that it is a part
of, please refer to Drum Brake System; Service and Repair.
Page 5591
Splice Location
I1 Cowl Wire
I2 Cowl Wire
I3 Cowl Wire
I4 Cowl Wire
I5 Cowl Wire
I6 Cowl Wire
I7 Engine Wire
I8 Engine Wire
I9 Engine Wire
I10 Engine Wire
I11 Engine Wire
I12 Engine Wire
I13 Engine Wire
I14 Engine Wire
I15 Engine Wire
I16 Cowl Wire
Body
Splice Location (Access Cab)
B1 Speaker Tweeter Wire LH
B2 Front Door LH Wire
B3 Front Door LH Wire
B4 Roof Wire
B5 Speaker Tweeter Wire RH
B6 B7
Front Door RH Wire
B8 Front Door RH Wire
B9 Rear Door No. 1 Wire RH
B10 Frame Wire
Page 1498
Valve Clearance: Testing and Inspection
INSPECTION
HINT: Inspect and adjust the valve clearance when the engine is cold.
1. REMOVE BATTERY CLAMP COVER 2. REMOVE THROTTLE BODY COVER 3. REMOVE AIR
CLEANER AND INTAKE AIR CONNECTOR ASSEMBLY 4. REMOVE NO.3 TIMING BELT
COVERS 5. REMOVE IGNITION COILS 6. REMOVE RH CYLINDER HEAD COVER
Remove the 9 bolts, seal washers and cylinder head cover.
7. REMOVE LH CYLINDER HEAD COVER
a. Remove the oil dipstick for the transmission. b. Disconnect the PCV hose. c. Disconnect the
engine wire clamp from the wire bracket on the cylinder head cover. d. Remove the 9 bolts, 9 seal
washers and cylinder head cover.
8. SET NO.1 CYLINDER TO TDC/COMPRESSION
a. Turn the crankshaft pulley, and align its groove with timing mark "0" of the No.1 timing belt cover.
b. Check that the timing marks of the camshaft timing pulleys and timing belt rear plates are
aligned.
If not, turn the crankshaft 1 revolution (360°) and align the mark.
9. INSPECT VALVE CLEARANCE
Testing and Inspection
Speedometer Head: Testing and Inspection
INSPECT SPEEDOMETER ON-VEHICLE Using a speedometer tester, inspect the speedometer
for allowable indication error and check the operation of the odometer.
HINT: Tire wear and tire over or under inflation will increase the indication error.
If error is excessive, replace the speedometer.
INSPECT SPEEDOMETER RESISTANCE Measure the resistance between terminals while fixing
pointer to the stopper. If resistance value is not as the specified, replace the meter.
Electrical Specifications
Resistance
Page 4537
Alternator: Diagrams
Generator (Part 1)
Page 6281
Audible Warning Device Control Module: Ground Locations
Engine Compartment
Ground Location
EA Front Left Fender
EB Rear Bank of Right Cylinder
EC Rear Bank of Left Cylinder
Connector Location
EA1 Cowl Wire Harness and Wire Harness (Connector Location)
EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B)
EC1 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC2 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC3 Engine No. 2 Wire and Engine Wire (Near the Starter)
ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission)
Engine Controls - Bank 1/Bank 2 O2 Sensor identification
Oxygen Sensor: All Technical Service Bulletins Engine Controls - Bank 1/Bank 2 O2 Sensor
identification
ENGINE EG034-07
Title: ENGINE BANK 1 AND BANK 2 A/F AND O2 IDENTIFICATION
Models: '93 - '08 Applicable Models
June 28, 2007
The information contained in this TSB supercedes TSB No. EG037-04. TSB No. EG037-04 is now
obsolete and should be discarded.
Introduction
This service bulletin provides information on the proper identification of engine bank 1 and engine
bank 2 for correct A/F sensor and oxygen sensor replacement.
This bulletin contains information that identifies engine bank 1 and engine bank 2 on the following
engines: 1AZ-FE, 2AZ-FE, 2AZ-FE (PZEV), 1GR-FE, 2GR-FE, 2GR-FSE, 2JZ-GE, 1MZ-FE,
3MZ-FE, 1UR-FSE, 3UR-FE, 2UZ-FE, 3UZ-FE, 5VZ-FE, and 1ZZ-FE.
^ Bank 1 (B1) refers to the bank that includes cylinder No. 1.
^ Bank 2 (B2) refers to the bank opposite bank 1.
^ Sensor 1 (S1) refers to the sensor that is located before the catalytic converters.
^ Sensor 2 (S2) refers to the sensor that is located after the catalytic converters.
Warranty Information
Page 4954
1. REMOVE 2 TURN PRESSURE TUBES
a. Using Special Service Tool (SST), remove the 2 turn pressure tubes.
SST 09023-12700
b. Remove the 4 O-rings from the tubes.
2. SECURE PS GEAR ASSEMBLY IN VISE
Using SST, 2 bolts and nuts, secure the gear assembly in a vise, as shown in the illustration. SST
09612-00012 Reference:
Bolt: 90105-10346 Nut: 90170-10198
HINT: Use 2 of the same type of SST
3. REMOVE RIGHT-HAND AND LEFT-HAND TIE ROD ENDS AND LOCK NUTS
a. Place matchmarks on the tie rod end, lock nut and rack end. b. Loosen the lock nut, remove the
tie rod end and lock nut. c. Employ the same manner described to the other side.
Page 1925
CHART 20
Page 6849
Backup Lamp Relay: Testing and Inspection
INSPECT BACK-UP LIGHT RELAY CONTINUITY If continuity is not as specified, replace the
relay.
Page 5803
The ground points circuit diagram shows the connections from all major parts to the respective
ground points. When troubleshooting a faulty ground point, checking the system circuits which use
a common ground may help you identify the problem ground quickly. The relationship between
ground points (EA, IB and IC) can also be checked this way.
How to Read Power Source
HOW TO READ POWER SOURCE
Page 4887
Repair Procedure
1. Disconnect the cable from the negative (-) battery terminal for MORE THAN two (2) seconds.
2. Reconnect the cable to the negative (-) battery terminal.
3. Perform the applicable zero point calibration of the yaw rate sensor and/or the steering angle
sensor.
HINT Refer to the applicable TSB or Repair Manual for the zero point calibration procedure.
4. Re-initialize all applicable systems available on the vehicle (power window sunroof power lift
door etc.).
Page 1115
Continuity And Resistance Check
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Continuity And Resistance Check
C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the
electrical circuit.
Finding A Short Circuit
Finding A Short Circuit
Finding A Short Circuit
A. Remove the blown fuse and disconnect all loads of the fuse.
Locations
Clockspring Assembly / Spiral Cable: Locations
Steering Wheel Pad And Spiral Cable
Front
Wheel Fastener: Service and Repair Front
REPLACEMENT
1. REMOVE FRONT WHEEL
2. REMOVE BRAKE CALIPER AND DISC
a. Remove the bolt and brake line clamp from the steering knuckle. b. Remove the 2 bolts, brake
caliper and disc. c. Support the brake caliper securely.
3. REMOVE HUB BOLT
Using Special Service Tool (SST) and a screwdriver or an equivalent, remove the hub bolt. SST
09650-17011
4. INSTALL HUB BOLT
a. Install a washer and nut to a new hub bolt as shown in the illustration. b. Using a screwdriver or
an equivalent to hold, install the hub bolt by torquing the nut. c. Remove the nut and washer.
5. INSTALL BRAKE DISC AND CALIPER
a. Install the brake disc, caliper and 2 bolts.
Torque: 123 Nm (1,250 kgf-cm, 90 ft. lbs.)
b. Install the brake line clamp to the steering knuckle with bolt.
Torque: 28 Nm (285 kgf-cm, 21 ft. lbs.)
6. INSTALL FRONT WHEEL
Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.)
7. DEPRESS BRAKE PEDAL SEVERAL TIMES
Page 5835
promoters. However, the application of adhesion promoters on earlier model bumpers made from
PP/TPU (Polypropylene/Thermoplastic Urethane) and PUR (Polyurethane) is also recommended.
Page 5939
Page 6726
Continuity And Resistance Check
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Continuity And Resistance Check
C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the
electrical circuit.
Finding A Short Circuit
Finding A Short Circuit
Finding A Short Circuit
A. Remove the blown fuse and disconnect all loads of the fuse.
Page 689
Voltage: 4.2 - 4.8 V
d. Turn the ignition switch OFF. e. Reconnect the vacuum hose to the vapor pressure sensor.
Page 4181
Required Tools & Material
NOTE:
Additional Diagnostic Tester Kits, Program Cards or SSTs may be ordered by calling SPX-OTC at
1-800-933-8335.
Page 4185
Remove the 4 bolts and disconnect the lower ball joint.
9. REMOVE STEERING KNUCKLE
A. Remove the cotter pin and loosen the nut.
B. Using the following SSTs, disconnect the steering knuckle.
^ 09950-40011 (09951-04010, 09952-04010, 09553-04020, 09554-04010, 09955-04031,
09958-04011)
C. Remove the nut and steering knuckle.
NOTE:
4WD: Be careful not to damage the oil seal and drive shaft boot.
HINT:
4WD: When it is difficult to disconnect the drive shaft, tap the tip of the drive shaft with a plastic
hammer.
10. 2WD: REMOVE GREASE CAP
A. Mount the axle hub in a soft jaw vise.
HINT:
Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further.
B. Using a screwdriver, remove the grease cap.
HINT:
Be careful not to damage the grease cap.
11. 4WD: REMOVE OIL SEAL (INSIDE)
A. Mount the axle hub in a soft jaw vise.
HINT:
Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further.
B. Using a screwdriver, remove the oil seal (inside).
Page 5099
Page 1509
Water Pump: Service and Repair
Page 5400
3. Connect the SST connector to the airbag connector of the spiral cable.
SST 09082-00700
4. Move the SST at least 10 m (33 ft) away from the front of the vehicle. 5. Close all the doors and
windows of the vehicle.
NOTE: Take care not to damage the SST wire harness.
6. Connect the SST red clip to the battery positive (+) terminal and the black clip to the negative (-)
terminal
c. Deploy the airbag.
1. Confirm that no one is inside the vehicle or within 10 m (33 ft) area around the vehicle. 2. Press
the SST activation switch and deploy the airbag.
HINT: The airbag deploys simultaneously as the LED of the SST activation switch lights up.
d. Dispose the steering wheel pad (with airbag).
CAUTION: The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30
minutes after deployment.
- When moving a vehicle for scrapping which has a steering wheel pad with deployed airbag, use
gloves and safety glasses.
- Use gloves and safety glasses when handling a steering wheel pad with the deployed airbag.
- Always wash your hands with water after completing the operation.
- Do not apply water, etc. to a steering wheel pad with the deployed airbag.
HINT: When scrapping a vehicle, deploy the airbag and scrap the vehicle with the steering wheel
pad still installed.
Deployment When Disposing of Steering Wheel Pad
DISPOSAL
Page 2004
CHART 29
Page 1736
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 1909
Service and Repair
Fluid Pump: Service and Repair
For further information regarding this component and the system that it is a part of, please refer to
Transfer Case; Service and Repair.
Page 4428
6. BLEED BRAKE LINE 7. CHECK AND ADJUST LSP & BV FLUID PRESSURE
Page 1979
CHART 5
CHART 6
Electrical Specifications
Resistance
Page 5054
A. AFFECTED VIN RANGE
III. Preparation
A. PARTS
^ No parts are required for the inspection.
B. EQUIPMENT & MATERIALS
^ Protective eyewear
^ Standard heater core hose
Page 17
Driver Side J/B And Integration Relay
Page 4757
b. Push the secondary locking device or terminal retainer in to the full lock position.
5. CONNECT CONNECTOR
Disconnection of Male and Female Connectors
Disconnection of Male and Female Connectors
Disconnection Of Male And Female Connectors
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Page 5174
8. REMOVE STEERING KNUCKLE
a. Remove the coffer pin and loosen the nut. b. Using Special Service Tool (SST), disconnect the
steering knuckle.
SST 09950-40011 (09951-04010, 09952-04010, 09553-04020, 09554-04010, 09955-04031,
09958-04011)
c. Remove the nut and steering knuckle.
NOTICE: 4WD: Be careful not to damage the oil seal and drive shaft boot.
HINT: 4WD: When it is difficult to disconnect the drive shaft, tap the tip of the drive shaft with a
plastic hammer.
INSTALLATION
1. INSTALL STEERING KNUCKLE
a. 4WD: Insert the drive shaft into the axle hub and temporarily tighten the nut.
NOTICE: Be careful not to damage the oil seal and drive shaft boot.
b. Connect the steering knuckle to the upper suspension arm. c. Install the nut and a new cotter
pin.
If the holes for the cotter pin are not aligned, tighten the nut further up to 60°. Torque: 105 Nm
(1,100 kgf-cm, 77 ft. lbs.)
2. CONNECT LOWER BALL JOINT
Connect the lower ball joint to the steering knuckle with 4 bolts. Torque: 80 Nm (820 kgf-cm, 59 ft.
lbs.)
3. INSTALL SHOCK ABSORBER 4. INSTALL BRAKE CALIPER
a. Install the disc, brake caliper and 2 bolts.
Torque: 123 Nm (1,250 kgf-cm, 90 ft. lbs.)
b. Install the brake line clamp to the steering knuckle with bolt.
Torque: 28 Nm (285 kgf-cm, 21 ft. lbs.)
5. w/ ABS: CONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP
Connect the ABS speed sensor and wire harness clamp to the steering knuckle with 2 bolts.
Torque: 8.0 Nm (82 kgf-cm, 71 ft. lbs.)
6. 4WD: INSTALL DRIVE SHAFT LOCK NUT
a. While applying the brakes, tighten the nut.
Torque: 235 Nm (2,400 kgf-cm, 173 ft. lbs.)
b. Install the lock cap and a new cotter pin.
If the holes for the cotter pin are not aligned, tighten the nut further up to 60°.
7. INSTALL GREASE CAP 8. INSTALL FRONT WHEEL
Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.)
9. DEPRESS BRAKE PEDAL SEVERAL TIMES
10. CHECK FRONT WHEEL ALIGNMENT 11. CHECK ABS SPEED SENSOR SIGNAL
Disassembly and Reassembly
Description and Operation
Transmission Position Switch/Sensor: Description and Operation
PARK / NEUTRAL POSITION SWITCH
Engine Control System
The park/neutral position switch comes on when the shift lever is in the N or P position. When it
comes on, terminal NSW of the ECM is grounded to the body ground via the starter relay, thus the
terminal NSW voltage becomes 0 V. When the shift lever is in the D, 2, L or R position, the
park/neutral position switch goes off, so the voltage of the terminal NSW becomes battery voltage
and the voltage of the ECM internal power source. If the shift lever is moved from the N position to
the D position, this signal is used for air-fuel ratio correction and for idle speed control (estimated
control), etc.
Transmission Control System
The park/neutral position switch detects the shift lever position and sends signals to the ECM.
The ECM receives signals (NSW, R, D, 2 and L) from the park/neutral position switch.
Page 4333
Remove the 4 bolts and disconnect the lower ball joint.
9. REMOVE STEERING KNUCKLE
A. Remove the cotter pin and loosen the nut.
B. Using the following SSTs, disconnect the steering knuckle.
^ 09950-40011 (09951-04010, 09952-04010, 09553-04020, 09554-04010, 09955-04031,
09958-04011)
C. Remove the nut and steering knuckle.
NOTE:
4WD: Be careful not to damage the oil seal and drive shaft boot.
HINT:
4WD: When it is difficult to disconnect the drive shaft, tap the tip of the drive shaft with a plastic
hammer.
10. 2WD: REMOVE GREASE CAP
A. Mount the axle hub in a soft jaw vise.
HINT:
Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further.
B. Using a screwdriver, remove the grease cap.
HINT:
Be careful not to damage the grease cap.
11. 4WD: REMOVE OIL SEAL (INSIDE)
A. Mount the axle hub in a soft jaw vise.
HINT:
Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further.
B. Using a screwdriver, remove the oil seal (inside).
Page 5377
Airbag Sensor Assembly: Service and Repair Removal and Installation
Airbag Sensor Assembly
REMOVAL
NOTE: Do not open the cover or the case of the ECU and various electrical devices unless
absolutely necessary (If the IC terminals are touched, the IC may be destroyed by static
electricity.).
1. REMOVE LOWER CENTER COVER
Remove the 2 clips and lower center cover.
Page 4186
12. 2WD: REMOVE LOCK NUT AND ABS SPEED SENSOR ROTOR (W/ABS) OR SPACER (W/O
ABS)
Using a chisel and hammer, loosen the staked part of the lock nut.
NOTE:
Be careful not to damage the bushing.
A. Using the following SST, remove the lock nut.
^ 00002-00909 (09318-12010)
NOTE:
Do NOT use air wrench.
B. Remove the ABS speed sensor rotor or spacer.
NOTE:
Take care not to scratch the serration of the speed sensor rotor.
13. REMOVE AXLE HUB FROM STEERING KNUCKLE
A. Remove the 4 bolts and shift the dust cover toward the hub side (outside).
B. Using the following SSTs, remove the axle hub from the steering knuckle.
^ 09710-28012-01 (09710-07031)
^ 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04031,
09957-04010, 09958-04011)
HINT
If necessary, use a press to remove the axle hub from the steering knuckle.
C. Remove the dust cover from the steering knuckle.
D. 4WD: Remove the bearing spacer and ABS speed sensor rotor (W/ABS) or spacer (W/O ABS).
NOTE:
Take care not to scratch the serration of the speed sensor rotor.
Page 1501
Exhaust: N = T + (A - 0.30 mm (0.012 inch))
3. Select a new shim with thickness as close as possible to the calculated value.
HINT: Shims are available in 41 increments of 0.020 mm (0.0008 inch), from 2.00 mm (0.0787
inch) to 2.80 mm (0.1102 inch).
e. Place a new adjusting shim on the valve. f.
Place the valve lifter.
Page 6184
Cruise Control: Ground Locations
Engine Compartment
Ground Location
EA Front Left Fender
EB Rear Bank of Right Cylinder
EC Rear Bank of Left Cylinder
Connector Location
EA1 Cowl Wire Harness and Wire Harness (Connector Location)
EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B)
EC1 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC2 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC3 Engine No. 2 Wire and Engine Wire (Near the Starter)
ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission)
Page 3666
3. CHECK BEARING BACKLASH AND AXLE SHAFT DEVIATION
a. Using a dial indicator, check the backlash in the bearing shaft direction.
Maximum: 0.7 mm (0.028 inch) If the backlash exceeds the maximum, replace the bearing.
b. Using a dial indicator, check the deviation at the surface of the axle shaft outside the hub bolt.
Maximum: 0.1 mm (0.004 inch) If the deviation exceeds the maximum, replace the axle shaft.
4. w/ ABS: REMOVE ABS SPEED SENSOR FROM REAR AXLE HOUSING
Remove the bolt and ABS speed sensor.
5. REMOVE REAR BRAKE ASSEMBLY
6. DISCONNECT BRAKE LINE AND PARKING BRAKE CABLE
a. Using Special Service Tool (SST), disconnect the brake line from the wheel cylinder.
SST 09023-00100
b. Remove the clip and pin, and disconnect the parking brake cable.
7. REMOVE REAR AXLE SHAFT ASSEMBLY
a. Remove the 4 backing plate mounting nuts. b. Pull out the rear axle shaft assembly from the rear
axle housing.
NOTICE: Be careful not to damage the oil seal.
8. REMOVE O-RING FROM REAR AXLE HOUSING
INSPECTION
1. w/ ABS: REMOVE BEARING RETAINER (DIFFERENTIAL SIDE) AND ABS SPEED SENSOR
ROTOR
a. Attach 4 nuts to the serration bolts and using a hammer remove the serration bolts from the
backing plate.
NOTICE: At the time of installation, do not reuse the nuts.
Page 6199
B: Junction Connector
Indicates a connector which is connected to a short terminal.
Junction connector in this include a short terminal which is connected to a number of wire
harnesses. Always perform inspection with the short terminal installed. (When installing the wire
harnesses, the harnesses can be connected to any position within the short terminal grouping.
Accordingly, in other vehicles, the same position in the short terminal may be connected to wire
harness from a different part.) Wire harness sharing the same short terminal grouping ha the same
color.
C: Parts Code
The first letter of the code is taken from the first letter of part, and the numbers indicates its order in
parts which start with the same letter.
D: Connector Color
Connectors not indicated are milky white in color.
How to Read Ground Points
HOW TO READ GROUND POINTS
Page 2438
Page 6291
Body
Connector Location (Standard Cab)
BA1 Front Door LH Wire and Speaker Tweeter Wire LH (Inside of Front Door LH)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Seat
Connector Location
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
BJ1 Seat No. 1 Wire and Seat No. 2 Wire (Under the Driver's Seat)
Page 2097
Step 1
Page 1983
CHART 11
Page 5607
Seat Belt Reminder Lamp: Diagnostic Aids
Voltage Check
Voltage Check
Voltage Check
A. Establish conditions in which voltage is present at the check point.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(SW 2 OFF)
B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or
component terminal. This check can be done with a test light instead of a voltmeter.
Continuity and Resistance Check
Continuity and Resistance Check
Continuity And Resistance Check
A. Disconnect the battery terminal or wire so there is no voltage between the check points. B.
Contact the two leads of an ohmmeter to each of the check points.
Page 6405
Key Reminder Switch: Ground Locations
Engine Compartment
Ground Location
EA Front Left Fender
EB Rear Bank of Right Cylinder
EC Rear Bank of Left Cylinder
Connector Location
EA1 Cowl Wire Harness and Wire Harness (Connector Location)
EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B)
EC1 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC2 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC3 Engine No. 2 Wire and Engine Wire (Near the Starter)
ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission)
Page 5097
Page 3940
Steps 1 - 2
Diagram Information and Instructions
Key Reminder Switch: Diagram Information and Instructions
Key to Diagrams
A: System Title
B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to
distinguish it from the J/B
Example: 1 Indicates Relay Block No.1
C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type,
or specification is different.
D: Indicates related system.
Page 2352
Terminals Of ECU - Connector Pinouts (Part 2)
INSPECTION
1. REMOVE ECM
2. INSPECT ECM
3. REINSTALL ECM
Bleeding the Brake System
Brake Bleeding: Service and Repair Bleeding the Brake System
BRAKE FLUID BLEEDING
HINT: If any work is done on the brake system or if air is suspected in the brake lines, bleed the air
from the system.
NOTICE: Do not let brake fluid remain on a painted surface. Wash it off immediately.
1. FILL BRAKE RESERVOIR WITH BRAKE FLUID
Check the fluid level in the reservoir after bleeding each wheel. Add fluid, if necessary. Fluid: SAE
J1703 or FMVSS No. 116 DOT3
2. BLEED MASTER CYLINDER
HINT: If the master cylinder was disassembled or if the reservoir becomes empty, bleed the air
from the master cylinder.
(a) Disconnect the brake lines from the master cylinder.
SST 09023-00100
(b) Slowly depress the brake pedal and hold it.
(c) Block off the outlet plug with your finger, and release the brake pedal. (d) Repeat (b) and (c) 3
or 4 times.
Page 2936
Leak Detection Solenoid: Testing and Inspection
VSV FOR VAPOR PRESSURE SENSOR
INSPECTION
1. REMOVE VSV
2. INSPECT VSV
a. Inspect the VSV for open circuit.
Using an ohmmeter, check that there is no continuity between the terminals.
Resistance: 37 - 44 ohms at 20 °C (68 °F)
If there is no continuity, replace the VSV.
b. Inspect the VSV for ground.
Using an ohmmeter, check that there is no continuity between each terminal and the body. If there
is continuity, replace the VSV.
c. Inspect the VSV operation.
1. Check that air flows from ports E to G.
Page 4983
2. Using 3 wire harness, wind the wire harness at least 2 times each around the bolts installed on
the left and right sides of the steering wheel pad.
CAUTION: Tightly wind the wire harness around the bolts so that there is no slack.
- If there is slackness in the wire harness, the steering wheel pad may come loose due to the shock
when the airbag is deployed. This is highly dangerous.
3. Face the upper surface of the steering wheel pad upward. Separately tie the left and right sides
of the steering wheel pad to the disc wheel
through the hub nut holes. Position the steering wheel pad connector so that it hangs downward
through a hub hole in the disc wheel.
CAUTION: Make sure that the wire harness is tight. It is very dangerous when looseness in the wire harness
results in the steering wheel pad coming free due to the shock from the airbag deploying.
- Always tie down the steering wheel pad with the pad side facing upward. It is very dangerous if
the steering wheel pad is tied down with the metal surface facing upward as the wire harness will
be cut by the shock from the airbag deploying and the steering wheel pad will be thrown into the
air.
NOTE: The disc wheel will be marked by airbag deployment, so when disposing of the airbag use a
redundant disc wheel
d. Check functioning of the SST.
Page 6414
Body
Connector Location (Access Cab)
BA1 Front Door LH Wire and Wire Harness (Connector Location)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel)
BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel)
BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel)
BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Testing and Inspection
Overdrive Switch: Testing and Inspection
O/D Main Switch & O/D OFF Indicator Light Circuit
CIRCUIT DESCRIPTION
The O/D main switch contacts go open when the switch is pushed in and go closed when it is
pushed out.
If O/D main switch is at OFF position, the O/D OFF indicator light lights up, and the ECM prohibits
shifting O/D.
Wiring Diagram
INSPECTION PROCEDURE
Page 6052
be used during this type of repair due to the higher potential of damaging the paint surface.
Remember no broken paint.
Page 3575
Non-Waterproof Type Connector
"Case 1" Raise the terminal retainer up to the temporary lock position.
Non-Waterproof Type Connector
"Case 2" Open the secondary locking device.
Page 2270
The calibration file contains the Calibration ID number(s) for a specific vehicle ECU (see Figure 1).
NOTE:
The total number of Calibration ID numbers corresponds to the number of reprogrammable
processors in the ECU (see Figure 2).
Operation Procedure
LOCATE CALIBRATION FILE
The following steps in this bulletin describe how to properly flash reprogram an ECU.
1. Locate calibration file on TIS.
Calibration files may be found in two areas (see Figure 3):
A. Search by model and year for a Technical Service Bulletin addressing a specific Product issue.
^ Within the TSB, click on the link for the calibration file.
B. Search by model under the ECU Flash Reprogramming Section.
^ Under the ECU Flash Reprogramming section on TIS, a drop-down list of the latest calibration
files will be displayed.
C. Proceed to step 2 for instructions on how to download the calibration file from TIS to the
Diagnostic Tester Program Card.
Page 5601
Splice Point
J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel,
and "B" for the Body).
The Location of splice Point I5 is shaded.
K: Indicates a shielded cable.
L: Indicates the pin number of the connector.
The numbering system is different for female and male connectors.
M: Indicates a ground point.
The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for
the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body
and Surrounding area.
How to Read Connector List
HOW TO READ CONNECTOR LIST
A: Indicates connector to be connected to a part. (The numeral indicates the pin No.)
Page 5762
Trailer Connector: Harness Locations
Engine Compartment
Connector Location
EA1 Cowl Wire Harness and Wire Harness (Connector Location)
EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B)
EC1 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC2 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC3 Engine No. 2 Wire and Engine Wire (Near the Starter)
ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission)
2ND Gear Clutch
Clutch: Specifications
2nd Coast Brake Piston Stroke 1.5 - 3.0 mm
Piston Rod Length 72.9 mm
71.4 mm
2nd Brake Pack Clearance 0.50 - 1.76 mm
Piston Return Spring Standard Free Length 16.61 mm
Page 639
CHART 28
Page 5129
3. REMOVE U-BOLTS
a. Remove the 4 U-bolt mounting nuts and washers. b. Remove the spring seat and 2 U-bolts. c.
Remove the spring bumper.
4. REMOVE LEAF SPRING
a. Remove the nut, washer and bolt.
b. Remove the 2 nuts, washers, bolts, shackle and leaf spring.
REPLACEMENT
1. REPLACE BUSHINGS
a. Using a saw, cut the both bushing tabs as shown in the illustration.
Upper
Page 6341
Body
Connector Location (Access Cab)
BA1 Front Door LH Wire and Wire Harness (Connector Location)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel)
BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel)
BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel)
BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Page 1793
Engine Control Module: Connector Views
Terminals Of ECM - Connector View
Terminals Of ECU - Connector Pinouts (Part 1)
Page 3111
If you have no TOYOTA hand-held tester, measure voltage between terminals VPA and E2 of the
ECM connector.
d. Inspect the air assist system.
1. Start the engine and check that the MIL does not light up. 2. Allow the engine to warm up to
normal operating temperature. 3. Turn the A/C compressor ON to OFF, and check the idle speed.
Idle speed (Transmission in neutral): 700 ± 50 rpm
NOTE: Perform inspection under condition without electrical load.
e. After checking the above (b) to (d), perform the driving test and check that there is no sense of
incongruity.
3. INSPECT THROTTLE CONTROL MOTOR
a. Disconnect the throttle control motor connector. b. Using an ohmmeter, measure the motor
resistance between terminal 1 (M+) and 2 (M-).
Motor resistance: 0.3 - 100 ohms at 20 °C (68 °F)
If the resistance is not as specified, replace the throttle control motor.
c. Using an ohmmeter, measure the clutch resistance between terminal 3 (CL-) and 4 (CL+).
Clutch resistance: 4.2 - 5.2 ohms at 20 °C (68 °F)
If the resistance is not as specified, replace the throttle control motor.
d. Reconnect the throttle control motor connector.
Page 2205
B: Junction Connector
Indicates a connector which is connected to a short terminal.
Junction connector in this include a short terminal which is connected to a number of wire
harnesses. Always perform inspection with the short terminal installed. (When installing the wire
harnesses, the harnesses can be connected to any position within the short terminal grouping.
Accordingly, in other vehicles, the same position in the short terminal may be connected to wire
harness from a different part.) Wire harness sharing the same short terminal grouping ha the same
color.
C: Parts Code
The first letter of the code is taken from the first letter of part, and the numbers indicates its order in
parts which start with the same letter.
D: Connector Color
Connectors not indicated are milky white in color.
How to Read Ground Points
HOW TO READ GROUND POINTS
Page 3631
4. INSPECT A.D.D. RELAY
a. Check the continuity between each terminal, as shown in the chart.
*: There is a diode between the terminals 6 and 7. If no continuity exists, check that continuity
exists when changing the position of (+) probe for the position of negative (-) probe of tester.
b. Apply battery positive voltage between each terminal and check the continuity between each
terminal, as shown in the chart.
If continuity is not as specified, replace the relay.
5. INSPECT TRANSFER 4WD POSITION SWITCH 6. REMOVE A.D.D. ACTUATOR
7. INSPECT CLUTCH HUB AND CLUTCH SLEEVE
a. Check the clutch hub and clutch sleeve for wear and damage.
If necessary, replace them.
b. Check that clutch sleeve slides smoothly on the clutch hub.
8. MEASURE SLEEVE FORK AND CLUTCH SLEEVE CLEARANCE
Using a feeler gauge, measure the clearance between the sleeve fork and clutch sleeve.
Page 349
Engine Coolant Temperature (ECT) Sensor
Page 674
B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(Connect the Relay) and SW 2 OFF (or Disconnect SW 2)
D. Disconnect and reconnect the connectors while watching the test light.
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
E. Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION:
a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals
are touched, the IC may be destroyed by
static electricity.)
b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact
with the terminals of leads from the IC, etc. of the replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
Special Tool
1. PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown.
2. DISCONNECT CONNECTOR
3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
a. Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the
secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
A: For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
Page 1768
L. The calibration file will now be downloaded to the Diagnostic Tester Program Card. This process
takes approximately 2-6 minutes (see Figure 15).
M. The CUW will prompt when the calibration file is completely downloaded. Click OK to close the
CUW (Figure 16).
NOTE:
With the calibration file loaded on the Diagnostic Tester Program Card, it is not necessary to repeat
the above steps to reprogram a different vehicle needing the same calibration file. The steps above
are only required when a new calibration file must be loaded onto the Diagnostic Tester Program
Card.
The Diagnostic Tester now has the calibration file stored and you may proceed to the next step to
reprogram the vehicle ECU.
REPROGRAM ECU WITH TESTER
3. Reprogram the vehicle ECU with the Diagnostic Tester.
NOTICE:
Errors during the flash reprogramming process can permanently damage the vehicle ECU.
Minimize the risks by following the steps below.
^ Battery voltage MUST NOT FALL BELOW 11.4 volts during reprogramming.
^ Confirm battery voltage is higher than 11.4 volts, but be sure voltage DOES NOT RISE ABOVE
16.0 volts during reprogramming.
^ Turn off all electrical accessories (e.g. Audio system, A/C, interior lights, DRL, etc.).
^ Do not add to or significantly change the vehicle's electrical load while reprogramming.
^ Confirm the hood is open and ensure under hood temperatures do not exceed 158°F.
Drivetrain - Revised Rear Axle Oil Seal/Installation
Seals and Gaskets: Technical Service Bulletins Drivetrain - Revised Rear Axle Oil Seal/Installation
DRIVELINE & DIFFERENTIAL DL002-03
August 6, 2003
Title: REAR AXLE SEAL DESIGN CHANGE
Models: '01 - '02 Sequoia, '95 - '02 Tacoma & '00 - '02 Tundra
Introduction
The rear axle seal lip design has been changed from a flat face type to an angled face type. A
different SST seal driver is required to install the seal properly and prevent damaging the oil seal
during the installation process.
NOTE:
Use of SST part number 09951-00610 (Replacer 6-4) as listed in the Repair Manual to install the
newly designed rear axle seal can damage the seal assembly causing it to leak. Repair Manual
update on Technical Information System (TIS) is in process.
Applicable Vehicles ^
2001 - 2002 model year Sequoia vehicles.
^ 1995 - 2002 model year Tacoma vehicles.
^ 2000 - 2002 model year Tundra vehicles.
Parts Information
Required SSTs
NOTE:
Additional SSTs may be ordered by calling SPX/OTC at 1-800-933-8335.
Required Tools & Material
Warranty Information
Identification Procedure
Page 5175
DISASSEMBLY
1. 2WD: REMOVE GREASE CAP
a. Mount the axle hub in a soft jaw vise.
HINT: Close the vise until it holds hub bolts. Do not tighten further.
b. Using a screwdriver, remove the grease cap.
2. 4WD: REMOVE OIL SEAL (INSIDE)
a. Mount the axle hub in a soft jaw vise.
HINT: Close the vise until it holds hub bolts. Do not tighten further.
b. Using a screwdriver, remove the oil seal (inside).
Page 5794
Trailer Connector: Harness Locations
Engine Compartment
Connector Location
EA1 Cowl Wire Harness and Wire Harness (Connector Location)
EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B)
EC1 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC2 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC3 Engine No. 2 Wire and Engine Wire (Near the Starter)
ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission)
Page 1241
Valve Cover: Service and Repair
For further information regarding this component and the system that it is a part of, please refer to
Cylinder Head Assembly; Service and Repair.
Page 1460
Fuel Pressure: Testing and Inspection
CHECK FUEL PRESSURE
a. Check the battery positive voltage is above 12 V. b. Disconnect the negative (-) terminal cable
from the battery. c. Remove the front fuel pipe from the LH delivery pipe.
d. Install the front fuel pipe and SST (pressure gauge) to the delivery pipe with 3 lower gaskets and
SST (adapter).
SST 09268-45014 (09268-1190, 90405-06167)
Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)
e. Wipe off any splattered gasoline. f.
Reconnect the negative (-) terminal cable to the battery.
g. Connect a TOYOTA hand-held tester to the DLC3. (See step 1 in check fuel pump operation (a)
to (e)) h. Measure the fuel pressure.
Fuel pressure: 265 - 304 kPa (2.7 - 3.1 kgf/sq.cm, 38 - 44 psi)
If pressure is high, replace the fuel pressure regulator. If pressure is low, check the fuel hoses and
connections, fuel pump, fuel filter and fuel pressure regulator.
i. Disconnect the TOYOTA hand-held tester from the DLC3.
j. Start the engine.
k. Measure the fuel pressure at idle.
Fuel pressure: 265 - 304 kPa (2.7 - 3.1 kgf/sq.cm, 38 - 44 psi)
l. Stop the engine.
m. Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped.
Fuel pressure: 147 kPa (1.5 kgf/sq.cm, 21 psi) or more
If pressure is not as specified, check the fuel pump, pressure regulator and/or injectors.
n. After checking fuel pressure, disconnect the negative (-) terminal cable from the battery and
carefully remove the SST to prevent gasoline from
splashing. SST 09268-45014
o. Reinstall the front fuel pipe to the LH delivery pipe. p. Reconnect the negative (-) terminal cable
to the battery. q. Check for fuel leaks.
Capacity Specifications
Fluid - A/T: Capacity Specifications
Automatic Transmission Capacity (Drain & Refill)
........................................................................................................................... up to 2.0L (2.1 US
qt.)
Service and Repair
Fuel Pressure Release: Service and Repair
SFI SYSTEM
PRECAUTION
1. BEFORE WORKING ON FUEL SYSTEM, DISCONNECT NEGATIVE (-) TERMINAL CABLE
FROM BATTERY
HINT: Any diagnostic trouble code retained by the computer will be erased when the negative (-)
terminal cable is removed from the battery.
Therefore, if necessary, read the diagnosis before removing the negative (-) terminal cable from the
battery.
2. DO NOT SMOKE OR WORK NEAR AN OPEN FLAME WHEN WORKING ON THE FUEL
SYSTEM
3. KEEP GASOLINE AWAY FROM RUBBER OR LEATHER PARTS
4. FUEL SYSTEM
a. When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so
observe these procedures:
1. Disconnect the fuel pump connector. 2. Start the engine. After the engine has stopped on its
own, turn the ignition switch OFF.
3. Put a container under the connection. 4. Slowly loosen the connection. 5. Disconnect the
connection. 6. Plug the connection with a rubber plug. 7. Reconnect the fuel pump connector.
b. When connecting the union bolt (fuel pressure pulsation damper) on the high pressure pipe
union, observe these procedures:
1. Always use 2 new gaskets.
Page 2047
Install the No.1 vehicle speed sensor with the bolt.
Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.)
6. CONNECT NO. I VEHICLE SPEED SENSOR CONNECTOR
Vehicle Speed Sensor NO.2
Vehicle speed Sensor NO.2 on-vehicle repair
1. DISCONNECT NO. 2 VEHICLE SPEED SENSOR CONNECTOR
2. REMOVE NO. 2 VEHICLE SPEED SENSOR
a. Remove the bolt and No. 2 vehicle speed sensor. b. Remove the O-ring from the No. 2 vehicle
speed sensor.
3. INSTALL NO. 2 VEHICLE SPEED SENSOR
a. Coat a new O-ring with ATF and install it to the No. 2 vehicle speed sensor. b. Install the No. 2
vehicle speed sensor with the bolt.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
4. CONNECT NO. 2 VEHICLE SPEED SENSOR CONNECTOR
Page 1895
A/F and 02 Sensor Identification
Page 3154
Knock Sensor: Locations
Knock Sensor (Part 1)
Locations
Engine Room R/B
Page 4129
Parts Information
Diagnosis Procedure
1. Confirm the customer complaint.
2. Determine if vibration is from front or rear (while brakes are still warm from confirmation driving).
The following procedure will isolate the drum brakes from the rest of the hydraulic system by using
the parking brake (PKB).
NOTE:
Remember, with a foot PKB (on automatic transmission) the pedal must be pressed a second time
to disengage the parking brake.
HINT:
When diagnosing a Tundra with a foot PKB, slowly apply the PKB until the first "click, " then press
the PKB pedal a second time so it will disengage if it is released. At this time the PKB can be
pressed to the desired level for continued diagnosis.
A. Drive the Tundra along a smooth, level section of road at approximately 40 mph - 50 mph.
B. Slowly apply the PKB while driving until the brake begins to engage and slow the vehicle. Do not
apply the PKB past this point of initial engagement.
C. Hold the PKB at this point of initial engagement for a few seconds to slowly reduce the vehicle
speed and allow adequate time to monitor the ride condition.
D. Disengage the PKB.
E. If brake vibration is felt during step (C), then it indicates that the rear brake drums are one
source of brake vibration on this vehicle.
Refer to TSB BR003-02 for parts and repair information relating to Tundra rear brake vibration.
F. If no vibration is felt during step (C), then the front brake assemblies are the cause of brake
vibration on this vehicle.
Proceed to the following repair procedure.
Repair Procedure
Electrical Specifications
Resistance
Page 3126
Camshaft Position Sensor: Mechanical Specifications
Torque: ................................................................................................................................................
.................................. 7.5 N.m (80 kgf.cm, 66 in.lbf)
Page 5391
Clockspring Assembly / Spiral Cable: Description and Operation
SPIRAL CABLE (in COMBINATION SWITCH)
A spiral cable is used as an electrical joint from the vehicle body side to the steering wheel.
Page 5486
A. Pull out the seat belt about 300 mm and attach a clip as shown in the illustration.
HINT:
Preventing the seat belt from retraction with a clip will make the following work easier.
B. Put the Velcro tape (in the parts kit) through the hole of the shoulder belt anchor, brush-shaped
side to the anchor.
C. Pull both ends of the Velcro tape with your hand and shave off the dirt on the shoulder belt
anchor by moving the Velcro tape several times as shown in the illustration.
NOTE:
Remove the dirt completely. Otherwise, the fluorocarbon resin tape may not adhere properly.
2. INSTALL FLUOROCARBON RESIN TAPE
A. Place the fluorocarbon resin tape onto the seat belt as shown in the illustration.
NOTE:
Diagram Information and Instructions
Key Reminder Switch: Diagram Information and Instructions
Key to Diagrams
A: System Title
B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to
distinguish it from the J/B
Example: 1 Indicates Relay Block No.1
C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type,
or specification is different.
D: Indicates related system.
Front Seat Cover - Damaged
Seat Bottom Frame: All Technical Service Bulletins Front Seat Cover - Damaged
BODY
BO006-02
Title: FRONT SEAT COVER DAMAGE
Models: '00 - '02 Tundra & '01 - '02 Sequoia Equipped with Power Seats
March 1, 2002
Introduction
Due to the unique curvature of the front seat frames' outboard edge, the driver or passenger could
potentially wear a hole into the seat cover material during entry and exit of the vehicle. This
condition has been addressed and corrected in production. The instructions below will illustrate
how to properly repair vehicles with this condition.
Applicable Vehicles
2000 - 2002 model year Tundra vehicles equipped with power seats produced before the VIN
shown below.
2001 - 2002 model year Sequoia vehicles equipped with power seats produced before the VIN
shown below.
Production Change 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.
Removal and Installation
Brake Caliper: Service and Repair Removal and Installation
REMOVAL
1. REMOVE FRONT WHEEL
Remove the wheel and temporarily fasten the disc with hub nuts. Torque: 113 Nm (1,150 kgf-cm,
83 ft. lbs.)
2. DISCONNECT BRAKE LINE
Using SST, disconnect the brake line. Use a container to catch the brake fluid. SST 09023-00100
Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.)
Page 2847
Throttle Position Sensor: Testing and Inspection
ON-VEHICLE INSPECTION
1. REMOVE THROTTLE BODY COVER
2. INSPECT SYSTEM OPERATION
a. Check that the throttle linkage moves smoothly.
b. Inspect the throttle control motor for operating sound.
1. Turn the ignition switch ON. 2. When turning the accelerator pedal position sensor lever, check
the running sound of the motor. Also, check that there is no friction sound.
If operation is not as specified, check the throttle control motor (See step 3), wiring and ECM.
c. Inspect the accelerator pedal position sensor.
1. Connect the TOYOTA hand-held tester to the DLC3. 2. Check that the MIL does not light up. 3.
When turning the accelerator pedal position sensor lever to the full-open position, check that the
throttle valve opening percentage
(THROTTLE POS) of the CURRENT DATA shows the standard value.
Standard throttle valve opening percentage: 60 % or more
If operation is not as specified, check that the accelerator pedal position sensor (See step 5), wiring
and ECM.
Page 6841
b. Push the secondary locking device or terminal retainer in to the full lock position.
5. CONNECT CONNECTOR
Disconnection of Male and Female Connectors
Disconnection of Male and Female Connectors
Disconnection Of Male And Female Connectors
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Specifications
Brake Fluid: Specifications
Required Brake Fluid FMVSS No. 116 DOT3
Page 336
Wheel Speed Sensor: Service and Repair Speed Sensor, Rear
REMOVAL
1. DISCONNECT SPEED SENSOR CONNECTOR
2. REMOVE SPEED SENSOR
(a) Remove the 2 clamp bolts, clamp nut and 5 resin clips holding the sensor wire harness from the
axle and the fuel tank.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)
HINT: When installing the rear sensor wire harness, never use the removed resin clips, which are service
parts.
- When replacing clips, set up new resin clips at the same angle of the removed resin clips.
(b) Remove the bolt and speed sensor from the axle carrier.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
INSTALLATION
Installation is in the reverse order of removal.
HINT: After installation, check speed sensor signal.
Page 4082
14. REMOVE OIL SEAL (OUTSIDE)
Using a screwdriver, remove the oil seal (outside) from the steering knuckle.
15. REMOVE BEARING FROM STEERING KNUCKLE
A. Using snap ring pliers, remove the snap ring.
B. Using the following SSTs and a press, remove the bearing from the steering knuckle.
^ 09950-60020 (09951-00810)
^ 09950-70010 (09951-07150)
16. INSTALL NEW BEARING
A. Using the following SSTs and a press, install a NEW bearing to the steering knuckle.
^ 09527-17011
^ 09950-60020 (09951-00910)
B. Using Snap ring pliers, install a NEW snap ring.
17. INSTALL NEW OIL SEAL (OUTSIDE)
A. Using the following SSTs and a plastic hammer, install a NEW oil seal (outside).
^ 09223-15030
Page 5494
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for
36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Parts Information
Repair Procedure
1. Shift the tongue plate to the upper portion of the tongue plate stopper and temporarily hold it with
a clip or tape.
2. Remove any pieces of the original tongue plate stopper in the webbing with a pair of diagonal
pliers.
NOTE
Be careful not to damage the webbing, since this may compromise the safety of this seatbelt.
CAUTION
Damaged or weakened seat belts may break in an accident and injure the occupant. The seat belt
assembly MUST be replaced if:
^ The webbing is cut, frayed, worn, or damaged.
^ It has been used during a severe impact (inspect the label to ensure no impact damage has
occurred)
Page 5225
AFTER REASSEMBLY, CHECK MAGNETIC CLUTCH CLEARANCE
a. Set the dial indicator to the pressure plate of the magnetic clutch.
b. Connect the magnetic clutch lead wire to the positive (+) terminal of the battery.
c. Check the clearance between the pressure plate and rotor when connecting the negative (-)
terminal to the battery.
Standard clearance: 0.5 ± 0.15 mm (0.020 ± 0.0059 in.)
If the clearance is not within the standard clearance, adjust the clearance using shims to obtain the
standard clearance.
Standard thickness: 0.1 mm (0.004 in.) 0.3 mm (0.012 in.) 0.5 mm (0.020 in.)
Page 2348
Terminals Of ECU - Connector Pinouts (Part 2)
Page 2334
Splice Point
J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel,
and "B" for the Body).
The Location of splice Point I5 is shaded.
K: Indicates a shielded cable.
L: Indicates the pin number of the connector.
The numbering system is different for female and male connectors.
M: Indicates a ground point.
The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for
the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body
and Surrounding area.
How to Read Connector List
HOW TO READ CONNECTOR LIST
A: Indicates connector to be connected to a part. (The numeral indicates the pin No.)
Diagrams
Page 1063
Engine Room R/B
Details
Page 2162
Intake Air Temperature Sensor: Description and Operation
Intake Air Temperature Sensor
The intake air temperature sensor is built into the air cleaner cap and senses the intake air
temperature. A thermistor built in the sensor changes the resistance value according to the intake
air temperature.
The lower the intake air temperature, the greater the thermistor resistance value, and the higher
the intake air temperature, the lower the thermistor resistance value.
The intake air temperature sensor is connected to the ECM. The 5 V power source voltage in the
ECM is applied to the intake air temperature sensor from the terminal THA via a resistor R.
That is, the resistor R and the intake air temperature sensor are connected in series. When the
resistance value of the intake air temperature sensor changes in accordance with changes in the
intake air temperature, the potential at terminal THA also changes. Based on this signal, the ECM
increases the fuel injection volume to improve driveability during cold engine operation.
Page 6732
Brake Lamp: Electrical Diagrams
Service Hints
S4 STOP LIGHT SW
2 - 1 : Closed with brake pedal depressed
Page 2863
B: Junction Connector
Indicates a connector which is connected to a short terminal.
Junction connector in this include a short terminal which is connected to a number of wire
harnesses. Always perform inspection with the short terminal installed. (When installing the wire
harnesses, the harnesses can be connected to any position within the short terminal grouping.
Accordingly, in other vehicles, the same position in the short terminal may be connected to wire
harness from a different part.) Wire harness sharing the same short terminal grouping ha the same
color.
C: Parts Code
The first letter of the code is taken from the first letter of part, and the numbers indicates its order in
parts which start with the same letter.
D: Connector Color
Connectors not indicated are milky white in color.
How to Read Ground Points
HOW TO READ GROUND POINTS
Engine Controls - MIL ON/DTC's P0135/P0155 Stored
Oxygen Sensor: Customer Interest Engine Controls - MIL ON/DTC's P0135/P0155 Stored
ENGINE EG019-02 REVISED
October 3, 2002
Title M.I.L. "ON" P0135 AND/OR P0155
Models: '00 - '02 Tundra (2UZ-FE) & '01 - '02 Sequoia
TSB REVISION NOTICE:
January 14, 2004: A Previous Part Number in the Parts Information table and one OFP number in
the Warranty Information table has been changed. All previous versions of this TSB should be
discarded.
Introduction
Certain 2000 - 2002 model year Tundra trucks (2UZ-FE) and 2001 - 2002 model year Sequoia
vehicles may exhibit a M.I.L. ON" condition with Diagnostic Trouble Code P0135 and/or P0155 in
the Engine Control Module (ECM)/SAE equivalent (PCM). The oxygen sensors have been
improved to correct this condition.
Applicable Vehicles ^
2000 - 2002 model year Tundra trucks with 2UZ-FE engines produced BEFORE the Production
Change Effective VINs listed below.
^ 2001 - 2002 model year Sequoia vehicles produced BEFORE the Production Change Effective
VINs listed below.
Production Change Information
Parts Information
Warranty Information
Applicable Warranty*:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36
months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Page 6210
b. Push the secondary locking device or terminal retainer in to the full lock position.
5. CONNECT CONNECTOR
Disconnection of Male and Female Connectors
Disconnection of Male and Female Connectors
Disconnection Of Male And Female Connectors
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Page 2149
g. Reinstall the camshafts. h. Reinstall the timing belt. i.
Recheck the valve clearance.
11. REINSTALL CYLINDER HEAD COVERS 12. REINSTALL IGNITION COILS 13. REINSTALL
NO.3 TIMING BELT COVERS 14. REINSTALL AIR CLEANER AND INTAKE AIR CONNECTOR
ASSEMBLY 15. REINSTALL THROTTLE BODY COVER 16. REINSTALL BATTERY CLAMP
COVER
Page 230
Non-Waterproof Type Connector
"Case 1" Raise the terminal retainer up to the temporary lock position.
Non-Waterproof Type Connector
"Case 2" Open the secondary locking device.
Page 5291
Heater Core Case: Testing and Inspection
HEATER UNIT
INSPECTION
INSPECT FINS FOR BLOCKAGE If the fins are clogged, clean them with compressed air.
Page 49
Headlamp Dimmer Relay: Testing and Inspection
INSPECT HEADLIGHT CONTROL RELAY CONTINUITY If continuity is not as specified, replace
the relay.
Page 4637
Non-Waterproof Type Connector
"Case 1" Raise the terminal retainer up to the temporary lock position.
Non-Waterproof Type Connector
"Case 2" Open the secondary locking device.
Page 4633
Glossary Of Terms And Symbols (Part 2)
Page 998
Fluid - A/T: Testing and Inspection
FLUID INSPECTION
1. Check fluid level, as follows:
NOTE:
Drive the vehicle so that the engine and transaxle are at normal operating temperature. ATF
temperature: 70 - 80°C (158 - 176°F). Only use the COOL range on the dipstick as a rough
reference when the fluid is replaced or the engine does not run.
a. Park the vehicle on a level surface and set the parking brake.
b. With the engine idling and the brake pedal depressed, shift the shift lever into all positions from
the Park (P) to Low (L) position and return to
the P position.
c. Pull out the oil level gauge and wipe it clean. d. Push it back fully into the pipe.
e. Pull it out and check that the fluid level is in the HOT range. If the level is at the low side, add
new Automatic Transmission Fluid.
Fluid type: ATF D-II or DEXRON III (DEXRON II)
NOTICE: Do not overfill.
2. Check fluid condition. If the fluid smells burnt or is black, replace fluid.
Page 3235
Glossary Of Terms And Symbols (Part 2)
Page 4756
Terminal Retainer
Push the terminal retainer down to the temporary lock position.
c. Release the locking lug from terminal and pull the terminal out from rear.
4. INSTALL TERMINAL TO CONNECTOR
a. Insert the terminal.
HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug
locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position.
Page 4862
Power Steering Fluid: Testing and Inspection
INSPECTION
1. CHECK FLUID LEVEL
a. Keep the vehicle level.
b. With the engine stopped, check the fluid level in the oil reservoir.
If necessary, add fluid. Fluid: ATF DEXRON(R) II or III
HINT: Check that the fluid level is within the HOT LEVEL range on the reservoir/reservoir cap
dipstick.
If the fluid is cold, check that it is within the COLD LEVEL range.
c. Start the engine and run it at idle. d. Turn the steering wheel from lock to lock several times to
boost fluid temperature.
Fluid temperature: 80°C (176°F)
e. Check for foaming or emulsification. If there is foaming or emulsification, bleed power steering
system.
f. With the engine idling, measure the fluid level in the oil reservoir.
g. Stop the engine. h. Wait a few minutes and remeasure the fluid level in the oil reservoir.
Maximum fluid level rise: 5 mm (0.20 inch) If a problem is found, bleed power steering system.
i. Check the fluid level.
Electrical Specifications
Page 2333
Wiring Harness Connector
E: Indicates the wiring harness and wiring harness connector. The wiring harness with male
terminal is shown with arrows.
Outside numerals are pin numbers.
The first letter of the code for each wiring harness and wiring harness connector(s) indicates the
component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and
Surrounding area, and "B" for the Body and Surrounding area.
When more than one code has the first and second letters in common, followed by numbers (e.g,
IH1, IH2), this indicates the same type of wiring harness and wiring harness connector.
F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in
parts position.
G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside
it). Junction Blocks are shaded to clearly separate
them from other parts.
H: When 2 parts both use one connector in common, the parts connector name used in wire
routing is shown in square brackets [ ].
Wiring Color
I: Indicates the wiring color.
Wire colors are indicated by an alphabetical code.
B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR =
Brown SB = Sky Blue LG = Light Green GR = Gray
The first letter indicates the basic wire color and the second letter indicates the color of the stripe.
Page 213
A. The new calibration file should be displayed as the current ECU calibration file.
B. Using a permanent marker or ball point pen, enter the required information on the Authorized
Modifications Label (Figures 21 and 22).
C. Affix this label under the hood in the location determined by the specific vehicle TSB or
Campaign.
NOTE:
Wait 60-90 seconds for ink to set before handling.
Diagram Information and Instructions
Seat Belt Reminder Lamp: Diagram Information and Instructions
Key to Diagrams
A: System Title
B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to
distinguish it from the J/B
Example: 1 Indicates Relay Block No.1
C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type,
or specification is different.
D: Indicates related system.
Page 1786
Engine Control Module: Diagnostic Aids
Voltage Check
Voltage Check
Voltage Check
A. Establish conditions in which voltage is present at the check point.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(SW 2 OFF)
B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or
component terminal. This check can be done with a test light instead of a voltmeter.
Continuity and Resistance Check
Continuity and Resistance Check
Continuity And Resistance Check
A. Disconnect the battery terminal or wire so there is no voltage between the check points. B.
Contact the two leads of an ohmmeter to each of the check points.
Page 6319
Glossary Of Terms And Symbols (Part 2)
Testing and Inspection
Overdrive Switch: Testing and Inspection
O/D Main Switch & O/D OFF Indicator Light Circuit
CIRCUIT DESCRIPTION
The O/D main switch contacts go open when the switch is pushed in and go closed when it is
pushed out.
If O/D main switch is at OFF position, the O/D OFF indicator light lights up, and the ECM prohibits
shifting O/D.
Wiring Diagram
INSPECTION PROCEDURE
Specifications
Engine Oil Pressure: Specifications
Oil Pressure
Oil Pressure at Idle ..............................................................................................................................
........................................................................ 29 kPa Oil Pressure at 3000 rpm ...............................
....................................................................................................................................................
294-588 kPa
Service and Repair
Valve Guide: Service and Repair
For further information regarding this component and the system that it is a part of, please refer to
Cylinder Head Assembly; Service and Repair.
Page 6541
Seat Belt Reminder Lamp: Splice Locations
Engine Compartment
Splice Location
E1 Engine Room Main Wire
E2 Engine Room Main Wire
E3 Engine Room Main Wire
E4 Engine No. 2 Wire
E5 Engine Wire
E6 Engine Wire
E7 Engine Wire
E8 Engine Wire
Instrument Panel
Description and Operation
Transmission Position Switch/Sensor: Description and Operation
PARK / NEUTRAL POSITION SWITCH
Engine Control System
The park/neutral position switch comes on when the shift lever is in the N or P position. When it
comes on, terminal NSW of the ECM is grounded to the body ground via the starter relay, thus the
terminal NSW voltage becomes 0 V. When the shift lever is in the D, 2, L or R position, the
park/neutral position switch goes off, so the voltage of the terminal NSW becomes battery voltage
and the voltage of the ECM internal power source. If the shift lever is moved from the N position to
the D position, this signal is used for air-fuel ratio correction and for idle speed control (estimated
control), etc.
Transmission Control System
The park/neutral position switch detects the shift lever position and sends signals to the ECM.
The ECM receives signals (NSW, R, D, 2 and L) from the park/neutral position switch.
Page 714
Camshaft Position Sensor: Testing and Inspection
ON-VEHICLE INSPECTION
NOTE: "Cold" and "Hot" in these sentences express the temperature of the coils themselves.
"Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F).
INSPECT CAMSHAFT POSITION SENSOR
a. Disconnect the camshaft position sensor connector.
Resistance
b. Using an ohmmeter, measure the resistance between terminals.
If the resistance is not as specified, replace the camshaft position sensor.
c. Reconnect the camshaft position sensor connector.
Page 1473
e. Install the injector to the delivery pipe and lower intake manifold as shown in the illustration.
Before installing the injector, must apply spindle oil or gasoline on the place where a delivery pipe
or an intake manifold touches an O-ring of the injector.
f. Observe these precautions when disconnecting the fuel tube connector (quick type): 1. Check
that there is any dirt or the like on the pipe and around the connector before disconnecting them
and clean the dirt away. 2. Be sure to disconnect by hands. 3. When the connector and the pipe
are stuck, turn and pull the connector to free to disconnect and pull it out. Do not use any tools at
this
time.
4. Inspect if there is any dirt or the like on the seal surface of the disconnected pipe and clean it
away.
5. Prevent the disconnected pipe and connector from being damaged or mixed with foreign objects
by covering them with a vinyl bag.
g. Observe these precautions when connecting the fuel tube connector (quick type):
1. Do not reuse the retainer removed from the pipe. 2. Must use hands to remove the retainer from
the pipe. 3. Check that there is any damage or foreign objects on the connected part of the pipe.
Page 5536
Rear Seat Belt Extender Applications
NOTE:
A seat belt extender must not be used for the center rear seat belt.
Part Number Information
Owner Instructions
Page 6598
B: Junction Connector
Indicates a connector which is connected to a short terminal.
Junction connector in this include a short terminal which is connected to a number of wire
harnesses. Always perform inspection with the short terminal installed. (When installing the wire
harnesses, the harnesses can be connected to any position within the short terminal grouping.
Accordingly, in other vehicles, the same position in the short terminal may be connected to wire
harness from a different part.) Wire harness sharing the same short terminal grouping ha the same
color.
C: Parts Code
The first letter of the code is taken from the first letter of part, and the numbers indicates its order in
parts which start with the same letter.
D: Connector Color
Connectors not indicated are milky white in color.
How to Read Ground Points
HOW TO READ GROUND POINTS
Page 5347
b. Perform a visual check which includes the following items with the front seat outer belt removed
from the vehicle.
- Standard cab: Check for deformation of the quarter panel.
- Access cab: Check for deformation of the ELR bracket.
- Check for damage on the connector and wire harness.
* Refer to SRS Warning Light Check, and How to Display and Read Diagnostic Trouble Codes.
REPLACE REQUIREMENTS
In the following cases, replace the seat belt pretensioner.
- If the seat belt pretensioner has been activated.
- If the seat belt pretensioner has been found to be faulty in troubleshooting.
- If the front seat outer belt has been found to be faulty during checking item functioning of SST.
- If the front seat outer belt has been dropped.
CAUTION: Be sure to follow the correct procedure, for removal and installation of the seat belt
pretensioner.
Page 6419
Splice Point
J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel,
and "B" for the Body).
The Location of splice Point I5 is shaded.
K: Indicates a shielded cable.
L: Indicates the pin number of the connector.
The numbering system is different for female and male connectors.
M: Indicates a ground point.
The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for
the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body
and Surrounding area.
How to Read Connector List
HOW TO READ CONNECTOR LIST
A: Indicates connector to be connected to a part. (The numeral indicates the pin No.)
Page 3423
Fluid - A/T: Service Precautions
DO NOT over fill transmission beyond normal fluid level markings. Fluid foaming and transmission
damage may occur.
Page 788
Steps 1 - 2
Page 2290
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.
Cooling System - Radiator Cap Inspection Procedure
Radiator Cap: Technical Service Bulletins Cooling System - Radiator Cap Inspection Procedure
ENGINE EG014-05
Title: RADIATOR CAP INSPECTION
Models: All Toyota Models
March 28, 2005
Introduction
The procedure for inspecting the radiator cap has been revised. Please refer to the following
procedures when inspecting the radiator cap on all Toyota models.
Applicable Vehicles
^ All Toyota and Scion models.
Required Equipment
Warranty Information
Page 417
b. Push the secondary locking device or terminal retainer in to the full lock position.
5. CONNECT CONNECTOR
Disconnection of Male and Female Connectors
Disconnection of Male and Female Connectors
Disconnection Of Male And Female Connectors
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Page 2609
The calibration file contains the Calibration ID number(s) for a specific vehicle ECU (see Figure 1).
NOTE:
The total number of Calibration ID numbers corresponds to the number of reprogrammable
processors in the ECU (see Figure 2).
Operation Procedure
LOCATE CALIBRATION FILE
The following steps in this bulletin describe how to properly flash reprogram an ECU.
1. Locate calibration file on TIS.
Calibration files may be found in two areas (see Figure 3):
A. Search by model and year for a Technical Service Bulletin addressing a specific Product issue.
^ Within the TSB, click on the link for the calibration file.
B. Search by model under the ECU Flash Reprogramming Section.
^ Under the ECU Flash Reprogramming section on TIS, a drop-down list of the latest calibration
files will be displayed.
C. Proceed to step 2 for instructions on how to download the calibration file from TIS to the
Diagnostic Tester Program Card.
Page 5594
Seat Belt Reminder Lamp: Harness Locations
Engine Compartment
Connector Location
EA1 Cowl Wire Harness and Wire Harness (Connector Location)
EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B)
EC1 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC2 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC3 Engine No. 2 Wire and Engine Wire (Near the Starter)
ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission)
Page 2870
B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(Connect the Relay) and SW 2 OFF (or Disconnect SW 2)
D. Disconnect and reconnect the connectors while watching the test light.
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
E. Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION:
a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals
are touched, the IC may be destroyed by
static electricity.)
b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact
with the terminals of leads from the IC, etc. of the replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
Special Tool
1. PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown.
2. DISCONNECT CONNECTOR
3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
a. Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the
secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
A: For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
Page 1978
CHART 2
CHART 3
CHART 4
Specifications
Valve Clearance: Specifications
Valve Clearance (Cold)
Intake ...................................................................................................................................................
.......................................................... 0.15 - 0.25 mm Exhaust ...........................................................
............................................................................................................................................... 0.25 0.35 mm
Page 4617
Driver Side J/B And Integration Relay Fuse Applications (Part 1)
Page 2619
Page 1420
Camshaft Gear/Sprocket: Service and Repair
For further information regarding this component and the system that it is a part of, please refer to
Cylinder Head Assembly; Service and Repair.
Page 3993
Part 2 of 2
Locations
Airbag Sensor Assembly: Locations
Instrument Panel
Page 6253
Audible Warning Device: Harness Locations
Engine Compartment
Connector Location
EA1 Cowl Wire Harness and Wire Harness (Connector Location)
EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B)
EC1 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC2 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC3 Engine No. 2 Wire and Engine Wire (Near the Starter)
ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission)
Electrical Specifications
Oxygen Sensor: Electrical Specifications
Air/Fuel Ratio Sensor
Resistance:
at 20°C (68°F): 0.8 - 1.4 ohms
at 800°C (1,472°F): 1.8 - 3.2 ohms
Heated Oxygen Sensor
Resistance Between Terminals +B and HT:
at 20°C (68°F) 11 - 16 Ohms
at 800°C (1,472°F) 23 - 32 Ohms
Page 4782
Relay Box: Diagnostic Aids
Voltage Check
Voltage Check
Voltage Check
A. Establish conditions in which voltage is present at the check point.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(SW 2 OFF)
B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or
component terminal. This check can be done with a test light instead of a voltmeter.
Continuity and Resistance Check
Continuity and Resistance Check
Continuity And Resistance Check
A. Disconnect the battery terminal or wire so there is no voltage between the check points. B.
Contact the two leads of an ohmmeter to each of the check points.
Page 3896
Instrument Panel
Connector Location
IA1 Engine Room Main and Cowl Wire (Left Kick Panel)
IA2 Engine Room Main and Cowl Wire (Left Kick Panel)
IA3 Engine Room Main and Cowl Wire (Left Kick Panel)
IA4 Engine Room Main and Cowl Wire (Left Kick Panel)
IB1 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IB2 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IB3 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IC1 Cowl Wire and Roof Wire (Left Side of Instrument Panel)
Instrument Panel
Connector Location
ID1 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH)
ID2 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH)
IE1 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IE2 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IE3 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IF1 Front Door RH Wire and Cowl Wire (Right Kick Panel)
IF2 Front Door RH Wire and Cowl Wire (Right Kick Panel)
IF3 Front Door RH Wire and Cowl Wire (Right Kick Panel)
Page 474
Camshaft Position Sensor: Description and Operation
The Camshaft Position Sensor
Camshaft position sensor (G signal) consists of a magnet iron core and pickup coil.
The G signal plate has 1 tooth on its outer circumference and is installed on the LH camshaft timing
pulley. When the camshafts rotate, protrusion on the signal plate and air gap on the pickup coil
change, causing fluctuations in the magnetic field and generating an electromotive force in the
pickup coil.
The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor
generates 34 signals at every engine revolution. The ECM detects the standard angle of the
crankshaft based on the G signal and the actual angle of the crankshaft and the engine speed by
the NE signal.
Page 3978
Step 4
INSPECTION PROCEDURE
HINT: Troubleshoot in accordance with the chart for each trouble symptom.
Page 1552
1. Turn the temperature control knob to the full cold position.
2. Inspect the clearance between the water control valve lever and the lever stop.
If the lever does not contact the lever stop, proceed to step 3.
3. If the lever does not contact the lever stop:
A. Disengage the cable retaining clip.
B. Pull up on the cable sheath until the water control valve lever contacts the lever stop.
C. Re-fasten the cable retaining clip.
Page 5504
NOTE:
Affix the fluorocarbon resin tape on the shoulder belt anchor to the other side following the same
procedure.
NOTE:
If the seat belt requires cleaning to remove dirt, only use a neutral detergent or lukewarm water to
clean. Use the seat belt after it is completely dried, to confirm proper operation.
Page 6427
B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(Connect the Relay) and SW 2 OFF (or Disconnect SW 2)
D. Disconnect and reconnect the connectors while watching the test light.
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
E. Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION:
a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals
are touched, the IC may be destroyed by
static electricity.)
b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact
with the terminals of leads from the IC, etc. of the replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
Special Tool
1. PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown.
2. DISCONNECT CONNECTOR
3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
a. Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the
secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
A: For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
Page 6607
Waterproof Type Connector
B: For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White
: Gray
Black or White : Dark Gray
Gray or White : Black
Waterproof Type Connector
"Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up
to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Waterproof Type Connector
"Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 4370
INSTALL NEW OIL SEAL (INSIDE)
A. Using the following SST and a plastic hammer, install a NEW oil seal (inside).
09527-17011
NOTE:
Lightly strike the SST on its circumference evenly.
B. Coat MP grease to the oil seal lip.
23. INSTALL STEERING KNUCKLE
A. 4WD:
Insert the drive shaft into the axle hub and temporarily tighten the nut.
NOTE:
Be careful not to damage the oil seal and drive shaft boot.
B. Connect the steering knuckle to the upper suspension arm.
C. Install the nut and a NEW cotter pin. If the holes for the cotter pin are not aligned, tighten the nut
further up to 600.
Torque: 105 N.m (1,100 kgf.cm, 77 ft.lbf)
24. CONNECT LOWER BALL JOINT
Connect the lower ball joint to the steering knuckle with 4 bolts.
Torque: 50 N.m (510 kgf.cm, 37 ft.lbf)
25. INSTALL SHOCK ABSORBER WITH COIL SPRING
A. Install the upper side of shock absorber to the chassis frame with the 3 nuts.
Torque: 64 N.m (650 kgf.cm, 47 ft.lbf)
B. Connect the lower side of shock absorber to the lower suspension arm with bolt, washer and
nut.
Torque: 135 N.m (1,400 kgf.cm, 100 ft.lbf)
26. INSPECT AND INSTALL THE BRAKE ROTOR AND INSTALL THE BRAKE CALIPER WITH
NEW MOUNTING BOLTS
A. Inspect the brake rotors, and machine using an on-the-car brake lathe. Replace the rotor if it is
below minimum thickness values
Minimum Thickness: 26.0 mm (1.024 in.)
NOTE:
It is necessary to turn the rotors using the on-the-car brake lathe to ensure even and uniform rotor
run out. DO NOT turn the rotor using an off-the-car brake lathe.
B. Install the disc, brake caliper and 2 NEW bolts.
Torque: 123 N.m (1,259 kgf.cm, 90 ft.lbf)
C. Install the brake line clamp to the steering knuckle with the bolt.
Torque: 28 N.m (285 kgf.cm, 21 ft.lbf)
27. INSTALL NEW BRAKE LINE
Using the SST, connect NEW brake line.
09023-00100
Page 151
D. The Calibration Update Wizard (CUW) launches automatically when a calibration file link is
selected (or clicked). Verify that the CUW version is 6.0 or higher. If not, refer to the Note below.
The CUW will guide you through the steps to download the calibration file to the Diagnostic Tester
Program Card. Click NEXT on the first screen (Figure 7).
NOTE:
If the CUW does not launch, or the version is older than 6.0, install Diagnostic Software (TIS
Diagnostic Applications Installer). Specific installation instructions (Reprogramming with CUW 6.0)
are located under Diagnostics ECU Flash Reprogramming (Figure 6).
Page 6614
Key Reminder Switch: Component Tests and General Diagnostics
INSPECTION
1. INSPECT IGNITION SWITCH CONTINUITY
If continuity is not as specified, replace the switch.
2. INSPECT KEY UNLOCK WARNING SWITCH CONTINUITY
If continuity is not as specified, replace the switch.
3. Key unlock warning system:
INSPECT COMBINATION METER OPERATION a. Disconnect the connector from the combination
meter. b. Ground terminal 1 and 10 on the wire harness side connector. c. Check the buzzer
sounds.
Specifications
Brake Pad: Specifications
Brake Pad Standard Thickness 11.5 mm
Minimum Thickness 1 mm
Page 3576
Waterproof Type Connector
B: For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White
: Gray
Black or White : Dark Gray
Gray or White : Black
Waterproof Type Connector
"Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up
to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Waterproof Type Connector
"Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 3384
J. The top half of the CUW screen displays the calibrations currently stored on the Diagnostic
Tester Program Card. The bottom half of the screen displays the new calibration to be loaded onto
the Diagnostic Tester Program Card (see Figure 13). Click NEXT to continue the process.
K. Confirm the calibration file to be sent to the Diagnostic Tester Program Card (Figure 14). Click
SEND.
Page 5931
Page 5804
The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit
breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery
power is supplied to each system are explained. Since all System Circuit diagrams start from the
power source, the power source system must be fully understood.
Page 3340
^ Confirm cable connections between the vehicle and Diagnostic Tester are secure. (Reference
TSB No. SS004-01, "ECU Flash Reprogramming Error Message.")
^ Do not disconnect or turn off the Diagnostic Tester or the vehicle ignition during reprogramming.
^ Set the parking brake.
^ Complete ALL flash calibration updates provided for each ECU.
If the battery's state of charge or capacity are in question, test with SST No. 00002-MP815-T,
"Midtronics Battery Tester," and follow TSB No. PG017-02, "Battery Maintenance for In-Stock
Vehicles & Pre-Delivery."
To ensure stable battery voltage, a battery charger may be connected during reprogramming if:
^ Voltage does not fall below 11.4 volts.
^ Voltage does not rise above 16.0 volts.
^ Setting is on SLOW charge and not BOOST.
A. Connect the Diagnostic Tester to the vehicle and select CURRENT ECU CAL from the ECU
REPROGRAM MAIN MENU. Determine the vehicle's current ECU calibration. (See Figure 17.)
NOTE:
The vehicle may contain up to 3 separate calibration ID numbers. In the example shown, the
vehicle ECU contains only 2 calibration IDs.
Page 3646
9. INSTALL COMPANION FLANGE
a. Place the companion flange on the drive pinion. b. Coat the threads of a new nut with hypoid
gear oil. c. Using SST to hold the flange, torque the nut.
SST 09330-00021 Torque: 108 Nm (1,100 kgf-cm, 80 ft. lbs.)
10. ADJUST DRIVE PINION PRELOAD 11. STAKE DRIVE PINION NUT 12. INSTALL FRONT
PROPELLER SHAFT
13. FILL DIFFERENTIAL WITH HYPOID GEAR OIL
Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.) Oil type: Hypoid gear oil API GL-5 Recommended oil
viscosity: SAE 75W-90 Capacity: 1.15 liters (1.22 US qts., 1.01 Imp. qts.)
14. INSTALL ENGINE UNDER COVER
Page 3894
Splice Location
B11
Ground Locations
Seat Belt Reminder Lamp: Ground Locations
Engine Compartment
Ground Location
EA Front Left Fender
EB Rear Bank of Right Cylinder
EC Rear Bank of Left Cylinder
Connector Location
EA1 Cowl Wire Harness and Wire Harness (Connector Location)
EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B)
EC1 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC2 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC3 Engine No. 2 Wire and Engine Wire (Near the Starter)
ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission)
Testing and Inspection
Power Window Switch: Testing and Inspection
Driver's Switch
Passenger's Switch : Window Unlock
Passenger's Switch : Window Lock
INSPECT POWER WINDOW MASTER SWITCH CONTINUITY
If continuity is not as specified, replace the switch.
Page 4608
Auxiliary Power Outlet: Electrical Diagrams
Service Hints
CIGARETTE LIGHTER AND POWER OUTLET
C7 CIGARETTE LIGHTER
2 - GROUND : Approx. 12 volts with ignition SW at ON or ACC position 1 - GROUND : Always
continuity
P6, P7 POWER OUTLET
2 - GROUND : Approx. 12 volts with the ignition SW at ON or ACC position 1 - GROUND : Always
continuity
Page 3562
Body
Connector Location (Standard Cab)
BA1 Front Door LH Wire and Speaker Tweeter Wire LH (Inside of Front Door LH)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Seat
Connector Location
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
BJ1 Seat No. 1 Wire and Seat No. 2 Wire (Under the Driver's Seat)
Page 3580
Electronically Controlled Transmission And A/T Indicator (Part 2)
Page 5321
Refrigerant Pressure Sensor / Switch: Service and Repair
REMOVAL
1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM
HINT: At the time of installation, please refer to the following item. Evacuate air from refrigeration
system. Charge system with refrigerant and inspect for leakage of refrigerant.
Specified amount: 600 ± 50 g (21.16 ± 1.76 oz.)
2. REMOVE PRESSURE SWITCH FROM LIQUID TUBE
Disconnect the connector and remove the pressure switch.
Torque: 10 N.m (100 kgf.cm, 7 ft.lbf)
HINT: Lock the switch mount on the tube with an open end wrench, being careful not to deform the tube,
and remove the switch.
- At the time of installation, please refer to the following item. Lubricate a new O-ring with the
compressor oil and install them to the switch.
INSTALLATION
Installation is in the reverse order of removal.
Page 5519
Seat Belt: Testing and Inspection
INSPECTION
CAUTION: Replace the seat belt assembly (outer belt, inner belt, bolts,nuts or sill-bar) if it has been
used in a severe impact. The entire assembly should be replaced even if damage is not obvious.
1. Except manual type:
RUNNING TEST (IN SAFE AREA) a. Fasten the front seat belts.
b. Drive the car at 10 mph (16 km/h) and slam on the brakes. Check that the belt locks and cannot
be extended at this time.
HINT: Conduct this test in a safe area. It the belt does not lock, remove the belt mechanism
assembly and conduct the following static check. Also, whenever installing a new belt assembly,
verify the proper operation before installation.
2. Driver's seat belt (ELR):
STATIC TEST a. Make sure that the belt locks when pulled out quickly. b. Remove the locking
retractor assembly. c. Tilt the retractor slowly.
d. Make sure that the belt can be pulled out at a tilt of 15 degrees or less, and cannot be pulled out
over 45 degrees of tilt.
If a problem is found, replace the assembly.
3. Except driver's seat belt (ALR/ELR):
STATIC TEST a. Make sure that the belt locks when pulled out quickly. b. Remove the locking
retractor assembly. c. Pull out the whole belt and measure the length of the whole belt. Then retract
the belt slightly and pull it out again. d. Make sure that the belt cannot be extended further.
If a problem is found, replace the assembly.
Page 6853
Engine Room R/B
Page 1584
^ The points shown in the rib sides near here cannot be staked with SST. Use pliers or similar
object and be careful not to damage the core plates.
b. Check the lock plate height (H) after completing the caulking.
Plate height (H): 7.4 - 7.8 mm (0.2959 - 0.3119 inch) If not within the specified height, adjust the
stopper bolt of the handle again and caulk again.
5. INSTALL DRAIN PLUG
a. Install a new O-ring to the drain plug. b. Apply soapy water to the O-ring. c. Install the drain plug.
6. CHECK FOR WATER LEAKS
a. Using SST, plug the inlet and outlet pipes of the radiator.
SST 09230-01010
b. Using a radiator cap tester, apply pressure to the radiator.
Test pressure: 147 kPa (1.5 kgf/cm2, 21 psi)
c. Check for water leaks.
HINT: On radiators with resin tanks, there is a clearance between the core plate and tank plate
where a minute amount of air will remain, giving the appearance of an air leak when the radiator is
submerged in water. Therefore, before performing the water leak test, first swirl the radiator around
in the water until all air bubbles disappear.
7. INSTALL RADIATOR SUPPORTS
Page 5732
Continuity And Resistance Check
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Continuity And Resistance Check
C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the
electrical circuit.
Finding A Short Circuit
Finding A Short Circuit
Finding A Short Circuit
A. Remove the blown fuse and disconnect all loads of the fuse.
Service and Repair
Camshaft: Service and Repair
For further information regarding this component and the system that it is a part of, please refer to
Cylinder Head Assembly; Service and Repair.
Page 4833
Page 4383
^ 09527-17011
B. Coat MP grease to the oil seal lip.
18. INSTALL NEW DUST COVER AND AXLE HUB TO STEERING KNUCKLE
A. Install the NEW dust cover to the steering knuckle with the 4 bolts.
Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)
B. Using the following SST and a press, install the axle hub to the steering knuckle.
^ 09649-17010
19. INSTALL ABS SPEED SENSOR ROTOR (W/ABS) OR SPACER (W/O ABS)
NOTE:
Take care not to scratch the serration of the speed sensor rotor.
20. 2WD: INSTALL NEW LOCK NUT
A. Using the following SST, install and torque a NEW lock nut to the axle hub.
^ 00002-00909 (09318-12010)
Torque: 274 N.m (2,800 kgf.cm, 203 ft.lbf)
NOTE:
Do NOT use air wrench.
B. Using a chisel and hammer, stake the lock nut.
21. 4WD: INSTALL BEARING SPACER
Page 5806
Glossary Of Terms And Symbols (Part 2)
Symptom Related Diagnostic Procedures
Problem Symptoms Table - Ignition Switch And Key Unlock Warning Switch
Page 5477
- Do not release the airbag activation prevention mechanism unless specifically directed by the
troubleshooting procedure.
- If the inserted paper is too thick the terminal and short spring may be damaged, so always use
paper with the same thickness as the male terminal.
Page 3383
memory, the CUW will ask you to select the calibration file(s) to delete from the Diagnostic Tester
Program Card to make room for the new calibration file.
If necessary, check the calibration file(s) to delete, as shown in Figure 11. Click DELETE.
NOTE:
If there is adequate memory to store the calibration file, skip to Step J.
I. The CUW will now delete the calibration file(s) selected (see Figure 12).
Testing and Inspection
Four Wheel Drive Indicator Lamp: Testing and Inspection
5VZ-FE: INSPECT "4Lo/4Hi", 4WD" INDICATOR LIGHT a. Disconnect the connectors from the
ADD actuator. b. "4WD" indicator: Ground terminal 3 on the wire harness side connector. c. Turn
the ignition switch ON, check that the warning light lights up.
If the warning light does not light up, inspect the bulb or wire harness.
2UZ-FE: INSPECT "4Lo/4Hi", "4WD" INDICATOR LIGHT a. Remove the center cluster finish
panel. b. Disconnect the connectors from the center cluster integration. c. "4Lo" indicator: Ground
terminal 3 on the wire harness side connector. d. "4Hi" indicator: Ground terminal 2 on the wire
harness side connector.
Locations
Engine Room R/B
Specifications
Fuel Pressure Regulator
Page 4747
The ground points circuit diagram shows the connections from all major parts to the respective
ground points. When troubleshooting a faulty ground point, checking the system circuits which use
a common ground may help you identify the problem ground quickly. The relationship between
ground points (EA, IB and IC) can also be checked this way.
How to Read Power Source
HOW TO READ POWER SOURCE
Page 4632
Glossary Of Terms And Symbols (Part 1)
Page 4143
Parts Information
NOTE:
Refer to TSB No. BR004-02, "Front Brake Vibration," when installing new design caliper assembly.
Page 232
Terminal Retainer
Push the terminal retainer down to the temporary lock position.
c. Release the locking lug from terminal and pull the terminal out from rear.
4. INSTALL TERMINAL TO CONNECTOR
a. Insert the terminal.
HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug
locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position.
Page 511
Knock Sensor: Service and Repair
1. REMOVE THROTTLE BODY COVER
2. REMOVE INTAKE AIR CONNECTOR
3. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS
4. REMOVE UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY
5. INSPECT KNOCK SENSOR 1,2
Disconnect the knock sensor connectors.
1. REPLACE THE SENSOR WITH SST.
SST 09816-30010
Torque: 45 N.m (450 kgf.cm, 33 ft.lbf)
Reconnect the knock sensor connectors.
2. REINSTALL UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY
3. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS
4. REINSTALL INTAKE AIR CONNECTOR
5. REINSTALL THROTTLE BODY COVER
Component Tests and General Diagnostics
Engine Control Module: Component Tests and General Diagnostics
Terminals Of ECM - Connector View
Terminals Of ECU - Connector Pinouts (Part 1)
Locations
Fuse: Locations
Driver Side J/B And Integration Relay
Page 3073
EFI Main Relay: Testing and Inspection
EFI MAIN RELAY
INSPECTION
1. REMOVE RELAY BOX COVER
2. REMOVE EFI MAIN RELAY (Marking: EFI)
3. INSPECT EFI MAIN RELAY CONTINUITY
a. Using an ohmmeter, check that there is continuity between terminals 1 and 2.
If there is no continuity, replace the relay.
b. Check that there is no continuity between terminals 3 and 5.
If there is continuity, replace the relay.
4. INSPECT EFI MAIN RELAY OPERATION
a. Apply battery voltage across terminals 1 and 2. b. Using an ohmmeter, check that there is
continuity between terminals 3 and 5.
If there is no continuity, replace the relay.
5. REINSTALL EFI MAIN RELAY
6. REINSTALL RELAY BOX COVER
Page 5108
Blower Motor
Blower Motor: Testing and Inspection Blower Motor
INSPECTION
1. REMOVE BLOWER MOTOR
a. Disconnect the connector. b. Remove the 3 screws and motor.
2. INSPECT BLOWER MOTOR OPERATION
Connect the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal 2,
then check that the motor operations smoothly. If operation is not as specified, replace the blower
motor.
3. INSTALL BLOWER MOTOR
a. Install the motor with the 3 screws. b. Connect the connector.
Page 6986
a. Remove the 4 screws and windshield outside moulding. b. Employ the same manner described
above to the other side.
13. REMOVE WINDSHIELD OUTSIDE UPPER MOULDING
a. Using a knife, cut off the moulding as shown in the illustration.
NOTE: Do not damage the body with the knife.
b. Remove the remaining moulding.
14. REMOVE WINDSHIELD GLASS
a. Push piano wire through between the body and glass from the interior. b. Tie both wire ends to
wooden blocks or similar objects.
HINT: Apply protective tape to the outer surface to keep the surface from being scratched.
NOTE: When separating the glass, take care not to damage the paint and exterior ornaments. To
prevent scratching the safety pad when removing the windshield, place a plastic sheet between the
piano wire and safety pad.
Lower
Ball Joint: Service and Repair Lower
REMOVAL
1. REMOVE FRONT WHEEL
2. LOOSEN 4 LOWER BALL JOINT SET BOLTS
HINT: Do not remove the bolts.
3. DISCONNECT TIE ROD END
a. Remove the coffer pin and nut from the tie rod end. b. Using Special Service Tool (SST),
disconnect the tie rod end from the lower ball joint.
SST 09610-20012
Page 1779
Wiring Harness Connector
E: Indicates the wiring harness and wiring harness connector. The wiring harness with male
terminal is shown with arrows.
Outside numerals are pin numbers.
The first letter of the code for each wiring harness and wiring harness connector(s) indicates the
component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and
Surrounding area, and "B" for the Body and Surrounding area.
When more than one code has the first and second letters in common, followed by numbers (e.g,
IH1, IH2), this indicates the same type of wiring harness and wiring harness connector.
F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in
parts position.
G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside
it). Junction Blocks are shaded to clearly separate
them from other parts.
H: When 2 parts both use one connector in common, the parts connector name used in wire
routing is shown in square brackets [ ].
Wiring Color
I: Indicates the wiring color.
Wire colors are indicated by an alphabetical code.
B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR =
Brown SB = Sky Blue LG = Light Green GR = Gray
The first letter indicates the basic wire color and the second letter indicates the color of the stripe.
Page 3341
Page 4875
Power Steering Pump: Service and Repair Disassembly and Reassembly
Page 4671
b. Push the secondary locking device or terminal retainer in to the full lock position.
5. CONNECT CONNECTOR
Disconnection of Male and Female Connectors
Disconnection of Male and Female Connectors
Disconnection Of Male And Female Connectors
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Page 5130
b. Using Special Service Tool (SST) and a press, press out the both inner tubes and rubber parts
of the bushings.
SST 09950-60010 (09951-00350) 09950-70010 (09951-07150)
c. Using a chisel and hammer, tap out the outer tubes.
d. Using SST and a press, install 2 new bushings.
SST 09710-28012 (09710-07062), 09710-30041 09710-03211)
2. REPLACE LEAF SPRING
a. Bend to open the spring clips.
Using a chisel and hammer, pry up the 2 spring clips.
b. Remove the center bolt and nut.
Hold the spring near the spring center bolt in a vise and remove the center bolt and nut.
c. Replace the spring clip.
1. Drill off the head of the rivet and drive it out. 2. Install a new rivet into the holes of the spring leaf
and clip. Then rivet with a press.
d. Install spring center bolt and nut.
1. Align the leaf spring holes and secure the leaves with a vise. 2. Install the spring center bolt and
nut.
Torque: 44 Nm (450 kgf-cm, 33 ft. lbs.)
Diagram Information and Instructions
Lamp Control Module: Diagram Information and Instructions
Key to Diagrams
A: System Title
B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to
distinguish it from the J/B
Example: 1 Indicates Relay Block No.1
C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type,
or specification is different.
D: Indicates related system.
Page 4808
Continuity And Resistance Check
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Continuity And Resistance Check
C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the
electrical circuit.
Finding A Short Circuit
Finding A Short Circuit
Finding A Short Circuit
A. Remove the blown fuse and disconnect all loads of the fuse.
Page 3368
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 2017
4. INSPECT THROTTLE POSITION SENSOR
a. Disconnect the throttle position sensor connector. b. Using an ohmmeter, measure the
resistance between terminals VC and E2.
Resistance: 1.25 - 2.35 kohms at 20 °C (68 °F)
If the resistance is not as specified, replace the throttle position sensor.
c. Reconnect the throttle position sensor connector.
5. INSPECT ACCELERATOR PEDAL POSITION SENSOR
a. Disconnect the pedal position sensor connector. b. Using an ohmmeter, measure the resistance
between terminals VC and E2.
Resistance: 1.64 - 3.28 kohms at 20 °C (68 °F)
If the resistance is not as specified, replace the accelerator pedal position sensor.
c. Reconnect the pedal position sensor connector.
6. REINSTALL THROTTLE BODY COVER
Recall - Rear Cross-Member Corrosion
Technical Service Bulletin # SC90M Date: 091116
Page 6809
Wiring Harness Connector
E: Indicates the wiring harness and wiring harness connector. The wiring harness with male
terminal is shown with arrows.
Outside numerals are pin numbers.
The first letter of the code for each wiring harness and wiring harness connector(s) indicates the
component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and
Surrounding area, and "B" for the Body and Surrounding area.
When more than one code has the first and second letters in common, followed by numbers (e.g,
IH1, IH2), this indicates the same type of wiring harness and wiring harness connector.
F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in
parts position.
G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside
it). Junction Blocks are shaded to clearly separate
them from other parts.
H: When 2 parts both use one connector in common, the parts connector name used in wire
routing is shown in square brackets [ ].
Wiring Color
I: Indicates the wiring color.
Wire colors are indicated by an alphabetical code.
B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR =
Brown SB = Sky Blue LG = Light Green GR = Gray
The first letter indicates the basic wire color and the second letter indicates the color of the stripe.
Page 2271
DOWNLOAD FILE TO TESTER
2. Download the calibration file to the Diagnostic Tester.
The Calibration Update Wizard (CUW) is a new application on TIS which downloads calibration
files from TIS onto the Diagnostic Tester Program Card.
NOTE:
Before you begin, ensure that the Diagnostic Tester is equipped with software version 8.0a, or
later. Only a 12 MB program card (P/N 01002593-005) may be used for this process.
A. Before downloading a new calibration file from TIS, check the current calibration files stored on
the Diagnostic Tester Program Card by following the screen flow shown (Figure 4).
NOTE:
^ Screen D may be blank if no calibrations are stored on the Diagnostic Tester Program Card.
^ If the desired calibration file is already on the Diagnostic Tester, proceed to Step 3 (Reprogram
ECU with Tester shown).
^ A maximum of two calibration files may be loaded on the tester at one time with Diagnostic Tester
software version 10.2a and later. Prior versions may store up to four calibration files.
Body - Acid Rain Paint Damage Prevention/Repair
Paint: Technical Service Bulletins Body - Acid Rain Paint Damage Prevention/Repair
TITLE: ACID RAIN PAINT FINISH DAMAGE - PREVENTION & REPAIR
SECTION: EXTERIOR
BULLETIN # 165
MODELS: ALL TOYOTA LEXUS and SCION
DATE: MARCH 2008
Condition & Cause
'Acid Rain' is the result of rainwater and other forms of airborne moisture mixing with atmospheric
impurities, often referred to as industrial fallout. The mixing forms varying degrees of corrosive
acidic compounds that can settle on exposed surfaces. Depending on geographic location,
concentration level, and length of exposure; vehicle paint finish damage can occur. Horizontal
surfaces such as roof, hood, and trunk panels are most vulnerable.
Prevention of Finish Damage
While Toyota, Lexus, and Scion paint finishes are engineered to look great and provide long-term
durability, if not cared for properly they can sustain damage as a result of acid rain exposure.
Exposure can occur at any time in the life-cycle of a vehicle, be it transport, storage, or consumer
use.
Dealers should refer to the Toyota Warranty Policy and Procedures Manual,
Policy No.2.3 for information on Storage and Protection of New Vehicles.
Detailed information is also provided on proper finish care in the Owner's Manual of all models.
In brief, following washing and wax application recommendations should keep paint looking good.
Inspection & Repair
Acid rain damage can usually be identified visually and by touch. Stains look similar to hard-water
spotting however, advanced stages of damage result in etching and depressions from the corrosive
effect. Lightly rubbing a finger across a suspected acid rain stain may help to confirm etching.
University of Toyota e-learning course E257- Vehicle Delivery Quality- Paint Finish Repair, provides
detailed information on paint finish types, damage assessment methods, and repair techniques.
And, Collision Repair & Refinish T101 and L101 'Paint Finish Repair' provide hands-on training.
There is no substitute for a good training experience. Visit (www.crrtraining.com) for more
information about hands-on training.
Locations
Instrument Panel
Page 5727
The ground points circuit diagram shows the connections from all major parts to the respective
ground points. When troubleshooting a faulty ground point, checking the system circuits which use
a common ground may help you identify the problem ground quickly. The relationship between
ground points (EA, IB and IC) can also be checked this way.
How to Read Power Source
HOW TO READ POWER SOURCE
Replacement Requirements
Airbag Sensor Assembly: Service and Repair Replacement Requirements
REPLACEMENT REQUIREMENTS
In the following cases, replace the airbag sensor assembly.
- If the SRS has been deployed in a collision.
- If the airbag sensor assembly has been found to be faulty in troubleshooting.
- If the airbag sensor assembly has been dropped.
CAUTION: For removal and installation of the airbag sensor assembly. Be sure to follow the correct
procedure.
Page 6678
Continuity And Resistance Check
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Continuity And Resistance Check
C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the
electrical circuit.
Finding A Short Circuit
Finding A Short Circuit
Finding A Short Circuit
A. Remove the blown fuse and disconnect all loads of the fuse.
Page 5007
Inspection Information
On-Vehicle Inspection
NOTE:
^ Be sure to check the table for the applicable inspection type based on the vehicle model.
^ Refer to the table for the standard free play values.
1. Inspect Lower Ball Joint Free Play
Page 1049
HINT: The brake pedal should not be depressed twice and/or returned while setting to the specified
pressure. Read the value of rear brake pressure after holding the specified fluid pressure for 2
seconds. If the brake pressure is incorrect, adjust the fluid pressure.
4. IF NECESSARY, ADJUST FLUID PRESSURE
(a) Loosen the lock nut.
(b) Adjust the length of the shackle No. 2.
Low pressure: Lengthen A High pressure: Shorten A Initial set: 120 mm (4.72 inch) Adjustment
range: 112 - 128 mm (4.41 - 5.04 inch)
HINT: One turn of the nut changes the fluid pressure as shown in the following specification.
7.4 kPa (0.76 kgf/cm, 11 psi)
(c) Torque the lock nut.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)
(d) If the pressure cannot be adjusted by the shackle No. 2, raise or lower the valve body.
Low pressure-Lower body High pressure-Raise body
(e) Torque the nuts.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.) Adjust the length of the shackle No. 2 again. If it cannot be
adjusted, inspect the valve body.
5. IF NECESSARY, CHECK VALVE BODY
(a) Assemble the valve body in the uppermost position.
HINT: When the brakes are applied, the piston will move down about 0.8 mm (0.03 inch). Even at
this time, the piston should not make contact with the load sensing spring or move it.
Page 6964
c. Push piano wire through from the interior. d. Tie both wire ends to wooden blocks or similar
objects.
HINT: Apply protective tape to the outer surface to keep the surface from being scratched.
NOTE: When separating the glass, take care not to damage the paint and exterior.
e. Cut the adhesive by pulling the piano wire around it.
HINT: Cut the adhesive areas as shown in the illustration, leaving the adhesive where the stud
bolts are.
f. Let the piano wire pass as shown in the illustration, cut off the adhered part to the stud bolts.
g. Remove the glass.
NOTE: Leave as much of the adhesive on the body as possible when cutting off the glass.
INSTALLATION
HINT: For step 8 to 10, refer to Headliner.
1. CLEAN AND SHAPE CONTACT SURFACE OF BODY
Page 2622
Engine Control Module: Specifications
Terminals Of ECU - Connector Pinouts (Part 2)
Page 6681
Waterproof Type Connector
B: For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White
: Gray
Black or White : Dark Gray
Gray or White : Black
Waterproof Type Connector
"Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up
to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Waterproof Type Connector
"Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 4933
Key Reminder And Seat Belt Warning
Page 2544
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 6840
Terminal Retainer
Push the terminal retainer down to the temporary lock position.
c. Release the locking lug from terminal and pull the terminal out from rear.
4. INSTALL TERMINAL TO CONNECTOR
a. Insert the terminal.
HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug
locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position.
Engine Controls - O2 Sensor Monitor Threshold Values
Oxygen Sensor: All Technical Service Bulletins Engine Controls - O2 Sensor Monitor Threshold
Values
SPECIAL SERVICE TOOLS SS002-03
December 17, 2003
Title O2S TEST RESULTS (MODE 05)
Models All '96 - '03, '04 Corolla, ECHO, Matrix, Sienna & Scion xA & xB
Introduction
This Service Bulletin contains Oxygen Sensor (O2S) Monitor threshold values for all models from
1996 to 2003 and some 2004 models. Starting in 2004, the O2S Monitor threshold values can be
found in the repair manual. These values are used when analyzing the O2S test results to
determine the O2S condition.
Applicable Vehicles ^
All 1996 - 2003 model year Toyota vehicles.
^ 2004 model year Corolla, ECHO, Matrix and Sienna vehicles.
^ 2004 model year Scion xA and xB vehicles.
Function Description
Checking O2S Test Results
To view O2S test results, the O2S Monitor must be completed and the test results must be
checked within the same key cycle. If the ignition key is cycled OFF, the O2S test results will be set
to the minimum or maximum limits, and all test results will be erased. The O2S test results are
stored in the ECU (SAE term: Powertrain Control Module/PCM) when the monitor is completed.
The test results are static and will not change once the monitor is complete.
The process for checking 02S test results is described in the following three basic steps:
1. Completing the O2S Readiness Monitor.
2. Accessing O2S Test Results.
3. Comparing O2S Test Results to Failure Thresholds.
Required SSTs
NOTE:
Additional Diagnostic Tester Kits, Program Cards or other SSTs may be ordered by calling
SPX-OTC at 1-800-933-8335.
Warranty Information
Completing O2S Readiness Monitor
1. Clear any stored Diagnostic Trouble Codes (DTCs) using the Toyota Diagnostic Tester.
Page 6224
Problem Symptom Confirmation (Road Test)
PROBLEM SYMPTOM CONFIRMATION (Road Test)
Page 5913
Page 1847
Engine Coolant Temperature (ECT) Sensor
Testing and Inspection
Parking Brake Warning Switch: Testing and Inspection
INSPECT PARKING BRAKE SWITCH CONTINUITY a. Check that there is continuity terminals
with the switch ON (switch pin released). b. Check that there is no continuity between terminals
with the switch OFF (switch pin pushed in).
If operation is not as specified, replace the switch.
Page 5338
Note 3 - Inspect and if necessary replace the Steering Wheel: ^ If the steering wheel is diagnosed
as needing replacement during inspection
Note 4 - Replace the Passenger Airbag assembly: ^ If the passenger airbag has been deployed or
dropped ^ If the airbag is diagnosed as needing replacement when troubleshooting or during
inspection
Note 5 - Visually inspect and if necessary replace the following items if deformed: ^ Instrument
panel and instrument panel reinforcement ^ Glove compartment or glove compartment door
Note 6 - Replace the Front Impact Sensors: ^ If either the driver or passenger airbag has deployed
(replace both front impact sensors) ^ If a front airbag sensor is diagnosed as needing replacement
when troubleshooting or during inspection
Note 7 - Replace the Airbag Sensor Assembly: ^ If any airbag has been deployed in a collision or
the airbag sensor assembly has been dropped or is diagnosed as needing replacement when
troubleshooting
Note 8 - Inspect and if necessary replace the Wire Harness or Connector: ^ If any part of the SRS
wire harness or any connector is diagnosed as needing replacement when troubleshooting or
during inspection
Note 9 - Replace the: ^ Side Impact Airbag if it has been deployed dropped or is diagnosed as
needing replacement when troubleshooting or during inspection ^ Seat cover if it has cuts and/or
frayed seams or is diagnosed as needing replacement during inspection ^ Seat frame if it is bent or
has become damaged
Note 10 - Replace the Side Impact Sensors: ^ If the side airbag assembly has been deployed
dropped or is diagnosed as needing replacement when troubleshooting or during inspection
Note 10 - Replace the Side and Curtain Shield Impact Sensors: ^ If either the side or curtain shield
airbag assembly have been deployed dropped or are diagnosed as needing replacement when
troubleshooting or
during inspection
Note 11 - In the event of driver or passenger airbag deployment replace all seatbelt Pretensioners.
Note 12 - Replace the: ^ Curtain Shield Airbag if it has been deployed dropped or is diagnosed as
needing replacement when troubleshooting or during inspection ^ Visually inspect and if necessary
replace the following items if deformed or cracked:
- Headliner and/or interior trim panels
- Body components where the Curtain Shield Airbag is mounted
Page 5774
Glossary Of Terms And Symbols (Part 2)
Locations
Engine Room R/B
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 5563
Body
Connector Location (Access Cab)
BA1 Front Door LH Wire and Wire Harness (Connector Location)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel)
BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel)
BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel)
BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Locations
VSV For Vapor Pressure Sensor
Page 2158
Mass Air Flow Meter: Service and Repair
MASS AIR FLOW (MAF) METER
1. DISCONNECT MAF METER CONNECTOR
2. REMOVE MAF METER
Remove the 2 screws and MAF meter.
3. REINSTALL MAF METER
Install the MAF meter with the 2 screws.
4. RECONNECT MAF METER CONNECTOR
Page 4524
Battery Replacement
If a vehicle battery needs to be replaced for a warrantable condition, complete a Warranty Battery
Label and affix it to the failed battery for proper warranty parts and claim processing. Include the
Vehicle Identification Number ("IN) and warranty code on the Warranty Battery Label.
Battery Maintenance
Recommended Battery Maintenance:
In addition to this new pre-delivery battery test, a monthly battery inspection is still required for
stored vehicles. If your dealership is located in an area subject to extreme temperatures (hot or
cold), periodic maintenance may need to be performed more frequently.
To reduce parasitic battery drain on vehicles in storage for one week or more, the negative (-)
battery cable should always be disconnected to reduce battery discharge. When the negative (-)
battery cable is reconnected, please check and reset electrical components, such as the clock,
radio, etc., and re-initialize all applicable systems/functions.
Refer to the appropriate model and year service bulletins for specific details. For example:
^ TSB No. PD008-05, "Power System Initialization During PDS" (2005 model year)
^ TSB No. PDO14-06, "Power System Initialization During PDS" (2006 model year)
Page 5520
e. Retract the whole belt, then pull out the belt until 200 mm (7.87 in.) of belt remains retracted. f.
Tilt the retractor slowly.
g. Make sure that the belt can be pulled out at a tilt of 15 degrees or less, and cannot be pulled out
at over 45 degrees of tilt.
If a problem is found, replace the assembly.
4. Manual type:
TESTING
a. Adjust the belt to the proper length. b. Apply a firm load to the belt. c. Make sure that the belt
does not extend.
Page 1893
Page 82
Engine Room R/B
Details
Page 2254
Refer to Reset Procedure 1 for the vehicles with Electronically Controlled Automatic
Transmissions:
Page 6251
Body
Splice Location (Standard Cab)
B1 Speaker Tweeter Wire LH
B2 Front Door LH Wire
B3 Front Door LH Wire
B4 Roof Wire
B5 Speaker Tweeter Wire RH
B6 B7
Front Door RH Wire
B10 Frame Wire
Seat
Page 6225
a. Inspect the SET switch.
1. Push the main switch ON. 2. Drive at a desired speed (40 km/h (25 mph) or higher). 3. Push the
control switch downward for the SET/COAST. 4. After releasing the switch, check that the vehicle
cruises at the desired speed.
b. Inspect the ACC (acceleration) switch.
1. Push the main switch ON. 2. Drive at a desired speed (40 km/h (25 mph) or higher). 3. Check
that the vehicle speed increases while the control switch is turned to RES/ACC, and that the
vehicle cruises at the set speed when the
switch is released.
4. Momentarily push the control switch upward in the RES/ACC direction and then immediately
release it. Check that the vehicle speed increases
by about 1.5 km/h (Tap-up function).
c. Inspect the COAST switch.
1. Push the main switch ON. 2. Drive at a desired speed (40 km/h (25 mph) or higher). 3. Check
that the vehicle speed decreases while the control switch is turned to SET/COAST; and the vehicle
cruises at the set speed when the
switch is released.
4. Momentarily push the control switch downward for the SET/COAST, and then immediately
release it. Check that the vehicle speed decreases
by about 1.5 km/h (Tap-down function).
d. Inspect the CANCEL switch.
1. Push the main switch ON. 2. Drive at a desired speed (40 km/h (25 mph) or higher). 3. When
operating one of the followings, check that the cruise control system is cancelled and that the
normal driving mode is reset.
- Depress the brake pedal.
- Shift into except D position.
- Push the main switch OFF.
- Pull the cruise control switch for CANCEL.
Page 5088
Page 2534
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 6544
Splice Location
B11
Page 4269
Applicable Warranty*:
This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or
36,000 miles, whichever occurs first, from the vehicle's in-service date.
*Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Page 1695
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 4522
10. Select the appropriate model and press the NEXT soft key.
11. Select OEM battery type and press the NEXT soft key.
12. Choose the correct battery (model number and CCA) and press the NEXT soft key.
The battery will be tested before charging will occur. The progress bar fills in across the screen
while testing.
Page 3532
2. REMOVE PARKING LOCK CABLE ASSEMBLY
a. Remove the screw and cable No. 2. b. Using a torx socket wrench, remove the 2 screws and
cable No. 1. c. Remove the spring. d. Remove the 2 bolts and parking lock cable housing.
3. REMOVE SHIFT LEVER
a. Disconnect the connector. b. Using a torx socket wrench, remove the torx screw and shift lever.
c. Remove the upper No. 2 steering column cover.
4. REMOVE SHIFT LEVER HOUSING
Using a torx socket wrench, remove the 3 torx screws and shift lever housing.
INSTALLATION
1. INSTALL SHIFT LEVER HOUSING
Using a torx socket wrench, install the shift lever housing with the 3 new screws. Torque: 12 Nm
(120 kgf-cm, 9 ft. lbs.)
2. INSTALL SHIFT LEVER
a. Install the upper No. 2 steering column cover. b. Using a torx socket wrench, install the shift
lever with a new screw.
Torque: 18 Nm (180 kgf-cm, 13 ft. lbs.)
c. Connect the connector.
3. INSTALL PARKING LOCK CABLE NO. 1 AND NO. 2
a. Apply MP grease on the lock pin and internal surface of shift lever housing. b. Install the spring
and parking lock cable No. 1 into the shift lever housing.
NOTICE: Be careful not to bend or twist the cable abnormally.
c. Using a torx socket wrench, install 2 new screws.
Torque: 2.9 Nm (29 kgf-cm, 25 inch lbs.)
d. Wire the cable No. 1 and No. 2. e. Install the cable housing to steering column assembly with 2
new bolts temporarily.
NOTICE: Be careful not to bend or twist the cable abnormally.
Page 3365
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 2180
Coolant Temperature Sensor/Switch (For Computer): Mechanical Specifications
New gasket and the ECT sensor. Torque: ..........................................................................................
.................................................................................... 20.4 N.m (208 kgf.cm, 15 ft.lbf)
New gasket and the throttle body with the 2 bolts and 2 nuts. Torque: ...............................................
.................................................................................................................................. 18 N.m (185
kgf.cm, 13 ft.lbf)
Page 5749
Wire Harness Fuse Location
Troubleshooting Procedure
Page 5602
B: Junction Connector
Indicates a connector which is connected to a short terminal.
Junction connector in this include a short terminal which is connected to a number of wire
harnesses. Always perform inspection with the short terminal installed. (When installing the wire
harnesses, the harnesses can be connected to any position within the short terminal grouping.
Accordingly, in other vehicles, the same position in the short terminal may be connected to wire
harness from a different part.) Wire harness sharing the same short terminal grouping ha the same
color.
C: Parts Code
The first letter of the code is taken from the first letter of part, and the numbers indicates its order in
parts which start with the same letter.
D: Connector Color
Connectors not indicated are milky white in color.
How to Read Ground Points
HOW TO READ GROUND POINTS
Page 2801
2. Start the engine.
3. Perform the drive pattern to run and complete the Oxygen Sensor (O2S) Monitor.
HINT:
The 02S Monitor is completed when the following conditions are met:
^ Two (2) minutes or more passed after the engine start.
^ The Engine Coolant Temperature (ECT) is 167°F (75°C) or more.
^ Cumulative running time at 30 mph (48 km/h) or more exceeds 6 minutes.
^ Vehicle is in closed loop.
^ The fuel-cut is operated for 8 seconds or more (for Rear O2S Monitor).
A. Allow the engine to idle for two minutes.
B. Warm up the engine until the Engine Coolant Temperature (ECT) reaches 167°F (75°C).
C. Drive the vehicle over 30 mph (48 km/h) for more than 40 seconds.
D. Stop the vehicle and allow the engine to idle for more than 20 seconds.
E. Repeat steps C and D at least 8 times in one driving cycle. (Do not cycle the ignition key.)
In addition, perform the following steps for the Rear O2S Readiness Monitor:
A. Select second gear.
B. Allow the vehicle to run at 30 mph (48 km/h) or more.
C. Keep the accelerator pedal "off-idle" for more than 10 seconds.
D. Immediately after step C, release the accelerator pedal for at least 10 seconds without
depressing the brake pedal (to execute the fuel-cut).
E. Decelerate the vehicle until the vehicle speed reaches less than 6mph (10km/h).
F. Repeat steps B - E at least twice in one driving cycle.
Accessing O2S Test Results
1. On the Diagnostic Tester* screen, select the following menus:
^ DIAGNOSTICS
^ CARB OBD II
Capacity Specifications
Engine Oil: Capacity Specifications
Engine Oil
With filter ..............................................................................................................................................
.......................................................... 6.4 Qts.(6.1L) Without filter .......................................................
............................................................................................................................................ 6.0
Qts.(5.7L)
Page 6080
4RUNNER LTD (Cladding & Overfender)
4RUNNER LTD Full
Specifications
Extension Housing: Specifications
Extension Housing x Transmission Case 36 Nm
No.2 Vehicle Speed Sensor x Extension Housing 5.4 Nm
Specifications
Knock Sensor: Specifications
SST 09816-30010
Torque: ................................................................................................................................................
................................. 45 N.m (450 kgf.cm, 33 ft.lbf)
Page 2958
2. Tighten the union bolt by hand.
3. Using SST, tighten the union bolt to the specified torque.
SST 09612-24014 (09617-24011)
Torque: 33 N.m (340 kgf.cm, 24 ft.lbf) for use with SST 39 N.m (400 kgf.cm, 29 ft.lbf)
HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
c. When connecting the flare nut on the high pressure pipe union, observe these procedures:
1. Apply a light coat of engine oil to the flare nut, and tighten the flare nut by hand. 2. Using SST,
tighten the flare nut to the specified torque.
SST 09023-38400
NOTE: Do not rotate the fuel filter outlet, when tightening the flare nut.
Torque: 28 N.m (285 kgf.cm, 21 ft.lbf) for use with SST 34.3 N.m (350 kgf.cm, 25 ft.lbf)
HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
d. Observe these precautions when removing and installing the injectors.
1. Never reuse the O-ring. 2. When placing a new O-ring on the injector, take care not to damage it
in any way. 3. Coat a new O-ring with spindle oil or gasoline before installing-never use engine,
gear or brake oil.
Page 5879
Deck Top Protector
Page 6930
Turn Signal Flasher: Testing and Inspection
INSPECT TURN SIGNAL FLASHER OPERATION Disconnect the connector from the turn signal
flasher and inspect the connector on the wire harness side,as shown.
Instruments - Coolant Temperature Gauge Inaccurate
Temperature Gauge: Customer Interest Instruments - Coolant Temperature Gauge Inaccurate
ELECTRICAL EL009-01
October 12, 2001
Title: TEMPERATURE GAUGE INACCURATE
Models: '00 - '01 Tundra
Introduction Some 2000 - 2001 model year Tundra trucks may experience a condition in which the
engine coolant temperature gauge displays an abnormally high reading during normal engine
operating temperatures. To address this condition, an updated Temperature Gauge has been
made available.
Applicable Vehicles ^
2000 - 2001 model year Tundra trucks, built prior to the VIN shown.
Production Change Information
Parts Information
Repair Procedure
IMPORTANT:
Verify that the engine is operating at a normal temperature with the Scan Tool before replacing the
temperature gauge.
1. Remove the four bolts securing the combination meter assembly.
2. Replace the Temperature Gauge.
3. Reassemble the combination meter.
Warranty Information
Applicable Warranty *:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36
months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Page 756
a. Install the front airbag sensors with the 4 bolts.
Torque: 20 N.m (205 kgf.cm, 15 ft.lbf)
HINT: Install the front airbag sensor with the arrow on the sensor facing toward the front of the
vehicle.
NOTE: Connection of the connector is done after the sensor has been installed.
- Make sure the sensor is installed with the specified torque.
- If the sensor has been dropped, or there are cracks, dents or other defects in the case, brackets
or connector, replace the removed sensor with a new one.
- The front sensor is equipped with an electrical connection check mechanism. Be sure to lock this
mechanism securely when connecting the connector. If the connector is not securely locked, a
malfunction code will be detected by the diagnostic system.
b. Connect the front airbag sensor connectors.
c. Install the air cleaner assembly.
d. 2UZ-FE engine:
Install the battery tray, battery and battery carrier.
Page 5503
Before installation of the fluorocarbon resin tape, it is necessary to pre-release the colored film
about 5 mm for each side. (Not fully released.)
B. By pulling up the seat belt, put the fluorocarbon resin tape through the hole of the shoulder belt
anchor. Match the shoulder belt anchor to the center of the tape.
C. Remove the upper side colored film from the fluorocarbon resin tape, and securely affix the tape
to the outside of the shoulder belt anchor.
D. Remove the lower side colored film from the fluorocarbon resin tape, and securely affix the tape
to the outside of the shoulder belt anchor.
NOTE:
^ Be sure to affix the fluorocarbon tape securely along all edges.
^ Pay attention not to make any wrinkles or slack in the fluorocarbon resin tape.
E. Remove the clip.
F. By pulling the seat belt up and down several times, as shown in the illustration, securely affix the
fluorocarbon resin tape and confirm the smoothness of the belt movement.
Page 5614
Seat Belt Reminder Lamp: Electrical Diagrams
Key Reminder And Seat Belt Warning
Service Hints
KEY REMINDER AND SEAT BELT WARNING
Page 1317
Engine Oil: Fluid Type Specifications
Engine Oil Type
GRADE ..................................................................................................................................... API
SJ Energy-Conserving or ILSAC multigrade engine oil All temperatures ............................................
............................................................................................................................................ 5W-30
(preferred) Above 0° F .........................................................................................................................
....................................................................................... 10W-30
Page 914
1. INSPECT TIMING BELT
NOTICE: Do not bend, twist or turn the timing belt inside out.
- Do not allow the timing belt to come into contact with oil, water or steam.
- Do not utilize timing belt tension when installing or removing the mount bolt of the camshaft timing
pulley.
If there is any defect, as shown in the illustration, check these points:
a. Premature parting
- Check for proper installation.
- Check the timing cover gasket for damage and proper installation.
b. If the belt teeth are cracked or damaged, check to see if either camshaft is locked. c. If there is
noticeable wear or cracks on the belt face, check to see if there are nicks on the side of the idler
pulley lock and water pump. d. If there is wear or damage on even one side of the belt, check the
belt guide and the alignment of each pulley. e. If there is noticeable wear on the belt teeth, check
timing cover for damage and for foreign material on the pulley teeth.
If necessary, replace the timing belt.
2. INSPECT IDLER PULLEYS
a. Visually check the seal portion of the idler pulley for oil leakage.
If leakage is found, replace the idler pulley.
b. Check that the idler pulley turns smoothly.
If necessary, replace the idler pulley.
3. INSPECT TIMING BELT TENSIONER
a. Visually check the seal portion of the tensioner for oil leakage.
HINT: If there is only the faintest trace of oil on the seal on the push rod side, the tensioner is all
right. If leakage is found, replace the tensioner.
Page 2771
CHART 25
Page 703
If you have no TOYOTA hand-held tester, measure voltage between terminals VPA and E2 of the
ECM connector.
d. Inspect the air assist system.
1. Start the engine and check that the MIL does not light up. 2. Allow the engine to warm up to
normal operating temperature. 3. Turn the A/C compressor ON to OFF, and check the idle speed.
Idle speed (Transmission in neutral): 700 ± 50 rpm
NOTE: Perform inspection under condition without electrical load.
e. After checking the above (b) to (d), perform the driving test and check that there is no sense of
incongruity.
3. INSPECT THROTTLE CONTROL MOTOR
a. Disconnect the throttle control motor connector. b. Using an ohmmeter, measure the motor
resistance between terminal 1 (M+) and 2 (M-).
Motor resistance: 0.3 - 100 ohms at 20 °C (68 °F)
If the resistance is not as specified, replace the throttle control motor.
c. Using an ohmmeter, measure the clutch resistance between terminal 3 (CL-) and 4 (CL+).
Clutch resistance: 4.2 - 5.2 ohms at 20 °C (68 °F)
If the resistance is not as specified, replace the throttle control motor.
d. Reconnect the throttle control motor connector.
Page 555
CHART 11
SRS/Interior - Seat Cover Replacement Caution
Seat Cover: All Technical Service Bulletins SRS/Interior - Seat Cover Replacement Caution
BODY BO014-05
Title: SEAT COVER REPLACEMENT FOR SIDE AIRBAG EQUIPPED VEHICLES
Models: '98 - '06 All Models
November 10, 2005
TSB UPDATE NOTICE:
The information contained in this TSB supercedes TSB No. B0025-97. TSB No. B0025-97 is now
obsolete and should be discarded.
Introduction
Beginning in 1998, Toyota introduced side airbags as optional equipment.
Toyota does NOT recommend replacement of original seat covers* with non-Toyota leather or
other seat cover materials on vehicles due to the following:
^ Seat covers NOT recommended by Toyota may affect side airbag performance, in general or in
part, during an accident.
^ Modifications that negatively affect side airbag performance can result in severe occupant
injuries.
^ Seat covers are an integral part of this safety system. Replacing fabric seat covers* with
non-Toyota leather or other seat cover materials may compromise the effectiveness of this safety
system.
^ The design of the seat is complex, integrating safety and strength with comfort and luxury.
*NOTE:
Toyota original seat covers that were NOT designed for side airbag equipped seats cannot be used
due to the effect on proper airbag performance.
Toyota strongly discourages modifying original equipment seats that have optional side airbags.
Additionally, Toyota strongly advises against the installation or use of aftermarket seat covers,
which could impair the performance of the side airbags in the event of an accident.
Applicable Vehicles
^ All 1998 - 2006 model year Toyota and Scion vehicles equipped with side airbags.
Warranty Information
Page 5810
Non-Waterproof Type Connector
"Case 1" Raise the terminal retainer up to the temporary lock position.
Non-Waterproof Type Connector
"Case 2" Open the secondary locking device.
Page 6399
An airbag activation prevention mechanism is built into the connector for the squib circuit of the
SRS.
When release of the airbag activation prevention mechanism is directed in the troubleshooting
procedure, as shown in the illustration of the connectors, insert paper which has the same
thickness as the male terminal, between the terminal and the short spring.
CAUTION: Never release the airbag activation prevention mechanism on the steering wheel pad
connector.
NOTE:
Page 2649
Windows 2000 SP2 or later Windows XP Pro SP1 or later
For more information about the J2534 devices listed above, contact the vendors. To report
compatibility problems with listed hardware/software, please contact the device manufacturer.
For more information about Toyota vehicle reprogramming CDs or to report problems running
Toyota's Calibration Update Wizard software, please contact Toyota.
OBTAINING A CALIBRATION CD
The Calibration CD is compatible with the above mentioned scantools and J2534 interfaces. A
Calibration CD contains all of the most current vehicle calibration files, applicable TSBs, the
Calibration Update Wizard application software for a Windows PC, and instructions for use.
Calibration CDs can be ordered through the Toyota Material Distribution Center; order P/N
00456-REPRG-001.
IMPORTANT NOTICE
It is possible to permanently damage a vehicle controller during the flash reprogramming process.
It is especially important to understand that once started, the reprogramming process must not be
interrupted, reprogramming devices must not be disconnected and PCs must not be allowed to go
into standby, hibernation or similar power management modes. The information provided herein is
intended expressly for use by qualified professional automobile technicians. To prevent damage to
your customer's vehicle and ensure safe service practice, read these materials completely and
thoroughly before servicing the vehicle and be sure to follow all instructions.
Capacity Specifications
Fluid - Differential: Capacity Specifications
Differential Fluid
Front ....................................................................................................................................................
......................................................................... 1.2 Qt Rear ................................................................
..............................................................................................................................................................
3.7 Qt
Electrical Specifications
Resistance
Page 6992
Install the cowl louver with the 8 screws and 6 clips.
15. INSTALL WIPER ARMS
a. Operate the wipers once and turn the wiper switch OFF. b. Install the wiper arms and tighten the
nuts by hand.
c. Adjust the installation positions of the wiper arms to the positions shown in the illustration.
A: Approx. 25.7 mm (1.012 in.) B: Approx. 39.7 mm (1.563 in.)
HINT: When installing wiper arms, make sure that the tips of the blades are not beyond the ceramic
edge as indicated by "C" part in the illustration.
d. Torque the nuts.
Torque: 20 N.m (204 kgf.cm, 15 ft.lbf)
e. Install the caps.
16. INSTALL FRONT PART OF ROOF HEADLINING 17. INSTALL SUN VISOR HOLDERS
Install the 2 sun visor holders with the 2 screws.
18. INSTALL FRONT PERSONAL LIGHT
a. Connect the connector, then install the front personal light. b. Install the 2 screws and the clip.
HINT: When installing the front personal light, attach the clip to the housing and push it to the
bracket.
c. Install the left side lens.
19. INSTALL SUB-VISORS
Install the 2 sub-visors with the 4 screws.
20. INSTALL SUN VISORS
a. w/ Light:
Connect the connector.
b. Install the 2 sun visors with the 4 screws.
21. INSTALL FRONT PILLAR GARNISH
Page 6591
Instrument Panel
Connector Location
IA1 Engine Room Main and Cowl Wire (Left Kick Panel)
IA2 Engine Room Main and Cowl Wire (Left Kick Panel)
IA3 Engine Room Main and Cowl Wire (Left Kick Panel)
IA4 Engine Room Main and Cowl Wire (Left Kick Panel)
IB1 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IB2 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IB3 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IC1 Cowl Wire and Roof Wire (Left Side of Instrument Panel)
Instrument Panel
Connector Location
ID1 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH)
ID2 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH)
IE1 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IE2 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IE3 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IF1 Front Door RH Wire and Cowl Wire (Right Kick Panel)
IF2 Front Door RH Wire and Cowl Wire (Right Kick Panel)
IF3 Front Door RH Wire and Cowl Wire (Right Kick Panel)
Page 3739
Transmission Mode Indicator - A/T: Splice Locations
Engine Compartment
Splice Location
E1 Engine Room Main Wire
E2 Engine Room Main Wire
E3 Engine Room Main Wire
E4 Engine No. 2 Wire
E5 Engine Wire
E6 Engine Wire
E7 Engine Wire
E8 Engine Wire
Instrument Panel
Page 5100
Page 4068
B. Using Snap ring pliers, install a NEW snap ring.
17. INSTALL NEW OIL SEAL (OUTSIDE)
A. Using the following SSTs and a plastic hammer, install a NEW oil seal (outside).
^ 09223-15030
^ 09527-17011
B. Coat MP grease to the oil seal lip.
18. INSTALL NEW DUST COVER AND AXLE HUB TO STEERING KNUCKLE
A. Install the NEW dust cover to the steering knuckle with the 4 bolts.
Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)
B. Using the following SST and a press, install the axle hub to the steering knuckle.
09649-17010
19. INSTALL ABS SPEED SENSOR
ROTOR (W/ABS) OR SPACER (W/O ABS)
NOTE:
Take care not to scratch the serration of the speed sensor rotor.
Page 148
The calibration file contains the Calibration ID number(s) for a specific vehicle ECU (see Figure 1).
NOTE:
The total number of Calibration ID numbers corresponds to the number of reprogrammable
processors in the ECU (see Figure 2).
Operation Procedure
LOCATE CALIBRATION FILE
The following steps in this bulletin describe how to properly flash reprogram an ECU.
1. Locate calibration file on TIS.
Calibration files may be found in two areas (see Figure 3):
A. Search by model and year for a Technical Service Bulletin addressing a specific Product issue.
^ Within the TSB, click on the link for the calibration file.
B. Search by model under the ECU Flash Reprogramming Section.
^ Under the ECU Flash Reprogramming section on TIS, a drop-down list of the latest calibration
files will be displayed.
C. Proceed to step 2 for instructions on how to download the calibration file from TIS to the
Diagnostic Tester Program Card.
Page 5095
Page 4995
- The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30
minutes after deployment.
- Use gloves and safety glasses when handling a steering wheel pad with the deployed airbag.
- Always wash your hands with water after completing the operation.
- Do not apply water, etc.to a steering wheel pad with the deployed airbag.
CAUTION:
- The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30
minutes after deployment.
- When moving a vehicle for scrapping which has a steering wheel pad with the deployed airbag,
use gloves and safety glasses.
- Use gloves and safety glasses when handling a steering wheel pad with deployed airbag.
- Always wash your hands with water after completing the operation.
- Do not apply water, etc.to a steering wheel pad with deployed airbag.
1. Remove the steering wheel pad from the steering wheel. 2. Place the steering wheel pad in a
vinyl bag, tie the end tightly and dispose of it in the same way as other general parts disposal.
Page 6349
The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit
breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery
power is supplied to each system are explained. Since all System Circuit diagrams start from the
power source, the power source system must be fully understood.
Page 4355
Torque: 50 N.m (510 kgf.cm, 37 ft.lbf)
25. Install shock absorber with coil spring.
A. Install the upper side of shock absorber to the chassis frame with the 3 nuts.
Torque: 64 N.m (650 kgf.cm, 47 ft.lbf)
B. Connect the lower side of shock absorber to the lower suspension arm with bolt, washer, and
nut.
Torque: 135 N.m (1,400 kgf.cm, 100 ft.lbf)
26. Inspect and install the brake rotor and install the brake caliper with new mounting bolts.
A. Inspect the brake rotors and machine using an on-the-car brake lathe. Replace the rotor if it is
below minimum thickness values
Minimum Thickness: 26.0 mm (1.024 in.)
NOTE:
It is necessary to turn the rotors using the on-the-car brake lathe to ensure even and uniform rotor
run out. DO NOT turn the rotor using an off-the-car brake lathe.
B. Install the disc, brake caliper, and 2 NEW bolts.
Torque: 123 N.m (1,259 kgf.cm, 90 ft.lbf)
C. Install the brake line clamp to the steering knuckle with the bolt.
Torque: 28 N.m (285 kgf.cm, 21 ft.lbf)
27. Install new brake line.
Using the SST, connect NEW brake line.
SST P/N: 09023-00100
Torque: 15 N.m (155 kgf.cm, 11 ft.lbf)
28. With ABS:
Connect the ABS speed sensor and wire harness clamp to the steering knuckle with the 2 bolts.
Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
29. 4WD:
Install drive shaft lock nut.
A. While applying the brakes, tighten the nut.
Torque: 235 N.m (2,400 kgf.cm, 173 ft.lbf)
B. Install the lock cap and a NEW cotter pin. If the holes for the cotter pin are not aligned, tighten
the nut further up to 600.
30. 2WD:
Install grease cap.
31. Install front wheel.
NOTE:
Do NOT use an air wrench.
Torque: 110 N.m (1,150 kgf.cm, 83 ft.lbf)
Page 4692
B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(Connect the Relay) and SW 2 OFF (or Disconnect SW 2)
D. Disconnect and reconnect the connectors while watching the test light.
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
E. Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION:
a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals
are touched, the IC may be destroyed by
static electricity.)
b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact
with the terminals of leads from the IC, etc. of the replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
Special Tool
1. PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown.
2. DISCONNECT CONNECTOR
3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
a. Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the
secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
A: For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
Locations
Anti-Lock Brake System
Page 2255
Refer to Reset Procedure 2 for the vehicles with Electronically Controlled Automatic
Transmissions:
Reset Procedure 1
1. Connect the Toyota Diagnostic Tester to the vehicle.
2. Reset the ECM (PCM). Refer to the procedures below.
Drivetrain - Drive/Axle Shaft Replacement Precautions
Drive/Propeller Shaft: Technical Service Bulletins Drivetrain - Drive/Axle Shaft Replacement
Precautions
TRANSMISSION & CLUTCH TC003-07
Title: DRIVESHAFT ASSEMBLY REPLACEMENT
Models: '90 - '07 Toyota
Introduction The purpose of this bulletin is to provide information regarding anti-corrosion grease
that is present on replacement driveshaft assemblies. It is important to remove this grease prior to
installing the hub nut to prevent overtightening. This also applies when reusing an old driveshaft
that may have come into contact with oil or foreign matter.
Applicable Vehicles
^ 1990 - 2007 model year Toyota vehicles.
Required Tools & Material
Repair Procedure
Clean the threaded area of the driveshaft with Toyota Brake Cleaner (or equivalent) to remove the
anti-corrosion grease, oil, or foreign matter before installing the driveshaft into the vehicle.
NOTE:
A new axle hub nut may be required when installing the driveshaft. Check the Repair Manual
procedure for more information.
Warranty Information
Page 4752
Continuity And Resistance Check
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Continuity And Resistance Check
C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the
electrical circuit.
Finding A Short Circuit
Finding A Short Circuit
Finding A Short Circuit
A. Remove the blown fuse and disconnect all loads of the fuse.
Page 3891
Transmission Mode Indicator - A/T: Splice Locations
Engine Compartment
Splice Location
E1 Engine Room Main Wire
E2 Engine Room Main Wire
E3 Engine Room Main Wire
E4 Engine No. 2 Wire
E5 Engine Wire
E6 Engine Wire
E7 Engine Wire
E8 Engine Wire
Instrument Panel
ABS/TCS - Zero Point Calibration Information
Steering Angle Sensor: Technical Service Bulletins ABS/TCS - Zero Point Calibration Information
T-SB-0020-08
March 25, 2008
Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment
Service Category Brake
Section Brake Control/Dynamic Control System
Market USA
Applicability
Introduction
The purpose of this TSB is to provide information on when and how to perform the zero point
calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting
the battery is a necessary step for performing the zero point calibration.
Warranty Information
Required Tools & Equipment
^ Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE).
^ The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the
service procedures listed in this bulletin.
Preliminary Information
Perform this procedure if any of these repairs have been performed on the vehicle:
^ Wheel alignment has been adjusted.
^ Any chassis components have been removed/installed or replaced.
Page 4550
1. PLACE RECTIFIER END FRAME ON PULLEY
2. INSTALL ROTOR TO DRIVE END FRAME
3. INSTALL RECTIFIER END FRAME
a. Place the generator washer on the rotor.
b. Using a 29 mm socket wrench and press, slowly press in the rectifier end frame.
c. Install the 3 nuts.
Torque: 4.5 N.m (46 kgf.cm, 39 in.lbf)
4. INSTALL PULLEY
Page 4538
Generator (Part 2)
Instruments - Oil Pressure Gauge Reads Abnormally Low
Oil Pressure Sender: All Technical Service Bulletins Instruments - Oil Pressure Gauge Reads
Abnormally Low
ELECTRICAL EL017-03
December 23, 2503
Title OIL PRESSURE GAUGE READS LOW
Models '01 - '04 Sequoia & '00 - '02 Tundra
TSB UPDATE NOTICE:
This TSB updates EL006-03. TSB EL006-03 is now obsolete and should be discarded.
Introduction
Some customers with Sequoia or Tundra vehicles may encounter an oil pressure gauge that reads
abnormally low at idle. An updated oil pressure sender has been created to address this condition.
Applicable Vehicles ^
2001 - 2004 model year Sequoia vehicles produced BEFORE the Production Change Effective
VINs shown below.
^ 2000 - 2002 model year Tundra vehicles produced BEFORE the Production Change Effective
VIN shown below.
Production Change Information
Parts Information
Repair Procedure
1. Replace the Oil Pressure Sender.
2. Verify proper operation of the Oil Pressure Gauge.
Warranty Information
Applicable Warranty*:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36
months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Page 5906
Page 4108
Parts Information
NOTE:
Refer to TSB No. BR004-02, "Front Brake Vibration," when installing new design caliper assembly.
Instruments - Coolant Temperature Gauge Inaccurate
Temperature Gauge: Customer Interest Instruments - Coolant Temperature Gauge Inaccurate
ELECTRICAL EL009-01
October 12, 2001
Title: TEMPERATURE GAUGE INACCURATE
Models: '00 - '01 Tundra
Introduction Some 2000 - 2001 model year Tundra trucks may experience a condition in which the
engine coolant temperature gauge displays an abnormally high reading during normal engine
operating temperatures. To address this condition, an updated Temperature Gauge has been
made available.
Applicable Vehicles ^
2000 - 2001 model year Tundra trucks, built prior to the VIN shown.
Production Change Information
Parts Information
Repair Procedure
IMPORTANT:
Verify that the engine is operating at a normal temperature with the Scan Tool before replacing the
temperature gauge.
1. Remove the four bolts securing the combination meter assembly.
2. Replace the Temperature Gauge.
3. Reassemble the combination meter.
Warranty Information
Applicable Warranty *:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36
months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Page 3750
Splice Point
J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel,
and "B" for the Body).
The Location of splice Point I5 is shaded.
K: Indicates a shielded cable.
L: Indicates the pin number of the connector.
The numbering system is different for female and male connectors.
M: Indicates a ground point.
The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for
the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body
and Surrounding area.
How to Read Connector List
HOW TO READ CONNECTOR LIST
A: Indicates connector to be connected to a part. (The numeral indicates the pin No.)
Page 6685
Electronically Controlled Transmission And A/T Indicator (Part 2)
Page 4170
9. Remove steering knuckle.
A. Remove the cotter pin and loosen the nut.
B. Using the following SSTs, disconnect the steering knuckle.
SST P/N: 09950-40011 (09951-04010, 09952-04010, 09553-04020, 09554-04010 09955-04031,
09958-04011)
C. Remove the nut and steering knuckle.
NOTE:
4WD: Be careful not to damage the oil seal and drive shaft boot.
HINT: 4WD: When it is difficult to disconnect the drive shaft, tap the tip of the drive shaft with a
plastic hammer.
10. 2WD: Remove grease cap.
A. Mount the axle hub in a soft jaw vise.
NOTE:
Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further (refer to
the illustration).
HINT: Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further
(refer to the illustration).
B. Using a screwdriver, remove the grease cap.
NOTE:
Be careful not to damage the grease cap.
Page 4006
Repair Procedure
1. Disconnect the cable from the negative (-) battery terminal for MORE THAN two (2) seconds.
2. Reconnect the cable to the negative (-) battery terminal.
3. Perform the applicable zero point calibration of the yaw rate sensor and/or the steering angle
sensor.
HINT Refer to the applicable TSB or Repair Manual for the zero point calibration procedure.
4. Re-initialize all applicable systems available on the vehicle (power window sunroof power lift
door etc.).
Page 3398
Case: Service and Repair
For further information regarding this component and the system that it is a part of, please refer to
Automatic Transmission/Transaxle; Service and Repair.
Page 920
Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.)
21. INSTALL RH NO.3 TIMING BELT COVER
a. Fit the RH No.3 timing belt cover, matching it with the fan bracket. b. Install the RH No.3 timing
belt cover with the 3 bolts and nut.
Torque: 7.5 Nm (80 kgf-cm, 66 inch lbs.)
22. INSTALL LH NO.3 TIMING BELT COVER
a. Install the oil cooler pipe with the bolt and nut. b. Run the camshaft position sensor wire through
the LH No.3 timing belt cover hole. c. Fit the LH No.3 timing belt cover, matching it with the fan
bracket. d. Install the LH No.3 timing belt cover with the 4 bolts and nut.
Torque: 7.5 Nm (80 kgf-cm, 66 inch lbs.)
e. Install the wire grommet to the LH No.3 timing belt cover. f.
Install the camshaft position sensor connector to the connector bracket.
g. Connect the camshaft position sensor connector. h. Install the sensor wire to the wire clamp on
the LH No.3 timing belt cover. i.
Install the engine wire to the 2 wire clamps on the LH No.3 timing belt cover.
23. INSTALL DRIVE BELT IDLER PULLEY
Install the idler pulley and cover plate with the bolt. Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.)
24. INSTALL PS PUMP
Install the PS pump with the 3 bolts. Torque: 17 Nm (175 kgf-cm, 13 ft. lbs.)
25. INSTALL FAN PULLEY, FAN, FLUID COUPLING AND DRIVE BELT
a. Temporarily install the fan pulley, the fan, fluid coupling assembly with the 4 nuts. b. Install the
drive belt. c. Tighten the 4 nuts holding the fluid coupling to the fan bracket.
Torque: 21 Nm (215 kgf-cm, 16 ft. lbs.)
26. INTAKE AIR CONNECTOR ASSEMBLY 27. INSTALL THROTTLE BODY COVER 28.
INSTALL RADIATOR ASSEMBLY 29. FILL WITH ENGINE COOLANT 30. START ENGINE AND
CHECK FOR LEAKS
Page 3005
Fuel Injector: Testing and Inspection Component Inspection
INSPECTION
1. INSPECT INJECTOR INJECTION
CAUTION: Keep injector clean of sparks during the test.
a. Disconnect the fuel inlet hose (fuel tube connector) from the fuel filter. b. Connect SST
(attachment and hose) to the fuel tube.
SST 09268-41047 (09268-52011)
c. Remove the pressure regulator from the delivery pipe. d. Install the O-ring to the fuel inlet of the
pressure regulator. e. Connect SST (hose) to the fuel inlet of the pressure regulator with SST
(union) and the 2 bolts.
SST 09268-41047 (09268-41091)
Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf)
f. Connect the fuel return hose to the fuel outlet of the pressure regulator.
g. Install the O-ring to the injector. h. Connect SST (adapter and hose) to the injector, and hold the
injector and union with SST (clamp).
SST 09268-41047 (09268-41110, 09268-41300)
i. Put the injector into the graduated cylinder.
CAUTION: Install a suitable vinyl hose onto the injector to prevent gasoline from splashing out.
Locations
Engine Room R/B
Page 4579
HINT: At the time of assembly, please refer to the following item. Use a new O-ring.
c. Using a screwdriver, hold the spring back and disconnect the brush from the brush holder.
Disconnect the 4 brushes, and remove the brush
holder.
NOTE: Check that the positive (+) lead wires are not grounded.
6. REMOVE ARMATURE FROM FIELD FRAME
REASSEMBLY
Reassembly is in the reverse order of disassembly.
HINT: At the time of assembly, please refer to the following items. Use high-temperature grease to
lubricate the bearing and gears when assembling the starter.
REPLACEMENT
1. REPLACE REAR BEARING
a. Using SST, remove the bearing.
SST 09286-46011
b. Using a press, press in a new bearing.
2. REPLACE FRONT BEARING
Description and Operation
Brake Fluid Solenoid Valve Relay: Description and Operation
ABS Solenoid Relay
This relay supplies power to each ABS solenoid. After the ignition switch is turned ON, if the initial
check is OK, the relay goes on.
Locations
Intake Air Temperature Sensor: Locations
Mass Air Flow (MAF) Meter
The Intake Air Temperature (IAT) Sensor is installed in the Mass Air Flow (MAF) Meter.
Page 2776
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 3874
6. INSPECT LIMIT SWITCH CONTINUITY
a. Start the engine and raise the vehicle. b. With the actuator connector connected, shift the
transfer shift lever and after checking the operating sound, disconnect the connector and
inspect the continuity between each terminal.
HINT: When shifting the actuator fork shaft, connect the connectors.
7. INSPECT VEHICLE SPEED SENSOR 8. INSPECT 4HI AND 4LO INDICATOR LIGHT Check
the combination meter.
9. INSPECT 4WD CONTROL ECU
Connect the wire harness side connector to the 4WD control ECU and inspect wire harness side
connector from the back side.
Page 4967
c. Using a brass bar and hammer, stake the washer.
NOTICE: Avoid any impact on the rack.
d. Employ the same manner described to the other side.
17. INSTALL RIGHT-HAND AND LEFT-HAND RACK BOOTS, CLAMPS AND CLIPS
a. Ensure that the steering rack hole is not clogged with grease.
HINT: If the hole is clogged, the pressure inside the boot will change after it is assembled and the
steering wheel is turned.
b. Set a new clamp to the groove of the rack boot.
c. Install the boot.
NOTICE: Be careful not to damage or twist the boot.
d. Using SST, tighten the clamp as shown in the illustration.
SST 09521-24010
e. Install the clip to the rack boot. f.
Employ the same manner described to the other side.
18. INSTALL RIGHT-HAND AND LEFT-HAND TIE ROD ENDS AND LOCK NUTS
a. Screw the lock nut and tie rod end onto the rack end until the matchmarks are aligned. b. After
adjusting toe-in, torque the nut.
Torque: 55 Nm (560 kgf-cm, 41 ft. lbs.)
Page 4736
Interior Panel Fuse Details
Brakes - Front Brakes Vibrate Upon Application
Technical Service Bulletin # BR004R-02 Date: 050404
Brakes - Front Brakes Vibrate Upon Application
BRAKES BR004-02 REVISED
Title: FRONT BRAKE VIBRATION
Models: '00 - '05 Tundra
September 12, 2002
TSB REVISION NOTICE:
^ April 4, 2005: Applicable Vehicles has been updated to include 2003 - 2005 model years. The
following sections have been updated, expanded, or added: Introduction, Warranty Information,
Production Change Information, Parts Information, Required SSTs, Diagnosis Procedure, Repair
Procedure No.1, and Repair Procedure No.2. PLEASE READ ENTIRE TSB.
^ September 24, 2004: A note has been added, step 26.
^ March 5, 2004: A torque specification in step 24, was changed.
^ September 8, 2003: A torque specification in step 28, was changed.
Previous versions of this TSB should be discarded.
Introduction
Under certain usage conditions, some Tundra trucks may exhibit front brake vibration.
Improvements have been made to various brake components to help improve this condition.
Applicable Vehicles
^ 2000 - 2005 model year Tundra vehicles produced BEFORE the Production Change Effective
VINs shown.
Production Change Information
Page 1079
B: Junction Connector
Indicates a connector which is connected to a short terminal.
Junction connector in this include a short terminal which is connected to a number of wire
harnesses. Always perform inspection with the short terminal installed. (When installing the wire
harnesses, the harnesses can be connected to any position within the short terminal grouping.
Accordingly, in other vehicles, the same position in the short terminal may be connected to wire
harness from a different part.) Wire harness sharing the same short terminal grouping ha the same
color.
C: Parts Code
The first letter of the code is taken from the first letter of part, and the numbers indicates its order in
parts which start with the same letter.
D: Connector Color
Connectors not indicated are milky white in color.
How to Read Ground Points
HOW TO READ GROUND POINTS
Page 5726
B: Junction Connector
Indicates a connector which is connected to a short terminal.
Junction connector in this include a short terminal which is connected to a number of wire
harnesses. Always perform inspection with the short terminal installed. (When installing the wire
harnesses, the harnesses can be connected to any position within the short terminal grouping.
Accordingly, in other vehicles, the same position in the short terminal may be connected to wire
harness from a different part.) Wire harness sharing the same short terminal grouping ha the same
color.
C: Parts Code
The first letter of the code is taken from the first letter of part, and the numbers indicates its order in
parts which start with the same letter.
D: Connector Color
Connectors not indicated are milky white in color.
How to Read Ground Points
HOW TO READ GROUND POINTS
Page 4047
B. Slowly apply the PKB while driving until the brake begins to engage and slow the vehicle. Do not
apply the PKB past this point of initial engagement.
NOTE:
Remember with a foot PKB (on automatic transmission), the pedal must be pressed a second time
to disengage the parking brake.
HINT:
When diagnosing a Tundra with a foot PKB, slowly apply the PKB until the first "click". Then press
the PKB pedal a second time so it will disengage when it is released. At this time the PKB can be
pressed to the desired level for continued diagnosis.
C. Hold the PKB at this point of initial engagement for a few seconds to slowly reduce the vehicle
speed and allow adequate time to monitor the ride condition.
D. Disengage the PKB.
E. If brake vibration is felt during step (C), then it indicates that the rear brake drums are one
source of brake vibration on this vehicle.
Refer to TSB No. BR003-02, "Rear Brake Vibration," for parts and repair information relating to
Tundra rear brake vibration.
F. If no vibration is felt during step (C), then the front brake assemblies are the most likely cause of
brake vibration on this vehicle.
G. Determine if TSB BROO4-02 has already been performed.
Repair Procedure No. 1
1. Remove the front wheel.
2. 2WD:
Using a screwdriver and hammer remove the grease cap.
3. 4WD:
Disconnect drive shaft.
A. Remove the cotter pin and lock cap.
B. While applying the brakes, remove the lock nut.
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 4577
Starter Motor: Service and Repair Disassembly and Reassembly
DISASSEMBLY
1. REMOVE 2 DUST PROTECTORS
2. REMOVE FIELD FRAME AND ARMATURE
a. Remove the nut, and disconnect the lead wire from the magnetic switch terminal.
Torque: 5.9 N.m (60 kgf.cm, 52 in.lbf)
b. Remove the 2 through bolts.
Torque: 1.4 kW type
: 5.9 N.m (60 kgf.cm, 52 in.lbf)
2.0 kW type : 9.3 N.m (95 kgf.cm, 82 in.lbf)
c. Pull out the field frame together with the armature from the magnetic switch assembly.
NOTE: At the time of notice, please refer to the following items. Align the protrusion of the field
frame with the groove of the magnetic switch.
d. Remove the O-ring from the field frame.
HINT: At the time of assembly, please refer to the following items. Use a new O-ring.
3. REMOVE STARTER HOUSING, CLUTCH ASSEMBLY AND GEAR
Page 4874
a. Install the air cleaner assembly with air cleaner hose and the 3 bolts. b. Install the clamp. c.
Connect the hoses. d. Connect the MAF meter connector.
7. BLEED POWER STEERING SYSTEM
Page 2586
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 951
Drive Belt: Service and Repair
REMOVAL
REMOVE DRIVE BELT
Loosen the drive belt tension by turning the drive belt tensioner counterclockwise, and remove the
drive belt.
INSTALLATION
INSTALL DRIVE BELT
Turn the drive belt tensioner counterclockwise then install the drive belt.
Page 4247
NOTE:
If replacing the rear axle shaft and if the vehicle is equipped with ABS, ensure proper installation of
the ABS speed sensor rotor and the bearing retainer (differential side). Use SST P/N:
09521-25011-01 to press and install a new sensor rotor and new bearing retainer to the axle shaft
(Refer to Figure 2).
4. Replace the rear brake shoes and brake drums. For additional information on rear brake shoes
and brake drum replacement, refer to the Technical Information System (TIS): 2000 - 2005 model
year Tundra Repair Manual: Brakes: Rear Drum Brake: Removal/Installation.
5. Adjust the PKB to specifications.
6. Remount the tire and wheel assembly to the vehicle. Torque all wheel nuts to the vehicle
according to the vehicle specifications found in TIS: 2000 - 2005 model year Tundra Repair
Manual: Brakes: Rear Drum Brake: Removal/Installation.
7. Road test the vehicle to determine if all brake vibration has been eliminated.
8. If brake vibration remains, determine if the vibration is from the front or the rear (while brakes are
still warm from confirmation driving). If it is front vibration, refer to TSB No. BR004-02, Front Brake
Vibration," for parts and repair information relating to Tundra front brake vibration.
Page 2565
The calibration file contains the Calibration ID number(s) for a specific vehicle ECU (see Figure 1).
NOTE:
The total number of Calibration ID numbers corresponds to the number of reprogrammable
processors in the ECU (see Figure 2).
Operation Procedure
LOCATE CALIBRATION FILE
The following steps in this bulletin describe how to properly flash reprogram an ECU.
1. Locate calibration file on TIS.
Calibration files may be found in two areas (see Figure 3):
A. Search by model and year for a Technical Service Bulletin addressing a specific Product issue.
^ Within the TSB, click on the link for the calibration file.
B. Search by model under the ECU Flash Reprogramming Section.
^ Under the ECU Flash Reprogramming section on TIS, a drop-down list of the latest calibration
files will be displayed.
C. Proceed to step 2 for instructions on how to download the calibration file from TIS to the
Diagnostic Tester Program Card.
Page 1194
Connecting Rod: Specifications Torque Specifications
INSTALL CONNECTING ROD CAP BOLTS
HINT: The connecting rod cap bolts are tightened in 2 progressive steps (steps (b) and (d)).
- If any one of the connecting rod cap bolts is broken or deformed, replace it.
a. Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap
bolts. b. Install and alternately tighten the 2 connecting rod cap bolts in several passes.
Torque: 24.5 Nm (250 kgf-cm, 18 ft. lbs.) If any one of the connecting rod cap bolts does not meet
the torque specification, replace the connecting rod cap bolts.
c. Mark the front of the connecting cap bolt with paint. d. Retighten the cap bolts by 90° as shown.
e. Check that the painted mark is now at a 90° angle to the front. f.
Check that the crankshaft turns smoothly.
Page 4947
Page 3146
Ignition Coil: Service and Repair
Ignition Coil
REMOVAL
Page 4948
REMOVAL
1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 2. REMOVE STEERING WHEEL PAD
3. REMOVE STEERING WHEEL 4. DISCONNECT RIGHT-HAND AND LEFT-HAND TIE ROD
ENDS 5. DISCONNECT NO. 2 INTERMEDIATE SHAFT ASSEMBLY 6. DISCONNECT CLAMP
PLATE
Remove the bolt and disconnect the clamp plate.
Page 2976
Mass Air Flow Meter: Service and Repair
MASS AIR FLOW (MAF) METER
1. DISCONNECT MAF METER CONNECTOR
2. REMOVE MAF METER
Remove the 2 screws and MAF meter.
3. REINSTALL MAF METER
Install the MAF meter with the 2 screws.
4. RECONNECT MAF METER CONNECTOR
Page 5538
Seat Belt Extension: Technical Service Bulletins Seat Belt Extender - Increases Belt Length
BODY BO023-01
September 14, 2001
Title: SEAT BELT EXTENDER
Models: '00 -'02 Model Year
Introduction
Toyota customers who find it necessary to increase the length of their seat belts may obtain Seat
Belt Extenders at no cost through their local Toyota dealer.
^ The extender is available in 6 inch, 9 inch, 12 inch, 15 inch and 18 inch lengths.
^ The extender is available only in black.
^ Owners are informed of the Seat Belt Extender availability through the Toyota Owner's Manual
included in each vehicle.
The customer (individual requiring the extender) must visit a Toyota dealership to have the required
measurements made and to complete the Seat Belt Extender Worksheet. The worksheet will allow
the proper fitting and selection of a Seat Belt Extender for the customer. The dealership personnel
should then determine the applicable part number and place a Critical Order through the TDN Parts
Network or Dealer Daily.
The dealership service department should complete the affixed Seat Belt Extender Customer
Information Label on the part and review the Owner Instruction Sheet" with the customer. The
dealership should give a copy of the completed worksheet to the customer and keep the original in
the customer's file.
To assure utmost owner satisfaction, it is recommended that a dealership designate one person to
coordinate all activities related to the Seat Belt Extender issue.
It is recommended that dealerships do NOT stock Seat Belt Extenders due to the need for proper
fitting to individual customers.
This bulletin contains the following information:
Procedure and Sample Label Application Charts Part Number Information Owner Instructions Seat
Belt Extender Worksheet
Applicable Vehicles ^
2000 through 2002 model year Toyota vehicles.
Page 1912
O2S Application Table
O2S Failure Threshold Charts
Page 6428
Non-Waterproof Type Connector
"Case 1" Raise the terminal retainer up to the temporary lock position.
Non-Waterproof Type Connector
"Case 2" Open the secondary locking device.
Page 2323
^ Confirm cable connections between the vehicle and Diagnostic Tester are secure. (Reference
TSB No. SS004-01, "ECU Flash Reprogramming Error Message.")
^ Do not disconnect or turn off the Diagnostic Tester or the vehicle ignition during reprogramming.
^ Set the parking brake.
^ Complete ALL flash calibration updates provided for each ECU.
If the battery's state of charge or capacity are in question, test with SST No. 00002-MP815-T,
"Midtronics Battery Tester," and follow TSB No. PG017-02, "Battery Maintenance for In-Stock
Vehicles & Pre-Delivery."
To ensure stable battery voltage, a battery charger may be connected during reprogramming if:
^ Voltage does not fall below 11.4 volts.
^ Voltage does not rise above 16.0 volts.
^ Setting is on SLOW charge and not BOOST.
A. Connect the Diagnostic Tester to the vehicle and select CURRENT ECU CAL from the ECU
REPROGRAM MAIN MENU. Determine the vehicle's current ECU calibration. (See Figure 17.)
NOTE:
The vehicle may contain up to 3 separate calibration ID numbers. In the example shown, the
vehicle ECU contains only 2 calibration IDs.
Page 4785
Non-Waterproof Type Connector
"Case 1" Raise the terminal retainer up to the temporary lock position.
Non-Waterproof Type Connector
"Case 2" Open the secondary locking device.
Page 6459
Oil Pressure Gauge: Testing and Inspection
INSPECT OIL PRESSURE GAUGE RESISTANCE Measure the resistance between terminals A
and B. If resistance value is not as specified, replace the receiver gauge.
Page 5051
Information
PRELIMINARY INSPECTION INSTRUCTIONS
Deck Top Protector
Upper Side Moulding / Trim: Service and Repair Deck Top Protector
DECK TOP PROTECTOR
Deck Top Protector
REMOVAL
Capacity Specifications
Fluid - Transfer Case: Capacity Specifications
Transfer Case
Capacity ...............................................................................................................................................
............................................................. 1.0L (1.1 Qt)
Page 5341
- There should be no interference between the instrument panel and the front passenger airbag
assembly.
CAUTION: Be sure to follow the correct procedure, for removal and installation of the front
passenger airbag assembly.
VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED
a. Do a diagnostic system check. b. Do a visual check which includes the following items with the
front passenger airbag assembly removed from the vehicle.
- Check the deformation or cracks on the instrument panel and instrument panel reinforcement.
- Check the damage on the connector and wire harness.
HINT: If the instrument panel or instrument panel reinforcement is deformed or cracked, never
repair it. Always replace it with a new one.
REPLACEMENT REQUIREMENTS
CAUTION: Be sure to follow the correct procedure, for replacement of the front passenger air bag
assembly.
STEERING WHEEL PAD AND SPIRAL CABLE
VEHICLE NOT INVOLVED IN COLLISION
a. Do a diagnostic system check.
See: Air Bag Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble
Codes/Displaying & Reading Trouble Codes
b. Do a visual check which includes the following item with the steering wheel pad (with airbag)
installed in the vehicle.
Page 2763
CHART 20
Page 6674
The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit
breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery
power is supplied to each system are explained. Since all System Circuit diagrams start from the
power source, the power source system must be fully understood.
Page 240
Engine Control Module: Service and Repair
VEHICLE REPROGRAMMING
Beginning with some 2001 models and expanding to all models by 2007, Toyota/Scion and Lexus
vehicles are equipped with flash reprogrammable Powertrain Control Modules (PCM).
Reprogramming should only be performed if a Technical Service Bulletin or Service Campaign
provides direction to do so.
Flash reprogramming may be accomplished using one of the following methods: Toyota/Lexus factory scantool
- Vetronix Mastertech
- J2534 Compatible Vehicle Interface (Toyota validated and approved)
REPROGRAMMING WITH SCANTOOL
Toyota/Scion/Lexus ECMs can be reprogrammed using either the Toyota/Lexus factory scantool,
or the Vetronix Mastertech scantool. The ECM reprogramming function is only available with the
authentic Toyota factory scantool software which runs on either of the above mentioned scantools.
Scantool software version requirements are specified in applicable Technical Service Bulletin
(TSB)/Service Communication (SC) documents.
The Toyota/Lexus factory scantool and/or authentic factory software program cards can be
purchased through the official Toyota and Lexus Special Service Tool provider, SPX Corp. To
order, call (800) 933-8335 and request either: P/N 01001271 for the Toyota/Lexus factory scantool including factory software program card
- P/N 01002593-005 for the "stand alone" program card
Program cards are provided with the latest production version software available at time of
purchase.
Vehicle recalibration using a scantool requires use of the following: Personal Computer running a Microsoft Windows 2000 or Windows XP operating system
- Toyota Diagnostic Tester or Vetronix Mastertech Scantool with Toyota factory software
- Toyota/Lexus factory scantool program card
- PC Interface Cable (P/N 01001090) to transfer data from PC to scantool
- Calibration CD (00456-REPRG-001)
REPROGRAMMING WITH J2534 INTERFACE
Toyota/Scion/Lexus ECMs that can be reprogrammed with a scantool can also be reprogrammed
using a Toyota validated J2534-1 interface. Vehicle recalibration requires the use of the following: Toyota validated J2534 interface
- Toyota Calibration Update Wizard software (available on calibration CD)
- Personal Computer running Microsoft Windows 2000/XP or later operating system
- Calibration CD (00456-REPRG-001)
Toyota strongly recommends USING ONLY VALIDATED INTERFACE DEVICES that appear on
this list.
Validated J2534 Devices Toyota works closely with J2534 interface manufacturers to ensure that
their hardware works safely and efficiently with their products. Every device listed on this page has
been thoroughly tested and validated on Toyota, Scion and Lexus vehicles.
It is important to understand that only the specific devices, firmware, DLLs and APIs listed here
have been tested by Toyota. Toyota does not recommend use of any other J2534 device, firmware,
DLL or API that is not listed here. Changes to J2534 hardware/software is outside of Toyota's
control; in some cases, changes made to device hardware/software can negatively impact
reprogramming performance. Toyota makes every effort to continue to work with J2534 interface
manufacturers to ensure continued product compatibility as the respective products evolve.
Requirement for device:
Supplier Device Name Version (Firmware* / DLL* / API*)
Drew Technologies CarDAQ Plus (01.08.06 / 01.08.06 / 04.04)
Actia PassThru+ XS (02.01 / 02.01 / 04.04)
Vetronix Corporation ES6510 Flasher (06.12 / 04.23 / 04.04)
EASE Diagnostics Universal Reprogrammer (JPI1_11b / 1.3.0.13 / 04.04)
Snap-On Pass Thru Pro (02.01 / 02.01 / 04.04)
Blue Streak Electronics Inc. BSE-2534 Global Programmer (01.21 / 02.27 / 04.04)
* Original validated firmware/DLL versions may be superceded by the device manufacturer.
Contact the device manufacturer if you are unable to find the versions listed above.
Support OS:
OS Name and Version:
Page 6303
Cigarette Lighter: Splice Locations
Engine Compartment
Splice Location
E1 Engine Room Main Wire
E2 Engine Room Main Wire
E3 Engine Room Main Wire
E4 Engine No. 2 Wire
E5 Engine Wire
E6 Engine Wire
E7 Engine Wire
E8 Engine Wire
Instrument Panel
Page 806
b. Connect the oil cooler pipe.
Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.)
c. Install the 3 clamps with the 3 bolts.
7. FILL ATF AND CHECK FLUID LEVEL
Page 5119
Repair Procedure
1. Disconnect the cable from the negative (-) battery terminal for MORE THAN two (2) seconds.
2. Reconnect the cable to the negative (-) battery terminal.
3. Perform the applicable zero point calibration of the yaw rate sensor and/or the steering angle
sensor.
HINT Refer to the applicable TSB or Repair Manual for the zero point calibration procedure.
4. Re-initialize all applicable systems available on the vehicle (power window sunroof power lift
door etc.).
Page 147
Materials System.
Required SSTs
NOTE:
Additional Diagnostic Tester Kits, CAN Interface Modules, Program Cards or SSTs may be ordered
by calling SPX/OTC at 1-800-933-8335.
Process Overview
ECU Flash Reprogramming is a 4-step process:
1. Locate the desired calibration file on TIS (Technical Information System).
Calibration files may be found in two areas:
a. Search by model and year for a Technical Service Bulletin addressing a specific product issue.
b. Search by model under the ECU Flash Reprogramming section.
2. Download the calibration file from TIS to the Diagnostic Tester.
The Calibration Update Wizard (CUW) is an application on TIS which downloads calibration files
from TIS to the Diagnostic Tester Program Card. This step is only required when the calibration file
is not currently stored on the Diagnostic Tester Program Card.
3. Reprogram the vehicle ECU with the Diagnostic Tester.
Diagnostic Tester Software now incorporates a function to update a vehicle's ECU calibration
through flash reprogramming.
4. Confirm successful flash update and affix calibration update sticker.
Modifications to ECU calibration files must be recorded and properly displayed on the vehicle using
the calibration update sticker.
NOTE:
Page 3093
Throttle Body: Locations
Throttle Body (Part 1)
Page 5825
2. Scrub the bumper covers with the soap and water solution, making sure all difficult-to-reach
areas are thoroughly cleaned.
3. Rinse the entire bumper cover with clean deionized water, making sure all difficult-to-reach
areas are thoroughly rinsed.
4. Dry the surface with a clean towel before water dries on the surface. Clean, dry compressed air
from an oil-less compressor may be substituted for
drying with a towel.
5. Degrease the surface with a wax, grease, and silicone remover.
Note: Lacquer thinner or brake cleaner will NOT remove silicone. You MUST use a wax, grease,
and silicone remover. Carefully follow application instructions on the container label. Fish eyes or
other paint irregularities may result from not following instructions.
6. Apply a generous amount of sanding paste with a gray 3M ScotchBrite pad. Only a gray pad
should be used during the sanding process. Sand the
entire bumper cover surface. Be sure all difficult-to-reach areas are thoroughly sanded.
7. Clean the entire bumper cover with car wash soap and water. Be sure all difficult-to-reach areas
are thoroughly cleaned.
8. Rinse the entire bumper with clean deionized water. Be sure all difficult-to-reach areas are
thoroughly rinsed.
9. Degrease the surface with an anti-static plastic parts cleaner and a white body shop towel or
paper towel.
Note: Never use a red shop towel to wipe the surface (contains silicone).
10. Assure the bumper is firmly held in place to a steady fixture.
11. Apply a plastic parts adhesion promoter to the surface, according to the manufacturer's
recommendations.
12. Apply plastic parts primer to the surface, according to the paint manufacturer's
recommendations.
13. Since bumpers are made of flexible plastic urethane material, use a two-part urethane finish
paint system with plasticizer (flex agent) for all
bumper and cladding repairs. Apply the appropriate top coat to the surface, according to the paint
manufacturer's recommendations.
14. If heat is applied to cure the paint, assure the surface temperature does not exceed 80°C
(176°F.)
For additional information concerning the refinish process for plastic bumpers/cladding, please
contact your respective refinish paint manufacturer's local representative.
Page 6649
Temperature Gauge: Testing and Inspection
INSPECT ENGINE COOLANT TEMPERATURE RECEIVER GAUGE OPERATION
a. Disconnect the connector from the sender gauge. b. Turn the ignition switch ON, check that the
receiver gauge needle indicates COOL.
c. Ground terminal on the wire harness side connector through a 3.4 W test bulb. d. Turn the
ignition switch ON, check that the bulb lights up and the receiver gauge needle moves to the hot
side.
If operation is as specified, replace the sender gauge. Then, recheck the system. If operation is not
as specified, measure the receiver gauge resistance.
INSPECT ENGINE COOLANT TEMPERATURE RECEIVER GAUGE RESISTANCE
Measure the resistance between terminals.
w/ Tachometer
Page 2564
Materials System.
Required SSTs
NOTE:
Additional Diagnostic Tester Kits, CAN Interface Modules, Program Cards or SSTs may be ordered
by calling SPX/OTC at 1-800-933-8335.
Process Overview
ECU Flash Reprogramming is a 4-step process:
1. Locate the desired calibration file on TIS (Technical Information System).
Calibration files may be found in two areas:
a. Search by model and year for a Technical Service Bulletin addressing a specific product issue.
b. Search by model under the ECU Flash Reprogramming section.
2. Download the calibration file from TIS to the Diagnostic Tester.
The Calibration Update Wizard (CUW) is an application on TIS which downloads calibration files
from TIS to the Diagnostic Tester Program Card. This step is only required when the calibration file
is not currently stored on the Diagnostic Tester Program Card.
3. Reprogram the vehicle ECU with the Diagnostic Tester.
Diagnostic Tester Software now incorporates a function to update a vehicle's ECU calibration
through flash reprogramming.
4. Confirm successful flash update and affix calibration update sticker.
Modifications to ECU calibration files must be recorded and properly displayed on the vehicle using
the calibration update sticker.
NOTE:
Diagram Information and Instructions
Fuse Block: Diagram Information and Instructions
Key to Diagrams
A: System Title
B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to
distinguish it from the J/B
Example: 1 Indicates Relay Block No.1
C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type,
or specification is different.
D: Indicates related system.
Page 1910
Page 4802
B: Junction Connector
Indicates a connector which is connected to a short terminal.
Junction connector in this include a short terminal which is connected to a number of wire
harnesses. Always perform inspection with the short terminal installed. (When installing the wire
harnesses, the harnesses can be connected to any position within the short terminal grouping.
Accordingly, in other vehicles, the same position in the short terminal may be connected to wire
harness from a different part.) Wire harness sharing the same short terminal grouping ha the same
color.
C: Parts Code
The first letter of the code is taken from the first letter of part, and the numbers indicates its order in
parts which start with the same letter.
D: Connector Color
Connectors not indicated are milky white in color.
How to Read Ground Points
HOW TO READ GROUND POINTS
Testing and Inspection
Seat Sensor/Switch: Testing and Inspection
Passenger's seat only: INSPECT SEAT BELT WARNING OCCUPANT DETECTION SENSOR
CONTINUITY
Check that continuity exists between the terminals 1 and 2 when pressing the sensing part. If
operation is not as specified, replace the sensor.
Page 2308
3. Start the engine and warm it up to normal operating temperatures before test-driving.
4. Perform a thorough test drive with several accelerations from a stop with "light throttle"
application until proper transmission shifting is verified.
Reset Procedure 2
1. Disconnect the negative battery cable for 5 minutes.
2. Reconnect battery cable.
3. Start the engine and warm it up to normal operating temperatures before test-driving.
4. Perform a thorough test drive with several accelerations from a stop with "light throttle"
application until proper transmission shifting is verified.
Brakes - Front Brake Caliper Identification
Brake Caliper: All Technical Service Bulletins Brakes - Front Brake Caliper Identification
BRAKES BR001-03 REVISED
January 8, 2003
Title: FRONT BRAKE COMPONENT IDENTIFICATION
Models: '00 - '05 Tundra, '01 - '05 Sequoia
TSB UPDATE NOTICE:
The information contained in this TSB supercedes TSB No. BR003-00. TSB No. BR003-00 is now
obsolete and should be discarded.
TSB REVISION NOTICE:
March 25, 2005: Parts Information - Part titles and part numbers have been updated and "Note"
added.
The previous TSB should be discarded.
Introduction
There are two caliper designs that are in use for Tundra and Sequoia vehicles. The brake pads and
fitting kits for these two calipers are not interchangeable. The pictures and parts lists below are
intended to assist you in identifying and ordering the correct replacement pads and fitting kits.
Applicable Vehicles: ^
2000 - 2005 model year Tundra vehicles.
^ 2001 - 2005 model year Sequoia vehicles.
Warranty Information
Page 4640
b. Push the secondary locking device or terminal retainer in to the full lock position.
5. CONNECT CONNECTOR
Disconnection of Male and Female Connectors
Disconnection of Male and Female Connectors
Disconnection Of Male And Female Connectors
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Page 5890
INSTALLATION
1. Temporarily install the new parts and measure each part in accordance with the body dimension
diagram. 2. Temporarily install the front fender and hood, and check the fit.
Locations
EFI Main Relay: Locations
Engine Room R/B
Brakes - Front Brakes Vibrating
Technical Service Bulletin # BR004R-02 Date: 040305
Brakes - Front Brakes Vibrating
BRAKES BR004-02 REVISED
September 16, 2002
Title: FRONT BRAKE VIBRATION
Models: '00 - '03 Tundra
TSB REVISION NOTICE: ^
March 5, 2004: A torque specification in, step 24, was changed.
^ September 8, 2003: A torque specification in, step 28, was changed.
The previous TSB should be discarded.
Introduction
Under certain usage conditions, some Tundra trucks may exhibit front brake vibration. Improved
brake caliper assemblies have been introduced to correct this condition.
Applicable Vehicles ^
2000 - 2003 model year Tundra trucks built before the VIN shown below.
Production Change Information
Warranty Information
Applicable Warranty:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36
months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Page 1494
Compression Check: Testing and Inspection
INSPECTION
HINT: If there is lack of power, excessive oil consumption or poor fuel economy, measure the
compression pressure.
1. WARM UP AND STOP ENGINE
Allow the engine to warm up to normal operating temperature.
2. REMOVE SPARK PLUGS
3. CHECK CYLINDER COMPRESSION PRESSURE
a. Insert a compression gauge into the spark plug hole. b. Fully open the throttle. c. While cranking
the engine, measure the compression pressure.
HINT: Always use a fully charged battery to obtain engine speed of 250 rpm or more.
d. Repeat steps (a) through (c) for each cylinder.
NOTICE: This measurement must be done in as short a time as possible.
Compression pressure: 1,324 kPa (13.5 kgf/cm2, 192 psi) or more Minimum pressure: 981 kPa
(10.0 kgf/cm2, 142 psi) Difference between each cylinder: 98 kPa (1.0 kgf/cm2, 14 psi) or less
e. If the cylinder compression in one or more cylinders is low, pour small amount of engine oil into
the cylinder through the spark plug hole and
repeat steps (a) through (c) for cylinders with low compression. If adding oil helps the compression, chances are that the piston rings and/or cylinder bore are worn
or damaged.
- If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage
past the gasket.
4. REINSTALL SPARK PLUGS
Page 4567
12. INSPECT BRUSH HOLDER INSULATION
Using an ohmmeter, check that there is no continuity between the positive (+) and negative (-)
brush holders. If there is continuity, repair or replace the brush holder.
13. INSPECT GEAR TEETH
Check the gear teeth on the pinion gear, idle gear and the clutch assembly for wear or damage.
If damaged, replace the gear or clutch assembly. If damaged, also check the drive plate ring gear
for wear or damage
14. INSPECT CLUTCH PINION GEAR
Rotate the pinion gear clockwise, and check that it turns freely. Try to rotate the pinion gear
counterclockwise and check that it locks. If necessary, replace the clutch assembly.
15. INSPECT FRONT AND REAR BEARING
Turn the bearing by hand while applying inward force. If resistance is felt or the bearing sticks,
replace the bearing.
16. DO PULL-IN COIL OPEN CIRCUIT TEST
Using an ohmmeter, check that there is continuity between terminals 50 and C. If there is no
continuity, check and replace the magnetic switch.
Page 3566
Splice Point
J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel,
and "B" for the Body).
The Location of splice Point I5 is shaded.
K: Indicates a shielded cable.
L: Indicates the pin number of the connector.
The numbering system is different for female and male connectors.
M: Indicates a ground point.
The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for
the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body
and Surrounding area.
How to Read Connector List
HOW TO READ CONNECTOR LIST
A: Indicates connector to be connected to a part. (The numeral indicates the pin No.)
Testing and Inspection
Oil Filter: Testing and Inspection
For further information regarding this component and the system that it is a part of, please refer to
Engine Lubrication; Testing and Inspection; Procedures.
Locations
Testing and Inspection
Low Fuel Lamp/Indicator: Testing and Inspection
INSPECT FUEL LEVEL WARNING LIGHT
a. Disconnect the connector from the sender gauge. b. Connect terminals 1 and 3 on the wire
harness side connector. c. Turn the ignition switch ON, check that the warning light lights up.
If the warning light does not light up, test the bulb or inspect wire harness.
Testing and Inspection
Washer Fluid Level Indicator: Testing and Inspection
INSPECT WASHER LEVEL WARNING LIGHT a. Disconnect the connectors from the level
warning switch. b. Connect terminals on the wire harness side connector of the level warning
switch connector. c. Turn the ignition switch ON, check that the warning light come on.
If the warning light does not light up, test the bulb.
Page 4100
SST P/N: 09527-17011
B. Coat MP grease to the oil seal lip.
18. Install new dust cover and axle hub to steering knuckle.
A. Install the NEW dust cover to the steering knuckle with the 4 bolts.
Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)
B. Using the following SST and a press, install the axle hub to the steering knuckle.
SST P/N: 09649-17010
19. Install ABS speed sensor rotor (with ABS) or spacer (without ABS).
NOTE:
Take care not to scratch the serration of the speed sensor rotor and ensure the speed sensor is
installed completely.
20. 2WD:
Install new lock nut.
A. Using the following SST, install and torque a NEW lock nut to the axle hub.
SST P/N: 00002-00909 (09318-12010)
Torque: 274 N.m (2,800 kgf.cm, 203 ft.lbf)
NOTE:
Do NOT use air wrench.
B. Using a chisel and hammer, stake the lock nut.
Page 4346
Required SSTs
Diagnosis Procedure
1. Confirm the customer complaint.
2. Determine if vibration is from front or rear (while brakes are still warm from confirmation test
driving).
The following procedure will isolate the drum brakes from the rest of the hydraulic system by using
the parking brake (PKB).
A. Drive the Tundra along a smooth, level section of road at approximately 40 mph - 50 mph.
Specifications
Water Pump: Specifications
Water Pump W/ Bolts, Stud Bolts, and Nut Bolt 21 Nm
Stud Bolt and Nut 18 Nm
Page 4377
Parts Information
Diagnosis Procedure
1. Confirm the customer complaint.
2. Determine if vibration is from front or rear (while brakes are still warm from confirmation driving).
The following procedure will isolate the drum brakes from the rest of the hydraulic system by using
the parking brake (PKB).
NOTE:
Remember, with a foot PKB (on automatic transmission) the pedal must be pressed a second time
to disengage the parking brake.
HINT:
When diagnosing a Tundra with a foot PKB, slowly apply the PKB until the first "click, " then press
the PKB pedal a second time so it will disengage if it is released. At this time the PKB can be
pressed to the desired level for continued diagnosis.
A. Drive the Tundra along a smooth, level section of road at approximately 40 mph - 50 mph.
B. Slowly apply the PKB while driving until the brake begins to engage and slow the vehicle. Do not
apply the PKB past this point of initial engagement.
C. Hold the PKB at this point of initial engagement for a few seconds to slowly reduce the vehicle
speed and allow adequate time to monitor the ride condition.
D. Disengage the PKB.
E. If brake vibration is felt during step (C), then it indicates that the rear brake drums are one
source of brake vibration on this vehicle.
Refer to TSB BR003-02 for parts and repair information relating to Tundra rear brake vibration.
F. If no vibration is felt during step (C), then the front brake assemblies are the cause of brake
vibration on this vehicle.
Proceed to the following repair procedure.
Repair Procedure
Page 2414
A. The Diagnostic Tester displays 17" as a value of the Time $81" (see illustration).
B. Find the Conversion Factor value of Time $81" in the O2S Failure Threshold chart. 0.3906 is
specified for Time $81 in this chart.
C. Multiply "17" in step "A" by 0.3906 (Conversion Factor) in step "B."
17 x 0.3906 = 6.6%
D. If the answer is within the Standard Value of TEST LIMIT, the Time $81" can be confirmed to be
normal.
NOTE:
^ "LOW SW V" indicates the O2S voltage when the O2S status changes from rich to lean.
^ "HIGH SW V" indicates the O2S voltage when the O2S status changes from lean to rich.
^ If the O2S voltage is lower than "LOW SW V," the O2S status is lean.
^ If the O2S voltage is higher than "HIGH SW V," the O2S status is rich.
NOTE:
Before the O2S Monitor completes or after the ignition switch is turned OFF, the Diagnostic Tester
displays the viewable upper limit or a lower limit of the test value (example: 0 V, 1.275 V, Os
[seconds], 10.2s, 0 and 255).
Page 2749
Page 4943
Part 2 of 3
Page 6713
Instrument Panel
Connector Location
IA1 Engine Room Main and Cowl Wire (Left Kick Panel)
IA2 Engine Room Main and Cowl Wire (Left Kick Panel)
IA3 Engine Room Main and Cowl Wire (Left Kick Panel)
IA4 Engine Room Main and Cowl Wire (Left Kick Panel)
IB1 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IB2 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IB3 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IC1 Cowl Wire and Roof Wire (Left Side of Instrument Panel)
Instrument Panel
Connector Location
ID1 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH)
ID2 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH)
IE1 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IE2 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IE3 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IF1 Front Door RH Wire and Cowl Wire (Right Kick Panel)
IF2 Front Door RH Wire and Cowl Wire (Right Kick Panel)
IF3 Front Door RH Wire and Cowl Wire (Right Kick Panel)
Page 187
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 5937
- Length: 6 in.
^ Ratcheting tie down strap (quantity 1)
- Minimum Width & Length: 1 in. x 6 ft.
^ Bicycle Cable Lock (quantity 1)
- Minimum Width & Length: 3/8 in. x 5 ft.
- Built-in lock with key
- Bell: P/N 1002107, Master Lock: P/N 8126D, Kryptonite: P/N 999782 or equivalent
IV. Background
On certain 2000 through 2003 model year Tundra vehicles operated in cold climate areas with high
road salt use (Severe Cold Climate States) excessive corrosion may be exhibited on the rear frame
cross-member. In the worst case the spare tire stowed under the truck bed may become separated
from the rear cross-member. Eventually excessive corrosion of the rear cross-member may also
affect the functionality of the brake system Load Sensing Proportioning & By-Pass Valve and/or
associated brake lines.
Page 1930
CHART 23
Page 5252
REMOVE CENTER CLUSTER INTEGRATION PANEL
a. Remove the 3 heater control knobs.
b. Remove the 5 screws.
c. Remove integration control panel by pulling the portions indicated by arrows in the illustration.
d. Disconnect the connector.
INSTALLATION
Installation is in the reverse order of removal.
Disassembly and Reassembly
AIR CONDITIONING CONTROL ASSEMBLY (Center Cluster Integration)
DISASSEMBLY
1. REMOVE AIRBAG INDICATOR CIRCUIT
Release the 2 claws and remove the indicator circuit, then disconnect the connector.
2. REMOVE BULBS
Remove the 5 bulbs.
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 2938
VSV For Vapor Pressure Sensor
Page 5079
A. AFFECTED VIN RANGE
III. Preparation
A. PARTS
^ No parts are required for the inspection.
B. EQUIPMENT & MATERIALS
^ Protective eyewear
^ Standard heater core hose
Page 672
Vehicle Speed Sensor: Diagnostic Aids
Voltage Check
Voltage Check
Voltage Check
A. Establish conditions in which voltage is present at the check point.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(SW 2 OFF)
B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or
component terminal. This check can be done with a test light instead of a voltmeter.
Continuity and Resistance Check
Continuity and Resistance Check
Continuity And Resistance Check
A. Disconnect the battery terminal or wire so there is no voltage between the check points. B.
Contact the two leads of an ohmmeter to each of the check points.
Replacement Requirements
Airbag Sensor Assembly: Service and Repair Replacement Requirements
REPLACEMENT REQUIREMENTS
In the following cases, replace the airbag sensor assembly.
- If the SRS has been deployed in a collision.
- If the airbag sensor assembly has been found to be faulty in troubleshooting.
- If the airbag sensor assembly has been dropped.
CAUTION: For removal and installation of the airbag sensor assembly. Be sure to follow the correct
procedure.
Page 4221
Using the following SSTs and a press, install the bearing spacer.
^ 09950-60010 (09951-00650)
^ 09950-70010 (09951-07150)
22. 4WD: INSTALL NEW OIL SEAL (INSIDE)
A. Using the following SST and a plastic hammer, install a NEW oil seal (inside).
^ 09527-17011
NOTE:
Lightly strike the SST on its circumference evenly.
B. Coat MP grease to the oil seal lip.
23. INSTALL STEERING KNUCKLE
A. 4WD: Insert the drive shaft into the axle hub and temporarily tighten the nut.
NOTE:
Be careful not to damage the oil seal and drive shaft boot.
B. Connect the steering knuckle to the upper suspension arm.
C. Install the nut and a NEW cotter pin. If the holes for the cotter pin are not aligned, tighten the nut
further up to 60°.
Torque: 105 N.m (1,100 kgf.cm, 77 ft.lbf)
24. CONNECT LOWER BALL JOINT
Connect the lower ball joint to the steering knuckle with 4 bolts.
Torque: 50 N.m (510 kgf.cm, 37 ft.lbf)
25. INSTALL SHOCK ABSORBER WITH COIL SPRING
A. Install the upper side of shock absorber to the chassis frame with the 3 nuts.
Page 2018
Throttle Position Sensor: Service and Repair
Refer to Fuel Delivery and Air Induction / Throttle Body / Service and Repair, for removal and
installation of this component.
Page 2361
Knock Sensor: Locations
Knock Sensor (Part 1)
Page 3458
B: Junction Connector
Indicates a connector which is connected to a short terminal.
Junction connector in this include a short terminal which is connected to a number of wire
harnesses. Always perform inspection with the short terminal installed. (When installing the wire
harnesses, the harnesses can be connected to any position within the short terminal grouping.
Accordingly, in other vehicles, the same position in the short terminal may be connected to wire
harness from a different part.) Wire harness sharing the same short terminal grouping ha the same
color.
C: Parts Code
The first letter of the code is taken from the first letter of part, and the numbers indicates its order in
parts which start with the same letter.
D: Connector Color
Connectors not indicated are milky white in color.
How to Read Ground Points
HOW TO READ GROUND POINTS
Page 2690
Crankshaft Position Sensor: Description and Operation
Crankshaft Position Sensor
Crankshaft position sensor (NE signal) consists of a signal plate and pick up coil.
The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor
generates 34 signals of every engine revolution.
The ECM detects the standard crankshaft angle based on the G signals, and the actual crankshaft
angle the engine speed by the NE signals.
Locations
Engine Room R/B
Page 4642
Driver Side J/B And Integration Relay
Page 730
Knock Sensor: Locations
Knock Sensor (Part 1)
Page 1098
Engine Room R/B
Details
Component Locations
Ignition Switch And Key Unlock Warning Switch
Page 1166
Compression Check: Testing and Inspection
INSPECTION
HINT: If there is lack of power, excessive oil consumption or poor fuel economy, measure the
compression pressure.
1. WARM UP AND STOP ENGINE
Allow the engine to warm up to normal operating temperature.
2. REMOVE SPARK PLUGS
3. CHECK CYLINDER COMPRESSION PRESSURE
a. Insert a compression gauge into the spark plug hole. b. Fully open the throttle. c. While cranking
the engine, measure the compression pressure.
HINT: Always use a fully charged battery to obtain engine speed of 250 rpm or more.
d. Repeat steps (a) through (c) for each cylinder.
NOTICE: This measurement must be done in as short a time as possible.
Compression pressure: 1,324 kPa (13.5 kgf/cm2, 192 psi) or more Minimum pressure: 981 kPa
(10.0 kgf/cm2, 142 psi) Difference between each cylinder: 98 kPa (1.0 kgf/cm2, 14 psi) or less
e. If the cylinder compression in one or more cylinders is low, pour small amount of engine oil into
the cylinder through the spark plug hole and
repeat steps (a) through (c) for cylinders with low compression. If adding oil helps the compression, chances are that the piston rings and/or cylinder bore are worn
or damaged.
- If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage
past the gasket.
4. REINSTALL SPARK PLUGS
Page 592
A/F and 02 Sensor Identification
Page 2628
Wiring Harness Connector
E: Indicates the wiring harness and wiring harness connector. The wiring harness with male
terminal is shown with arrows.
Outside numerals are pin numbers.
The first letter of the code for each wiring harness and wiring harness connector(s) indicates the
component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and
Surrounding area, and "B" for the Body and Surrounding area.
When more than one code has the first and second letters in common, followed by numbers (e.g,
IH1, IH2), this indicates the same type of wiring harness and wiring harness connector.
F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in
parts position.
G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside
it). Junction Blocks are shaded to clearly separate
them from other parts.
H: When 2 parts both use one connector in common, the parts connector name used in wire
routing is shown in square brackets [ ].
Wiring Color
I: Indicates the wiring color.
Wire colors are indicated by an alphabetical code.
B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR =
Brown SB = Sky Blue LG = Light Green GR = Gray
The first letter indicates the basic wire color and the second letter indicates the color of the stripe.
Page 2811
CHART 5
CHART 6
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 6880
Continuity And Resistance Check
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Continuity And Resistance Check
C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the
electrical circuit.
Finding A Short Circuit
Finding A Short Circuit
Finding A Short Circuit
A. Remove the blown fuse and disconnect all loads of the fuse.
Specifications
Axle Nut: Specifications
Front Drive Shaft Lock Nut 235 Nm (173 ft.lb)
Page 1916
CHART 7
Page 4968
19. INSTALL 2 TURN PRESSURE TUBES
a. Coat 4 new O-rings with power steering fluid and install them to the turn pressure tubes. b. Using
SST, install the 2 turn pressure tubes.
SST 09023-12700 Torque: 12 Nm (117 kgf-cm, 9 ft. lbs.)
HINT: ^
Use a torque wrench with a fulcrum length of 250 mm (9.84 inch).
^ This torque value is effective in case that SST is parallel to a torque wrench.
Page 2424
CHART 8
CHART 9
Page 3463
Transmission Mode Indicator - A/T: Diagnostic Aids
Voltage Check
Voltage Check
Voltage Check
A. Establish conditions in which voltage is present at the check point.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(SW 2 OFF)
B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or
component terminal. This check can be done with a test light instead of a voltmeter.
Continuity and Resistance Check
Continuity and Resistance Check
Continuity And Resistance Check
A. Disconnect the battery terminal or wire so there is no voltage between the check points. B.
Contact the two leads of an ohmmeter to each of the check points.
Page 4840
Measuring Point Reference
5. INSPECT TOE-IN
If the toe-in is not within the specified value, adjust the rack ends.
6. ADJUST TOE-IN AND WHEEL ANGLE
a. Remove the 2 clips.
b. Loosen the tie rod end lock nuts. c. Turn the right and left rack ends by an equal amount to
adjust the toe-in.
HINT: Try to adjust the toe-in to the center of the specified value.
d. Make sure that the lengths of the right and left rack ends are the same.
Rack end length difference: 1.5 mm (0.059 inch) or less
e. Tighten the tie rod end lock nuts.
Torque: 55 Nm (560 kgf-cm, 41 ft. lbs.)
f. Place the boots on the seats and install the clips.
HINT: Make sure that the boots are not twisted.
g. Inspect the wheel angle.
Turn the steering wheel fully and measure the turning angle.
Page 2094
Knock Sensor: Locations
Knock Sensor (Part 1)
Page 5497
D. Verify the male pin of the tongue plate stopper has deformed evenly in the hole of the female
part and is firmly held to the belt webbing.
Page 3170
Camshaft Position Sensor: Mechanical Specifications
Torque: ................................................................................................................................................
.................................. 7.5 N.m (80 kgf.cm, 66 in.lbf)
Page 6603
Key Reminder Switch: Diagnostic Aids
Voltage Check
Voltage Check
Voltage Check
A. Establish conditions in which voltage is present at the check point.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(SW 2 OFF)
B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or
component terminal. This check can be done with a test light instead of a voltmeter.
Continuity and Resistance Check
Continuity and Resistance Check
Continuity And Resistance Check
A. Disconnect the battery terminal or wire so there is no voltage between the check points. B.
Contact the two leads of an ohmmeter to each of the check points.
Page 5177
1. INSTALL NEW BEARING
a. Using Special Service Tool (SST) and a press, install a new bearing to the steering knuckle.
SST 09527-17011, 09950-60020 (09951-00910)
b. Using snap ring pliers, install a new snap ring.
2. INSTALL NEW OIL SEAL (OUTSIDE)
a. Using SST and a plastic hammer, install a new oil seal (outside).
SST 09223-15030, 09527-17011
b. Coat MP grease to the oil seal lip.
3. INSTALL AXLE HUB TO STEERING KNUCKLE
a. Install the dust cover to the steering knuckle with the 4 bolts.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)
b. Using SST and a press, install the axle hub to the steering knuckle.
SST 09649-17010
4. INSTALL ABS SPEED SENSOR ROTOR (w/ ABS)/SPACER (w/o ABS)
NOTICE: Do not scratch the serration of the speed sensor rotor.
5. 2WD: INSTALL NEW LOCK NUT
a. Using SST install and torque a new lock nut to the axle hub.
SST 09318-12010 Torque: 274 Nm (2,800 kgf-cm, 203 ft. lbs.)
b. Using a chisel and hammer, stake the lock nut.
Page 2557
A. Connect Diagnostic Tester cables DLC (P/N 02001637) and CAN Interface Module / J1962
OBDII together (P/N 01002744).
B. Test for continuity.
^ If there is continuity, the cable is OK. Check steps 1 and 2 above to complete the flash
reprogramming process.
^ If there is no continuity, proceed to CABLE TEST 2.
CABLE TEST 2.
A. Disconnect Diagnostic Tester cables DLC (P/N 02001637) and CAN Interface Module /J1962
OBDII (P/N 01002744).
B. Test DLC cable (P/N 02001637) for continuity.
^ If there is continuity, the cable is OK. Proceed to CABLE TEST 3.
^ If there is no continuity, the cable needs to be replaced.
CABLE TEST 3.
Page 4926
Key Reminder Switch: Diagnostic Aids
Voltage Check
Voltage Check
Voltage Check
A. Establish conditions in which voltage is present at the check point.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(SW 2 OFF)
B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or
component terminal. This check can be done with a test light instead of a voltmeter.
Continuity and Resistance Check
Continuity and Resistance Check
Continuity And Resistance Check
A. Disconnect the battery terminal or wire so there is no voltage between the check points. B.
Contact the two leads of an ohmmeter to each of the check points.
Page 98
Terminal Retainer
Push the terminal retainer down to the temporary lock position.
c. Release the locking lug from terminal and pull the terminal out from rear.
4. INSTALL TERMINAL TO CONNECTOR
a. Insert the terminal.
HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug
locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position.
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 6206
B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(Connect the Relay) and SW 2 OFF (or Disconnect SW 2)
D. Disconnect and reconnect the connectors while watching the test light.
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
E. Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION:
a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals
are touched, the IC may be destroyed by
static electricity.)
b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact
with the terminals of leads from the IC, etc. of the replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
Special Tool
1. PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown.
2. DISCONNECT CONNECTOR
3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
a. Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the
secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
A: For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
Airbag(s) Arming and Disarming
Air Bag(s) Arming and Disarming: Service and Repair Airbag(s) Arming and Disarming
CAUTION: *
Work must be started 90 seconds after the ignition switch is turned to the "LOCK" position and the
negative (-) terminal cable is disconnected from the battery. (The SRS is equipped with a back-up
power source so that if work is started within 90 seconds of disconnecting the negative (-) terminal
cable of the battery, the SRS may be deployed.)
* When the negative (-) terminal cable is disconnected from the battery, the memory of the clock
and audio system will be canceled. So before starting work, make a record of the contents
memorized in the audio memory system. When work is finished, reset the audio systems as before
and adjust the clock. To avoid erasing the memory of each memory system, never use a backup
power supply from outside the vehicle.
* Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during
repairs.
* Do not expose the steering wheel pad, front passenger airbag assembly, airbag sensor assembly
or front airbag sensor directly to hot air or flames.
AIR BAG SYSTEM DISARMING
The Air Bag/Supplemental Restraint System (SRS) incorporates a backup energy source that
maintains sufficient deployment voltage for up to 90 seconds after the ignition is turned Off and the
battery has been disconnected. Before disconnecting battery, note radio station settings, since all
vehicle memory will be lost. Never use a backup power source from outside the vehicle.
1. Turn ignition to Lock, then disconnect battery ground cable. 2. Wait at least 90 seconds after
disconnection before beginning service or diagnostic procedures.
AIR BAG SYSTEM ARMING
1. Ensure ignition is in Lock position. 2. Connect battery ground cable. 3. Wait at least 10 seconds
before turning ignition from Lock position. 4. Turn ignition to ACC or On position and ensure SRS
lamp lights, then goes off after approximately six seconds. If lamp remains lit, an SRS
condition is indicated. Refer to Restraint Systems, Air Bag Systems, Testing And Inspection. See:
Restraint Systems/Air Bag Systems/Testing and Inspection
Page 6327
Cigarette Lighter And Power Outlet
Page 1432
REMOVAL
1. REMOVE ENGINE UNDER COVER 2. DRAIN ENGINE COOLANT 3. REMOVE RADIATOR
ASSEMBLY 4. REMOVE THROTTLE BODY COVER 5. REMOVE INTAKE AIR CONNECTOR
ASSEMBLY
Page 6321
Continuity And Resistance Check
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Continuity And Resistance Check
C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the
electrical circuit.
Finding A Short Circuit
Finding A Short Circuit
Finding A Short Circuit
A. Remove the blown fuse and disconnect all loads of the fuse.
Recall - Rear Cross-Member Corrosion
Technical Service Bulletin # SC90M Date: 091116
Page 5975
Page 177
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 1784
Glossary Of Terms And Symbols (Part 1)
Page 6733
Stop Light
Page 6583
Key Reminder Switch: Ground Locations
Engine Compartment
Ground Location
EA Front Left Fender
EB Rear Bank of Right Cylinder
EC Rear Bank of Left Cylinder
Connector Location
EA1 Cowl Wire Harness and Wire Harness (Connector Location)
EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B)
EC1 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC2 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC3 Engine No. 2 Wire and Engine Wire (Near the Starter)
ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission)
Page 2478
CHART 1
Page 2602
Refer to Reset Procedure 2 for the vehicles with Electronically Controlled Automatic
Transmissions:
Reset Procedure 1
1. Connect the Toyota Diagnostic Tester to the vehicle.
2. Reset the ECM (PCM). Refer to the procedures below.
Page 6666
Body
Connector Location (Access Cab)
BA1 Front Door LH Wire and Wire Harness (Connector Location)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel)
BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel)
BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel)
BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Locations
Engine Room R/B
Page 6214
Cruise Control: Description and Operation
SYSTEM OUTLINE
The cruise control system is a constant vehicle speed controller which controls the opening angle
of the engine throttle valve by the SW, and allows driving at a constant speed without depressing
the accelerator pedal.
SET CONTROL
When the SET/COAST SW is operated while traveling with the main SW on, the speed when the
SET/COAST SW is operated to off is memorized, and the vehicle speed is controlled at that speed.
COAST CONTROL
When the SET/COAST SW is operated to on, the cruise control opening angle requirement is
turned to 0 to decrease the vehicle speed, and the speed when the SET/COAST SW is operated to
off is memorized, and the vehicle speed is controlled at that speed.
Furthermore, every time the SET/COAST SW is operated momentarily (Approx. 0.5 sec.) to on, the
memorized vehicle speed is decreased by approx. 1.5 km/h (0.9 mph).
ACCEL CONTROL
When the RES/ACC SW is operated to on, the throttle motor rotates the throttle valve to open
direction to increase the vehicle speed, and the speed when the RES/ACC SW is operated to off is
memorized, and the vehicle speed is controlled at that speed.
Furthermore, every time the RES/ACC SW is operated momentarily (Approx. 0.5 sec.) to on, the
memorized vehicle speed is increased by approx. 1.5 km/h (0.9 mph).
MANUAL CANCEL MECHANISM
If any of the following signals are input during cruise control traveling, the current to the motor flows
in the direction to close the throttle valve, and cancel the cruise control.
1. Stop lamp SW is on (Brake pedal is depressed) 2. The CANCEL SW of the control SW is on 3.
CRUISE SW is off
RESUME CONTROL
After canceling the cruise control (Except when the main SW is off) if the vehicle speed is above
the minimum speed limit (Approx. 40 km/h, 25mph), operating the RES/ACC SW to on from off will
cause the system to accelerate and resume to the vehicle speed before manual cancellation.
OVERDRIVE FUNCTION
The overdrive may be cut on an uphill grade, while traveling with the cruise control.
After the overdrive is cut, if the vehicle speed reaches the overdrive resume speed (Set speed
minus 2 km/h (1.2 mph) ), and if the system determines that the uphill grade has finished, the
overdrive will resume after the overdrive timer operation.
AUTO CANCEL OPERATION
If any of the following conditions are detected, the set speed is erased and the control is canceled.
1. Disconnection and/or short in the stop light SW 2. Malfunction in the vehicle speed signal 3.
Malfunction in the electronic throttle parts 4. Malfunction in the stop light SW input circuit 5.
Malfunction in the cancel circuit 6. The actual vehicle speed becomes slower than the minimum
speed limit 7. The actual vehicle speed becomes -16 km/h (10 mph) slower than the set speed
Electrode Gap Specification
Spark Plug: Specifications Electrode Gap Specification
Electrode Gap
Correct Gap .........................................................................................................................................
........................................................................ 0.8 mm
Page 658
Transmission Position Switch/Sensor: Service and Repair
ON-VEHICLE REPAIR
1. DISCONNECT OIL COOLER PIPE 2. REMOVE PARK/NEUTRAL POSITION SWITCH
a. Disconnect the connector. b. Pry off the lock washer and remove the nut. c. Remove the bolt and
park/neutral position switch.
3. INSTALL PARK/NEUTRAL POSITION SWITCH
a. Install the park/neutral position switch and bolt.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)
b. Install a new lock plate and the nut.
Torque: 3.9 Nm (40 kgf-cm, 35 inch lbs.)
c. Bend claws on the lock plate to fix the nut. d. Connect the connector. e. Check that the engine
can be started with the shift lever only in the N or P position, but not in other positions. If not as
stated, carry out the
adjustment procedure. See: Transmission and Drivetrain/Automatic
Transmission/Transaxle/Testing and Inspection/Initial Inspection and Diagnostic Overview
4. CONNECT OIL COOLER PIPE 5. FILL ATF AND CHECK FLUID LEVEL 6. TEST DRIVE
VEHICLE
Page 235
Terminals Of ECU - Connector Pinouts (Part 2)
Component Locations
Page 6842
Lamp Control Module: Electrical Diagrams
Service Hints
LIGHT AUTO TURN OFF
HEAD RELAY
2 - 1 : Closed with the light control SW at HEAD position or the dimmer SW at FLASH position.
Closed with the engine running and the parking brake lever released (w/ daytime running light)
C15 LIGHT CONTROL SW [COMB. SW]
13 - 16 : Closed with light control SW at HEAD position
14 - 16 : Closed with light control SW at TAIL or HEAD position
D16 DOOR COURTESY SW FRONT LH
1 - GROUND : Continuity with the front LH door open
INTEGRATION RELAY
9 - GROUND : Approx. 12 volts with the ignition SW at ON position
14 - GROUND : Continuity with the front LH door open
3, 6 - GROUND : Always approx. 12 volts
8 - GROUND : Always continuity
ILLUMINATION
C15 LIGHT CONTROL SW [COMB. SW]
14 - 16 : Closed with light control SW at TAIL or HEAD position
Page 6724
Glossary Of Terms And Symbols (Part 2)
Page 2973
Mass Air Flow Meter: Description and Operation
Mass Air Flow Meter
The mass air flow meter uses a platinum hot wire. The hot wire air flow meter consists of a
platinum hot wire, thermistor and a control circuit installed in a plastic housing. The hot wire air flow
meter works in principle that the hot wire and thermistor located in the intake air bypass of the
housing detect any changes in the intake air temperature.
The hot wire is maintained at the set temperature by controlling the current flow through the hot
wire. This current flow is then measured as an output voltage of the mass air flow meter.
The circuit is constructed so that the platinum hot wire and thermistor provide a bridge circuit, with
the power transistor, and controlled so that the potential of A and B remains equal in order to
maintain the set temperature.
Page 414
Non-Waterproof Type Connector
"Case 1" Raise the terminal retainer up to the temporary lock position.
Non-Waterproof Type Connector
"Case 2" Open the secondary locking device.
Page 398
Key Reminder Switch: Harness Locations
Engine Compartment
Connector Location
EA1 Cowl Wire Harness and Wire Harness (Connector Location)
EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B)
EC1 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC2 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC3 Engine No. 2 Wire and Engine Wire (Near the Starter)
ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission)
Page 5140
Compress and extend the shock absorber rod and check that there is no abnormal resistance or
unusual operation sounds. If there is any abnormality, replace the shock absorber with a new one.
NOTICE: When discarding the shock absorber, see DISPOSAL.
DISPOSAL
1. FULLY EXTEND SHOCK ABSORBER ROD
2. DRILL HOLE TO DISCHARGE GAS FROM CYLINDER
Using a drill, make a hole in the cylinder as shown in the illustration to discharge the gas inside.
CAUTION: The discharged gas is harmless, but be careful of chips which may fly up when drilling.
REASSEMBLY
1. INSTALL COIL SPRING TO SHOCK ABSORBER
a. Using Special Service Tool (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 the SST.
b. Install the coil spring to the shock absorber.
HINT: Fit the lower end of the coil spring into the gap of the spring seat of the shock absorber.
Page 1735
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 100
Relay Box: Connector Views
Engine Room R/B
Page 4759
Driver Side J/B And Integration Relay
Page 1529
Engine Coolant Temperature (ECT) Sensor
Page 6100
a. Connect the positive (+) lead from the battery to terminal 1, the positive (+) lead from the
ammeter to terminal 2 and the negative (-) lead to the
battery negative (-) terminal, then move the seat cushion to the lowest position.
b. Continue to apply voltage, check that the current changes to less than 1 ampere within 4 to 90
seconds.
c. Disconnect the leads from the terminals. d. Approximately 60 seconds later, connect the positive
(+) lead from the battery to terminal 2 and the negative (-) lead to terminal 1, check that the
seat cushion begins to ascend. If operation is not as specified, replace the seat adjuster.
INSPECT RECLINING MOTOR OPERATION
a. Connect the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal
2, check that the motor turns clockwise. b. Reverse the polarity, check that the motor turns
counterclockwise.
If operation is not as specified, replace the seat adjuster.
INSPECT RECLINING MOTOR PTC THERMISTOR OPERATION
a. Connect the positive (+) lead from the battery to terminal 2, the positive (+) lead from the
ammeter to terminal 1 and the negative (-) lead to the
battery negative (-) terminal, then recline the seat back to the most forward position.
Page 2212
B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(Connect the Relay) and SW 2 OFF (or Disconnect SW 2)
D. Disconnect and reconnect the connectors while watching the test light.
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
E. Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION:
a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals
are touched, the IC may be destroyed by
static electricity.)
b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact
with the terminals of leads from the IC, etc. of the replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
Special Tool
1. PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown.
2. DISCONNECT CONNECTOR
3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
a. Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the
secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
A: For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
Brakes - Front Brakes Vibrating
Technical Service Bulletin # BR004R-02 Date: 040305
Brakes - Front Brakes Vibrating
BRAKES BR004-02 REVISED
September 16, 2002
Title: FRONT BRAKE VIBRATION
Models: '00 - '03 Tundra
TSB REVISION NOTICE: ^
March 5, 2004: A torque specification in, step 24, was changed.
^ September 8, 2003: A torque specification in, step 28, was changed.
The previous TSB should be discarded.
Introduction
Under certain usage conditions, some Tundra trucks may exhibit front brake vibration. Improved
brake caliper assemblies have been introduced to correct this condition.
Applicable Vehicles ^
2000 - 2003 model year Tundra trucks built before the VIN shown below.
Production Change Information
Warranty Information
Applicable Warranty:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36
months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Page 1488
Spark Plug: Application and ID
Recommended Spark Plugs
DENSO K20R-U
NGK BKR6EYA
Page 4409
Anti-Lock Brake System
Recall - Rear Cross-Member Corrosion
Technical Service Bulletin # SC90M Date: 091116
Page 1740
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 5514
Seat Belt: Specifications
Seat Belt
Page 4606
Terminal Retainer
Push the terminal retainer down to the temporary lock position.
c. Release the locking lug from terminal and pull the terminal out from rear.
4. INSTALL TERMINAL TO CONNECTOR
a. Insert the terminal.
HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug
locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position.
Page 2764
Page 6727
B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(Connect the Relay) and SW 2 OFF (or Disconnect SW 2)
D. Disconnect and reconnect the connectors while watching the test light.
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
E. Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION:
a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals
are touched, the IC may be destroyed by
static electricity.)
b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact
with the terminals of leads from the IC, etc. of the replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
Special Tool
1. PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown.
2. DISCONNECT CONNECTOR
3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
a. Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the
secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
A: For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
Page 6102
move the lumbar support to front end position.
b. Continue to apply voltage, check that a circuit breaker operation noise can be heard within 4 to
60 seconds. c. Reverse the polarity, check that the lumbar support begins to move release side
with in approximately 60 seconds.
If operation is not as specified, replace the lumber support adjuster.
Page 2154
Mass Air Flow (MAF) Meter
Page 1287
Drive Belt: Service and Repair
REMOVAL
REMOVE DRIVE BELT
Loosen the drive belt tension by turning the drive belt tensioner counterclockwise, and remove the
drive belt.
INSTALLATION
INSTALL DRIVE BELT
Turn the drive belt tensioner counterclockwise then install the drive belt.
Page 1719
D. The Calibration Update Wizard (CUW) launches automatically when a calibration file link is
selected (or clicked). Verify that the CUW version is 6.0 or higher. If not, refer to the Note below.
The CUW will guide you through the steps to download the calibration file to the Diagnostic Tester
Program Card. Click NEXT on the first screen (Figure 7).
NOTE:
If the CUW does not launch, or the version is older than 6.0, install Diagnostic Software (TIS
Diagnostic Applications Installer). Specific installation instructions (Reprogramming with CUW 6.0)
are located under Diagnostics ECU Flash Reprogramming (Figure 6).
Page 227
Engine Control Module: Diagnostic Aids
Voltage Check
Voltage Check
Voltage Check
A. Establish conditions in which voltage is present at the check point.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(SW 2 OFF)
B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or
component terminal. This check can be done with a test light instead of a voltmeter.
Continuity and Resistance Check
Continuity and Resistance Check
Continuity And Resistance Check
A. Disconnect the battery terminal or wire so there is no voltage between the check points. B.
Contact the two leads of an ohmmeter to each of the check points.
Page 4569
Disconnect the negative (-) lead from the starter body. Check that the pinion gear returns inward.
4. DO NO-LOAD PERFORMANCE TEST
a. Connect the battery and ammeter to the starter as shown. b. Check that the starter rotates
smoothly and steadily with the pinion gear moving out. Check that the ammeter shows the
specified current.
Specified current
Page 1074
Engine Compartment
Instrument Panel
Locations
Page 1639
Part 3 of 3
Page 1687
^ 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
Application and ID
Valve Spring Shim: Application and ID
ADJUSTING SHIM SELECTION CHART
Intake
Page 5237
Connector View
Pinouts (Part 1)
Page 1434
11. REMOVE NO.2 TIMING BELT COVER
Remove the 2 bolts and No.2 timing belt cover.
12. w/ A/C: DISCONNECT A/C COMPRESSOR FROM ENGINE
13. REMOVE FAN BRACKET
Remove the 2 bolts, 2 nuts and fan bracket.
14. IF RE-USING TIMING BELT, CHECK INSTALLATION MARKS ON TIMING BELT
Check that there are 3 installation marks on the timing belt by turning the crankshaft pulley as
shown in the illustration.
HINT: If the installation marks have disappeared, place a new installation mark on the timing belt
before removing each part.
15. LOOSEN CRANKSHAFT PULLEY BOLT Using SST, loosen the pulley bolt.
SST 09213-70010 (90100-08076), 09330-00021
16. SET NO.1 CYLINDER TO TDC/COMPRESSION
Page 6606
Non-Waterproof Type Connector
"Case 1" Raise the terminal retainer up to the temporary lock position.
Non-Waterproof Type Connector
"Case 2" Open the secondary locking device.
Page 6706
Instrument Panel
Ground Location
IE Left Kick Panel
IF Left Kick Panel
IG Instrument Panel Brace RH
IH Right Kick Panel
II Right Kick Panel
Body
Ground Location (Access Cab)
Page 6884
Terminal Retainer
Push the terminal retainer down to the temporary lock position.
c. Release the locking lug from terminal and pull the terminal out from rear.
4. INSTALL TERMINAL TO CONNECTOR
a. Insert the terminal.
HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug
locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position.
Page 6814
Glossary Of Terms And Symbols (Part 1)
Page 6532
Key Reminder And Seat Belt Warning
Page 6855
INSPECT DAYTIME RUNNING LIGHT RELAY NO.4 CONTINUITY If continuity is not as specified,
replace the relay.
Page 142
A. Test the CAN Interface Module (P/N 01002744) for continuity.
^ If there is no continuity, the CAN Interface Module needs to be replaced.
^ If there is continuity, the CAN Interface Module is OK. Re-check Cable Tests 1, 2, 3, and 4 while
wiggling and flexing the cables.
Speed Sensor, Front
Wheel Speed Sensor: Service and Repair Speed Sensor, Front
REMOVAL
1. REMOVE FRONT WHEEL
Torque: 113 Nm (1,150 kgf-cm, 83 ft. lbs.)
2. DISCONNECT SPEED SENSOR CONNECTOR
3. REMOVE SPEED SENSOR
(a) Remove the clips and 3 clamp bolts holding the sensor harness from the frame, upper arm and
steering knuckle.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
(b) Remove the bolt and speed sensor from the steering knuckle.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
INSTALLATION
Installation is in the reverse order of removal.
HINT: After installation, check speed sensor signal.
Diagrams
Cooling Unit
Page 1859
Crankshaft Position Sensor: Testing and Inspection
INSPECTION
NOTE: "Cold" and "Hot" in these sentences express the temperature of the coils themselves.
"Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F).
INSPECT CRANKSHAFT POSITION SENSOR
Resistance
Using an ohmmeter, measure the resistance between the terminals.
If the resistance is not as specified, replace the crankshaft position sensor.
Page 472
Camshaft Position Sensor: Mechanical Specifications
Torque: ................................................................................................................................................
.................................. 7.5 N.m (80 kgf.cm, 66 in.lbf)
Page 149
DOWNLOAD FILE TO TESTER
2. Download the calibration file to the Diagnostic Tester.
The Calibration Update Wizard (CUW) is a new application on TIS which downloads calibration
files from TIS onto the Diagnostic Tester Program Card.
NOTE:
Before you begin, ensure that the Diagnostic Tester is equipped with software version 8.0a, or
later. Only a 12 MB program card (P/N 01002593-005) may be used for this process.
A. Before downloading a new calibration file from TIS, check the current calibration files stored on
the Diagnostic Tester Program Card by following the screen flow shown (Figure 4).
NOTE:
^ Screen D may be blank if no calibrations are stored on the Diagnostic Tester Program Card.
^ If the desired calibration file is already on the Diagnostic Tester, proceed to Step 3 (Reprogram
ECU with Tester shown).
^ A maximum of two calibration files may be loaded on the tester at one time with Diagnostic Tester
software version 10.2a and later. Prior versions may store up to four calibration files.
Page 5337
*Some Toyota vehicles are equipped with a Passenger Airbag Manual On-Off Switch, and other
Toyota models may have a retrofit passenger airbag switch installed at the dealership. To analyze
the condition of the manual on-off switch technicians must follow specific inspection procedures
which are outlined in this bulletin. However complete airbag manual on-off switch inspection and
repair procedures can be found in vehicle-specific Toyota Repair Manuals.
Note - for all Toyota vehicles Following all collisions when the SRS does NOT deploy inspect:
^ Steering wheel pad ^ Side airbags and seat frames ^ Front & side airbag sensors ^ Wiring
harness and connectors ^ Front passenger airbag assembly ^ Malfunction indicator lamp for correct
operation
Component Replacement Notes
Note 1 - Replace the Steering Wheel Pad: ^ If the airbag has been deployed or dropped ^ If the
steering wheel pad is diagnosed as needing replacement when troubleshooting or during
inspection
Note 2 - Inspect and if necessary replace the Spiral Cable: ^ If the spiral cable is diagnosed as
needing replacement when troubleshooting or during inspection
Page 2767
Page 2039
Non-Waterproof Type Connector
"Case 1" Raise the terminal retainer up to the temporary lock position.
Non-Waterproof Type Connector
"Case 2" Open the secondary locking device.
Page 2868
Vehicle Speed Sensor: Diagnostic Aids
Voltage Check
Voltage Check
Voltage Check
A. Establish conditions in which voltage is present at the check point.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(SW 2 OFF)
B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or
component terminal. This check can be done with a test light instead of a voltmeter.
Continuity and Resistance Check
Continuity and Resistance Check
Continuity And Resistance Check
A. Disconnect the battery terminal or wire so there is no voltage between the check points. B.
Contact the two leads of an ohmmeter to each of the check points.
Engine Controls - MIL ON/DTC's P0135/P0155 Stored
Oxygen Sensor: Customer Interest Engine Controls - MIL ON/DTC's P0135/P0155 Stored
ENGINE EG019-02 REVISED
October 3, 2002
Title M.I.L. "ON" P0135 AND/OR P0155
Models: '00 - '02 Tundra (2UZ-FE) & '01 - '02 Sequoia
TSB REVISION NOTICE:
January 14, 2004: A Previous Part Number in the Parts Information table and one OFP number in
the Warranty Information table has been changed. All previous versions of this TSB should be
discarded.
Introduction
Certain 2000 - 2002 model year Tundra trucks (2UZ-FE) and 2001 - 2002 model year Sequoia
vehicles may exhibit a M.I.L. ON" condition with Diagnostic Trouble Code P0135 and/or P0155 in
the Engine Control Module (ECM)/SAE equivalent (PCM). The oxygen sensors have been
improved to correct this condition.
Applicable Vehicles ^
2000 - 2002 model year Tundra trucks with 2UZ-FE engines produced BEFORE the Production
Change Effective VINs listed below.
^ 2001 - 2002 model year Sequoia vehicles produced BEFORE the Production Change Effective
VINs listed below.
Production Change Information
Parts Information
Warranty Information
Applicable Warranty*:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36
months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Page 5420
Impact Sensor: Testing and Inspection Replacement Requirements
REPLACEMENT REQUIREMENTS
In the following cases, replace the front airbag sensor.
- If the SRS has been deployed in a collision. (Replace both the left and right airbag sensors.)
- If the front airbag sensor has been found to be faulty in troubleshooting.
- If the front airbag sensor has been found to be faulty during checking items.
- If the front airbag sensor has been dropped.
CAUTION: Be sure to follow the correct procedure for removal and installation of the front airbag
sensor.
Page 1804
Page 6609
b. Push the secondary locking device or terminal retainer in to the full lock position.
5. CONNECT CONNECTOR
Disconnection of Male and Female Connectors
Disconnection of Male and Female Connectors
Disconnection Of Male And Female Connectors
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Page 206
F. Confirm the Diagnostic Tester software version and connections to the TIS workstation are
correct.
* NOTE:
This screen displays the required version of Diagnostic Tester software that is compatible with the
selected calibration file, and the other required steps to properly connect the Diagnostic Tester to
your PC.
^ Type I calibration files are only compatible with software version 10.1a and older versions.
^ Type II calibration files are only compatible with software version 10.2a and newer versions.
G. Place the Diagnostic Tester in the "GET CAL FROM PC" mode to receive the calibration file
(Figure 10).
Click NEXT on the TIS workstation. Once communications begin between the PC and the
Diagnostic Tester, the Diagnostic Tester display will flash CONNECTED.
H. The CUW determines if there is enough memory to store the calibration file on the Diagnostic
Tester Program Card. If there is insufficient
Page 5102
FOR
SPECIAL SERVICE CAMPAIGN
REAR FRAME CROSS MEMBER &
LOAD SENSING PROPORTIONING & BY-PASS VALVE INSPECTION
2000-2003 MODEL YEAR TUNDRA
Page 2817
CHART 14
Page 5004
Page 2086
Crankshaft Position Sensor
Symptom Related Diagnostic Procedures
Problem Symptoms Table - Stop Light System
Brakes - Front Brake Caliper Identification
Brake Caliper: All Technical Service Bulletins Brakes - Front Brake Caliper Identification
BRAKES BR001-03 REVISED
January 8, 2003
Title: FRONT BRAKE COMPONENT IDENTIFICATION
Models: '00 - '05 Tundra, '01 - '05 Sequoia
TSB UPDATE NOTICE:
The information contained in this TSB supercedes TSB No. BR003-00. TSB No. BR003-00 is now
obsolete and should be discarded.
TSB REVISION NOTICE:
March 25, 2005: Parts Information - Part titles and part numbers have been updated and "Note"
added.
The previous TSB should be discarded.
Introduction
There are two caliper designs that are in use for Tundra and Sequoia vehicles. The brake pads and
fitting kits for these two calipers are not interchangeable. The pictures and parts lists below are
intended to assist you in identifying and ordering the correct replacement pads and fitting kits.
Applicable Vehicles: ^
2000 - 2005 model year Tundra vehicles.
^ 2001 - 2005 model year Sequoia vehicles.
Warranty Information
Page 2174
Camshaft Position Sensor: Service and Repair
Camshaft Position Sensor
REMOVAL
1. DRAIN ENGINE COOLANT
2. REMOVE DRIVE BELT
3. REMOVE LH NO.3 TIMING BELT COVER
Page 4695
Terminal Retainer
Push the terminal retainer down to the temporary lock position.
c. Release the locking lug from terminal and pull the terminal out from rear.
4. INSTALL TERMINAL TO CONNECTOR
a. Insert the terminal.
HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug
locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position.
Instruments - Coolant Temperature Gauge Inaccurate
Temperature Gauge: Customer Interest Instruments - Coolant Temperature Gauge Inaccurate
ELECTRICAL EL009-01
October 12, 2001
Title: TEMPERATURE GAUGE INACCURATE
Models: '00 - '01 Tundra
Introduction Some 2000 - 2001 model year Tundra trucks may experience a condition in which the
engine coolant temperature gauge displays an abnormally high reading during normal engine
operating temperatures. To address this condition, an updated Temperature Gauge has been
made available.
Applicable Vehicles ^
2000 - 2001 model year Tundra trucks, built prior to the VIN shown.
Production Change Information
Parts Information
Repair Procedure
IMPORTANT:
Verify that the engine is operating at a normal temperature with the Scan Tool before replacing the
temperature gauge.
1. Remove the four bolts securing the combination meter assembly.
2. Replace the Temperature Gauge.
3. Reassemble the combination meter.
Warranty Information
Applicable Warranty *:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36
months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Page 5516
Seat Belt
Page 6801
Body
Splice Location (Standard Cab)
B1 Speaker Tweeter Wire LH
B2 Front Door LH Wire
B3 Front Door LH Wire
B4 Roof Wire
B5 Speaker Tweeter Wire RH
B6 B7
Front Door RH Wire
B10 Frame Wire
Seat
Page 4368
B. Using Snap ring pliers, install a NEW snap ring.
17. INSTALL NEW OIL SEAL (OUTSIDE)
A. Using the following SSTs and a plastic hammer, install a NEW oil seal (outside).
^ 09223-15030
^ 09527-17011
B. Coat MP grease to the oil seal lip.
18. INSTALL NEW DUST COVER AND AXLE HUB TO STEERING KNUCKLE
A. Install the NEW dust cover to the steering knuckle with the 4 bolts.
Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)
B. Using the following SST and a press, install the axle hub to the steering knuckle.
09649-17010
19. INSTALL ABS SPEED SENSOR
ROTOR (W/ABS) OR SPACER (W/O ABS)
NOTE:
Take care not to scratch the serration of the speed sensor rotor.
Page 1692
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 2866
Glossary Of Terms And Symbols (Part 1)
Page 4944
Part 3 of 3
Page 6601
Glossary Of Terms And Symbols (Part 1)
Page 3556
Splice Location
I1 Cowl Wire
I2 Cowl Wire
I3 Cowl Wire
I4 Cowl Wire
I5 Cowl Wire
I6 Cowl Wire
I7 Engine Wire
I8 Engine Wire
I9 Engine Wire
I10 Engine Wire
I11 Engine Wire
I12 Engine Wire
I13 Engine Wire
I14 Engine Wire
I15 Engine Wire
I16 Cowl Wire
Body
Splice Location (Access Cab)
B1 Speaker Tweeter Wire LH
B2 Front Door LH Wire
B3 Front Door LH Wire
B4 Roof Wire
B5 Speaker Tweeter Wire RH
B6 B7
Front Door RH Wire
B8 Front Door RH Wire
B9 Rear Door No. 1 Wire RH
B10 Frame Wire
Page 6525
Seat Belt Reminder Buzzer: Diagnostic Aids
Voltage Check
Voltage Check
Voltage Check
A. Establish conditions in which voltage is present at the check point.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(SW 2 OFF)
B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or
component terminal. This check can be done with a test light instead of a voltmeter.
Continuity and Resistance Check
Continuity and Resistance Check
Continuity And Resistance Check
A. Disconnect the battery terminal or wire so there is no voltage between the check points. B.
Contact the two leads of an ohmmeter to each of the check points.
Page 5994
Roof Headlining
Page 2779
CHART 30
Page 5656
Impact Sensor: Testing and Inspection Replacement Requirements
REPLACEMENT REQUIREMENTS
In the following cases, replace the front airbag sensor.
- If the SRS has been deployed in a collision. (Replace both the left and right airbag sensors.)
- If the front airbag sensor has been found to be faulty in troubleshooting.
- If the front airbag sensor has been found to be faulty during checking items.
- If the front airbag sensor has been dropped.
CAUTION: Be sure to follow the correct procedure for removal and installation of the front airbag
sensor.
Page 2932
Voltage: 4.2 - 4.8 V
d. Turn the ignition switch OFF. e. Reconnect the vacuum hose to the vapor pressure sensor.
Page 6718
Wiring Harness Connector
E: Indicates the wiring harness and wiring harness connector. The wiring harness with male
terminal is shown with arrows.
Outside numerals are pin numbers.
The first letter of the code for each wiring harness and wiring harness connector(s) indicates the
component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and
Surrounding area, and "B" for the Body and Surrounding area.
When more than one code has the first and second letters in common, followed by numbers (e.g,
IH1, IH2), this indicates the same type of wiring harness and wiring harness connector.
F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in
parts position.
G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside
it). Junction Blocks are shaded to clearly separate
them from other parts.
H: When 2 parts both use one connector in common, the parts connector name used in wire
routing is shown in square brackets [ ].
Wiring Color
I: Indicates the wiring color.
Wire colors are indicated by an alphabetical code.
B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR =
Brown SB = Sky Blue LG = Light Green GR = Gray
The first letter indicates the basic wire color and the second letter indicates the color of the stripe.
Page 716
4. REMOVE CAMSHAFT POSITION SENSOR
Remove the bolt, stud bolt and camshaft position sensor.
INSTALLATION
1. INSTALL CAMSHAFT POSITION SENSOR
Install the camshaft position sensor with the bolt and stud bolt Torque: 7.5 N.m (80 kgf.cm, 66
in.lbf)
2. INSTALL LH NO.3 TIMING BELT COVER
3. INSTALL DRIVE BELT
4. FILL ENGINE COOLANT
5. CHECK ENGINE COOLANT FOR LEAKS
6. CHECK IGNITION TIMING
Page 1650
Three-Way Catalytic Converter (TWC) System
Page 5957
Page 392
Instrument Panel
Ground Location
IE Left Kick Panel
IF Left Kick Panel
IG Instrument Panel Brace RH
IH Right Kick Panel
II Right Kick Panel
Body
Ground Location (Access Cab)
Page 2830
Page 4994
- When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool)
Perform the operation in a place away from electrical noise. SST 09082-00700
- When deploying an airbag, perform the operation at least 10 m (33 ft) away from the steering
wheel pad.
- The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30
minutes after deployment.
- Use gloves and safety glasses when handling a steering wheel pad with the deployed airbag.
- Always wash your hands with water after completing the operation.
- Do not apply water, etc. to a steering wheel pad with the deployed airbag.
DEPLOYMENT WHEN DISPOSING OF STEERING WHEEL PAD WITH AIRBAG DEPLOYED IN
COLLISION
CAUTION:
- The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30
minutes after deployment.
- When moving a vehicle for scrapping which has a steering wheel pad with the deployed airbag,
use gloves and safety glasses.
- Use gloves and safety glasses when handling a steering wheel pad with deployed airbag.
- Always wash your hands with water after completing the operation.
- Do not apply water, etc. to a steering wheel pad with deployed airbag.
1. Remove the steering wheel pad from the steering wheel.
2. Place the steering wheel pad in a vinyl bag, tie the end tightly and dispose of it in the same way
as other general parts disposal.
Steering Wheel Airbag Disposal
HINT: When scrapping vehicle equipped with an SRS or disposing of a steering wheel pad (with
airbag), always first deploy the air bag in accordance with the procedure described. If any
abnormality occurs with the airbag deployment, contact the SERVICE DEPT. of TOYOTA MOTOR
SALES, U.S.A., INC.
CAUTION:
- Never dispose of a steering wheel pad which has an undeployed airbag.
- The airbag produces a sizeable exploding sound when it deploys, so perform the operation out-ofdoors and where it will not create a nuisance to nearby residents.
- When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool).
Perform the operation in a place away from electrical noise. SST 09082-00700
- When deploying an airbag, perform the operation at least 10 m (33 ft) away from the steering
wheel pad.
Procedures
Seat Belt Tensioner: Procedures
Replacement Requirements
REPLACE REQUIREMENTS
In the following cases, replace the seat belt pretensioner.
- If the seat belt pretensioner has been activated.
- If the seat belt pretensioner has been found to be faulty in troubleshooting.
- If the front seat outer belt has been found to be faulty during checking item functioning of SST.
- If the front seat outer belt has been dropped.
CAUTION: Be sure to follow the correct procedure, for removal and installation of the seat belt
pretensioner.
Deployment and Disposal
DISPOSAL
HINT: When scrapping vehicles equipped with a 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 procedure described below. If any abnormality occurs in the seat belt pretensioner
operation, contact the SERVICE DEPT. of TOYOTA MOTOR SALES, U.S.A.,INC. When disposing
of a front seat outer belt (with seat belt pretensioner) activated in a collision, follow the same
procedure given in step 1-(e) in "DISPOSAL".
CAUTION:
- Never dispose of front seat outer belt which has an inactivated pretensioner.
- The seat belt pretensioner produces a sizeable exploding sound when it activates, so perform the
operation out-of-door and where it will not create a nuisance to nearby residents.
- When activating the seat belt pretensioner, always use the specified SST. (SRS Airbag
Deployment Tool) Perform the operation in a place away from electrical noise.
SST 09082-00700,09082-00740
- When activating a front seat outer belt (with seat belt pretensioner), perform the operation at least
10 m (33 ft) away from the front seat outer belt.
- Use gloves and safety glasses when handling a front seat outer belt with activated pretensioner.
- Always wash your hands with water after completing the operation.
- Do not apply water, etc. to a front seat outer belt with activated pretensioner.
1. SEAT BELT PRETENSIONER ACTIVATION WHEN SCRAPPING VEHICLE
HINT: Have a battery ready as the power source to activate the seat belt pretensioner.
Page 1288
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 2496
Page 3689
1. INSTALL NEW BEARING
a. Using Special Service Tool (SST) and a press, install a new bearing to the steering knuckle.
SST 09527-17011, 09950-60020 (09951-00910)
b. Using snap ring pliers, install a new snap ring.
2. INSTALL NEW OIL SEAL (OUTSIDE)
a. Using SST and a plastic hammer, install a new oil seal (outside).
SST 09223-15030, 09527-17011
b. Coat MP grease to the oil seal lip.
3. INSTALL AXLE HUB TO STEERING KNUCKLE
a. Install the dust cover to the steering knuckle with the 4 bolts.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)
b. Using SST and a press, install the axle hub to the steering knuckle.
SST 09649-17010
4. INSTALL ABS SPEED SENSOR ROTOR (w/ ABS)/SPACER (w/o ABS)
NOTICE: Do not scratch the serration of the speed sensor rotor.
5. 2WD: INSTALL NEW LOCK NUT
a. Using SST install and torque a new lock nut to the axle hub.
SST 09318-12010 Torque: 274 Nm (2,800 kgf-cm, 203 ft. lbs.)
b. Using a chisel and hammer, stake the lock nut.
Page 2643
Terminals Of ECU - Connector Pinouts (Part 2)
Page 5593
Splice Location
B11
Page 4102
Torque: 50 N.m (510 kgf.cm, 37 ft.lbf)
25. Install shock absorber with coil spring.
A. Install the upper side of shock absorber to the chassis frame with the 3 nuts.
Torque: 64 N.m (650 kgf.cm, 47 ft.lbf)
B. Connect the lower side of shock absorber to the lower suspension arm with bolt, washer, and
nut.
Torque: 135 N.m (1,400 kgf.cm, 100 ft.lbf)
26. Inspect and install the brake rotor and install the brake caliper with new mounting bolts.
A. Inspect the brake rotors and machine using an on-the-car brake lathe. Replace the rotor if it is
below minimum thickness values
Minimum Thickness: 26.0 mm (1.024 in.)
NOTE:
It is necessary to turn the rotors using the on-the-car brake lathe to ensure even and uniform rotor
run out. DO NOT turn the rotor using an off-the-car brake lathe.
B. Install the disc, brake caliper, and 2 NEW bolts.
Torque: 123 N.m (1,259 kgf.cm, 90 ft.lbf)
C. Install the brake line clamp to the steering knuckle with the bolt.
Torque: 28 N.m (285 kgf.cm, 21 ft.lbf)
27. Install new brake line.
Using the SST, connect NEW brake line.
SST P/N: 09023-00100
Torque: 15 N.m (155 kgf.cm, 11 ft.lbf)
28. With ABS:
Connect the ABS speed sensor and wire harness clamp to the steering knuckle with the 2 bolts.
Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
29. 4WD:
Install drive shaft lock nut.
A. While applying the brakes, tighten the nut.
Torque: 235 N.m (2,400 kgf.cm, 173 ft.lbf)
B. Install the lock cap and a NEW cotter pin. If the holes for the cotter pin are not aligned, tighten
the nut further up to 600.
30. 2WD:
Install grease cap.
31. Install front wheel.
NOTE:
Do NOT use an air wrench.
Torque: 110 N.m (1,150 kgf.cm, 83 ft.lbf)
Diagrams
Front Door Window Glass: Diagrams
Front Door (Part 1)
Page 6238
Steps 1 - 3
Removal and Installation
Starter Motor: Service and Repair Removal and Installation
Starter (Part 1)
Page 6123
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Parts Information
Repair Procedure
1. Remove the seat cushion cover following the instructions in the FRONT SEAT (Separate Type:
Power Adjuster) section of the applicable service manual.
2. Apply one piece of 1 mm thick felt tape (80 mm x 40 mm) to the seat cushion frame in the
location shown below.
3. Reassemble the front seat with the new seat cushion cover.
NOTE:
Do not use air tools when installing the seat assembly back into the vehicle.
Page 2907
Non-Waterproof Type Connector
"Case 1" Raise the terminal retainer up to the temporary lock position.
Non-Waterproof Type Connector
"Case 2" Open the secondary locking device.
Page 820
INSPECT PASSENGER'S DOOR POWER WINDOW SWITCH CONTINUITY
If continuity is not as specified, replace the switch.
INSPECT POWER WINDOW MASTER SWITCH CIRCUIT
Disconnect the connector from the master switch and inspect the connector on the wire harness
side.
* Exceptions: During 60 seconds after the ignition switch is turned ON to OFF (ACC) or until driver
or a passenger's door is opened after the ignition switch is turned ON to OFF (ACC).
If the circuit is not as specified, inspect the circuits connected to other parts.
Page 1741
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 5302
Hose/Line HVAC: Tools and Equipment
A/C Clamp Remover
AST tool# TOY 200
Page 5800
Wiring Harness Connector
E: Indicates the wiring harness and wiring harness connector. The wiring harness with male
terminal is shown with arrows.
Outside numerals are pin numbers.
The first letter of the code for each wiring harness and wiring harness connector(s) indicates the
component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and
Surrounding area, and "B" for the Body and Surrounding area.
When more than one code has the first and second letters in common, followed by numbers (e.g,
IH1, IH2), this indicates the same type of wiring harness and wiring harness connector.
F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in
parts position.
G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside
it). Junction Blocks are shaded to clearly separate
them from other parts.
H: When 2 parts both use one connector in common, the parts connector name used in wire
routing is shown in square brackets [ ].
Wiring Color
I: Indicates the wiring color.
Wire colors are indicated by an alphabetical code.
B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR =
Brown SB = Sky Blue LG = Light Green GR = Gray
The first letter indicates the basic wire color and the second letter indicates the color of the stripe.
Page 2692
Crankshaft Position Sensor: Service and Repair
Crankshaft Position Sensor
REMOVAL
1. REMOVE ENGINE UNDER COVER
Front
Fluid - Differential: Service and Repair Front
FILL DIFFERENTIAL WITH HYPOID GEAR OIL
Page 1954
Page 2637
B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(Connect the Relay) and SW 2 OFF (or Disconnect SW 2)
D. Disconnect and reconnect the connectors while watching the test light.
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
E. Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION:
a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals
are touched, the IC may be destroyed by
static electricity.)
b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact
with the terminals of leads from the IC, etc. of the replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
Special Tool
1. PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown.
2. DISCONNECT CONNECTOR
3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
a. Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the
secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
A: For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
Page 715
Camshaft Position Sensor: Service and Repair
Camshaft Position Sensor
REMOVAL
1. DRAIN ENGINE COOLANT
2. REMOVE DRIVE BELT
3. REMOVE LH NO.3 TIMING BELT COVER
Page 3548
1. REMOVE PIPE Loosen the 2 clips and disconnect the 2 hoses. 2. REMOVE OIL COOLER
a. Remove the 3 bolts and oil cooler.
Torque: 11 Nm (115 kgf-cm, 8 ft. lbs.)
b. Remove the bolt, transmission oil cooler bracket and grommet.
Torque: 4.9 Nm (50 kgf-cm, 43 inch lbs.)
c. Remove the 2 grommets and condenser mounting insulators.
3. REMOVE OIL COOLER TUBE
a. Loosen the 2 clips and disconnect the 2 hoses. b. Remove the bolt and oil cooler tube with the 2
hoses.
Torque: 5.0 Nm (50 kgf-cm, 48 inch lbs.)
c. Loosen the 2 clips and disconnect the 2 hoses.
INSTALLATION
Installation is in the reverse order of removal).
HINT: After installation, check fluid level.
Locations
EFI Main Relay: Locations
Engine Room R/B
Page 4634
Fuse Block: Diagnostic Aids
Voltage Check
Voltage Check
Voltage Check
A. Establish conditions in which voltage is present at the check point.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(SW 2 OFF)
B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or
component terminal. This check can be done with a test light instead of a voltmeter.
Continuity and Resistance Check
Continuity and Resistance Check
Continuity And Resistance Check
A. Disconnect the battery terminal or wire so there is no voltage between the check points. B.
Contact the two leads of an ohmmeter to each of the check points.
Page 6539
Instrument Panel
Ground Location
IE Left Kick Panel
IF Left Kick Panel
IG Instrument Panel Brace RH
IH Right Kick Panel
II Right Kick Panel
Body
Ground Location (Access Cab)
Page 5580
b. Push the secondary locking device or terminal retainer in to the full lock position.
5. CONNECT CONNECTOR
Disconnection of Male and Female Connectors
Disconnection of Male and Female Connectors
Disconnection Of Male And Female Connectors
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Page 5070
Page 1147
ERROR: stackunderflow
OFFENDING COMMAND: ~
STACK:
Page 3753
The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit
breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery
power is supplied to each system are explained. Since all System Circuit diagrams start from the
power source, the power source system must be fully understood.
Page 4754
Non-Waterproof Type Connector
"Case 1" Raise the terminal retainer up to the temporary lock position.
Non-Waterproof Type Connector
"Case 2" Open the secondary locking device.
Page 2808
O2S Application Table
O2S Failure Threshold Charts
Testing and Inspection
Power Mirror Switch: Testing and Inspection
Left side
INSPECT MIRROR SWITCH INSPECTION
Right side
INSPECT MIRROR SWITCH INSPECTION
If continuity is not as specified, replace the switch.
Page 5869
Wheel Opening Moulding
Page 2556
During ECU flash reprogramming, the Error screen shown may be displayed on the Diagnostic
Tester for one of the following reasons:
1. Immobilizer key not properly registered or auto-registration mode left open.
2. Ignition ON/OFF cycling not followed correctly during the flash reprogramming procedure.
3. The Diagnostic Tester cable is damaged, causing an open communication circuit.
NOTE:
The Diagnostic Tester may operate properly in other modes such as OBD, OBDII, or CARB, with a
damaged cable.
To eliminate the possibility of the first 2 reasons causing the error message, do the following:
1. Confirm the Immobilizer Transponder Master Key is properly registered and auto registration
mode is closed. Follow the appropriate Repair Manual procedure and consult TSB SS001-99,
"Scan tool Immobilizer key Code Utility
2. Conduct the ECU flash reprogramming process explicitly following key operation instructions.
Refer to TSB SS002-01, "ECU Flash Reprogramming Process, "for more details.
To determine if the Diagnostic Tester cable is damaged, follow the test procedures below to check
the electrical integrity of the cable. Conduct all continuity tests with an Ohm meter. For all five test
procedures, the resistance values must be below 6.0 ohms to pass.
Test CABLE TEST 1.
Page 4218
12. 2WD: REMOVE LOCK NUT AND ABS SPEED SENSOR ROTOR (W/ABS) OR SPACER (W/O
ABS)
Using a chisel and hammer, loosen the staked part of the lock nut.
NOTE:
Be careful not to damage the bushing.
A. Using the following SST, remove the lock nut.
^ 00002-00909 (09318-12010)
NOTE:
Do NOT use air wrench.
B. Remove the ABS speed sensor rotor or spacer.
NOTE:
Take care not to scratch the serration of the speed sensor rotor.
13. REMOVE AXLE HUB FROM STEERING KNUCKLE
A. Remove the 4 bolts and shift the dust cover toward the hub side (outside).
B. Using the following SSTs, remove the axle hub from the steering knuckle.
^ 09710-28012-01 (09710-07031)
^ 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04031,
09957-04010, 09958-04011)
HINT
If necessary, use a press to remove the axle hub from the steering knuckle.
C. Remove the dust cover from the steering knuckle.
D. 4WD: Remove the bearing spacer and ABS speed sensor rotor (W/ABS) or spacer (W/O ABS).
NOTE:
Take care not to scratch the serration of the speed sensor rotor.
Page 3220
Splice Location
I1 Cowl Wire
I2 Cowl Wire
I3 Cowl Wire
I4 Cowl Wire
I5 Cowl Wire
I6 Cowl Wire
I7 Engine Wire
I8 Engine Wire
I9 Engine Wire
I10 Engine Wire
I11 Engine Wire
I12 Engine Wire
I13 Engine Wire
I14 Engine Wire
I15 Engine Wire
I16 Cowl Wire
Body
Splice Location (Access Cab)
B1 Speaker Tweeter Wire LH
B2 Front Door LH Wire
B3 Front Door LH Wire
B4 Roof Wire
B5 Speaker Tweeter Wire RH
B6 B7
Front Door RH Wire
B8 Front Door RH Wire
B9 Rear Door No. 1 Wire RH
B10 Frame Wire
Page 352
Torque: 20.4 N.m (208 kgf.cm, 15 ft.lbf)
b. Connect the ECT sensor connector.
8. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS
a. Install a new gasket and the throttle body with the 2 bolts and 2 nuts.
Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)
b. Connect the accelerator cable to the throttle body.
9. REINSTALL INTAKE AIR CONNECTOR
10. REFILL WITH ENGINE COOLANT
11. REINSTALL THROTTLE BODY COVER
A/T - Fluid Requirements
Fluid - A/T: Technical Service Bulletins A/T - Fluid Requirements
TRANSMISSION & CLUTCH TC001-02
May 24, 2002
Title: AUTOMATIC TRANSMISSION FLUID REQUIREMENTS
Models: All '00 - '02 Models & '03 Corolla & Matrix
Introduction
Please refer to the table for correct application of Dexron(R) III (Dexron(R) II) and Toyota Type T-IV
Automatic Transmission Fluids or equivalent.
Parts Information
Warranty Information
Page 3966
6. INSPECT LIMIT SWITCH CONTINUITY
a. Start the engine and raise the vehicle. b. With the actuator connector connected, shift the
transfer shift lever and after checking the operating sound, disconnect the connector and
inspect the continuity between each terminal.
HINT: When shifting the actuator fork shaft, connect the connectors.
7. INSPECT VEHICLE SPEED SENSOR 8. INSPECT 4HI AND 4LO INDICATOR LIGHT Check
the combination meter.
9. INSPECT 4WD CONTROL ECU
Connect the wire harness side connector to the 4WD control ECU and inspect wire harness side
connector from the back side.
Page 1590
Required SSTs
Radiator Cap Identification Procedure
1. Use the illustration below to identify the vehicle's radiator cap type and kPa rating.
2. Proceed to the required inspection procedure for the radiator cap and kPa rating.
Radiator Cap Inspection Procedure
Type: N-cap, 88 kPa
1. Remove coolant and any foreign material on rubber points "A," "B," and "C."
2. Check that points "A," "B," and "C" are not deformed, cracked, or swollen.
3. Check that points "C" and "D" are not stuck together.
4. Apply engine coolant to points "B" and "C" before using the radiator cap tester.
^ Radiator Cap Tester: Snap-On/Sun P/N SVTS262A (or equivalent)
Page 4665
Relay Box: Diagnostic Aids
Voltage Check
Voltage Check
Voltage Check
A. Establish conditions in which voltage is present at the check point.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(SW 2 OFF)
B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or
component terminal. This check can be done with a test light instead of a voltmeter.
Continuity and Resistance Check
Continuity and Resistance Check
Continuity And Resistance Check
A. Disconnect the battery terminal or wire so there is no voltage between the check points. B.
Contact the two leads of an ohmmeter to each of the check points.
Engine/Transmission Controls - Resetting ECM Memory
Engine Control Module: All Technical Service Bulletins Engine/Transmission Controls - Resetting
ECM Memory
TRANSMISSION & CLUTCH TC002-03 REVISED
Title: ECM RESET MEMORY FUNCTION
Models: '00 - '05 All Models
June 10, 2003
TSB REVISION NOTICE:
^ December 20, 2004: Applicable Vehicles section has been updated - 2004 and 2005 model years
added, models and model years updated for various models; and Reset Procedure 2 has been
revised.
^ January 16, 2004: Tundra vehicles were added to the Applicable Vehicles chart.
^ December 17, 2003: T-100 vehicles were removed from the Applicable Vehicles chart.
Previous versions of this TSB should be discarded.
Introduction
Whenever an automatic transmission is replaced, overhauled or individual components are
replaced, use this procedure to clear Engine Control Module ( ECM, SAE term: Powertrain Control
Module, PCM) "Learned Values" to minimize subsequent performance concerns.
CAUTION:
Failure to follow the procedure below may lengthen the time to readjust the ECM "Learned Values,"
potentially resulting in performance concerns.
Required SSTs
Warranty Information
Applicable Vehicles
Page 753
Impact Sensor: Service and Repair Airbag Sensor Connectors
DISCONNECTION
a. While holding both flank sides of the outer, slide the outer to the direction directed by an arrow.
b. Lock of the connectors is released, then disconnect the connectors.
HINT: Be sure to hold both flank sides of the outer. If holding the top or bottom sides, it will obstruct
disconnection.
CONNECTION
a. Align the male connector (on the side of sensor) and female connector in the same direction as
shown in the illustration and fit in them without
rubbing.
b. As they are fitted in, the outer slides rearward. Press it until the outer returns to its original
position again.
If fitting stops half way, connectors will separate.
c. Be sure to insert until they are locked. After fitting in, pull them slightly to check that they are
locked (When locked, make sure that the outer
returns to its original position and sound at the time of fitting in can be heard.).
HINT: Do not fit in while holding the outer.
- When fitting in, the outer slides. Do not touch it.
Page 6741
Brake Light Switch: Pinout Values and Diagnostic Parameters
ABS
A6, A7 ABS SPEED SENSOR FRONT LH, RH
1 - 2 : 1.40 - 1.80 kOhms (20°C, 68°F)
A19 ABS SPEED SENSOR REAR
1 - 2 : 0.89 - 1.29 kOhms (20°C, 68°F)
3 - 4 : 0.89 - 1.29 kOhms (20°C, 68°F)
A5 ABS ACTUATOR WITH ECU
6 - GROUND : 10 - 14 volts with ignition SW at ON or ST position
24 - GROUND : 10 - 14 volts with stop light SW on (Brake pedal depressed)
2, 18 - GROUND : Always continuity
S4 STOP LIGHT SW
2 - 1 : Closed with brake pedal depressed
Locations
Impact Sensor: Locations
Front Airbag Sensor
Page 5449
Step 5
INSPECTION PROCEDURE
Page 1330
Oil Filter: Tools and Equipment
Toyota Oil Filter Wrench Set
AST tool# TOY 300
This set includes our tool numbers TOY640, TOY730, and M0219. With the TOY300 you have
every gas engine Toyota/Lexus model covered between 1980 and 2009.
- Covers all Toyota and Lexus vehicles 1980-2009, based on factory filters.
Contact AST for pricing.
Assenmacher Specialty Tools 1-800-525-2943
This Kit Contains the Following Tools:
TOY 640 - Toyota Oil Filter Wrench
Page 2754
CHART 7
Page 6308
Instrument Panel
Connector Location
IA1 Engine Room Main and Cowl Wire (Left Kick Panel)
IA2 Engine Room Main and Cowl Wire (Left Kick Panel)
IA3 Engine Room Main and Cowl Wire (Left Kick Panel)
IA4 Engine Room Main and Cowl Wire (Left Kick Panel)
IB1 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IB2 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IB3 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IC1 Cowl Wire and Roof Wire (Left Side of Instrument Panel)
Instrument Panel
Connector Location
ID1 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH)
ID2 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH)
IE1 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IE2 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IE3 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IF1 Front Door RH Wire and Cowl Wire (Right Kick Panel)
IF2 Front Door RH Wire and Cowl Wire (Right Kick Panel)
IF3 Front Door RH Wire and Cowl Wire (Right Kick Panel)
Diagram Information and Instructions
Auxiliary Power Outlet: Diagram Information and Instructions
Key to Diagrams
A: System Title
B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to
distinguish it from the J/B
Example: 1 Indicates Relay Block No.1
C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type,
or specification is different.
D: Indicates related system.
Page 6336
Splice Location
I1 Cowl Wire
I2 Cowl Wire
I3 Cowl Wire
I4 Cowl Wire
I5 Cowl Wire
I6 Cowl Wire
I7 Engine Wire
I8 Engine Wire
I9 Engine Wire
I10 Engine Wire
I11 Engine Wire
I12 Engine Wire
I13 Engine Wire
I14 Engine Wire
I15 Engine Wire
I16 Cowl Wire
Body
Splice Location (Access Cab)
B1 Speaker Tweeter Wire LH
B2 Front Door LH Wire
B3 Front Door LH Wire
B4 Roof Wire
B5 Speaker Tweeter Wire RH
B6 B7
Front Door RH Wire
B8 Front Door RH Wire
B9 Rear Door No. 1 Wire RH
B10 Frame Wire
Testing and Inspection
Refrigerant Pressure Sensor / Switch: Testing and Inspection
ON-VEHICLE INSPECTION
1. SET ON MANIFOLD GAUGE SET
2. DISCONNECT CONNECTOR
3. RUN ENGINE AT APPROX. 2,000 rpm
4. SET BLOWER SPEED CONTROL SWITCH TO "HI" POSITION
5. SET TEMPERATURE CONTROL LEVER TO "MAX. COOL" POSITION
6. A/C SWITCH ON
7. INSPECT PRESSURE SWITCH OPERATION
a. Connect the positive (+) lead from the ohmmeter to terminal 1 and negative (-) lead to terminal 2.
b. Check continuity between terminals when refrigerant pressure is changed, as shown in the
illustration.
If operation is not as specified, replace the pressure switch.
Page 4605
Waterproof Type Connector
B: For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White
: Gray
Black or White : Dark Gray
Gray or White : Black
Waterproof Type Connector
"Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up
to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Waterproof Type Connector
"Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 205
E. Confirm the Diagnostic Tester has the appropriate software for the type of calibration file that
was downloaded.
NOTE:
The calibration type is specific to the software version loaded on your Diagnostic Tester. If you
selected the wrong version when downloading the calibration file, you will receive an error when
attempting to install the file on the Diagnostic Tester.
Page 1642
REMOVAL
1. DRAIN ENGINE COOLANT 2. REMOVE TIMING BELT 3. REMOVE NO.2 IDLER PULLEY
Page 1195
Connecting Rod: Service and Repair
For further information regarding this component and the system that it is a part of, please refer to
Cylinder Block Assembly; Service and Repair.
Page 2592
^ 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 2185
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
1. DRAIN ENGINE COOLANT
2. REMOVE THROTTLE BODY COVER
3. REMOVE INTAKE AIR CONNECTOR
4. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS
a. Disconnect the accelerator cable from the throttle body. b. Remove the 2 bolts and 2 nuts, and
disconnect the throttle body from the intake manifold. c. Remove the gasket
5. REMOVE ECT SENSOR
a. Disconnect the ECT sensor connector. b. Remove the ECT sensor and gasket.
6. REINSTALL ECT SENSOR
a. Install a new gasket and the ECT sensor.
Torque: 20.4 N.m (208 kgf.cm, 15 ft.lbf)
b. Connect the ECT sensor connector.
7. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS
a. Install a new gasket and the throttle body with the 2 bolts and 2 nuts.
Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)
b. Connect the accelerator cable to the throttle body.
8. REINSTALL INTAKE AIR CONNECTOR
9. REFILL WITH ENGINE COOLANT
10. REINSTALL THROTTLE BODY COVER
Page 2328
Terminals Of ECU - Connector Pinouts (Part 1)
Intake Manifold Assembly
Intake Manifold: Specifications Intake Manifold Assembly
Intake Manifold
Upper Maximum Warpage ...................................................................................................................
.................................................................... 0.15 mm Lower Maximum Warpage ...............................
........................................................................................................................................................
0.15 mm
Intake Manifold W/ Bolts and Nuts Torque ..........................................................................................
............................................................................................................................... 18 Nm
Page 5724
Wiring Harness Connector
E: Indicates the wiring harness and wiring harness connector. The wiring harness with male
terminal is shown with arrows.
Outside numerals are pin numbers.
The first letter of the code for each wiring harness and wiring harness connector(s) indicates the
component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and
Surrounding area, and "B" for the Body and Surrounding area.
When more than one code has the first and second letters in common, followed by numbers (e.g,
IH1, IH2), this indicates the same type of wiring harness and wiring harness connector.
F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in
parts position.
G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside
it). Junction Blocks are shaded to clearly separate
them from other parts.
H: When 2 parts both use one connector in common, the parts connector name used in wire
routing is shown in square brackets [ ].
Wiring Color
I: Indicates the wiring color.
Wire colors are indicated by an alphabetical code.
B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR =
Brown SB = Sky Blue LG = Light Green GR = Gray
The first letter indicates the basic wire color and the second letter indicates the color of the stripe.
Page 5253
3. REMOVE HEATER CONTROL HOUSING
a. Remove the 5 screws. b. Remove the heater control housing.
4. REMOVE INTEGRATION CIRCUIT
a. Disconnect the 2 connectors. b. Remove the circuit.
5. REMOVE LENS
Release the 3 claws, then remove the lens.
REASSEMBLY
1. INSTALL LENS
Install the lens.
Page 3377
The calibration file contains the Calibration ID number(s) for a specific vehicle ECU (see Figure 1).
NOTE:
The total number of Calibration ID numbers corresponds to the number of reprogrammable
processors in the ECU (see Figure 2).
Operation Procedure
LOCATE CALIBRATION FILE
The following steps in this bulletin describe how to properly flash reprogram an ECU.
1. Locate calibration file on TIS.
Calibration files may be found in two areas (see Figure 3):
A. Search by model and year for a Technical Service Bulletin addressing a specific Product issue.
^ Within the TSB, click on the link for the calibration file.
B. Search by model under the ECU Flash Reprogramming Section.
^ Under the ECU Flash Reprogramming section on TIS, a drop-down list of the latest calibration
files will be displayed.
C. Proceed to step 2 for instructions on how to download the calibration file from TIS to the
Diagnostic Tester Program Card.
Page 3457
Splice Point
J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel,
and "B" for the Body).
The Location of splice Point I5 is shaded.
K: Indicates a shielded cable.
L: Indicates the pin number of the connector.
The numbering system is different for female and male connectors.
M: Indicates a ground point.
The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for
the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body
and Surrounding area.
How to Read Connector List
HOW TO READ CONNECTOR LIST
A: Indicates connector to be connected to a part. (The numeral indicates the pin No.)
Page 6513
Instrument Panel
Connector Location
IA1 Engine Room Main and Cowl Wire (Left Kick Panel)
IA2 Engine Room Main and Cowl Wire (Left Kick Panel)
IA3 Engine Room Main and Cowl Wire (Left Kick Panel)
IA4 Engine Room Main and Cowl Wire (Left Kick Panel)
IB1 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IB2 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IB3 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IC1 Cowl Wire and Roof Wire (Left Side of Instrument Panel)
Instrument Panel
Connector Location
ID1 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH)
ID2 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH)
IE1 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IE2 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IE3 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IF1 Front Door RH Wire and Cowl Wire (Right Kick Panel)
IF2 Front Door RH Wire and Cowl Wire (Right Kick Panel)
IF3 Front Door RH Wire and Cowl Wire (Right Kick Panel)
Page 597
Applicable Vehicles
Page 6357
Terminal Retainer
Push the terminal retainer down to the temporary lock position.
c. Release the locking lug from terminal and pull the terminal out from rear.
4. INSTALL TERMINAL TO CONNECTOR
a. Insert the terminal.
HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug
locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position.
Page 2802
^ O2S TEST RESULTS
A list of the available oxygen sensors will be displayed.
2. Select the desired oxygen sensor and press Enter.
NOTE:
The monitor result of the A/F sensor will not be displayed. If you select "Bank 1-Sensor 1" or Bank
2-Sensor 1" for a vehicle equipped with an A/F sensor, the Diagnostic Tester will display "No
parameter to display."
3. Compare the test results with the values listed in the Failure Threshold Chart.
* Although this procedure references the Toyota Diagnostic Tester, the O2S test results can be
checked using a generic OBD II scantool. Refer to your OBD II scantool operator's manual for
specific procedures.
Comparing O2S Test Results to Failure Thresholds
1. Determine the correct O2S Failure Threshold Chart for your vehicle by looking in the "O2S
Application Table," in this bulletin.
2. Select appropriate year, model, and engine for specified O2S Failure Threshold Chart.
3. Compare O2S test results with the specified O2S Failure Threshold Chart. It may be necessary
to convert O2S test results to a specific measurement unit using the conversion factor that is
supplied in the specified table. See example.
Example:
Page 2988
4. Match the axis of the connector with axis of the pipe, and push in the connector until the
connector makes a "click" sound. In case that the
connections is tight, apply small amount of fresh engine oil on the tip of the pipe.
5. After having finished the connection, check if the pipe and the connector are securely connected
by pulling them. 6. Check if there is any fuel leakage.
h. Observe these precautions when handling nylon tube.
1. Pay attention not to turn the connected part of the nylon tube and the quick connector by force
when connecting them. 2. Pay attention not to kink the nylon tube. 3. Do not remove the EPDM
protector from the outside of the nylon tube. 4. Must not close the piping with the nylon tube by
bending it.
i. Check that there is any fuel leak after maintenance anywhere on the fuel system. 1. Connect a
TOYOTA hand-held tester to the DLC3. 2. Turn the ignition switch ON and push the TOYOTA
hand-held tester main switch ON.
NOTE: Do not start the engine.
3. Select the ACTIVE TEST mode on the TOYOTA hand-held tester. 4. Please refer to the
TOYOTA hand-held tester operator's manual for further details.
Page 4986
2. Check that no one is within 10 m (33 ft) area around the disc wheel which the steering wheel pad
is tied to. 3. Press the SST activation switch and deploy the air-bag.
HINT: The airbag deploys simultaneously as the LED of the SST activation switch lights up.
h. Dispose of the steering wheel pad (with airbag).
CAUTION: The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30
minutes after deployment.
- Use gloves and safety glasses when handling a steering wheel pad with the deployed airbag.
- Always wash your hands with water after completing the operation.
- Do not apply water, etc. to a steering wheel pad with the deployed airbag.
1. Remove the steering wheel pad from the disc wheel. 2. Place the steering wheel pad in a vinyl
bag, tie the end tightly and dispose of it in the same way as other general parts disposal.
Deployment When Scrapping Vehicle
DISPOSAL
HINT: When scrapping vehicle equipped with an SRS or disposing of a steering wheel pad (with
airbag), always first deploy the airbag in accordance with the procedure described. If any
abnormality occurs with the airbag deployment, contact the SERVICE DEPT. of TOYOTA MOTOR
SALES, U.S.A., INC. When disposing of a steering wheel pad with an airbag deployed in a
collision, follow the same procedure given in step (d) in "AIRBAG DEPLOYMENT WHEN
SCRAPPING VEHICLE".
CAUTION:
- Never dispose of a steering wheel pad which has an undeployed airbag.
- The airbag produces a sizeable exploding sound when it deploys, so perform the operation
out-of-doors and where it will not create a nuisance to nearby residents.
- When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool).
Perform the operation in a place away from electrical noise. SST 09082-00700
- When deploying an airbag, perform the operation at least 10 m (33 ft) away from the steering
wheel pad.
Page 5312
Refrigerant: Fluid Type Specifications
Type R-134a
Page 620
CHART 12
CHART 13
System Diagnosis
Air/Fuel Mixture: Testing and Inspection
INSPECTION
HINT: This check is used only to determine whether or not the idle CO/HC complies with
regulations.
1. INITIAL CONDITIONS
a. Engine at normal operating temperature b. Air cleaner installed c. All pipes and hoses of air
induction system connected d. All accessories switched OFF e. All vacuum lines properly
connected f.
SFI system wiring connectors fully plugged
g. Ignition timing checked correctly h. Transmission in neutral position i.
Tachometer and CO/HC meter calibrated by hand
2. START ENGINE 3. RACE ENGINE AT 2,500 RPM FOR APPROXIMATELY 180 SECONDS
4. INSERT CO/HC METER TESTING PROBE AT LEAST 40 cm (1.3 ft) INTO TAILPIPE DURING
IDLING 5. IMMEDIATELY CHECK CO/HC CONCENTRATION AT IDLE AND/OR 2,500 RPM
HINT: When performing the 2 mode (2,500 rpm and idle) test, follow the measurement orders are
prescribed by the applicable local regulations.
If the CO/HC concentration does not comply with regulations, perform troubleshooting in the order
given. a. Check the heated oxygen sensors operation.
b. See the table for possible causes, and then inspect and correct the applicable causes if
necessary.
Page 2038
B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(Connect the Relay) and SW 2 OFF (or Disconnect SW 2)
D. Disconnect and reconnect the connectors while watching the test light.
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
E. Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION:
a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals
are touched, the IC may be destroyed by
static electricity.)
b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact
with the terminals of leads from the IC, etc. of the replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
Special Tool
1. PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown.
2. DISCONNECT CONNECTOR
3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
a. Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the
secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
A: For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
A/C - Insufficient Cabin Cooling
Heater Control Valve: Customer Interest A/C - Insufficient Cabin Cooling
HEATING & AIR CONDITIONING AC004-04
May 20, 2004
Title: POOR PERFORMANCE OF A/C SYSTEM
Models: '01 - '04 Sequoia & '00 - '04 Tundra
May 20, 2004
Introduction Some Sequoia and Tundra vehicles may exhibit a condition where the air conditioning
system does not sufficiently cool the cabin. Adjustment of the water control valve is necessary to
correct the condition.
Applicable ^
2001 - 2004 model year Sequoia vehicles produced BEFORE the Production Vehicles Change
Effective VINs shown below.
^ 2000 - 2004 model year Tundra vehicles produced BEFORE the Production Change Effective
VINs shown below.
Production Change Information
Warranty Information
Applicable Warranty*:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36
months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Repair Procedure
Page 3351
A. Test J1962 OBDIII CAN Interface Module (P/N 01002744) for continuity.
^ If there is continuity, the cable and CAN Interface Module are OK. Re-check Cable Tests 1, 2,
and 3 while wiggling and flexing the cables.
^ If there is no continuity, proceed to CABLE TEST 4.
CABLE TEST 4.
A. Disconnect the CAN Interface Module (P/N 01002744) from the J1962 OBDII cable using a
Phillips screwdriver.
B. Test J1962 OBDII cable (P/N 02003180) for continuity.
^ If there is no continuity, the cable needs to be replaced.
^ If there is continuity, proceed to CAN Interface Module Test 5.
CAN INTERFACE MODULE TEST 5.
Page 3904
The ground points circuit diagram shows the connections from all major parts to the respective
ground points. When troubleshooting a faulty ground point, checking the system circuits which use
a common ground may help you identify the problem ground quickly. The relationship between
ground points (EA, IB and IC) can also be checked this way.
How to Read Power Source
HOW TO READ POWER SOURCE
Page 486
Torque: 20.4 N.m (208 kgf.cm, 15 ft.lbf)
b. Connect the ECT sensor connector.
8. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS
a. Install a new gasket and the throttle body with the 2 bolts and 2 nuts.
Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)
b. Connect the accelerator cable to the throttle body.
9. REINSTALL INTAKE AIR CONNECTOR
10. REFILL WITH ENGINE COOLANT
11. REINSTALL THROTTLE BODY COVER
Page 4951
Steering Gear: Service and Repair Disassembly and Reassembly
Airbag - Inspection & Replacement After Collision
Repairs and Inspections Required After a Collision: Technical Service Bulletins Airbag - Inspection
& Replacement After Collision
COLLISION REPAIR INFORMATION CRIB110
TITLE: SRS AIRBAG COMPONENT REPLACEMENT
SECTION: ELECTRICAL BULLETIN # 110
MODELS: TOYOTA
DATE:
The SRS Airbag system is an important safety feature of Toyota vehicles. It supplements the
vehicle seat belt system by providing additional protection to vehicle occupants in the event of a
severe frontal or side collision (it equipped with side airbags).
In order to assure correct system operation it is necessary to replace certain components of the
airbag system following a collision. In order to assist technicians in determining which components
should be inspected tested or replaced the repair manual information has been organized in the
attached matrix and replacement notes.
Even in cases of a minor collision where the SRS does not deploy, the steering wheel pad, front
passenger airbag assembly, side airbag assembly, airbag sensor assembly, and side airbag
sensor assembly should be inspected and diagnostic tests should be performed. Always refer to
the Toyota service repair manual for the correct diagnostic and repair procedures.
The attached SRS airbag component replacement information includes: ^ A matrix indicating
components requiring replacement inspection or testing after the deployment of the driver and/or
passenger SRS airbag. ^ Component replacement notes.
CAUTION: SRS Airbag service work can only be performed AFTER 90 seconds from the time the
ignition switch is turned to the "lock" position and the negative (-) terminal cable is disconnected
from the battery.
Page 4013
Wheel Speed Sensor: Service and Repair Speed Sensor, Rear
REMOVAL
1. DISCONNECT SPEED SENSOR CONNECTOR
2. REMOVE SPEED SENSOR
(a) Remove the 2 clamp bolts, clamp nut and 5 resin clips holding the sensor wire harness from the
axle and the fuel tank.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)
HINT: When installing the rear sensor wire harness, never use the removed resin clips, which are service
parts.
- When replacing clips, set up new resin clips at the same angle of the removed resin clips.
(b) Remove the bolt and speed sensor from the axle carrier.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
INSTALLATION
Installation is in the reverse order of removal.
HINT: After installation, check speed sensor signal.
Page 5795
Instrument Panel
Connector Location
IA1 Engine Room Main and Cowl Wire (Left Kick Panel)
IA2 Engine Room Main and Cowl Wire (Left Kick Panel)
IA3 Engine Room Main and Cowl Wire (Left Kick Panel)
IA4 Engine Room Main and Cowl Wire (Left Kick Panel)
IB1 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IB2 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IB3 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IC1 Cowl Wire and Roof Wire (Left Side of Instrument Panel)
Instrument Panel
Connector Location
ID1 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH)
ID2 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH)
IE1 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IE2 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IE3 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IF1 Front Door RH Wire and Cowl Wire (Right Kick Panel)
IF2 Front Door RH Wire and Cowl Wire (Right Kick Panel)
IF3 Front Door RH Wire and Cowl Wire (Right Kick Panel)
Locations
Fuel Pump Resistor
Specifications
Wheel Bearing: Specifications
On models with serviceable wheel bearings, use a Lithium Multipurpose Grease.
Page 3160
Knock Sensor: Service and Repair
1. REMOVE THROTTLE BODY COVER
2. REMOVE INTAKE AIR CONNECTOR
3. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS
4. REMOVE UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY
5. INSPECT KNOCK SENSOR 1,2
Disconnect the knock sensor connectors.
1. REPLACE THE SENSOR WITH SST.
SST 09816-30010
Torque: 45 N.m (450 kgf.cm, 33 ft.lbf)
Reconnect the knock sensor connectors.
2. REINSTALL UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY
3. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS
4. REINSTALL INTAKE AIR CONNECTOR
5. REINSTALL THROTTLE BODY COVER
Page 1964
A/F and 02 Sensor Identification
Instruments - Oil Pressure Gauge Reads Abnormally Low
Oil Pressure Sender: All Technical Service Bulletins Instruments - Oil Pressure Gauge Reads
Abnormally Low
ELECTRICAL EL017-03
December 23, 2503
Title OIL PRESSURE GAUGE READS LOW
Models '01 - '04 Sequoia & '00 - '02 Tundra
TSB UPDATE NOTICE:
This TSB updates EL006-03. TSB EL006-03 is now obsolete and should be discarded.
Introduction
Some customers with Sequoia or Tundra vehicles may encounter an oil pressure gauge that reads
abnormally low at idle. An updated oil pressure sender has been created to address this condition.
Applicable Vehicles ^
2001 - 2004 model year Sequoia vehicles produced BEFORE the Production Change Effective
VINs shown below.
^ 2000 - 2002 model year Tundra vehicles produced BEFORE the Production Change Effective
VIN shown below.
Production Change Information
Parts Information
Repair Procedure
1. Replace the Oil Pressure Sender.
2. Verify proper operation of the Oil Pressure Gauge.
Warranty Information
Applicable Warranty*:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36
months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Page 3236
Transmission Mode Indicator - A/T: Diagnostic Aids
Voltage Check
Voltage Check
Voltage Check
A. Establish conditions in which voltage is present at the check point.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(SW 2 OFF)
B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or
component terminal. This check can be done with a test light instead of a voltmeter.
Continuity and Resistance Check
Continuity and Resistance Check
Continuity And Resistance Check
A. Disconnect the battery terminal or wire so there is no voltage between the check points. B.
Contact the two leads of an ohmmeter to each of the check points.
Page 2883
Throttle Position Sensor: Testing and Inspection
ON-VEHICLE INSPECTION
1. REMOVE THROTTLE BODY COVER
2. INSPECT SYSTEM OPERATION
a. Check that the throttle linkage moves smoothly.
b. Inspect the throttle control motor for operating sound.
1. Turn the ignition switch ON. 2. When turning the accelerator pedal position sensor lever, check
the running sound of the motor. Also, check that there is no friction sound.
If operation is not as specified, check the throttle control motor (See step 3), wiring and ECM.
c. Inspect the accelerator pedal position sensor.
1. Connect the TOYOTA hand-held tester to the DLC3. 2. Check that the MIL does not light up. 3.
When turning the accelerator pedal position sensor lever to the full-open position, check that the
throttle valve opening percentage
(THROTTLE POS) of the CURRENT DATA shows the standard value.
Standard throttle valve opening percentage: 60 % or more
If operation is not as specified, check that the accelerator pedal position sensor (See step 5), wiring
and ECM.
Locations
Daytime Running Lamp Relay: Locations
Instrument Panel
Page 2631
The ground points circuit diagram shows the connections from all major parts to the respective
ground points. When troubleshooting a faulty ground point, checking the system circuits which use
a common ground may help you identify the problem ground quickly. The relationship between
ground points (EA, IB and IC) can also be checked this way.
How to Read Power Source
HOW TO READ POWER SOURCE
Electrical Specifications
Resistance
Page 3234
Glossary Of Terms And Symbols (Part 1)
Page 4863
2. CHECK STEERING FLUID PRESSURE
a. 5VZ-FE engine: Remove the air cleaner assembly. b. 2UZ-FE engine: Remove the air cleaner
assembly with air cleaner hose. c. Disconnect the pressure feed tube from the PS vane pump. d.
Connect Special Service Tool (SST), as shown in the illustration.
SST 09640-10010 (09641-01010, 09641-01030, 09641-01060)
NOTICE: Check that the valve of the SST is in the open position.
e. Bleed the power steering system. f.
Start the engine and run it at idle.
g. Turn the steering wheel from lock to lock several times to boost fluid temperature.
Fluid temperature: 80°C (176°F)
h. With the engine idling, close the valve of the SST and observe the reading on the SST.
Minimum fluid pressure: 8,336 kPa (85 kgf/cm2, 1,209 psi)
NOTICE: ^
Do not keep the valve closed for more than 10 seconds.
^ Do not let the fluid temperature become too high.
i. With the engine idling, open the valve fully.
Description and Operation
Braking Sensor/Switch: Description and Operation
Stop Light Switch
This stop light switch senses whether the brake pedal is depressed or released, and sends the
signal to the ECU.
Engine - Accessory Drive Belt Squealing Noise
Drive Belt: Customer Interest Engine - Accessory Drive Belt Squealing Noise
ENGINE EG026-06 REVISED
Title: 2UZ-FE ACCESSORY DRIVE BELT NOISE
Models: '00 - '06 Tundra
April 21, 2006
TSB REVISION NOTICE:
^ July 9, 2007: The Introduction has been updated. Production Change Effective VINs have been
updated in the Production Change Information table. In the Repair Procedure steps 12 and 13 and
the illustration below step 13 have been updated, and steps 14 - 17 have been renumbered.
Previous versions of this TSB should be discarded.
Introduction
Some customers may experience an abnormal squeal noise from the engine accessory drive belt
area, usually during cold start-up. An improved accessory drive belt tensioner, A/C compressor
bracket, and revised installation procedure have been developed to address this condition.
Applicable Vehicles
^ 2000 - 2006 model year Tundra vehicles produced BEFORE the Production Change Effective
VINs shown below.
Production Change Information
Parts Information
Warranty Information
Applicable Warranty* This repair is covered under the Toyota Comprehensive Warranty. This
warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's
in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Repair Procedure
Testing and Inspection
Four Wheel Drive Indicator Lamp: Testing and Inspection
5VZ-FE: INSPECT "4Lo/4Hi", 4WD" INDICATOR LIGHT a. Disconnect the connectors from the
ADD actuator. b. "4WD" indicator: Ground terminal 3 on the wire harness side connector. c. Turn
the ignition switch ON, check that the warning light lights up.
If the warning light does not light up, inspect the bulb or wire harness.
2UZ-FE: INSPECT "4Lo/4Hi", "4WD" INDICATOR LIGHT a. Remove the center cluster finish
panel. b. Disconnect the connectors from the center cluster integration. c. "4Lo" indicator: Ground
terminal 3 on the wire harness side connector. d. "4Hi" indicator: Ground terminal 2 on the wire
harness side connector.
Testing and Inspection
Backup Lamp Switch: Testing and Inspection
INSPECT BACK-UP LIGHT SWITCH CONTINUITY If continuity is not as specified, replace the
switch.
Page 6529
Waterproof Type Connector
B: For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White
: Gray
Black or White : Dark Gray
Gray or White : Black
Waterproof Type Connector
"Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up
to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Waterproof Type Connector
"Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 4054
21. 4WD:
Using the following SSTs and a press, install the bearing spacer.
SST P/N: 09950-60010 (09951-00650)
SST P/N: 09950-70010 (09951-07150)
22. 4WD:
Install new oil seal (inside).
A. Using the following SST and a plastic hammer, install a NEW oil seal (inside).
SST P/N: 09527-17011
NOTE:
Lightly strike the SST on its circumference evenly.
B. Coat MP grease to the oil seal lip.
23. Install steering knuckle.
A. 4WD:
Insert the drive shaft into the axle hub and temporarily tighten the nut.
NOTE:
Be careful not to damage the oil seal and drive shaft boot.
B. Connect the steering knuckle to the upper suspension arm.
C. Install the nut and a NEW cotter pin. If the holes for the cotter pin are not aligned, tighten the nut
further up to 600.
Torque: 105 N.m (1,100 kgf.cm, 77 ft.lbf)
24. Connect the lower ball joint to the steering knuckle with 4 bolts.
Page 2848
If you have no TOYOTA hand-held tester, measure voltage between terminals VPA and E2 of the
ECM connector.
d. Inspect the air assist system.
1. Start the engine and check that the MIL does not light up. 2. Allow the engine to warm up to
normal operating temperature. 3. Turn the A/C compressor ON to OFF, and check the idle speed.
Idle speed (Transmission in neutral): 700 ± 50 rpm
NOTE: Perform inspection under condition without electrical load.
e. After checking the above (b) to (d), perform the driving test and check that there is no sense of
incongruity.
3. INSPECT THROTTLE CONTROL MOTOR
a. Disconnect the throttle control motor connector. b. Using an ohmmeter, measure the motor
resistance between terminal 1 (M+) and 2 (M-).
Motor resistance: 0.3 - 100 ohms at 20 °C (68 °F)
If the resistance is not as specified, replace the throttle control motor.
c. Using an ohmmeter, measure the clutch resistance between terminal 3 (CL-) and 4 (CL+).
Clutch resistance: 4.2 - 5.2 ohms at 20 °C (68 °F)
If the resistance is not as specified, replace the throttle control motor.
d. Reconnect the throttle control motor connector.
Page 4985
2. Move the SST to at least 10 m (33 ft) away from the steering wheel pad tied down on the disc
wheel.
f. Cover the steering wheel pad with a cardboard box or tires.
- Covering method using a cardboard box: Cover the steering wheel pad with the cardboard box
and weight the cardboard box down in 4 places with at least 190 N (20 kg, 44 lb).
Size of cardboard box. Must exceed the following dimensions: X = 460 mm (18.11 in.) Y = 650 mm
(25.59 in.)
NOTE: When dimension Y of the cardboard box exceeds the diameter of the disc wheel with tire to which
the steering wheel pad is tied, X should be the following size. X = 460 mm (18.11 in.) + width of tire
- If a cardboard box smaller than the specified size is used, the cardboard box will be broken by the
shock from the airbag deployment.
- Covering method using tires: Place at least 3 tires without disc wheel on top of the disc wheel with
tire to which the steering wheel pad is tied.
Tire size: Must exceed the following dimension- Width: 185 mm (7.87 in.) Inner diameter: 360 mm
(14.17 in.)
CAUTION: Do not use tires with disc wheels.
NOTE: The tires may be marked by the airbag deployment, so use the redundant tires.
g. Deploy the airbag.
1. Connect the SST red clip to the battery positive (+) terminal and the black clip to the battery
negative (-) terminal.
Page 5956
Page 2812
CHART 7
Page 4990
HINT: Have a battery ready as the power source to deploy the airbag.
a. Remove the steering wheel pad.
CAUTION: When storing the steering wheel pad, keep the upper surface of the pad facing upward.
b. Using a service-purpose wire harness, tie down the steering wheel pad to the disc wheel.
Wire harness: Stripped wire harness section 1.25 Sq.mm or more (0.0019 Sq.in.. or more)
CAUTION: If a wire harness which is too thin or some other thing is used to tie down the steering
wheel pad, it may be snapped by the shock when the airbag is deployed. This is highly dangerous.
Always use a wire harness for vehicle use which is at least 1.25 Sq.mm (0.0019 Sq.in).
HINT: To calculate the square of the stripped wire harness section: Square = 3.14 x (Diameter)2
divided by 4
1. Install the 2 bolts with washers in the 2 bolt holes in the steering wheel pad.
Bolt: L: 35.0 mm (1.387 in.) M: 6.0 mm (0.236 in.) Pitch: 1.0 mm (0.039 in.)
NOTE: Tighten the bolts by hand until the bolts become difficult to turn.
- Do not tighten the bolts too much.
Page 5562
Instrument Panel
Connector Location
IA1 Engine Room Main and Cowl Wire (Left Kick Panel)
IA2 Engine Room Main and Cowl Wire (Left Kick Panel)
IA3 Engine Room Main and Cowl Wire (Left Kick Panel)
IA4 Engine Room Main and Cowl Wire (Left Kick Panel)
IB1 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IB2 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IB3 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IC1 Cowl Wire and Roof Wire (Left Side of Instrument Panel)
Instrument Panel
Connector Location
ID1 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH)
ID2 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH)
IE1 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IE2 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IE3 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IF1 Front Door RH Wire and Cowl Wire (Right Kick Panel)
IF2 Front Door RH Wire and Cowl Wire (Right Kick Panel)
IF3 Front Door RH Wire and Cowl Wire (Right Kick Panel)
Page 4521
6. Select CHARGING from the Main Menu screen and press the SELECT soft key.
7. Select DIAGNOSTIC from the Charge Menu screen and press the SELECT soft key.
8. Select IN VEHICLE and press the NEXT soft key.
9. Select MODEL and press the NEXT soft key.
NOTE:
^ "MODEL" or "STOCK # " MUST be used to receive a warranty code if the tester determines that
the battery is bad.
^ "MODEL" and "STOCK # " are linked to custom algorithms and are the most accurate testing
procedures.
Page 1124
Driver Side J/B And Integration Relay Inner Circuit
Page 4923
The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit
breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery
power is supplied to each system are explained. Since all System Circuit diagrams start from the
power source, the power source system must be fully understood.
Page 4347
B. Slowly apply the PKB while driving until the brake begins to engage and slow the vehicle. Do not
apply the PKB past this point of initial engagement.
NOTE:
Remember with a foot PKB (on automatic transmission), the pedal must be pressed a second time
to disengage the parking brake.
HINT:
When diagnosing a Tundra with a foot PKB, slowly apply the PKB until the first "click". Then press
the PKB pedal a second time so it will disengage when it is released. At this time the PKB can be
pressed to the desired level for continued diagnosis.
C. Hold the PKB at this point of initial engagement for a few seconds to slowly reduce the vehicle
speed and allow adequate time to monitor the ride condition.
D. Disengage the PKB.
E. If brake vibration is felt during step (C), then it indicates that the rear brake drums are one
source of brake vibration on this vehicle.
Refer to TSB No. BR003-02, "Rear Brake Vibration," for parts and repair information relating to
Tundra rear brake vibration.
F. If no vibration is felt during step (C), then the front brake assemblies are the most likely cause of
brake vibration on this vehicle.
G. Determine if TSB BROO4-02 has already been performed.
Repair Procedure No. 1
1. Remove the front wheel.
2. 2WD:
Using a screwdriver and hammer remove the grease cap.
3. 4WD:
Disconnect drive shaft.
A. Remove the cotter pin and lock cap.
B. While applying the brakes, remove the lock nut.
Locations
Hydraulic Control Assembly - Antilock Brakes: Locations
Engine Compartment
Page 2098
Steps 2 - 3
INSPECTION PROCEDURE
HINT:
- DTC P0325 is for the left bank knock sensor circuit.
- DTC P0330 is for the right bank knock sensor circuit.
- Read freeze frame data using TOYOTA hand-held tester or OBD II scan tool, as freeze frame
data records the engine conditions when a malfunction is detected. When troubleshooting it is
useful for determining whether the vehicle was running or stopped, the engine was warmed up or
not, the air-fuel ratio was lean or rich, etc. at the time of the malfunction.
Page 2340
Engine Control Module: Diagnostic Aids
Voltage Check
Voltage Check
Voltage Check
A. Establish conditions in which voltage is present at the check point.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(SW 2 OFF)
B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or
component terminal. This check can be done with a test light instead of a voltmeter.
Continuity and Resistance Check
Continuity and Resistance Check
Continuity And Resistance Check
A. Disconnect the battery terminal or wire so there is no voltage between the check points. B.
Contact the two leads of an ohmmeter to each of the check points.
Page 2794
Page 2214
Waterproof Type Connector
B: For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White
: Gray
Black or White : Dark Gray
Gray or White : Black
Waterproof Type Connector
"Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up
to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Waterproof Type Connector
"Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 4834
Page 4222
Torque: 64 N.m (650 kgf.cm, 47 ft.lbf)
B. Connect the lower side of shock absorber to the lower suspension arm with bolt, washer and
nut.
Torque: 135 N.m (1,400 kgf.cm, 100 ft.lbf)
26. INSPECT AND INSTALL THE BRAKE ROTOR AND INSTALL THE BRAKE CALIPER WITH
NEW MOUNTING BOLTS
A. Inspect the brake rotors, and machine using an on-the-car brake lathe. Replace the rotor if it is
below minimum thickness values Minimum Thickness: 26.0 mm (1.024 in.)
B. Install the disc, brake caliper and 2 NEW bolts.
Torque: 123 N.m (1,259 kgf.cm, 90 ft.lbf)
C. Install the brake line clamp to the steering knuckle with the bolt.
Torque: 28 N.m (285 kgf.cm, 21 ft.lbf)
27. INSTALL NEW BRAKE LINE
Using the SST, connect NEW brake line.
^ 09023-00100
Torque: 15 N.m (155 kgf.cm, 11 ft.lbf)
28. W/ABS: CONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP
Connect the ABS speed sensor and wire harness clamp to the steering knuckle with the 2 bolts.
Torque: 8.0 N.m (82 kgf.cm, 71 in..lbf)
29. 4WD: INSTALL DRIVE SHAFT LOCK NUT
A. While applying the brakes, tighten the nut.
Torque: 235 N.m (2,400 kgf.cm, 173 ft.lbf)
B. Install the lock cap and a NEW cotter pin.
If the holes for the cotter pin are not aligned, tighten the nut further up to 60°.
30. 2WD: INSTALL GREASE CAP
31. INSTALL FRONT WHEEL
NOTE:
Do NOT use air wrench.
Torque: 110 N.m (1,150 kgf.cm, 83 ft.lbf)
32. DEPRESS BRAKE PEDAL SEVERAL TIMES
33. FILL THE BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM
34. CHECK ABS SPEED SENSOR SIGNAL (SEE REPAIR MANUAL)
Page 2135
Spark Plug: Application and ID
Recommended Spark Plugs
DENSO K20R-U
NGK BKR6EYA
Page 2075
Camshaft Position Sensor: Mechanical Specifications
Torque: ................................................................................................................................................
.................................. 7.5 N.m (80 kgf.cm, 66 in.lbf)
Page 215
Terminals Of ECU - Connector Pinouts (Part 1)
Page 6117
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Parts Information
Repair Procedure
1. Remove the seat cushion cover following the instructions in the FRONT SEAT (Separate Type:
Power Adjuster) section of the applicable service manual.
2. Apply one piece of 1 mm thick felt tape (80 mm x 40 mm) to the seat cushion frame in the
location shown below.
3. Reassemble the front seat with the new seat cushion cover.
NOTE:
Do not use air tools when installing the seat assembly back into the vehicle.
Diagram Information and Instructions
Transmission Mode Indicator - A/T: Diagram Information and Instructions
Key to Diagrams
A: System Title
B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to
distinguish it from the J/B
Example: 1 Indicates Relay Block No.1
C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type,
or specification is different.
D: Indicates related system.
Page 2272
B. You have the option to delete calibrations off the tester before downloading a new calibration.
The CUW also provides this option if there is not enough memory for the new calibration. To delete
one or all of the calibrations, follow the screen flow shown (Figure 5).
C. If this is the first time you have downloaded a calibration file from TIS to the Diagnostic Tester
Program Card, you MUST first install the latest version of the Calibration Update Wizard (CUW)
onto your TIS workstation PC, as shown in Figure 6.
This step is also required if you are using a version of CUW earlier than version 6.0. CUW 6.0 is
the only version compatible with Diagnostic Tester software version 10.2a and later. If necessary,
select the link to the TIS Diagnostic Applications Installer and follow the on-screen prompts to
install or reinstall CUW.
Initial Inspection and Diagnostic Overview
Cruise Control: Initial Inspection and Diagnostic Overview
Cruise Control System Check Sheet
Page 2905
Continuity And Resistance Check
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Continuity And Resistance Check
C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the
electrical circuit.
Finding A Short Circuit
Finding A Short Circuit
Finding A Short Circuit
A. Remove the blown fuse and disconnect all loads of the fuse.
Page 5005
Testing and Inspection
Control Module: Testing and Inspection
For further information regarding this component and the system that it is a part of, please refer to
Four Wheel Drive Selector Relay; Testing and Inspection; Procedures.
Page 4031
4. CHECK PEDAL RESERVE DISTANCE
Release the parking brake. With the engine running, depress the pedal and measure the pedal
reserve distance, as shown. Pedal reserve distance from asphalt sheet at 490 N (50 kgf, 110.2 lbs:
More than 95 mm (3.74 inch) If the reserve distance is incorrect, troubleshoot the brake system.
Page 5502
A. Pull out the seat belt about 300 mm and attach a clip as shown in the illustration.
HINT:
Preventing the seat belt from retraction with a clip will make the following work easier.
B. Put the Velcro tape (in the parts kit) through the hole of the shoulder belt anchor, brush-shaped
side to the anchor.
C. Pull both ends of the Velcro tape with your hand and shave off the dirt on the shoulder belt
anchor by moving the Velcro tape several times as shown in the illustration.
NOTE:
Remove the dirt completely. Otherwise, the fluorocarbon resin tape may not adhere properly.
2. INSTALL FLUOROCARBON RESIN TAPE
A. Place the fluorocarbon resin tape onto the seat belt as shown in the illustration.
NOTE:
Page 1431
Testing and Inspection
Temperature Sensor (Gauge): Testing and Inspection
INSPECT ENGINE COOLANT TEMPERATURE SENDER GAUGE RESISTANCE Connect the
wire harness as shown in the illustration, and adjust the ammeter pointer to indicate "0" using the
slide rheostat, then read the rheostat indication.
If resistance value is not as specified, replace the engine coolant sender gauge.
Page 2541
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.
Seat Belt Tongue Plate Stopper
Seat Belt: Service and Repair Seat Belt Tongue Plate Stopper
NOTE: The content of this article/image reflects the changes identified in TSB BO017-07.
Introduction
A new service part for the seat belt tongue plate stopper has been introduced. Installation
procedures are provided to supplement the Repair Procedures.
Installation Procedure
1. Preparation
A. Shift the tongue plate to the upper portion of the tongue plate stopper, and temporarily hold it
with a clip or tape.
B. Remove any pieces of the original tongue plate stopper in the webbing, with a pair of pliers.
CAUTION: Damaged or weakened seat belts may break in an accident and injure the occupant.
The seat belt assembly MUST be replaced if:
- The webbing is cut, frayed, worn, or damaged.
- It has been used in a severe impact.
Inspect the entire length of webbing for damage and replace the assembly if needed. Be careful
NOT to damage the webbing during repair.
2. Install the NEW tongue plate stopper
A. Install a NEW tongue plate stopper in the hole of the webbing.
NOTE: Be sure to install the stopper in the correct direction as shown in the illustration.
Page 3291
a. Ignition switch ON. b. Shift the transmission shift lever in N position. c. Turn the touch select 2-4
switch ON. d. Check that the 4LO indicator lights come on and the 4HI indicator lights go off when
the touch select high-low switch is in ON position. e. Check that the 4LO indicator lights go off and
the 4HI indicator lights come on when the touch select high-low switch is in OFF position.
HINT: Inspection should be performed with the vehicle stopped, and transmission shift lever in N position.
- If switching is not completed after 3 seconds of shift operation, the 4LO indicator light will flash.
3. INSPECT TOUCH SELECT 2 - 4 AND HIGH-LOW SWITCH CONTINUITY
a. Remove center integration panel assembly. b. Inspect the continuity between the each terminals.
Touch select 2-4 switch
Touch select high-low switch:
If continuity is not as specified, replace the center integration panel assembly.
4. INSPECT ACTUATOR RESISTANCE
a. Using an ohmmeter, measure the resistance between terminals 1 and 2.
Standard resistance: 0.3 - 100 Ohms
b. Using an ohmmeter, measure the resistance between terminals 1 or 2 and body ground.
Standard resistance: More than 0.5 M Ohms If resistance value is not as specified, replace the
actuator assembly.
Page 1789
Non-Waterproof Type Connector
"Case 1" Raise the terminal retainer up to the temporary lock position.
Non-Waterproof Type Connector
"Case 2" Open the secondary locking device.
Page 101
Driver Side J/B And Integration Relay
Engine - Accessory Drive Belt Squealing Noise
Drive Belt Tensioner: All Technical Service Bulletins Engine - Accessory Drive Belt Squealing
Noise
ENGINE EG026-06 REVISED
Title: 2UZ-FE ACCESSORY DRIVE BELT NOISE
Models: '00 - '06 Tundra
April 21, 2006
TSB REVISION NOTICE:
^ July 9, 2007: The Introduction has been updated. Production Change Effective VINs have been
updated in the Production Change Information table. In the Repair Procedure steps 12 and 13 and
the illustration below step 13 have been updated, and steps 14 - 17 have been renumbered.
Previous versions of this TSB should be discarded.
Introduction
Some customers may experience an abnormal squeal noise from the engine accessory drive belt
area, usually during cold start-up. An improved accessory drive belt tensioner, A/C compressor
bracket, and revised installation procedure have been developed to address this condition.
Applicable Vehicles
^ 2000 - 2006 model year Tundra vehicles produced BEFORE the Production Change Effective
VINs shown below.
Production Change Information
Parts Information
Warranty Information
Applicable Warranty* This repair is covered under the Toyota Comprehensive Warranty. This
warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's
in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Repair Procedure
Page 5299
Refrigerant Line (Part 2)
Description and Operation
Transmission Position Switch/Sensor: Description and Operation
PARK / NEUTRAL POSITION SWITCH
Engine Control System
The park/neutral position switch comes on when the shift lever is in the N or P position. When it
comes on, terminal NSW of the ECM is grounded to the body ground via the starter relay, thus the
terminal NSW voltage becomes 0 V. When the shift lever is in the D, 2, L or R position, the
park/neutral position switch goes off, so the voltage of the terminal NSW becomes battery voltage
and the voltage of the ECM internal power source. If the shift lever is moved from the N position to
the D position, this signal is used for air-fuel ratio correction and for idle speed control (estimated
control), etc.
Transmission Control System
The park/neutral position switch detects the shift lever position and sends signals to the ECM.
The ECM receives signals (NSW, R, D, 2 and L) from the park/neutral position switch.
Page 3902
Splice Point
J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel,
and "B" for the Body).
The Location of splice Point I5 is shaded.
K: Indicates a shielded cable.
L: Indicates the pin number of the connector.
The numbering system is different for female and male connectors.
M: Indicates a ground point.
The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for
the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body
and Surrounding area.
How to Read Connector List
HOW TO READ CONNECTOR LIST
A: Indicates connector to be connected to a part. (The numeral indicates the pin No.)
Page 5295
Heater Core Case: Service and Repair Disassembly and Reassembly
DISASSEMBLY
1. REMOVE HEATER RADIATOR
a. Remove the 5 screws and 3 clamps. b. Pull out the heater radiator. c. Remove the 2 screws and
2 clips, then disconnect the heater radiator pipes.
2. REMOVE AIR VENT DUCT
Remove the 2 screws and duct.
REASSEMBLY
Reassembly is in the reverse order of disassembly.
Page 7025
^ Using wipers instead of an ice scraper to remove frost and ice from the windshield during a car
warm up can dull, nick, or tear the rubber.
^ Banging wiper on the glass to remove ice & snow can cause the blade to bend and rubber to
come out of the blade providing the potential to scratch the glass.
^ Ice forms in wiper blade pin joints, which causes streaking and unwiped areas. To remove ice
from pin joints, compress the blade and rubber with your hand to loosen the frozen joints. To
prevent this condition, use winter blades with a rubber cover.
Page 2326
A. The new calibration file should be displayed as the current ECU calibration file.
B. Using a permanent marker or ball point pen, enter the required information on the Authorized
Modifications Label (Figures 21 and 22).
C. Affix this label under the hood in the location determined by the specific vehicle TSB or
Campaign.
NOTE:
Wait 60-90 seconds for ink to set before handling.
Page 2671
Camshaft Position Sensor: Testing and Inspection
ON-VEHICLE INSPECTION
NOTE: "Cold" and "Hot" in these sentences express the temperature of the coils themselves.
"Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F).
INSPECT CAMSHAFT POSITION SENSOR
a. Disconnect the camshaft position sensor connector.
Resistance
b. Using an ohmmeter, measure the resistance between terminals.
If the resistance is not as specified, replace the camshaft position sensor.
c. Reconnect the camshaft position sensor connector.
Engine/Transmission Controls - Resetting ECM Memory
Engine Control Module: All Technical Service Bulletins Engine/Transmission Controls - Resetting
ECM Memory
TRANSMISSION & CLUTCH TC002-03 REVISED
Title: ECM RESET MEMORY FUNCTION
Models: '00 - '05 All Models
June 10, 2003
TSB REVISION NOTICE:
^ December 20, 2004: Applicable Vehicles section has been updated - 2004 and 2005 model years
added, models and model years updated for various models; and Reset Procedure 2 has been
revised.
^ January 16, 2004: Tundra vehicles were added to the Applicable Vehicles chart.
^ December 17, 2003: T-100 vehicles were removed from the Applicable Vehicles chart.
Previous versions of this TSB should be discarded.
Introduction
Whenever an automatic transmission is replaced, overhauled or individual components are
replaced, use this procedure to clear Engine Control Module ( ECM, SAE term: Powertrain Control
Module, PCM) "Learned Values" to minimize subsequent performance concerns.
CAUTION:
Failure to follow the procedure below may lengthen the time to readjust the ECM "Learned Values,"
potentially resulting in performance concerns.
Required SSTs
Warranty Information
Applicable Vehicles
Page 4603
B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(Connect the Relay) and SW 2 OFF (or Disconnect SW 2)
D. Disconnect and reconnect the connectors while watching the test light.
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
E. Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION:
a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals
are touched, the IC may be destroyed by
static electricity.)
b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact
with the terminals of leads from the IC, etc. of the replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
Special Tool
1. PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown.
2. DISCONNECT CONNECTOR
3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
a. Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the
secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
A: For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
Page 2426
CHART 11
Page 3767
Transmission Mode Indicator - A/T: Testing and Inspection
ELECTRONICALLY CONTROLLED TRANSMISSION AND A/T INDICATOR
E1 ELECTRONICALLY CONTROLLED TRANSMISSION SOLENOID
4, 7, 8 - GROUND : Approx. 13 Ohms
O4 O/D MAIN SW
3 - 1 : Open with O/D main SW at ON position
Closed with O/D main SW at OFF position
S4 STOP LIGHT SW
1 - 2 : Closed with brake pedal depressed
E3 (A) E4 (B), E5 (C), E6 (D), E7 (E) ENGINE CONTROL MODULE
S1 - E1 : 9 - 14 volts with vehicle not move and shift lever in D position
S2, SL - E1 : 0 - 1.5 volts with vehicle not move
STP - E1 : 7.5 - 14 volts with brake pedal depressed 0 - 1.5 volts with brake pedal released
THW - E1 : 0.2 - 1.0 volts with idling, engine coolant temperature 60 °C (140 °F) -120 °C (248 °F)
OIL - E1 : Below 1.0 volts with fluid temperature 110 °C (230 °F)
VTA - E1 : 0.4 - 1.0 volts with ignition SW on and throttle valve fully closed : 3.2 - 4.8 volts with
ignition SW on and throttle valve fully open
VC - E1 : 4.5 - 5.5 volts with ignition SW at ON or ST position
ODMS - E1 : 9 - 14 volts with O/D main SW turned on : 0 - 3 volts with 0/D main SW turned off
SPD - E1 : Pulse generation with vehicle moving
2 - E1 : 7.5 - 14 volts with shift lever at 2 position : 0 - 1.5 volts with shift lever at except 2 position
L - E1 : 7.5 - 14 volts with shift lever at L position : 0 - 1.5 volts with shift lever at except L position
+B - E1 : 9 - 14 volts with ignition SW at ON or ST position
BATT - E1 : Always 9 - 14 volts
P1 A/T INDICATOR SW [PARK/NEUTRAL POSITION SW]
3 - 1 : Closed with shift lever in P position 3 - 2 : Closed with shift lever in R position 3 - 5 : Closed
with shift lever in N position 3 - 7 : Closed with shift lever in D position 3 - 4 : Closed with shift lever
in 2 position 3 - 8 : Closed with shift lever in L position
Page 802
Install the No.1 vehicle speed sensor with the bolt.
Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.)
6. CONNECT NO. I VEHICLE SPEED SENSOR CONNECTOR
Vehicle Speed Sensor NO.2
Vehicle speed Sensor NO.2 on-vehicle repair
1. DISCONNECT NO. 2 VEHICLE SPEED SENSOR CONNECTOR
2. REMOVE NO. 2 VEHICLE SPEED SENSOR
a. Remove the bolt and No. 2 vehicle speed sensor. b. Remove the O-ring from the No. 2 vehicle
speed sensor.
3. INSTALL NO. 2 VEHICLE SPEED SENSOR
a. Coat a new O-ring with ATF and install it to the No. 2 vehicle speed sensor. b. Install the No. 2
vehicle speed sensor with the bolt.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
4. CONNECT NO. 2 VEHICLE SPEED SENSOR CONNECTOR
Page 6304
Splice Location
I1 Cowl Wire
I2 Cowl Wire
I3 Cowl Wire
I4 Cowl Wire
I5 Cowl Wire
I6 Cowl Wire
I7 Engine Wire
I8 Engine Wire
I9 Engine Wire
I10 Engine Wire
I11 Engine Wire
I12 Engine Wire
I13 Engine Wire
I14 Engine Wire
I15 Engine Wire
I16 Cowl Wire
Body
Splice Location (Access Cab)
B1 Speaker Tweeter Wire LH
B2 Front Door LH Wire
B3 Front Door LH Wire
B4 Roof Wire
B5 Speaker Tweeter Wire RH
B6 B7
Front Door RH Wire
B8 Front Door RH Wire
B9 Rear Door No. 1 Wire RH
B10 Frame Wire
Page 3310
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 6608
Terminal Retainer
Push the terminal retainer down to the temporary lock position.
c. Release the locking lug from terminal and pull the terminal out from rear.
4. INSTALL TERMINAL TO CONNECTOR
a. Insert the terminal.
HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug
locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position.
Page 2682
Torque: 20.4 N.m (208 kgf.cm, 15 ft.lbf)
b. Connect the ECT sensor connector.
8. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS
a. Install a new gasket and the throttle body with the 2 bolts and 2 nuts.
Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)
b. Connect the accelerator cable to the throttle body.
9. REINSTALL INTAKE AIR CONNECTOR
10. REFILL WITH ENGINE COOLANT
11. REINSTALL THROTTLE BODY COVER
Page 394
Key Reminder Switch: Splice Locations
Engine Compartment
Splice Location
E1 Engine Room Main Wire
E2 Engine Room Main Wire
E3 Engine Room Main Wire
E4 Engine No. 2 Wire
E5 Engine Wire
E6 Engine Wire
E7 Engine Wire
E8 Engine Wire
Instrument Panel
Page 5733
B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(Connect the Relay) and SW 2 OFF (or Disconnect SW 2)
D. Disconnect and reconnect the connectors while watching the test light.
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
E. Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION:
a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals
are touched, the IC may be destroyed by
static electricity.)
b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact
with the terminals of leads from the IC, etc. of the replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
Special Tool
1. PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown.
2. DISCONNECT CONNECTOR
3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
a. Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the
secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
A: For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
Page 2532
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
Service and Repair
Hood Shock / Support: Service and Repair
HOOD SUPPORT
REPLACEMENT
1. REMOVE HOOD SUPPORT
a. Remove the bolt and hood support from the hood.
HINT: While supporting the hood by hand, remove the hood support from the hood.
b. Remove the bolt and hood support.
2. IF NECESSARY, REPLACE HOOD SUPPORT
NOTE: Handling the hood support Do not disassemble the support as the cylinder is filled with pressurized gas.
- If the hood support is to be replaced, drill a 2.0 - 3.0 mm (0.079 - 0.118 in.) hole in the area shown
in the illustration to completely release the high pressure gas before disposing of it.
- When drilling, chips may fly out so work carefully.
- The gas is colorless, odorless and non-toxic.
- When working, handle the hood support carefully. Never score or scratch the exposed part of the
piston rod, and allow any paint or oil to get on it.
- Do not turn the piston rod and cylinder with the hood support fully extended.
3. INSTALL HOOD SUPPORT
a. Install the bolt and hood support to the body.
Torque: 22 N.m (224 kgf.cm, 16 ft.lbf)
b. Install the bolt and hood support to the hood.
Torque: 22 N.m (224 kgf.cm, 16 ft.lbf)
Page 3541
^ 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.
Specifications
Firing Order: Specifications
Firing Order 1 - 8 - 4 - 3 - 6 - 5 - 7 - 2
Page 5063
Page 5763
Instrument Panel
Connector Location
IA1 Engine Room Main and Cowl Wire (Left Kick Panel)
IA2 Engine Room Main and Cowl Wire (Left Kick Panel)
IA3 Engine Room Main and Cowl Wire (Left Kick Panel)
IA4 Engine Room Main and Cowl Wire (Left Kick Panel)
IB1 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IB2 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IB3 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IC1 Cowl Wire and Roof Wire (Left Side of Instrument Panel)
Instrument Panel
Connector Location
ID1 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH)
ID2 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH)
IE1 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IE2 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IE3 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IF1 Front Door RH Wire and Cowl Wire (Right Kick Panel)
IF2 Front Door RH Wire and Cowl Wire (Right Kick Panel)
IF3 Front Door RH Wire and Cowl Wire (Right Kick Panel)
Page 4115
Repair Procedure
1. REMOVE FRONT WHEEL
2. 4WD:
REMOVE GREASE CAP
Using a screwdriver and hammer, remove the grease cap.
3. 4WD:
DISCONNECT DRIVE SHAFT
A. Remove the cotter pin and lock cap.
B. While applying the brakes, remove the lock nut.
4. W/ABS DISCONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP FROM
STEERING KNUCKLE
Remove the 2 bolts and disconnect the ABS speed sensor and wire harness clamp from the
steering knuckle.
5. DISCONNECT BRAKE LINE
Using the SST, disconnect the brake line. Use a container to catch the brake fluid.
Page 5867
Lower Side Moulding / Trim: Diagrams
Body Outside Moulding
Page 3690
6. 4WD: INSTALL BEARING SPACER
Using SST and a press, install the bearing spacer. SST 09950-60010 (09951-00650), 09950-70010
(09951-07150)
7. 2WD: INSTALL GREASE CAP
8. 4WD: INSTALL NEW OIL SEAL (INSIDE)
a. Using SST and a plastic hammer, install a new oil seal (inside).
SST 09527-17011
HINT: Lightly strike the SST on its circumference evenly.
b. Coat MP grease to the oil seal lip.
Page 567
Service and Repair
Universal Joint: Service and Repair
SPIDER BEARING REPLACEMENT
1. PLACE MATCHMARKS ON SHAFT AND YOKE
2. REMOVE SNAP RING
a. Using a brass bar and hammer, slightly tap in the bearing outer race. b. 4WD rear propeller
shaft: Using 2 screwdrivers, remove the 4 snap rings from the grooves. c. 2WD and 4WD front
propeller shaft: Using needle nose pliers, remove the 4 snap rings from the grooves.
3. REMOVE SPIDER BEARING
a. Using SST, push out the bearing from the flange yoke.
SST 09332-25010
HINT: Sufficiently raise the part indicated by "A" so that it does not come into contact with the
bearing.
b. Clamp the bearing outer race in a vise and tap off the flange with a hammer.
HINT: Remove the bearing on the opposite side in the same procedure.
c. Install the 2 removed bearing outer races to the spider, and clamp them in a vise. d. Using SST,
push out the bearing from the sleeve yoke.
SST 09332-25010
e. Clamp the outer bearing race in a vise and tap off the yoke with a hammer.
Airbag(s) Arming and Disarming
Air Bag(s) Arming and Disarming: Service and Repair Airbag(s) Arming and Disarming
CAUTION: *
Work must be started 90 seconds after the ignition switch is turned to the "LOCK" position and the
negative (-) terminal cable is disconnected from the battery. (The SRS is equipped with a back-up
power source so that if work is started within 90 seconds of disconnecting the negative (-) terminal
cable of the battery, the SRS may be deployed.)
* When the negative (-) terminal cable is disconnected from the battery, the memory of the clock
and audio system will be canceled. So before starting work, make a record of the contents
memorized in the audio memory system. When work is finished, reset the audio systems as before
and adjust the clock. To avoid erasing the memory of each memory system, never use a backup
power supply from outside the vehicle.
* Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during
repairs.
* Do not expose the steering wheel pad, front passenger airbag assembly, airbag sensor assembly
or front airbag sensor directly to hot air or flames.
AIR BAG SYSTEM DISARMING
The Air Bag/Supplemental Restraint System (SRS) incorporates a backup energy source that
maintains sufficient deployment voltage for up to 90 seconds after the ignition is turned Off and the
battery has been disconnected. Before disconnecting battery, note radio station settings, since all
vehicle memory will be lost. Never use a backup power source from outside the vehicle.
1. Turn ignition to Lock, then disconnect battery ground cable. 2. Wait at least 90 seconds after
disconnection before beginning service or diagnostic procedures.
AIR BAG SYSTEM ARMING
1. Ensure ignition is in Lock position. 2. Connect battery ground cable. 3. Wait at least 10 seconds
before turning ignition from Lock position. 4. Turn ignition to ACC or On position and ensure SRS
lamp lights, then goes off after approximately six seconds. If lamp remains lit, an SRS
condition is indicated. Refer to Restraint Systems, Air Bag Systems, Testing And Inspection. See:
Restraint Systems/Air Bag Systems/Testing and Inspection
Page 3722
^ 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 531
A/F and 02 Sensor Identification
Engine Controls - MIL ON/DTC's P0135/P0155 Stored
Oxygen Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0135/P0155
Stored
ENGINE EG019-02 REVISED
October 3, 2002
Title M.I.L. "ON" P0135 AND/OR P0155
Models: '00 - '02 Tundra (2UZ-FE) & '01 - '02 Sequoia
TSB REVISION NOTICE:
January 14, 2004: A Previous Part Number in the Parts Information table and one OFP number in
the Warranty Information table has been changed. All previous versions of this TSB should be
discarded.
Introduction
Certain 2000 - 2002 model year Tundra trucks (2UZ-FE) and 2001 - 2002 model year Sequoia
vehicles may exhibit a M.I.L. ON" condition with Diagnostic Trouble Code P0135 and/or P0155 in
the Engine Control Module (ECM)/SAE equivalent (PCM). The oxygen sensors have been
improved to correct this condition.
Applicable Vehicles ^
2000 - 2002 model year Tundra trucks with 2UZ-FE engines produced BEFORE the Production
Change Effective VINs listed below.
^ 2001 - 2002 model year Sequoia vehicles produced BEFORE the Production Change Effective
VINs listed below.
Production Change Information
Parts Information
Warranty Information
Applicable Warranty*:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36
months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Page 1926
Page 1345
Oil Pressure Gauge: Testing and Inspection
INSPECT OIL PRESSURE GAUGE RESISTANCE Measure the resistance between terminals A
and B. If resistance value is not as specified, replace the receiver gauge.
Page 1108
Splice Point
J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel,
and "B" for the Body).
The Location of splice Point I5 is shaded.
K: Indicates a shielded cable.
L: Indicates the pin number of the connector.
The numbering system is different for female and male connectors.
M: Indicates a ground point.
The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for
the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body
and Surrounding area.
How to Read Connector List
HOW TO READ CONNECTOR LIST
A: Indicates connector to be connected to a part. (The numeral indicates the pin No.)
Page 6324
Waterproof Type Connector
B: For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White
: Gray
Black or White : Dark Gray
Gray or White : Black
Waterproof Type Connector
"Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up
to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Waterproof Type Connector
"Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 4294
Required SSTs
Diagnosis Procedure
1. Confirm the customer complaint.
2. Determine if vibration is from front or rear (while brakes are still warm from confirmation test
driving).
The following procedure will isolate the drum brakes from the rest of the hydraulic system by using
the parking brake (PKB).
A. Drive the Tundra along a smooth, level section of road at approximately 40 mph - 50 mph.
Page 6730
Terminal Retainer
Push the terminal retainer down to the temporary lock position.
c. Release the locking lug from terminal and pull the terminal out from rear.
4. INSTALL TERMINAL TO CONNECTOR
a. Insert the terminal.
HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug
locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position.
Page 1050
(b) In this position. check the rear brake pressure
If the measured value is not within the standard, replace the valve body.
Page 6099
INSPECT FRONT TILT MOTOR OPERATION
a. Connect the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal
2, check that the motor turns clockwise. b. Reverse the polarity, check that the motor turns
counterclockwise.
If operation is not as specified, replace the seat adjuster.
INSPECT FRONT TILT MOTOR PTC THERMISTOR OPERATION
a. Connect the positive (+) lead from the battery to terminal 1, the positive (+) lead from the
ammeter to terminal 2 and the negative (-) lead to the
battery negative (-) terminal, then move the seat cushion to the highest position.
b. Continue to apply voltage, check that the current changes to less than 1 ampere within 4 to 90
seconds.
c. Disconnect the leads from the terminals. d. Approximately 60 seconds later, connect the positive
(+) lead from the battery to terminal 2 and the negative (-) lead to terminal 1, check that the
seat cushion begins to descend. If operation is not as specified, replace the seat adjuster.
INSPECT LIFTER MOTOR OPERATION
a. Connect the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal
2, check that the motor turns clockwise. b. Reverse the polarity, check that the motor turns
counterclockwise.
If operation is not as specified, replace the seat adjuster.
INSPECT LIFTER MOTOR PTC THERMISTOR OPERATION
Page 6189
Body
Splice Location (Standard Cab)
B1 Speaker Tweeter Wire LH
B2 Front Door LH Wire
B3 Front Door LH Wire
B4 Roof Wire
B5 Speaker Tweeter Wire RH
B6 B7
Front Door RH Wire
B10 Frame Wire
Seat
Page 5511
Inspect the entire length of webbing for damage and replace the assembly if needed. Be careful
NOT to damage the webbing during repair.
3. Install the NEW tongue plate stopper
A. Install a NEW tongue plate stopper in the hole of the webbing.
NOTE
Be sure to install the stopper in the correct direction as shown in the illustration.
B. Pinch the tongue plate stopper into the webbing using the tool shown in Figure 3 or use a small
"C" clamp.
NOTE
To prevent damage to the plastic tongue plate stopper when using a "C" clamp device, use light to
moderate clamping force when crimping the two halves of the tongue plate stopper together.
HINT
Press the adjustment screw locating the male and female parts of the tongue plate stopper parallel
to each other.
Page 1585
Install the 2 radiator supports, 2 bushings and 2 pipes with the 4 bolts. Torque: 12.7 Nm (130
kgf-cm, 9 ft. lbs.)
8. INSTALL RADIATOR CAP
INSTALLATION
1. INSTALL NO.1 FAN SHROUD
Install the No.1 fan shroud with the 4 bolts Torque: 5 Nm (50 kgf-cm, 44 inch lbs.)
2. INSTALL RADIATOR ASSEMBLY
a. Set the radiator bracket hooks to the radiator support holes. b. Install the 4 bolts.
Torque: 12 Nm (120 Nm, 9 ft. lbs.)
3. INSTALL NO.2 FAN SHROUD
Install the No.2 fan shroud with the 2 clips.
4. CONNECT A/T OIL COOLER HOSES TO RADIATOR 5. CONNECT UPPER RADIATOR HOSE
TO RADIATOR 6. CONNECT LOWER RADIATOR HOSE TO RADIATOR 7. CONNECT
RADIATOR RESERVOIR HOSE TO RADIATOR 8. FILL WITH ENGINE COOLANT 9. START
ENGINE AND CHECK FOR ENGINE COOLANT LEAKS
10. RECHECK ENGINE COOLANT LEVEL 11. INSTALL ENGINE UNDER COVER
Page 180
^ 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 6424
Glossary Of Terms And Symbols (Part 2)
Locations
Vehicle Lift And Support Locations
Page 2820
CHART 18
CHART 19
Page 4136
Using the following SSTs and a press, install the bearing spacer.
^ 09950-60010 (09951-00650)
^ 09950-70010 (09951-07150)
22. 4WD: INSTALL NEW OIL SEAL (INSIDE)
A. Using the following SST and a plastic hammer, install a NEW oil seal (inside).
^ 09527-17011
NOTE:
Lightly strike the SST on its circumference evenly.
B. Coat MP grease to the oil seal lip.
23. INSTALL STEERING KNUCKLE
A. 4WD: Insert the drive shaft into the axle hub and temporarily tighten the nut.
NOTE:
Be careful not to damage the oil seal and drive shaft boot.
B. Connect the steering knuckle to the upper suspension arm.
C. Install the nut and a NEW cotter pin. If the holes for the cotter pin are not aligned, tighten the nut
further up to 60°.
Torque: 105 N.m (1,100 kgf.cm, 77 ft.lbf)
24. CONNECT LOWER BALL JOINT
Connect the lower ball joint to the steering knuckle with 4 bolts.
Torque: 50 N.m (510 kgf.cm, 37 ft.lbf)
25. INSTALL SHOCK ABSORBER WITH COIL SPRING
A. Install the upper side of shock absorber to the chassis frame with the 3 nuts.
Page 3243
Transmission Mode Indicator - A/T: Electrical Diagrams
Electronically Controlled Transmission And A/T Indicator (Part 1)
Page 5564
Body
Connector Location (Standard Cab)
BA1 Front Door LH Wire and Speaker Tweeter Wire LH (Inside of Front Door LH)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Seat
Connector Location
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
BJ1 Seat No. 1 Wire and Seat No. 2 Wire (Under the Driver's Seat)
Diagrams
Control Assembly: Diagrams
Air Conditioning Control Assembly (Center Cluster Integration)
Page 6260
Splice Point
J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel,
and "B" for the Body).
The Location of splice Point I5 is shaded.
K: Indicates a shielded cable.
L: Indicates the pin number of the connector.
The numbering system is different for female and male connectors.
M: Indicates a ground point.
The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for
the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body
and Surrounding area.
How to Read Connector List
HOW TO READ CONNECTOR LIST
A: Indicates connector to be connected to a part. (The numeral indicates the pin No.)
Testing and Inspection
Four Wheel Drive Selector Switch: Testing and Inspection
INSPECTION
1. INSPECT 2WD -> 4HI SHIFT
a. Ignition switch ON. b. Check that the 4HI indicator lights come on when the touch select 2-4
switch is in ON position. c. Check that the 4HI indicator lights go off when the touch select 2-4
switch is in OFF position.
HINT: If the light does not light up, even though the switch has been turned ON, the vehicle should be
moved back and forth.
- If switching is not completed after 3 seconds of shift operation, the 4HI indicator light will flash.
2. INSPECT 4HI -> 4LO SHIFT
Page 5808
Continuity And Resistance Check
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Continuity And Resistance Check
C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the
electrical circuit.
Finding A Short Circuit
Finding A Short Circuit
Finding A Short Circuit
A. Remove the blown fuse and disconnect all loads of the fuse.
Page 3068
Fuel Pump Relay: Testing and Inspection Circuit Opening Relay
CIRCUIT OPENING RELAY
INSPECTION
1. REMOVE RELAY BOX COVER
2. REMOVE CIRCUIT OPENING RELAY (Marking: CIR OPN)
3. INSPECT CIRCUIT OPENING RELAY CONTINUITY
a. Using an ohmmeter, check that there is continuity between terminals 1 and 2.
If there is no continuity, replace the relay.
b. Check that there is no continuity between terminals 3 and 5.
If there is continuity, replace the relay.
4. INSPECT CIRCUIT OPENING RELAY OPERATION
a. Apply battery positive voltage across terminals 1 and 2. b. Using an ohmmeter, check that there
is continuity between terminals 3 and 5.
If there is no continuity, replace the relay.
5. REINSTALL CIRCUIT OPENING RELAY
6. REINSTALL RELAY BOX COVER
Page 3761
Terminal Retainer
Push the terminal retainer down to the temporary lock position.
c. Release the locking lug from terminal and pull the terminal out from rear.
4. INSTALL TERMINAL TO CONNECTOR
a. Insert the terminal.
HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug
locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position.
Page 3844
c. 4HI -> 4LO shift: Connect lines via a relay, then check that the actuator fork shaft moves to 4HI
-> 4LO position.
d. 4LO 4HI shift: Connect lines via a relay, then check that the actuator fork shaft moves to 4LO ->
4HI position.
HINT: When inspecting the operation described, use a heater main relay.
NOTICE: Connect the terminals being careful not to touch the neighboring terminals or metallic
parts of relay housing.
Specifications
Timing Belt Idler Pulley: Specifications
Torque Specifications
No.1 Idler Pulley ..................................................................................................................................
.................................................................... 34.5 Nm No.2 Idler Pulley ...............................................
.......................................................................................................................................................
34.5 Nm
Page 2324
Locations
Airbag Sensor Assembly: Locations
Instrument Panel
Page 5761
Splice Location
B11
Page 545
Locations
Instrument Panel
Page 5815
Trailer Connector: Testing and Inspection
TRAILER TOWING
T6 TRAILER SOCKET
2 - GROUND : Approx. 12 volts with light control SW at TAIL or HEAD position 1 - GROUND :
Approx. 12 volts with ignition SW at ON position and shift level in R position 4 - GROUND : Always
continuity
Page 3295
STANDARD VALUE OF ECU TERMINAL
Electrode Gap Specification
Spark Plug: Specifications Electrode Gap Specification
Electrode Gap
Correct Gap .........................................................................................................................................
........................................................................ 0.8 mm
Page 4900
An airbag activation prevention mechanism is built into the connector for the squib circuit of the
SRS.
When release of the airbag activation prevention mechanism is directed in the troubleshooting
procedure, as shown in the illustration of the connectors, insert paper which has the same
thickness as the male terminal, between the terminal and the short spring.
CAUTION: Never release the airbag activation prevention mechanism on the steering wheel pad
connector.
NOTE:
Page 1829
Mass Air Flow Meter: Testing and Inspection
MASS AIR FLOW (MAF) METER
INSPECTION
1. DISCONNECT MAF METER CONNECTOR
2. REMOVE MAF METER
Remove the 2 screws and MAF meter.
3. INSPECT MAF METER
a. Using an ohmmeter, measure the resistance between terminals THA and E2.
If the resistance is not as specified, replace the MAF meter.
b. Inspect for operation.
1. Connect the MAF meter connector. 2. Connect the negative (-) terminal cable to the battery. 3.
Turn the ignition switch ON. 4. Using a voltmeter, connect the positive (+) tester probe to terminal
VG, and negative (-) tester probe to terminal E2G. 5. Blow air into the MAF meter, and check that
the voltage fluctuates.
Testing and Inspection
Refrigerant Pressure Sensor / Switch: Testing and Inspection
ON-VEHICLE INSPECTION
1. SET ON MANIFOLD GAUGE SET
2. DISCONNECT CONNECTOR
3. RUN ENGINE AT APPROX. 2,000 rpm
4. SET BLOWER SPEED CONTROL SWITCH TO "HI" POSITION
5. SET TEMPERATURE CONTROL LEVER TO "MAX. COOL" POSITION
6. A/C SWITCH ON
7. INSPECT PRESSURE SWITCH OPERATION
a. Connect the positive (+) lead from the ohmmeter to terminal 1 and negative (-) lead to terminal 2.
b. Check continuity between terminals when refrigerant pressure is changed, as shown in the
illustration.
If operation is not as specified, replace the pressure switch.
Page 4691
Continuity And Resistance Check
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Continuity And Resistance Check
C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the
electrical circuit.
Finding A Short Circuit
Finding A Short Circuit
Finding A Short Circuit
A. Remove the blown fuse and disconnect all loads of the fuse.
Page 2429
CHART 15
Page 3630
Standard resistance: More than 0.5 M ohms If the resistance value is not as specified, replace the
actuator assembly.
2. INSPECT A.D.D. ACTUATOR OPERATION
Apply battery positive voltage between the terminal 2 or 6, and check the actuator operation by
sound, A.D.D. status and continuity between the terminal 3 and 4. If the operation is not as
specified, replace the actuator assembly.
3. INSPECT LIMIT SWITCH CONTINUITY
a. Connect the actuator connector.
b. Shift the transfer shift lever or switch the transfer operation switch to "H2" position. c. Check the
A.D.D. actuator operation by sound. d. Disconnect the actuator connector.
e. Check the continuity between each terminal, as shown in the chart. f.
Connect the actuator connector.
g. Shift the transfer shift lever or switch the transfer operation switch to "H4" position. h. Check the
A.D.D. actuator operation by sound. i.
Disconnect the actuator connector.
j. Check the continuity between each terminal, as shown in the chart.
k. Connect the actuator connector.
Page 5976
Wire Harness Fuse Location
Troubleshooting Procedure
Page 570
Page 5260
Evaporator Case: Testing and Inspection On-Vehicle Inspection
COOLING UNIT
ON-VEHICLE INSPECTION
1. INSPECT FOR LEAKAGE OF REFRIGERANT
a. Remove the glove compartment door. b. Remove the lower No.2 finish panel. c. Remove the
lower center cover. d. Remove the lower LH finish panel. e. Remove the lower cover.
f. Remove the blower resistor. 1. Disconnect the connector. 2. Remove the 2 screws and blower
resistor.
g. Using a gas leak detector, check for leakage.
If there is leakage, check the tightening torque at the joints or check the evaporator.
h. Install the blower resistor with the 2 screws. i.
Install the lower cover.
j. Install the lower LH finish panel.
k. Install the lower center cover. l.
Install the lower No.2 finish panel.
m. Install the glove compartment door.
2. INSPECT EXPANSION VALVE
a. Check quantity of gas during refrigeration cycle. b. Set on manifold gauge set. c. Run engine.
1. Run the engine at 1,500 rpm for at least 5 minutes. 2. Then check that the high pressure reading
is 1.37 - 1.57 Mpa (14 - 16 kgm/sq.cm, 199 - 288 psi).
d. Check expansion valve.
If the expansion valve is faulty, the low pressure reading will drop to 0 kPa (0 kgf/sq.cm, 0 psi).
HINT: When the lower pressure drop to 0 kPa (0 kgf/sq.cm, 0 psi), feel the receiver's IN and OUT
sides for no temperature difference.
Page 6410
Body
Splice Location (Standard Cab)
B1 Speaker Tweeter Wire LH
B2 Front Door LH Wire
B3 Front Door LH Wire
B4 Roof Wire
B5 Speaker Tweeter Wire RH
B6 B7
Front Door RH Wire
B10 Frame Wire
Seat
Page 5277
4. Cycle the temperature control knob several times and confirm proper water control valve
adjustment.
Diagram Information and Instructions
Seat Belt Reminder Buzzer: Diagram Information and Instructions
Key to Diagrams
A: System Title
B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to
distinguish it from the J/B
Example: 1 Indicates Relay Block No.1
C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type,
or specification is different.
D: Indicates related system.
Page 2871
Non-Waterproof Type Connector
"Case 1" Raise the terminal retainer up to the temporary lock position.
Non-Waterproof Type Connector
"Case 2" Open the secondary locking device.
Page 6269
Non-Waterproof Type Connector
"Case 1" Raise the terminal retainer up to the temporary lock position.
Non-Waterproof Type Connector
"Case 2" Open the secondary locking device.
Page 1289
Assenmacher Specialty Tools 1-800-525-2943
Page 5152
8. REMOVE STEERING KNUCKLE
a. Remove the coffer pin and loosen the nut. b. Using Special Service Tool (SST), disconnect the
steering knuckle.
SST 09950-40011 (09951-04010, 09952-04010, 09553-04020, 09554-04010, 09955-04031,
09958-04011)
c. Remove the nut and steering knuckle.
NOTICE: 4WD: Be careful not to damage the oil seal and drive shaft boot.
HINT: 4WD: When it is difficult to disconnect the drive shaft, tap the tip of the drive shaft with a
plastic hammer.
INSTALLATION
1. INSTALL STEERING KNUCKLE
a. 4WD: Insert the drive shaft into the axle hub and temporarily tighten the nut.
NOTICE: Be careful not to damage the oil seal and drive shaft boot.
b. Connect the steering knuckle to the upper suspension arm. c. Install the nut and a new cotter
pin.
If the holes for the cotter pin are not aligned, tighten the nut further up to 60°. Torque: 105 Nm
(1,100 kgf-cm, 77 ft. lbs.)
2. CONNECT LOWER BALL JOINT
Connect the lower ball joint to the steering knuckle with 4 bolts. Torque: 80 Nm (820 kgf-cm, 59 ft.
lbs.)
3. INSTALL SHOCK ABSORBER 4. INSTALL BRAKE CALIPER
a. Install the disc, brake caliper and 2 bolts.
Torque: 123 Nm (1,250 kgf-cm, 90 ft. lbs.)
b. Install the brake line clamp to the steering knuckle with bolt.
Torque: 28 Nm (285 kgf-cm, 21 ft. lbs.)
5. w/ ABS: CONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP
Connect the ABS speed sensor and wire harness clamp to the steering knuckle with 2 bolts.
Torque: 8.0 Nm (82 kgf-cm, 71 ft. lbs.)
6. 4WD: INSTALL DRIVE SHAFT LOCK NUT
a. While applying the brakes, tighten the nut.
Torque: 235 Nm (2,400 kgf-cm, 173 ft. lbs.)
b. Install the lock cap and a new cotter pin.
If the holes for the cotter pin are not aligned, tighten the nut further up to 60°.
7. INSTALL GREASE CAP 8. INSTALL FRONT WHEEL
Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.)
9. DEPRESS BRAKE PEDAL SEVERAL TIMES
10. CHECK FRONT WHEEL ALIGNMENT 11. CHECK ABS SPEED SENSOR SIGNAL
Disassembly and Reassembly
Page 3908
Transmission Mode Indicator - A/T: Diagnostic Aids
Voltage Check
Voltage Check
Voltage Check
A. Establish conditions in which voltage is present at the check point.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(SW 2 OFF)
B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or
component terminal. This check can be done with a test light instead of a voltmeter.
Continuity and Resistance Check
Continuity and Resistance Check
Continuity And Resistance Check
A. Disconnect the battery terminal or wire so there is no voltage between the check points. B.
Contact the two leads of an ohmmeter to each of the check points.
Page 5248
b. Set the temperature control dial at "MAX. COOL" position.
c. Adjust mode control cable.
Pull the air inlet control link to "FACE" position, connect the control cable and lock the clamp.
HINT: Lock the clamp during lightly pulling the outer cable in the direction, as shown in the
illustration by an arrow.
d. Adjust air mix control cable.
Pull the air inlet control link to "COOL" position, connect the control cable and lock the clamp.
HINT: Lock the clamp during lightly pushing the outer cable in the direction as shown in the
illustration by an arrow.
e. Adjust water valve control cable.
Pull the air inlet control link to "COOL" position, connect the control cable and lock the clamp.
HINT: Lock the clamp during lightly pushing the outer cable in the direction, as shown in the
illustration by an arrow.
3. INSTALL HEATER TO REGISTER DUCT NO.4
4. INSTALL LOWER NO.2 FINISH PANEL
5. INSTALL GLOVE COMPARTMENT PANEL
6. INSTALL HEATER TO REGISTER DUCT NO.2
7. INSTALL LOWER LH FINISH PANEL
Page 2669
Camshaft Position Sensor
Page 1917
CHART 8
CHART 9
Page 239
Terminals Of ECU - Connector Pinouts (Part 2)
INSPECTION
1. REMOVE ECM
2. INSPECT ECM
3. REINSTALL ECM
Page 2594
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 4369
20. 2WD: INSTALL NEW LOCK NUT
A. Using the following SST, install and torque a NEW lock nut to the axle hub.
00002-00909 (09318-12010)
Torque: 274 N.m (2,800 kgf.cm, 203 ft.lbf)
NOTE:
Do NOT use air wrench.
B. Using a chisel and hammer, stake the lock nut.
21. 4WD:
INSTALL BEARING SPACER
Using the following SSTs and a press, install the bearing spacer.
^ 09950-60010 (09951-00650)
^ 09950-70010 (09951-07150)
22. 4WD:
Page 5424
Impact Sensor: Service and Repair Removal and Installation
Front Airbag Sensor
REMOVAL
NOTE:
- If the wiring connector of the SRS is disconnected with the ignition switch at ON or ACC position,
DTCs will be recorded.
- Never use SRS parts from another vehicle. When replacing parts, replace them with new parts.
- Never reuse the sensor involved in a collision when the SRS has deployed.
- Never repair a sensor in order to reuse it.
Page 5447
Steps 1 - 3
Page 3379
B. You have the option to delete calibrations off the tester before downloading a new calibration.
The CUW also provides this option if there is not enough memory for the new calibration. To delete
one or all of the calibrations, follow the screen flow shown (Figure 5).
C. If this is the first time you have downloaded a calibration file from TIS to the Diagnostic Tester
Program Card, you MUST first install the latest version of the Calibration Update Wizard (CUW)
onto your TIS workstation PC, as shown in Figure 6.
This step is also required if you are using a version of CUW earlier than version 6.0. CUW 6.0 is
the only version compatible with Diagnostic Tester software version 10.2a and later. If necessary,
select the link to the TIS Diagnostic Applications Installer and follow the on-screen prompts to
install or reinstall CUW.
Page 5952
Page 895
Valve Clearance: Testing and Inspection
INSPECTION
HINT: Inspect and adjust the valve clearance when the engine is cold.
1. REMOVE BATTERY CLAMP COVER 2. REMOVE THROTTLE BODY COVER 3. REMOVE AIR
CLEANER AND INTAKE AIR CONNECTOR ASSEMBLY 4. REMOVE NO.3 TIMING BELT
COVERS 5. REMOVE IGNITION COILS 6. REMOVE RH CYLINDER HEAD COVER
Remove the 9 bolts, seal washers and cylinder head cover.
7. REMOVE LH CYLINDER HEAD COVER
a. Remove the oil dipstick for the transmission. b. Disconnect the PCV hose. c. Disconnect the
engine wire clamp from the wire bracket on the cylinder head cover. d. Remove the 9 bolts, 9 seal
washers and cylinder head cover.
8. SET NO.1 CYLINDER TO TDC/COMPRESSION
a. Turn the crankshaft pulley, and align its groove with timing mark "0" of the No.1 timing belt cover.
b. Check that the timing marks of the camshaft timing pulleys and timing belt rear plates are
aligned.
If not, turn the crankshaft 1 revolution (360°) and align the mark.
9. INSPECT VALVE CLEARANCE
Page 5920
Specifications
Wheel Cylinder: Specifications
Wheel Cylinder Mounting Bolts 10 Nm
Hydraulic Brake Line 15 Nm
Instruments - Coolant Temperature Gauge Inaccurate
Temperature Gauge: All Technical Service Bulletins Instruments - Coolant Temperature Gauge
Inaccurate
ELECTRICAL EL009-01
October 12, 2001
Title: TEMPERATURE GAUGE INACCURATE
Models: '00 - '01 Tundra
Introduction Some 2000 - 2001 model year Tundra trucks may experience a condition in which the
engine coolant temperature gauge displays an abnormally high reading during normal engine
operating temperatures. To address this condition, an updated Temperature Gauge has been
made available.
Applicable Vehicles ^
2000 - 2001 model year Tundra trucks, built prior to the VIN shown.
Production Change Information
Parts Information
Repair Procedure
IMPORTANT:
Verify that the engine is operating at a normal temperature with the Scan Tool before replacing the
temperature gauge.
1. Remove the four bolts securing the combination meter assembly.
2. Replace the Temperature Gauge.
3. Reassemble the combination meter.
Warranty Information
Applicable Warranty *:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36
months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Page 2376
Malfunction Indicator Lamp: Description and Operation
Malfunction Indicator Lamp (MIL)
OBD II regulations require that the vehicle's on-board computer lights up the Malfunction Indicator
Lamp (MIL) on the instrument panel when the computer detects a malfunction in the emission
control system/components or in the powertrain control components which affect vehicle
emissions, or a malfunction in the computer. In addition to the MIL lighting up when a malfunction is
detected, the applicable Diagnostic Trouble Codes (DTCs) prescribed by SAE J2012 are recorded
in the ECM memory.
If the malfunction does not reoccur in 3 consecutive trips, the MIL goes off automatically but the
DTCs remain recorded in the ECM memory.
Page 4252
Applicable Warranty*:
This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or
36,000 miles, whichever occurs first, from the vehicle's in-service date.
*Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Page 6881
B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(Connect the Relay) and SW 2 OFF (or Disconnect SW 2)
D. Disconnect and reconnect the connectors while watching the test light.
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
E. Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION:
a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals
are touched, the IC may be destroyed by
static electricity.)
b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact
with the terminals of leads from the IC, etc. of the replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
Special Tool
1. PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown.
2. DISCONNECT CONNECTOR
3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
a. Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the
secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
A: For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
Testing and Inspection
Seat Sensor/Switch: Testing and Inspection
Passenger's seat only: INSPECT SEAT BELT WARNING OCCUPANT DETECTION SENSOR
CONTINUITY
Check that continuity exists between the terminals 1 and 2 when pressing the sensing part. If
operation is not as specified, replace the sensor.
Page 2471
^ O2S TEST RESULTS
A list of the available oxygen sensors will be displayed.
2. Select the desired oxygen sensor and press Enter.
NOTE:
The monitor result of the A/F sensor will not be displayed. If you select "Bank 1-Sensor 1" or Bank
2-Sensor 1" for a vehicle equipped with an A/F sensor, the Diagnostic Tester will display "No
parameter to display."
3. Compare the test results with the values listed in the Failure Threshold Chart.
* Although this procedure references the Toyota Diagnostic Tester, the O2S test results can be
checked using a generic OBD II scantool. Refer to your OBD II scantool operator's manual for
specific procedures.
Comparing O2S Test Results to Failure Thresholds
1. Determine the correct O2S Failure Threshold Chart for your vehicle by looking in the "O2S
Application Table," in this bulletin.
2. Select appropriate year, model, and engine for specified O2S Failure Threshold Chart.
3. Compare O2S test results with the specified O2S Failure Threshold Chart. It may be necessary
to convert O2S test results to a specific measurement unit using the conversion factor that is
supplied in the specified table. See example.
Example:
Page 1707
During ECU flash reprogramming, the Error screen shown may be displayed on the Diagnostic
Tester for one of the following reasons:
1. Immobilizer key not properly registered or auto-registration mode left open.
2. Ignition ON/OFF cycling not followed correctly during the flash reprogramming procedure.
3. The Diagnostic Tester cable is damaged, causing an open communication circuit.
NOTE:
The Diagnostic Tester may operate properly in other modes such as OBD, OBDII, or CARB, with a
damaged cable.
To eliminate the possibility of the first 2 reasons causing the error message, do the following:
1. Confirm the Immobilizer Transponder Master Key is properly registered and auto registration
mode is closed. Follow the appropriate Repair Manual procedure and consult TSB SS001-99,
"Scan tool Immobilizer key Code Utility
2. Conduct the ECU flash reprogramming process explicitly following key operation instructions.
Refer to TSB SS002-01, "ECU Flash Reprogramming Process, "for more details.
To determine if the Diagnostic Tester cable is damaged, follow the test procedures below to check
the electrical integrity of the cable. Conduct all continuity tests with an Ohm meter. For all five test
procedures, the resistance values must be below 6.0 ohms to pass.
Test CABLE TEST 1.
Page 2243
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 5197
Blower Motor: Testing and Inspection Blower Unit
INSPECTION
INSPECT AIR INLET SERVOMOTOR OPERATION
a. Connect the positive (+) lead from the battery to terminal 7 and negative (-) lead to terminal 3.
b. Check the motor arm rotates counterclockwise and arm stops on the "FRESH" position.
c. Connect the positive (+) lead from the battery to terminal 7 and negative (-) lead to terminal 1.
d. Check the motor arm rotates counterclockwise and arm stops on the "RECIRC" position.
Page 5423
Impact Sensor: Service and Repair Airbag Sensor Connectors
DISCONNECTION
a. While holding both flank sides of the outer, slide the outer to the direction directed by an arrow.
b. Lock of the connectors is released, then disconnect the connectors.
HINT: Be sure to hold both flank sides of the outer. If holding the top or bottom sides, it will obstruct
disconnection.
CONNECTION
a. Align the male connector (on the side of sensor) and female connector in the same direction as
shown in the illustration and fit in them without
rubbing.
b. As they are fitted in, the outer slides rearward. Press it until the outer returns to its original
position again.
If fitting stops half way, connectors will separate.
c. Be sure to insert until they are locked. After fitting in, pull them slightly to check that they are
locked (When locked, make sure that the outer
returns to its original position and sound at the time of fitting in can be heard.).
HINT: Do not fit in while holding the outer.
- When fitting in, the outer slides. Do not touch it.
Page 93
Relay Box: Diagnostic Aids
Voltage Check
Voltage Check
Voltage Check
A. Establish conditions in which voltage is present at the check point.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(SW 2 OFF)
B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or
component terminal. This check can be done with a test light instead of a voltmeter.
Continuity and Resistance Check
Continuity and Resistance Check
Continuity And Resistance Check
A. Disconnect the battery terminal or wire so there is no voltage between the check points. B.
Contact the two leads of an ohmmeter to each of the check points.
Page 4775
Wiring Harness Connector
E: Indicates the wiring harness and wiring harness connector. The wiring harness with male
terminal is shown with arrows.
Outside numerals are pin numbers.
The first letter of the code for each wiring harness and wiring harness connector(s) indicates the
component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and
Surrounding area, and "B" for the Body and Surrounding area.
When more than one code has the first and second letters in common, followed by numbers (e.g,
IH1, IH2), this indicates the same type of wiring harness and wiring harness connector.
F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in
parts position.
G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside
it). Junction Blocks are shaded to clearly separate
them from other parts.
H: When 2 parts both use one connector in common, the parts connector name used in wire
routing is shown in square brackets [ ].
Wiring Color
I: Indicates the wiring color.
Wire colors are indicated by an alphabetical code.
B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR =
Brown SB = Sky Blue LG = Light Green GR = Gray
The first letter indicates the basic wire color and the second letter indicates the color of the stripe.
Page 2663
Mass Air Flow Meter: Service and Repair
MASS AIR FLOW (MAF) METER
1. DISCONNECT MAF METER CONNECTOR
2. REMOVE MAF METER
Remove the 2 screws and MAF meter.
3. REINSTALL MAF METER
Install the MAF meter with the 2 screws.
4. RECONNECT MAF METER CONNECTOR
Page 6984
Windshield: Service and Repair
REMOVAL
1. REMOVE INNER REAR VIEW MIRROR
Remove the inner rear view mirror as shown in the illustration.
2. REMOVE ASSIST GRIPS
a. Using a screwdriver, remove the caps.
HINT: Tape the screwdriver tip before use.
b. Driver's side:
Using a torx driver, remove the 2 torx screws and assist grip.
Torx driver: T30 (Part No.09041-00030 or locally manufactured tool)
c. Passenger's side:
Using a torx driver, remove the 4 torx screws and 2 assist grips.
Torx driver: T30 (Part No.09041-00030 or locally manufactured tool)
3. REMOVE FRONT PILLAR GARNISH
a. Using a screwdriver, remove the front pillar garnish.
HINT: Tape the screwdriver tip before use.
b. Employ the same manner described above to the other side.
4. REMOVE SUN VISORS
Page 747
Impact Sensor: Description and Operation
FRONT AIRBAG SENSOR
The front airbag sensor is mounted inside each of the aprons. The sensor unit is a mechanical
type. When the sensor detects deceleration force above a predetermined limit, contact is made in
the sensor, sending a signal to the airbag sensor assembly. The sensor cannot be disassembled.
Page 5961
A. AFFECTED VIN RANGE
III. Preparation
A. PARTS
^ No parts are required for the inspection.
B. EQUIPMENT & MATERIALS
^ Protective eyewear
^ Standard heater core hose
Page 4952
Page 3279
Transmission Speed Sensor: Description and Operation
Vehicle Speed Sensor NO.1
Vehicle Speed Sensor NO.1 Circuit Description
The vehicle speed sensor outputs a 4-pulse signal for every revolution of the rotor shaft, which is
rotated by the transmission output shaft via the driven gear. After this signal is converted into a
more precise rectangular waveform by the waveform shaping circuit inside the combination meter,
it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency
of these pulse signals.
Vehicle Speed Sensor NO.2
Vehicle Speed Sensor NO.2 Circuit Description
The No.2 vehicle speed sensor detects the rotation speed of the transmission output shaft and
sends signals to the ECM. The ECM determines the vehicle speed based on these signals.
Locations
Steering Wheel: Locations
Steering Wheel Pad And Spiral Cable
Page 5561
Seat Belt Reminder Buzzer: Harness Locations
Engine Compartment
Connector Location
EA1 Cowl Wire Harness and Wire Harness (Connector Location)
EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B)
EC1 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC2 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC3 Engine No. 2 Wire and Engine Wire (Near the Starter)
ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission)
Page 4996
Steering Wheel: Service and Repair Replacement Requirements
REPLACEMENT
In the following cases, replace the steering wheel pad, steering wheel or spiral cable.
CAUTION: For removal and installation of the steering wheel pad, and be sure to follow the correct
procedure.
Page 4810
Non-Waterproof Type Connector
"Case 1" Raise the terminal retainer up to the temporary lock position.
Non-Waterproof Type Connector
"Case 2" Open the secondary locking device.
Page 132
Refer to Reset Procedure 1 for the vehicles with Electronically Controlled Automatic
Transmissions:
Page 2897
Wiring Harness Connector
E: Indicates the wiring harness and wiring harness connector. The wiring harness with male
terminal is shown with arrows.
Outside numerals are pin numbers.
The first letter of the code for each wiring harness and wiring harness connector(s) indicates the
component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and
Surrounding area, and "B" for the Body and Surrounding area.
When more than one code has the first and second letters in common, followed by numbers (e.g,
IH1, IH2), this indicates the same type of wiring harness and wiring harness connector.
F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in
parts position.
G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside
it). Junction Blocks are shaded to clearly separate
them from other parts.
H: When 2 parts both use one connector in common, the parts connector name used in wire
routing is shown in square brackets [ ].
Wiring Color
I: Indicates the wiring color.
Wire colors are indicated by an alphabetical code.
B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR =
Brown SB = Sky Blue LG = Light Green GR = Gray
The first letter indicates the basic wire color and the second letter indicates the color of the stripe.
Page 4465
(a) Set the SST on the master cylinder, and lower the pin until its tip slightly touches the piston.
SST 09737-00011
(b) Turn the SST upside down, and set it on the booster.
SST 09737-00011
(c) Measure the clearance between the booster push rod and pin head (SST).
Clearance: 0 mm (0 inch)
(d) Using SST, adjust the booster push rod length until the push rod lightly touches the pin head.
SST 09737-00020
4. INSTALL MASTER CYLINDER 5. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED
BRAKE SYSTEM 6. CHECK FOR FLUID LEAKAGE 7. CHECK AND ADJUST BRAKE PEDAL 8.
DO OPERATIONAL CHECK
Page 2320
memory, the CUW will ask you to select the calibration file(s) to delete from the Diagnostic Tester
Program Card to make room for the new calibration file.
If necessary, check the calibration file(s) to delete, as shown in Figure 11. Click DELETE.
NOTE:
If there is adequate memory to store the calibration file, skip to Step J.
I. The CUW will now delete the calibration file(s) selected (see Figure 12).
Testing and Inspection
Parking Brake Warning Switch: Testing and Inspection
INSPECT PARKING BRAKE SWITCH CONTINUITY a. Check that there is continuity terminals
with the switch ON (switch pin released). b. Check that there is no continuity between terminals
with the switch OFF (switch pin pushed in).
If operation is not as specified, replace the switch.
Page 6566
B7 (A), (B) BUCKLE SW LH
(A) 1 - (A) 2, (B) 2 - (B) 1 : Closed with driver's seat belt in use
D16 DOOR COURTESY SW FRONT LH
1 - GROUND : Closed with front LH door open
U1 UNLOCK WARNING SW
1 - 2 : Closed with ignition key in cylinder
C11 (A), C12 (B), C13 (C) COMBINATION METER
(A) 12, (B) 15 - GROUND : Always continuity (B) 10 - GROUND
: Continuity with the front LH door open (Standard cab) : Continuity with the each LH door open
(Access cab)
(C) 1 - GROUND : Continuity with the ignition key in cylinder
(B) 9 - GROUND : Continuity with the driver's seat belt in use
(B) 5 - GROUND : Always approx. 12 volts
(A) 7 - GROUND : Approx. 12 volts with the ignition SW at ON or ST position
Page 5356
- Do not release the airbag activation prevention mechanism unless specifically directed by the
troubleshooting procedure.
- If the inserted paper is too thick the terminal and short spring may be damaged, so always use
paper with the same thickness as the male terminal.
Locations
Page 1980
CHART 7
Description and Operation
Transmission Position Switch/Sensor: Description and Operation
PARK / NEUTRAL POSITION SWITCH
Engine Control System
The park/neutral position switch comes on when the shift lever is in the N or P position. When it
comes on, terminal NSW of the ECM is grounded to the body ground via the starter relay, thus the
terminal NSW voltage becomes 0 V. When the shift lever is in the D, 2, L or R position, the
park/neutral position switch goes off, so the voltage of the terminal NSW becomes battery voltage
and the voltage of the ECM internal power source. If the shift lever is moved from the N position to
the D position, this signal is used for air-fuel ratio correction and for idle speed control (estimated
control), etc.
Transmission Control System
The park/neutral position switch detects the shift lever position and sends signals to the ECM.
The ECM receives signals (NSW, R, D, 2 and L) from the park/neutral position switch.
Page 94
Continuity And Resistance Check
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Continuity And Resistance Check
C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the
electrical circuit.
Finding A Short Circuit
Finding A Short Circuit
Finding A Short Circuit
A. Remove the blown fuse and disconnect all loads of the fuse.
Page 3525
b. Connect the oil cooler pipe.
Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.)
c. Install the 3 clamps with the 3 bolts.
7. FILL ATF AND CHECK FLUID LEVEL
Page 3807
Install the No.1 vehicle speed sensor with the bolt.
Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.)
6. CONNECT NO. I VEHICLE SPEED SENSOR CONNECTOR
Vehicle Speed Sensor NO.2
Vehicle speed Sensor NO.2 on-vehicle repair
1. DISCONNECT NO. 2 VEHICLE SPEED SENSOR CONNECTOR
2. REMOVE NO. 2 VEHICLE SPEED SENSOR
a. Remove the bolt and No. 2 vehicle speed sensor. b. Remove the O-ring from the No. 2 vehicle
speed sensor.
3. INSTALL NO. 2 VEHICLE SPEED SENSOR
a. Coat a new O-ring with ATF and install it to the No. 2 vehicle speed sensor. b. Install the No. 2
vehicle speed sensor with the bolt.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
4. CONNECT NO. 2 VEHICLE SPEED SENSOR CONNECTOR
Page 1839
Camshaft Position Sensor: Testing and Inspection
ON-VEHICLE INSPECTION
NOTE: "Cold" and "Hot" in these sentences express the temperature of the coils themselves.
"Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F).
INSPECT CAMSHAFT POSITION SENSOR
a. Disconnect the camshaft position sensor connector.
Resistance
b. Using an ohmmeter, measure the resistance between terminals.
If the resistance is not as specified, replace the camshaft position sensor.
c. Reconnect the camshaft position sensor connector.
Page 1487
Spark Plug: Specifications Torque Specification
Spark Plug x Cylinder Head ................................................................................................................
......................................................................... 18 Nm
Page 6219
e. Inspect the RES (resume) switch.
1. Push the main switch ON. 2. Drive at a desired speed (40 km/h (25 mph) or higher). 3. When
operating one of the followings, check that the cruise control system is cancelled and that the
normal driving mode is reset.
- Depress the brake pedal.
- Shift into except D position.
- Pull the cruise control switch for CANCEL.
4. After the control switch is turned to RES/ACC at the driving speed of more than 40 km/h (25
mph), check that the vehicle restores the speed
before the cancellation.
Page 3180
Crankshaft Position Sensor: Mechanical Specifications
Torque: ................................................................................................................................................
.................................. 6.5 N.m (65 kgf.cm, 58 in.lbf)
Page 4150
3. MEASURE DISC RUNOUT
Using a dial indicator, measure the disc runout at a position 10 mm (0.39 inch) from the outside
edge. Maximum disc runout: 0.07 mm (0.0028 inch) If the runout is greater than the maximum,
replace the disc or grind it on a "On-Car" brake lathe.
HINT: Before measuring the runout, confirm that the front hub bearing play is within the
specification.
4. IF NECESSARY, ADJUST DISC RUNOUT
(a) Remove the hub nuts and disc. Reinstall the disc 1/6 of a turnround from its original position on
the hub. Install and torque the hub nuts.
Torque: 113 Nm (1,150 kgf-cm, 83 ft. lbs.)
(b) Remeasure the disc runout. Make a note of the runout and the disc's position on the hub. (c)
Repeat (a) and (b) until the disc has been installed on the 4 remaining hub positions.
If the minimum runout recorded in (a) to (c) is less than the maximum disc runout, install the disc in
that position. If the minimum runout recorded in (a) to (c) is greater than the maximum disc runout,
replace the disc and repeat step 3.
REASSEMBLY
Reassembly is in the reverse order of disassembly.
NOTICE: Apply lithium soap tease glycol grease end disc brake grease to the parts indicated by
the arrows.
Page 1996
CHART 24
Page 5342
Check cuts, minute cracks or marked discoloration on the steering wheel pad top surface and in
the grooved portion.
VEHICLE INVOLVED IN COLLISION AND AIRBAG IS NOT DEPLOYED
a. Do a diagnostic system check.
See: Air Bag Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble
Codes/Displaying & Reading Trouble Codes
b. Do a visual check which includes the following items with the steering wheel pad (with airbag)
removed from the vehicle.
- Check cuts, minute cracks or marked discoloration on the steering wheel pad top surface and in
the grooved portion.
- Check cuts and cracks in wire harnesses, and chipping in connectors.
- Check the deformation of the horn button contact plate on the steering wheel pad.
HINT: If the horn button contact plate of the steering wheel pad is deformed, never repair it. Always
replace the steering wheel pad with a new one.
- There should be no interference between the steering wheel pad and steering wheel, and the
clearance should be uniform all the way around when the new steering wheel pad is installed on
the steering wheel.
CAUTION: Be sure to follow the correct procedure, for removal and installation of the steering
wheel pad.
VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED
a. Do a diagnostic system check. b. Do a visual check which includes the following items with the
steering wheel pad (with airbag) removed from the vehicle.
- Check the deformation on the horn button contact plate of the steering wheel.
- Check the damage on the spiral cable connector and wire harness.
HINT:
Page 1990
Page 90
The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit
breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery
power is supplied to each system are explained. Since all System Circuit diagrams start from the
power source, the power source system must be fully understood.
Page 4878
a. Using a micrometer, measure the height, thickness and length of the 10 plates.
Minimum height: 8.6 mm (0.339 inch) Minimum thickness: 1.397 mm (0.0550 inch) Minimum
length: 14.991 mm (0.5902 inch)
b. Using a feeler gauge, measure the clearance between the rotor groove and plate.
Maximum clearance: 0.033 mm (0.0013 inch)
If it is more than the maximum, replace the plate and/or rotor with one having the same mark
stamped on the cam ring. Inscribed mark: 1, 2, 3, 4 or None
HINT: There are 5 vane plate lengths with the rotor and cam ring marks:
3. INSPECT FLOW CONTROL VALVE
Page 6188
Splice Location
I1 Cowl Wire
I2 Cowl Wire
I3 Cowl Wire
I4 Cowl Wire
I5 Cowl Wire
I6 Cowl Wire
I7 Engine Wire
I8 Engine Wire
I9 Engine Wire
I10 Engine Wire
I11 Engine Wire
I12 Engine Wire
I13 Engine Wire
I14 Engine Wire
I15 Engine Wire
I16 Cowl Wire
Body
Splice Location (Access Cab)
B1 Speaker Tweeter Wire LH
B2 Front Door LH Wire
B3 Front Door LH Wire
B4 Roof Wire
B5 Speaker Tweeter Wire RH
B6 B7
Front Door RH Wire
B8 Front Door RH Wire
B9 Rear Door No. 1 Wire RH
B10 Frame Wire
Page 6363
Clock: Pinout Values and Diagnostic Parameters
I24 (A), I25 (B) INTEGRATION CONTROL AND PANEL
(B) 5 - GROUND : Always approx. 12 volts (Power for clock) (B) 13 - GROUND : Approx. 12 volts
with ignition SW at ON or ACC position (Power for indication) (A) 7 - GROUND : Approx. 12 volts
with light control SW at TAIL or HEAD position (Signal of indication) (B) 1 - GROUND : Always
continuity
Page 2751
CHART 1
Page 3332
DOWNLOAD FILE TO TESTER
2. Download the calibration file to the Diagnostic Tester.
The Calibration Update Wizard (CUW) is a new application on TIS which downloads calibration
files from TIS onto the Diagnostic Tester Program Card.
NOTE:
Before you begin, ensure that the Diagnostic Tester is equipped with software version 8.0a, or
later. Only a 12 MB program card (P/N 01002593-005) may be used for this process.
A. Before downloading a new calibration file from TIS, check the current calibration files stored on
the Diagnostic Tester Program Card by following the screen flow shown (Figure 4).
NOTE:
^ Screen D may be blank if no calibrations are stored on the Diagnostic Tester Program Card.
^ If the desired calibration file is already on the Diagnostic Tester, proceed to Step 3 (Reprogram
ECU with Tester shown).
^ A maximum of two calibration files may be loaded on the tester at one time with Diagnostic Tester
software version 10.2a and later. Prior versions may store up to four calibration files.
Page 4324
Torque: 15 N.m (155 kgf.cm, 11 ft.lbf)
28. W/ABS:
CONNECTABS SPEED SENSOR AND WIRE HARNESS CLAMP
Connect the ABS speed sensor and wire harness clamp to the steering knuckle with the 2 bolts.
Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
29. 4WD:
INSTALL DRIVE SHAFT LOCK NUT
A. While applying the brakes, tighten the nut.
Torque: 235 N.m (2,400 kgf.cm, 173 ft.lbf)
B. Install the lock cap and a NEW cotter pin.
If the holes for the cotter pin are not aligned, tighten the nut further up to 600.
30. 2WD:
INSTALL GREASE CAP
31. INSTALL FRONT WHEEL
NOTE:
Do NOT use air wrench.
Torque: 110 N.m (1,150 kgf.cm, 83 ft.lbf)
32. DEPRESS BRAKE PEDAL SEVERAL TIMES
33. FILL THE BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM
34. CHECK ABS SPEED SENSOR SIGNAL (SEE REPAIR MANUAL)
Page 613
CHART 1
Page 5910
II. Identification of Affected Vehicles
Page 2053
Voltage: 4.2 - 4.8 V
d. Turn the ignition switch OFF. e. Reconnect the vacuum hose to the vapor pressure sensor.
Page 4095
4. With ABS:
Disconnect ABS speed sensor and wire harness clamp from steering knuckle.
Remove the 2 bolts and disconnect the ABS speed sensor and wire harness clamp from the
steering knuckle.
5. Disconnect brake line.
Using the following SST, disconnect the brake line. Use a container to catch the brake fluid.
SST P/N: 09023-00100
6. Remove brake caliper and disc.
A. Remove the bolt and brake line clamp from the steering knuckle.
B. Remove the 2 bolts, brake caliper, and disc.
7. Remove shock absorber.
Page 2748
Page 2653
Page 220
Wiring Harness Connector
E: Indicates the wiring harness and wiring harness connector. The wiring harness with male
terminal is shown with arrows.
Outside numerals are pin numbers.
The first letter of the code for each wiring harness and wiring harness connector(s) indicates the
component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and
Surrounding area, and "B" for the Body and Surrounding area.
When more than one code has the first and second letters in common, followed by numbers (e.g,
IH1, IH2), this indicates the same type of wiring harness and wiring harness connector.
F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in
parts position.
G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside
it). Junction Blocks are shaded to clearly separate
them from other parts.
H: When 2 parts both use one connector in common, the parts connector name used in wire
routing is shown in square brackets [ ].
Wiring Color
I: Indicates the wiring color.
Wire colors are indicated by an alphabetical code.
B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR =
Brown SB = Sky Blue LG = Light Green GR = Gray
The first letter indicates the basic wire color and the second letter indicates the color of the stripe.
Vehicle - Long Term Storage Guidelines
Paint: 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 2247
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 3612
Valve Body: Service and Repair Upper Valve Body
1. COMPONENTS
2. SPRING AND RETAINER
Page 3113
Throttle Position Sensor: Service and Repair
Refer to Fuel Delivery and Air Induction / Throttle Body / Service and Repair, for removal and
installation of this component.
Page 5401
HINT: When scrapping vehicle equipped with an SRS or disposing of a steering wheel pad (with
airbag), always first deploy the airbag in accordance with the procedure described. If any
abnormality occurs with the airbag deployment, contact the SERVICE DEPT. of the TOYOTA
MOTOR SALES, U.S.A., INC.
CAUTION:
- Never dispose of a steering wheel pad which has an undeployed airbag.
- The airbag produces a sizeable exploding sound when it deploys, so perform the operation
out-of-doors and where it will not create a nuisance to nearby residents.
- When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool).
Perform the operation in a place away from electrical noise. SST 09082-00700
- When deploying an airbag, perform the operation at least 10 m (33 ft) away from the steering
wheel pad.
- The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30
minutes after deployment.
- Use gloves and safety glasses when handling a steering wheel pad with the deployed airbag.
- Always wash your hands with water after completing the operation.
- Do not apply water, etc. to a steering wheel pad with the deployed airbag.
DEPLOYMENT WHEN DISPOSING OF STEERING WHEEL PAD ONLY
NOTE:
- When disposing of the steering wheel pad (with airbag) only, never use the customers vehicle to
deploy the airbag.
- Be sure to follow the procedure given below when deploying the airbag.
HINT: Have a battery ready as the power source to deploy the airbag.
a. Remove the steering wheel pad.
CAUTION: When storing the steering wheel pad, keep the upper surface of the pad facing upward.
b. Remove the steering wheel pad connector.
Remove the connector on the rear surface of the steering wheel pad from the bracket.
Page 3445
BJ Inside of Rear Door LH
BK Inside of Rear Door RH
BL Surrounding of the Front of the Fuel Tank
Connector Location
BA1 Front Door LH Wire and Wire Harness (Connector Location)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel)
BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel)
BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel)
BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Page 179
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 2052
Evaporative Vapor Pressure Sensor: Testing and Inspection
VAPOR PRESSURE SENSOR
INSPECTION
1. INSPECT POWER SOURCE VOLTAGE OF VAPOR PRESSURE SENSOR
a. Disconnect the vapor pressure sensor connector. b. Turn the ignition switch ON. c. Using a
voltmeter, measure the voltage between connector terminals VC and E2 of the wiring harness side.
Voltage: 4.5 - 5.5 V
d. Turn the ignition switch OFF. e. Reconnect the vapor pressure sensor connector.
2. INSPECT POWER OUTPUT OF VAPOR PRESSURE SENSOR
a. Turn the ignition switch ON. b. Disconnect the vacuum hose from the vapor pressure sensor. c.
Connect a voltmeter to terminals PTNK and E2 of the ECM, and measure the output voltage under
these conditions:
1. Apply vacuum (2.0 kPa (15 mmHg, 0.59 in.Hg)) to the vapor pressure sensor.
Voltage: 1.3 - 2.1 V
2. Release the vacuum from the vapor pressure sensor.
Voltage: 3.0 - 3.6 V
3. Apply pressure (1.5 kPa (15 gf/sq.cm, 0.22 psi)) to the vapor pressure sensor.
Page 3201
Spark Plug: Application and ID
Recommended Spark Plugs
DENSO K20R-U
NGK BKR6EYA
Page 3912
Waterproof Type Connector
B: For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White
: Gray
Black or White : Dark Gray
Gray or White : Black
Waterproof Type Connector
"Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up
to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Waterproof Type Connector
"Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Specifications
Brake Master Cylinder: Specifications
Brake Master Cylinder Reservoir Retaining Screw 1.8 Nm
Retaining Bracket 13 Nm
Hydraulic Brake Lines 15 Nm
Piston Stopper Bolt 10 Nm
Page 2901
The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit
breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery
power is supplied to each system are explained. Since all System Circuit diagrams start from the
power source, the power source system must be fully understood.
Page 1253
Valve Spring Shim: Service and Repair
For further information regarding this component and the system that it is a part of, please refer to
Valve Clearance; Testing and Inspection.
Page 599
Engine Bank Identification
Ground Locations
Seat Belt Reminder Buzzer: Ground Locations
Engine Compartment
Ground Location
EA Front Left Fender
EB Rear Bank of Right Cylinder
EC Rear Bank of Left Cylinder
Connector Location
EA1 Cowl Wire Harness and Wire Harness (Connector Location)
EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B)
EC1 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC2 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC3 Engine No. 2 Wire and Engine Wire (Near the Starter)
ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission)
Specifications
Compression Check: Specifications
Compression Pressure ........................................................................................................................
...................................................... 1,324 kPa or More Minimum Pressure .........................................
...........................................................................................................................................................
981 kPa Difference Between Each Cylinder ........................................................................................
......................................................................... 98 kPa or Less
Page 3095
Throttle Body: Testing and Inspection
ON-VEHICLE INSPECTION
1. REMOVE THROTTLE BODY COVER
2. INSPECT SYSTEM OPERATION
a. Check that the throttle linkage moves smoothly.
b. Inspect the throttle control motor for operating sound.
1. Turn the ignition switch ON. 2. When turning the accelerator pedal position sensor lever, check
the running sound of the motor. Also, check that there is no friction sound.
If operation is not as specified, check the throttle control motor (See step 3), wiring and ECM.
c. Inspect the accelerator pedal position sensor.
1. Connect the TOYOTA hand-held tester to the DLC3. 2. Check that the MIL does not light up. 3.
When turning the accelerator pedal position sensor lever to the full-open position, check that the
throttle valve opening percentage
(THROTTLE POS) of the CURRENT DATA shows the standard value.
Standard throttle valve opening percentage: 60 % or more
If operation is not as specified, check that the accelerator pedal position sensor (See step 5), wiring
and ECM.
Page 4831
Page 2634
Glossary Of Terms And Symbols (Part 2)
Page 543
A. The Diagnostic Tester displays 17" as a value of the Time $81" (see illustration).
B. Find the Conversion Factor value of Time $81" in the O2S Failure Threshold chart. 0.3906 is
specified for Time $81 in this chart.
C. Multiply "17" in step "A" by 0.3906 (Conversion Factor) in step "B."
17 x 0.3906 = 6.6%
D. If the answer is within the Standard Value of TEST LIMIT, the Time $81" can be confirmed to be
normal.
NOTE:
^ "LOW SW V" indicates the O2S voltage when the O2S status changes from rich to lean.
^ "HIGH SW V" indicates the O2S voltage when the O2S status changes from lean to rich.
^ If the O2S voltage is lower than "LOW SW V," the O2S status is lean.
^ If the O2S voltage is higher than "HIGH SW V," the O2S status is rich.
NOTE:
Before the O2S Monitor completes or after the ignition switch is turned OFF, the Diagnostic Tester
displays the viewable upper limit or a lower limit of the test value (example: 0 V, 1.275 V, Os
[seconds], 10.2s, 0 and 255).
Page 5730
Glossary Of Terms And Symbols (Part 2)
Page 4835
Page 4693
Non-Waterproof Type Connector
"Case 1" Raise the terminal retainer up to the temporary lock position.
Non-Waterproof Type Connector
"Case 2" Open the secondary locking device.
Page 711
Camshaft Position Sensor: Mechanical Specifications
Torque: ................................................................................................................................................
.................................. 7.5 N.m (80 kgf.cm, 66 in.lbf)
Page 2016
If you have no TOYOTA hand-held tester, measure voltage between terminals VPA and E2 of the
ECM connector.
d. Inspect the air assist system.
1. Start the engine and check that the MIL does not light up. 2. Allow the engine to warm up to
normal operating temperature. 3. Turn the A/C compressor ON to OFF, and check the idle speed.
Idle speed (Transmission in neutral): 700 ± 50 rpm
NOTE: Perform inspection under condition without electrical load.
e. After checking the above (b) to (d), perform the driving test and check that there is no sense of
incongruity.
3. INSPECT THROTTLE CONTROL MOTOR
a. Disconnect the throttle control motor connector. b. Using an ohmmeter, measure the motor
resistance between terminal 1 (M+) and 2 (M-).
Motor resistance: 0.3 - 100 ohms at 20 °C (68 °F)
If the resistance is not as specified, replace the throttle control motor.
c. Using an ohmmeter, measure the clutch resistance between terminal 3 (CL-) and 4 (CL+).
Clutch resistance: 4.2 - 5.2 ohms at 20 °C (68 °F)
If the resistance is not as specified, replace the throttle control motor.
d. Reconnect the throttle control motor connector.
Locations
Transmission Speed Sensor: Locations
Vehicle Speed Sensor NO.1
Vehicle Speed Sensor NO.2
Vehicle Speed Sensor NO.1
Page 3898
Body
Connector Location (Standard Cab)
BA1 Front Door LH Wire and Speaker Tweeter Wire LH (Inside of Front Door LH)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Seat
Connector Location
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
BJ1 Seat No. 1 Wire and Seat No. 2 Wire (Under the Driver's Seat)
Page 5344
AIRBAG SENSOR FRONT
INSPECTION
1. VEHICLES NOT INVOLVED IN COLLISION
Do a diagnostic system check. *
2. VEHICLES INVOLVED IN COLLISION
a. Do a diagnostic system check. *
b. If the front fender of the car or its periphery is damaged, do a visual check for damage to the
front airbag sensor, which includes the following
items even if the airbag was not deployed: Check the bracket deformation.
- Check the paint peeling off the bracket.
- Check the cracks, dents or chips in the case.
- Check the cracks, dents, chipping and scratches in the connector.
- Check the peeling off of the label or damage to the serial number.
* Refer to SRS Warning Light Check, and How to Display and Read Diagnostic Trouble Codes.
REPLACEMENT REQUIREMENTS
In the following cases, replace the front airbag sensor.
- If the SRS has been deployed in a collision. (Replace both the left and right airbag sensors.)
- If the front airbag sensor has been found to be faulty in troubleshooting.
- If the front airbag sensor has been found to be faulty during checking items.
- If the front airbag sensor has been dropped.
CAUTION: Be sure to follow the correct procedure for removal and installation of the front airbag
sensor.
Description and Operation
Data Link Connector, A/T: Description and Operation
The vehicle's ECM uses the V.P.W. (Variable Pulse Width) for communication to comply with SAE
J1850. The terminal arrangement of DLC3 complies with SAE J1962 and matches the V.P.W.
format.
Page 4639
Terminal Retainer
Push the terminal retainer down to the temporary lock position.
c. Release the locking lug from terminal and pull the terminal out from rear.
4. INSTALL TERMINAL TO CONNECTOR
a. Insert the terminal.
HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug
locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position.
Page 5574
Seat Belt Reminder Buzzer: Diagnostic Aids
Voltage Check
Voltage Check
Voltage Check
A. Establish conditions in which voltage is present at the check point.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(SW 2 OFF)
B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or
component terminal. This check can be done with a test light instead of a voltmeter.
Continuity and Resistance Check
Continuity and Resistance Check
Continuity And Resistance Check
A. Disconnect the battery terminal or wire so there is no voltage between the check points. B.
Contact the two leads of an ohmmeter to each of the check points.
Page 6547
Body
Connector Location (Access Cab)
BA1 Front Door LH Wire and Wire Harness (Connector Location)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel)
BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel)
BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel)
BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Page 4961
c. Expand a new teflon ring with your fingers.
NOTICE: Be careful not to over-expand the teflon ring.
d. Coat the teflon ring with power steering fluid.
e. Install the teflon ring to the steering rack, and settle it down with your fingers.
5. IF NECESSARY, REPLACE TEFLON RINGS
a. Using a screwdriver, remove the 4 teflon rings from the control valve assembly.
NOTICE: Be careful not to damage the grooves for the teflon ring.
b. Expand 4 new teflon rings with your fingers.
NOTICE: Be careful not to overexpand the teflon ring.
c. Coat the teflon rings with power steering fluid. d. Install the teflon rings to the control valve
assembly, and settle them down with your fingers.
e. Carefully slide the tapered end of SST over the teflon rings until they fit to the control valve
assembly.
SST 09631-20081
NOTICE: Be careful not to damage the teflon rings.
Page 4688
Glossary Of Terms And Symbols (Part 1)
Page 399
Instrument Panel
Connector Location
IA1 Engine Room Main and Cowl Wire (Left Kick Panel)
IA2 Engine Room Main and Cowl Wire (Left Kick Panel)
IA3 Engine Room Main and Cowl Wire (Left Kick Panel)
IA4 Engine Room Main and Cowl Wire (Left Kick Panel)
IB1 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IB2 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IB3 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IC1 Cowl Wire and Roof Wire (Left Side of Instrument Panel)
Instrument Panel
Connector Location
ID1 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH)
ID2 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH)
IE1 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IE2 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IE3 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IF1 Front Door RH Wire and Cowl Wire (Right Kick Panel)
IF2 Front Door RH Wire and Cowl Wire (Right Kick Panel)
IF3 Front Door RH Wire and Cowl Wire (Right Kick Panel)
Page 6496
Audible Warning Device Control Module: Harness Locations
Engine Compartment
Connector Location
EA1 Cowl Wire Harness and Wire Harness (Connector Location)
EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B)
EC1 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC2 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC3 Engine No. 2 Wire and Engine Wire (Near the Starter)
ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission)
Page 4660
B: Junction Connector
Indicates a connector which is connected to a short terminal.
Junction connector in this include a short terminal which is connected to a number of wire
harnesses. Always perform inspection with the short terminal installed. (When installing the wire
harnesses, the harnesses can be connected to any position within the short terminal grouping.
Accordingly, in other vehicles, the same position in the short terminal may be connected to wire
harness from a different part.) Wire harness sharing the same short terminal grouping ha the same
color.
C: Parts Code
The first letter of the code is taken from the first letter of part, and the numbers indicates its order in
parts which start with the same letter.
D: Connector Color
Connectors not indicated are milky white in color.
How to Read Ground Points
HOW TO READ GROUND POINTS
Page 6494
Body
Splice Location (Standard Cab)
B1 Speaker Tweeter Wire LH
B2 Front Door LH Wire
B3 Front Door LH Wire
B4 Roof Wire
B5 Speaker Tweeter Wire RH
B6 B7
Front Door RH Wire
B10 Frame Wire
Seat
Locations
Anti-Lock Brake System
Page 1941
CHART 30
Page 5455
Supplemental Restraint System
Page 2000
Page 4300
A. Using snap ring pliers, remove the snap ring.
B. Using the following SSTs and a press, remove the bearing from the steering knuckle.
SST P/N: 09950-60020
(09951-00810)
SST P/N: 09950-70010
(09951-07150)
16. Install new bearing.
A. Using the following SSTs and a press, install a NEW bearing to the steering knuckle.
SST P/N: 09527-17011
SST P/N: 09950-60020 (09951-00910)
B. Using snap ring pliers, install a NEW snap ring.
17. Install new oil seal (outside).
A. Using the following SSTs and a plastic hammer, install a NEW oil seal (outside).
SST P/N: 09223-15030
Page 5770
B: Junction Connector
Indicates a connector which is connected to a short terminal.
Junction connector in this include a short terminal which is connected to a number of wire
harnesses. Always perform inspection with the short terminal installed. (When installing the wire
harnesses, the harnesses can be connected to any position within the short terminal grouping.
Accordingly, in other vehicles, the same position in the short terminal may be connected to wire
harness from a different part.) Wire harness sharing the same short terminal grouping ha the same
color.
C: Parts Code
The first letter of the code is taken from the first letter of part, and the numbers indicates its order in
parts which start with the same letter.
D: Connector Color
Connectors not indicated are milky white in color.
How to Read Ground Points
HOW TO READ GROUND POINTS
Page 6422
The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit
breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery
power is supplied to each system are explained. Since all System Circuit diagrams start from the
power source, the power source system must be fully understood.
Page 5633
Seat Belt Tensioner: Removal and Replacement
SEAT BELT PRETENSIONER
REMOVAL
NOTE:
- If the wiring connector of the seat belt pretensioner is disconnected with the ignition switch at ON
or ACC, diagnostic trouble codes will be recorded.
- Never use seat belt pretensioner from another vehicle. When replacing parts, replace them with
new parts.
1. Standard cab:
REMOVE FRONT SEAT OUTER BELT
a. Remove the 5 screws and front door scuff plate.
b. Remove the front pillar garnish.
1. Using a screwdriver, remove the caps.
HINT: Tape the screwdriver tip before use.
2. Using a torx driver, remove the torx screws and assist grip.
Torx driver: T30 (Part No. 09041-00030 or locally manufactured tool)
3. Using a screwdriver, remove the front pillar garnish.
HINT: Tape the screwdriver tip before use.
c. Using a screwdriver, remove the back panel upper garnish.
Page 2877
Vehicle Speed Sensor: Testing and Inspection
INSPECT VEHICLE SPEED SENSOR OPERATION
a. Connect the positive (+) lead from the battery to terminal 1 and negative (-) lead to terminal 2. b.
Connect the positive (+) lead from the tester to terminal 3 and the negative (-) lead to terminal 2. c.
Rotate the shaft. d. Check that there is voltage change from approx. 0 V to 11 V or more between
terminals 2 and 3.
HINT: The voltage change should be performed 4 times for every revolution of the speed sensor
shaft.
If operation is not as specified, replace the sensor.
Page 3409
Data Link Connector, A/T: Testing and Inspection
DLC 3 Inspection
The vehicle's ECM uses the V.P.W. (Variable Pulse Width) for communication to comply with SAE
J1850. The terminal arrangement of DLC3 complies with SAE J1962 and matches the V.P.W.
format.
HINT: If your display shows "UNABLE TO CONNECT TO VEHICLE" when you have connected the
cable of OBD II scan tool or TOYOTA hand-held tester to DLC3, turned the ignition switch ON and
operated the scan tool, there is a problem on the vehicle side or tool side. If communication is
normal when the tool is connected to another vehicle, inspect DLC3 on the original vehicle. If
communication is still not possible when the tool is connected to another vehicle, the problem is
probably in the tool itself, so consult the Service Department listed in the tool's instruction manual.
Page 6071
Page 4263
Applicable Warranty*:
This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or
36,000 miles, whichever occurs first, from the vehicle's in-service date.
*Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Page 4429
Load Compensator: Service and Repair Disassembly and Assembly
DISASSEMBLY
1. REMOVE VALVE BRACKET
(a) Remove the nut, washer, bolt and 2 plate washers. (b) Remove the 2 nuts, 2 washers, set plate
and valve bracket from the valve body.
2. DISCONNECT SPRING FROM VALVE
Using pliers, remove the clip, and remove the spring from the valve.
Page 5131
e. Bend the spring clips.
Using a hammer, bend the spring clips into the position.
INSTALLATION
1. INSTALL LEAF SPRING
Install the shackle and leaf spring with 3 bolts, washers and nuts. Torque: 170 Nm (1,735 kgf-cm,
125 ft. lbs.)
HINT: After stabilizing the suspension, torque the nuts.
2. INSTALL U-BOLTS
Install the spring bumper, spring seat and 2 U-bolts with the 4 washers and nuts. Torque: 133 Nm
(1,350 kgf-cm, 98 ft. lbs.)
HINT: Tighten the U-bolts so that the lengths of all the U-bolts under the spring seat are the same.
3. INSTALL REAR WHEEL
Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.)
4. REMOVE SAFETY STANDS
Engine Controls - ECU Reprogramming Procedure
Technical Service Bulletin # SS002R-01 Date: 030922
Engine Controls - ECU Reprogramming Procedure
SPECIAL SERVICE TOOLS SS002-01 REVISED
March 9, 2001
Title: ECU FLASH REPROGRAMMING PROCESS
Models: Applicable Models
TSB REVISION NOTICE:
^ September 22, 2003: Models added - 2002 (and later) Solara, 2003 (and later) Corolla and
Matrix, and 2004 models; Operation Procedures updated for CAN Interface Module with the latest
Diagnostic Tester software (v. 10.1a and 10.2a), Calibration Update Wizard (v.6.0), and calibration
files.
^ June 20, 2003: Camry and Tacoma models added; Special Service Tools table updated. The
previous TSB should be discarded.
Introduction
Electronic Control Unit (ECU) is a Toyota term used to describe integrated computerized devices
responsible for managing the operation of a system or sub-system. For the purposes of this
bulletin, the term "ECU" is used as a generic label for the following SAE J1930 standard
references:
^ Powertrain Control Module (PCM)
^ Engine Control Module (ECM)
^ Transmission Control Module (TCM)
^ or any other Toyota specific control unit
Flash reprogramming allows the ECU software to be updated for changes in vehicle calibrations
without removing the ECU from the vehicle. Flash calibration updates for specific vehicle
models/ECUs will be released as field fix procedures described in individual service bulletins. This
bulletin details the ECU flash reprogramming process and the applications within the Technical
Information System (TIS) and the Toyota Diagnostic Tester used for reprogramming.
Flash calibration updates can only be applied to the vehicle/ECU combination for which they are
intended. ECUs have internal security that will not allow them to be programmed with another
ECU's information.
Applicable Vehicles ^
2001 (and later) model year 4Runner, Highlander, Land Cruiser, RAV4, Sequoia and Tundra
vehicles.
^ 2002 (and later) model year Camry, Solara and Tacoma vehicles.
^ 2003 (and later) model year Corolla and Matrix vehicles.
^ All 2004 (and later) model year Toyota vehicles except Celica, MR2 Spyder, Avalon, and Tacoma
(3RZ-FE engine)
Warranty Information
Parts Information
NOTE:
Authorized Modifications Labels may be ordered in packages of 25 from the Materials Distribution
Center (MDC) through the TDN Dealer Support
Page 2193
Crankshaft Position Sensor: Testing and Inspection
INSPECTION
NOTE: "Cold" and "Hot" in these sentences express the temperature of the coils themselves.
"Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F).
INSPECT CRANKSHAFT POSITION SENSOR
Resistance
Using an ohmmeter, measure the resistance between the terminals.
If the resistance is not as specified, replace the crankshaft position sensor.
Page 3913
Terminal Retainer
Push the terminal retainer down to the temporary lock position.
c. Release the locking lug from terminal and pull the terminal out from rear.
4. INSTALL TERMINAL TO CONNECTOR
a. Insert the terminal.
HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug
locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position.
Diagram Information and Instructions
Key Reminder Switch: Diagram Information and Instructions
Key to Diagrams
A: System Title
B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to
distinguish it from the J/B
Example: 1 Indicates Relay Block No.1
C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type,
or specification is different.
D: Indicates related system.
Page 3918
Transmission Mode Indicator - A/T: Description and Operation
ELECTRONICALLY CONTROLLED TRANSMISSION AND A/T INDICATOR
SYSTEM OUTLINE
The electronically controlled transmission electrically controls the, throttle pressure, lock-up
pressure, and accumulator pressure etc. through the solenoid valve.
The electronically controlled transmission is a system which precisely controls the gear shift timing
and lock-up timing in response to the vehicle's driving conditions and the engine condition detected
by various sensors. It makes smooth driving possible by shift selection of the gear which is the
most appropriate to the driving conditions at that time, and by preventing downing, squat and gear
shift shock when starting off.
1. GEAR SHIFT OPERATION
When driving, the engine warm up condition is input as a control signal from the engine coolant
temperature sensor to TERMINAL THW of the engine control module, and the vehicle speed is
input to TERMINAL SP2+ of the engine control module from the vehicle speed sensor. At the same
time, the throttle valve opening signal from the throttle position sensor is input to TERMINALS VTA,
VTA2 of the engine control module as a throttle angle signal. Based on these signals, the engine
control module selects the best shift position for the driving conditions and sends current to the
electronically controlled transmission solenoid.
2. LOCK-UP OPERATION
When the engine control module decides based on each signal that the lock-up condition has been
met, the current flows from the engine control module TERMINAL SL to TERMINAL 7 of the
electronically controlled transmission solenoid to GROUND.
3. STOP LIGHT SW CIRCUIT
If the brake pedal is depressed (Stop light SW on) when driving in lock-up position, a signal is input
to TERMINAL STP of the engine control module. As a result, the engine control module cuts the
current to the solenoid to release the lock-up.
4. OVERDRIVE CIRCUIT
- O/D main SW on When the O/D main SW is switched to ON position, a signal is input to
TERMINAL ODMS of the engine control module, and enables shift change to the overdrive range,
through the control of the engine control module.
- O/D main SW off When the O/D main SW is switched to OFF position, a signal is input to
TERMINAL ODMS of the engine control module, and prohibits shift change to the overdrive range
through the control of the engine control module. When in the overdrive range already, shift down
is made.
Page 1812
Fuel Pump Relay: Testing and Inspection Circuit Opening Relay
CIRCUIT OPENING RELAY
INSPECTION
1. REMOVE RELAY BOX COVER
2. REMOVE CIRCUIT OPENING RELAY (Marking: CIR OPN)
3. INSPECT CIRCUIT OPENING RELAY CONTINUITY
a. Using an ohmmeter, check that there is continuity between terminals 1 and 2.
If there is no continuity, replace the relay.
b. Check that there is no continuity between terminals 3 and 5.
If there is continuity, replace the relay.
4. INSPECT CIRCUIT OPENING RELAY OPERATION
a. Apply battery positive voltage across terminals 1 and 2. b. Using an ohmmeter, check that there
is continuity between terminals 3 and 5.
If there is no continuity, replace the relay.
5. REINSTALL CIRCUIT OPENING RELAY
6. REINSTALL RELAY BOX COVER
Page 182
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).
Locations
Instrument Panel
Page 3741
Body
Splice Location (Standard Cab)
B1 Speaker Tweeter Wire LH
B2 Front Door LH Wire
B3 Front Door LH Wire
B4 Roof Wire
B5 Speaker Tweeter Wire RH
B6 B7
Front Door RH Wire
B10 Frame Wire
Seat
Locations
Fusible Link: Locations
Driver Side J/B And Integration Relay
Page 5935
II. Identification of Affected Vehicles
Page 2435
CHART 22
Page 2758
CHART 12
CHART 13
Page 1637
Water Pump: Diagrams
WATER PUMP REPLACEMENT W/ RELATED COMPONENTS
Part 1 of 3
Page 1324
Oil Cooler: Service and Repair
REMOVAL
1. DRAIN ENGINE COOLANT 2. REMOVE OIL FILTER
Page 2542
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 1800
Windows 2000 SP2 or later Windows XP Pro SP1 or later
For more information about the J2534 devices listed above, contact the vendors. To report
compatibility problems with listed hardware/software, please contact the device manufacturer.
For more information about Toyota vehicle reprogramming CDs or to report problems running
Toyota's Calibration Update Wizard software, please contact Toyota.
OBTAINING A CALIBRATION CD
The Calibration CD is compatible with the above mentioned scantools and J2534 interfaces. A
Calibration CD contains all of the most current vehicle calibration files, applicable TSBs, the
Calibration Update Wizard application software for a Windows PC, and instructions for use.
Calibration CDs can be ordered through the Toyota Material Distribution Center; order P/N
00456-REPRG-001.
IMPORTANT NOTICE
It is possible to permanently damage a vehicle controller during the flash reprogramming process.
It is especially important to understand that once started, the reprogramming process must not be
interrupted, reprogramming devices must not be disconnected and PCs must not be allowed to go
into standby, hibernation or similar power management modes. The information provided herein is
intended expressly for use by qualified professional automobile technicians. To prevent damage to
your customer's vehicle and ensure safe service practice, read these materials completely and
thoroughly before servicing the vehicle and be sure to follow all instructions.
Page 6429
Waterproof Type Connector
B: For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White
: Gray
Black or White : Dark Gray
Gray or White : Black
Waterproof Type Connector
"Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up
to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Waterproof Type Connector
"Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 3608
5. REMOVE 29 BOLTS
6. REMOVE UPPER VALVE BODY WITH PLATE AS A SINGLE UNIT
Hold the valve body plate to the upper valve body, and remove the upper valve body with the plate.
NOTICE: Be careful that the check balls and strainer do not fall out.
7. REMOVE OIL STRAINER
Remove the 3 oil strainers from the plate.
8. REMOVE CHECK VALVE AND SPRING 9. REMOVE 10 CHECK BALLS
10. REMOVE 2 GASKETS FROM PLATE
REASSEMBLY
Antenna - Loose Mast
Antenna Mast: Customer Interest Antenna - Loose Mast
AUDIO AU002-01
June 1, 2001
Title: ANTENNA MAST DURABILITY
Models: '00 - '01 Tundra
Introduction
Some customers may experience a loose Tundra antenna mast due to the breakage of the
antenna holder. A revised antenna holder assembly is available to resolve this issue.
Applicable Vehicles ^
2000 - 2001 model year Tundra vehicles.
Production Change Information
Parts Information
Repair Procedure
Replace antenna holder assembly.
Warranty Information
Applicable Warranty*:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36
months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Page 1914
CHART 2
CHART 3
CHART 4
Page 2854
Transmission Position Switch/Sensor: Service and Repair
ON-VEHICLE REPAIR
1. DISCONNECT OIL COOLER PIPE 2. REMOVE PARK/NEUTRAL POSITION SWITCH
a. Disconnect the connector. b. Pry off the lock washer and remove the nut. c. Remove the bolt and
park/neutral position switch.
3. INSTALL PARK/NEUTRAL POSITION SWITCH
a. Install the park/neutral position switch and bolt.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)
b. Install a new lock plate and the nut.
Torque: 3.9 Nm (40 kgf-cm, 35 inch lbs.)
c. Bend claws on the lock plate to fix the nut. d. Connect the connector. e. Check that the engine
can be started with the shift lever only in the N or P position, but not in other positions. If not as
stated, carry out the
adjustment procedure. See: Transmission and Drivetrain/Automatic
Transmission/Transaxle/Testing and Inspection/Initial Inspection and Diagnostic Overview
4. CONNECT OIL COOLER PIPE 5. FILL ATF AND CHECK FLUID LEVEL 6. TEST DRIVE
VEHICLE
Diagram Information and Instructions
Clock: Diagram Information and Instructions
Key to Diagrams
A: System Title
B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to
distinguish it from the J/B
Example: 1 Indicates Relay Block No.1
C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type,
or specification is different.
D: Indicates related system.
Page 4801
Splice Point
J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel,
and "B" for the Body).
The Location of splice Point I5 is shaded.
K: Indicates a shielded cable.
L: Indicates the pin number of the connector.
The numbering system is different for female and male connectors.
M: Indicates a ground point.
The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for
the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body
and Surrounding area.
How to Read Connector List
HOW TO READ CONNECTOR LIST
A: Indicates connector to be connected to a part. (The numeral indicates the pin No.)
Page 6667
Body
Connector Location (Standard Cab)
BA1 Front Door LH Wire and Speaker Tweeter Wire LH (Inside of Front Door LH)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Seat
Connector Location
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
BJ1 Seat No. 1 Wire and Seat No. 2 Wire (Under the Driver's Seat)
Page 3315
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 1058
- Do not release the airbag activation prevention mechanism unless specifically directed by the
troubleshooting procedure.
- If the inserted paper is too thick the terminal and short spring may be damaged, so always use
paper with the same thickness as the male terminal.
Page 575
CHART 28
Page 184
^ 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 1985
CHART 14
Page 6094
NOTE:The body color code is on the vehicle Certification Regulation Label, located on the left front
door "B" pillar or door rear lower surface.
Page 4515
Battery: Technical Service Bulletins Electrical - Battery Maintenance and Testing
PRODUCT GENERAL INFORMATION PG001-06
Title: BATTERY MAINTENANCE FOR IN-STOCK VEHICLES & PRE-DELIVERY
Models: All Models & Model Years
January 26, 2006
TSB REVISION NOTICE:
^ November 28, 2006: "Required SSTs" have been updated (SST P/N 00002-MCGR8 has been
added). "Recommended Equipment" has been removed (superseded by SST P/N 00002-MCGR8).
Screen prints and text have been updated in the "Battery Inspection Procedure". "Battery Service
Procedure" has been renamed "Battery Inspection Results". Two sections have been added for
SST P/N 00002-MCGR8: "Battery Charging Procedure" and "Battery Charging Results". PLEASE
READ ENTIRE TSB.
Previous versions of this TSB should be discarded.
TSB UPDATE NOTICE:
The information contained in this TSB supersedes TSB No. PG017-02. TSB No. PGO17-02 is now
obsolete and should be discarded.
Introduction
A battery in a stored vehicle is subject to conditions that can reduce its performance and life. These
conditions include storage period, temperature, parasitic drain, and battery load. Because of these
factors, battery inspection and maintenance are required in order to ensure proper operation and
optimal battery life.
As a matter of policy, Toyota does not provide battery warranty coverage for discharged and/or
failed batteries due to lack of maintenance. It is the dealer's responsibility to maintain the specified
State of Charge (SOC) of the vehicle's battery while in stock and assure proper State of Charge
(SOC) at delivery.
To eliminate customer service concerns due to an undercharged battery during the first few weeks
of ownership, all dealers should check battery State of Charge (SOC) and recharge, if necessary,
within 48 hours of delivery to customers.
Applicable Vehicles
^ All models and model years.
Warranty Information
Page 1988
CHART 18
CHART 19
Page 3466
Non-Waterproof Type Connector
"Case 1" Raise the terminal retainer up to the temporary lock position.
Non-Waterproof Type Connector
"Case 2" Open the secondary locking device.
Page 5737
b. Push the secondary locking device or terminal retainer in to the full lock position.
5. CONNECT CONNECTOR
Disconnection of Male and Female Connectors
Disconnection of Male and Female Connectors
Disconnection Of Male And Female Connectors
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Page 63
Glossary Of Terms And Symbols (Part 1)
Page 229
B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(Connect the Relay) and SW 2 OFF (or Disconnect SW 2)
D. Disconnect and reconnect the connectors while watching the test light.
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
E. Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION:
a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals
are touched, the IC may be destroyed by
static electricity.)
b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact
with the terminals of leads from the IC, etc. of the replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
Special Tool
1. PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown.
2. DISCONNECT CONNECTOR
3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
a. Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the
secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
A: For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
Page 1522
Coolant: Service and Repair
REPLACEMENT
1. REMOVE ENGINE UNDER COVER
2. DRAIN ENGINE COOLANT
a. Remove the radiator cap.
CAUTION: To avoid the danger of being burned, do not remove the radiator cap while the engine
and radiator are still hot, as fluid and steam can be blown out under pressure.
b. Remove the 3 drain plugs on the engine and radiator, and drain the coolant. c. Close the 3 drain
plugs.
Torque: 12.7 Nm (130 kgf-cm, 9 ft. lbs.) for engine
3. REFILL WITH ENGINE COOLANT
a. Slowly fill the system with coolant.
^ Use of improper coolants may damage engine cooling system.
^ Use "TOYOTA Long Life Coolant" or equivalent and mix it with plain water according to the
manufacturer's directions.
^ Use of the coolant which includes more than 50% [freezing protection down to -35°C (-31°F)] or
60% [freezing protection down to -50°C (-58°F)] of ethylene-glycol is recommended, but not more
than 70%.
NOTICE: ^
Do not use an alcohol type coolant or plain water alone.
^ The coolant should be mixed with plain water (preferably demineralized water or distilled water).
Capacity: 11.6 liters (12.3 US qts, 10.2 Imp. qts)
b. Install the radiator cap. c. Bleed the cooling system.
1. Start the engine, and open the heater water valve. 2. Maintain the engine speed at 2,000 - 2,500
rpm, and warm up the engine.
d. Stop the engine, and wait until the engine coolant cools down. e. Refill coolant into the reservoir
until it is "FULL".
4. CHECK FOR ENGINE COOLANT LEAKS 5. CHECK ENGINE COOLANT SPECIFIC GRAVITY
CORRECTLY 6. REINSTALL ENGINE UNDER COVER
Testing and Inspection
Center Mounted Brake Lamp: Testing and Inspection
INSPECT HI-MOUNTED STOP LIGHT ASSEMBLY CONTINUITY Using the ohmmeter, check that
continuity exists between terminal 1 and terminal 2. If continuity is not as specified, replace the light
assembly or bulb.
Page 5331
Refrigerant Pressure Sensor / Switch: Service and Repair
REMOVAL
1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM
HINT: At the time of installation, please refer to the following item. Evacuate air from refrigeration
system. Charge system with refrigerant and inspect for leakage of refrigerant.
Specified amount: 600 ± 50 g (21.16 ± 1.76 oz.)
2. REMOVE PRESSURE SWITCH FROM LIQUID TUBE
Disconnect the connector and remove the pressure switch.
Torque: 10 N.m (100 kgf.cm, 7 ft.lbf)
HINT: Lock the switch mount on the tube with an open end wrench, being careful not to deform the tube,
and remove the switch.
- At the time of installation, please refer to the following item. Lubricate a new O-ring with the
compressor oil and install them to the switch.
INSTALLATION
Installation is in the reverse order of removal.
Page 6187
Cruise Control: Splice Locations
Engine Compartment
Splice Location
E1 Engine Room Main Wire
E2 Engine Room Main Wire
E3 Engine Room Main Wire
E4 Engine No. 2 Wire
E5 Engine Wire
E6 Engine Wire
E7 Engine Wire
E8 Engine Wire
Instrument Panel
Page 3730
Steps 1 - 2
Page 5968
Page 2629
Splice Point
J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel,
and "B" for the Body).
The Location of splice Point I5 is shaded.
K: Indicates a shielded cable.
L: Indicates the pin number of the connector.
The numbering system is different for female and male connectors.
M: Indicates a ground point.
The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for
the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body
and Surrounding area.
How to Read Connector List
HOW TO READ CONNECTOR LIST
A: Indicates connector to be connected to a part. (The numeral indicates the pin No.)
Testing and Inspection
Fuel Gauge: Testing and Inspection
INSPECT FUEL RECEIVER GAUGE OPERATION
a. Disconnect the connector from the sender gauge. b. Turn the ignition switch ON, check that the
receiver gauge needle indicates EMPTY.
c. Connect terminals 1 and 3 on the wire harness side connector through a 3.4 watts test bulb. d.
Turn the ignition switch ON, check that the bulb lights up and the receiver gauge needle moves
towards the full side.
HINT: Because of the silicon oil in the gauge, it will take a short time for needle to stabilize.
If operation is not as specified, inspect the receiver gauge resistance.
INSPECT FUEL RECEIVER GAUGE RESISTANCE
Measure the resistance between terminals.
w/ Tachometer
Page 4096
A. Disconnect shock absorber from lower suspension arm.
B. Remove the shock absorber lower side set nut and washer.
NOTE:
Do not remove the
C. Wrap the bolt's head with vinyl tape to prevent the drive shaft boot from being damaged.
D. Pry down the lower suspension arm to remove the bolt and disconnect the shock absorber.
E. Remove the 3 nuts and shock absorber with the coil spring.
NOTE:
Do not damage the
8. Disconnect lower ball joint. Remove the 4 bolts and disconnect the lower ball joint.
Page 3072
Page 886
Spark Plug: Testing and Inspection
ON-VEHICLE INSPECTION
NOTE: "Cold" and "Hot" in these sentences express the temperature of the coils themselves.
"Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F).
INSPECT SPARK PLUGS
a. Remove the ignition coils (with igniter).
b. Using a 16 mm plug wrench, remove the spark plugs.
c. Clean the spark plugs.
If the electrode has traces of wet carbon, allow it to dry and then clean with a spark plug cleaner.
Air pressure: Below 588 kPa (6 kgf/sq.cm, 85 psi)
Duration: 20 seconds or less
HINT: If there are traces of oil, remove it with gasoline before using the spark plug cleaner.
Recommended Spark Plug
Page 4689
Glossary Of Terms And Symbols (Part 2)
Locations
Fuse Block: Locations
Driver Side J/B And Integration Relay
Page 5652
Supplemental Restraint System
Page 4295
B. Slowly apply the PKB while driving until the brake begins to engage and slow the vehicle. Do not
apply the PKB past this point of initial engagement.
NOTE:
Remember with a foot PKB (on automatic transmission), the pedal must be pressed a second time
to disengage the parking brake.
HINT:
When diagnosing a Tundra with a foot PKB, slowly apply the PKB until the first "click". Then press
the PKB pedal a second time so it will disengage when it is released. At this time the PKB can be
pressed to the desired level for continued diagnosis.
C. Hold the PKB at this point of initial engagement for a few seconds to slowly reduce the vehicle
speed and allow adequate time to monitor the ride condition.
D. Disengage the PKB.
E. If brake vibration is felt during step (C), then it indicates that the rear brake drums are one
source of brake vibration on this vehicle.
Refer to TSB No. BR003-02, "Rear Brake Vibration," for parts and repair information relating to
Tundra rear brake vibration.
F. If no vibration is felt during step (C), then the front brake assemblies are the most likely cause of
brake vibration on this vehicle.
G. Determine if TSB BROO4-02 has already been performed.
Repair Procedure No. 1
1. Remove the front wheel.
2. 2WD:
Using a screwdriver and hammer remove the grease cap.
3. 4WD:
Disconnect drive shaft.
A. Remove the cotter pin and lock cap.
B. While applying the brakes, remove the lock nut.
Page 2463
Page 2114
Idle Speed: Testing and Inspection
INSPECTION
1. INITIAL CONDITIONS
a. Engine at normal operating temperature b. Air cleaner installed c. All pipes and hoses of air
induction system connected d. All accessories switched OFF e. All vacuum lines properly
connected f.
SFI system wiring connectors fully plugged
g. Ignition timing checked correctly h. Transmission in neutral position i.
Air conditioning switched OFF
2. CONNECT TOYOTA HAND-HELD TESTER OR OBD II SCAN TOOL 3. INSPECT IDLE SPEED
a. Race the engine speed at 2,500 rpm for approximately 90 seconds. b. Check the idle speed.
Idle speed: 700 ± 50 rpm If the idle speed is not as specified, check the air intake system.
4. DISCONNECT TOYOTA HAND-HELD TESTER OR OBD II SCAN TOOL
Diagram Information and Instructions
Relay Box: Diagram Information and Instructions
Key to Diagrams
A: System Title
B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to
distinguish it from the J/B
Example: 1 Indicates Relay Block No.1
C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type,
or specification is different.
D: Indicates related system.
Page 4699
Driver Side J/B And Integration Relay
Page 5006
Page 6325
Terminal Retainer
Push the terminal retainer down to the temporary lock position.
c. Release the locking lug from terminal and pull the terminal out from rear.
4. INSTALL TERMINAL TO CONNECTOR
a. Insert the terminal.
HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug
locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position.
Page 5287
4. REMOVE WATER VALVE
Remove the bolt and water valve.
INSTALLATION
Installation is in the reverse order of removal.
Page 3268
Steps 1 - 2
Page 1118
Waterproof Type Connector
B: For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White
: Gray
Black or White : Dark Gray
Gray or White : Black
Waterproof Type Connector
"Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up
to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Waterproof Type Connector
"Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 2745
A. The Diagnostic Tester displays 17" as a value of the Time $81" (see illustration).
B. Find the Conversion Factor value of Time $81" in the O2S Failure Threshold chart. 0.3906 is
specified for Time $81 in this chart.
C. Multiply "17" in step "A" by 0.3906 (Conversion Factor) in step "B."
17 x 0.3906 = 6.6%
D. If the answer is within the Standard Value of TEST LIMIT, the Time $81" can be confirmed to be
normal.
NOTE:
^ "LOW SW V" indicates the O2S voltage when the O2S status changes from rich to lean.
^ "HIGH SW V" indicates the O2S voltage when the O2S status changes from lean to rich.
^ If the O2S voltage is lower than "LOW SW V," the O2S status is lean.
^ If the O2S voltage is higher than "HIGH SW V," the O2S status is rich.
NOTE:
Before the O2S Monitor completes or after the ignition switch is turned OFF, the Diagnostic Tester
displays the viewable upper limit or a lower limit of the test value (example: 0 V, 1.275 V, Os
[seconds], 10.2s, 0 and 255).
Service Precautions
Air Bag(s) Arming and Disarming: Service Precautions
SRS AIRBAG PRECAUTION
CAUTION: TOYOTA trucks are equipped with SRS, which comprises a driver airbag, front
passenger airbag and failure to carry out service operations in the correct sequence could cause
the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Further, if
a mistake is made in servicing the SRS, it is possible that the SRS may fail to operate when
required. Before performing servicing (including removal or installation of parts, inspection or
replacement), be sure to read the following items carefully, then follow the correct procedures
described.
Work must be started 90 seconds after the ignition switch is turned to the "LOCK" position and the
negative (-) terminal cable is disconnected from the battery.
The SRS is equipped with a back-up power source so that if work is started within 90 seconds from
disconnecting the negative (-) terminal cable of the battery, the SRS may be deployed.)
Do not expose the steering wheel pad, front passenger airbag assembly, airbag sensor assembly
or front airbag sensor directly to hot air or flames.
NOTE: Malfunction symptoms of the SRS are difficult to confirm, so the DTCs become the most
important source of information when troubleshooting. When troubleshooting the SRS, always
inspect the DTCs before disconnecting the battery.
Even in cases of a minor collision where the SRS does not deploy, the steering wheel pad, front
passenger airbag assembly, airbag sensor assembly and front airbag sensor should be inspected.
Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during
repairs.
Never use SRS parts from another vehicle. When replacing parts, replace them with new parts.
Never disassemble and repair the steering wheel pad, front passenger airbag assembly, airbag
sensor assembly or front airbag sensor, in order to reuse it.
If the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag
sensor, has been dropped, or if there are cracks, dents or other defects in the case, bracket or
connector, replace it with new one.
Use a volt/ohmmeter with high impedance (10 Kohms/V minimum) for troubleshooting the system's
electrical circuits.
Information labels are attached to the periphery of the SRS components. Follow the instructions on
the notices.
After work on the SRS is completed, check the SRS warning light check.
When the negative (-) terminal cable is disconnected from the battery, the memory of the clock and
audio system will be canceled. So before starting work, make a record of the contents memorized
in the audio memory system. When work is finished, reset the audio systems as they were before
and adjust the clock. To avoid erasing the memory in each memory system, never use a back-up
power supply from outside the vehicle.
If the vehicle is equipped with a mobile communication system, refer to the precaution.
Page 4344
Warranty Information
Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This
warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's
in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Page 4322
20. 2WD: INSTALL NEW LOCK NUT
A. Using the following SST, install and torque a NEW lock nut to the axle hub.
00002-00909 (09318-12010)
Torque: 274 N.m (2,800 kgf.cm, 203 ft.lbf)
NOTE:
Do NOT use air wrench.
B. Using a chisel and hammer, stake the lock nut.
21. 4WD:
INSTALL BEARING SPACER
Using the following SSTs and a press, install the bearing spacer.
^ 09950-60010 (09951-00650)
^ 09950-70010 (09951-07150)
22. 4WD:
Page 6982
Windshield
Page 6228
2. ECM TERMINAL VALUES MEASUREMENT BY USING TOYOTA BREAK-OUT-BOX AND
TOYOTA HAND-HELD TESTER
a. Connect the TOYOTA break-out-box and TOYOTA hand-held tester to the vehicle. b. Read the
ECM input/output values by following the prompts on the tester screen. c. Please refer to the
TOYOTA hand-held tester which has a "Snapshot" function. This records the measured data and is
effective in the diagnosis
of intermittent problems.
3. MONITOR ECM DATA BY USING TOYOTA HAND-HELD TESTER
a. Connect the TOYOTA hand-held tester to the DLC3. b. Monitor the ECM data by following the
prompts on the tester screen.
HINT: TOYOTA hand-held tester has a "Snapshot" function which records the monitored data.
Please refer to the TOYOTA hand-held tester operator's manual for further details.
Diagnostic Trouble Code Descriptions
For information regarding B, C, P, U and Manufacturer Code Descriptions - See: Powertrain
Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code
Descriptions
Diagnostic Trouble Code Tests and Associated Procedures
For information regarding diagnosis of all B, C, P, U and Manufacturer Codes - See: Powertrain
Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code
Descriptions
Page 4614
Engine Compartment
Instrument Panel
Locations
Page 5604
The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit
breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery
power is supplied to each system are explained. Since all System Circuit diagrams start from the
power source, the power source system must be fully understood.
Page 3438
Step 3
Page 5105
- Length: 6 in.
^ Ratcheting tie down strap (quantity 1)
- Minimum Width & Length: 1 in. x 6 ft.
^ Bicycle Cable Lock (quantity 1)
- Minimum Width & Length: 3/8 in. x 5 ft.
- Built-in lock with key
- Bell: P/N 1002107, Master Lock: P/N 8126D, Kryptonite: P/N 999782 or equivalent
IV. Background
On certain 2000 through 2003 model year Tundra vehicles operated in cold climate areas with high
road salt use (Severe Cold Climate States) excessive corrosion may be exhibited on the rear frame
cross-member. In the worst case the spare tire stowed under the truck bed may become separated
from the rear cross-member. Eventually excessive corrosion of the rear cross-member may also
affect the functionality of the brake system Load Sensing Proportioning & By-Pass Valve and/or
associated brake lines.
Page 6211
Cruise Control: Electrical Diagrams
Service Hints
C19 CRUISE CONTROL ECU
12 - GROUND: 4 pulse with 1 rotation of the rotor shaft 2 - GROUND : Approx. 12 volts with brake
pedal depressed 9 - GROUND : Approx. 12 volts with ignition SW at ON position 16 - GROUND:
Always continuity
C16 CRUISE CONTROL SW [COMB. SW]
5 - 3 : Approx. 1540 ohms with CANCEL SW on
Approx. 240 ohms with RES/ACC SW on Approx. 630 ohms with SET/COAST SW on
Page 2509
Oxygen Sensor: Mechanical Specifications
Torque: Sensor 1 .................................................................................................................................
...............................................
44 N.m (450 kgf.cm, 32 ft.lbf)
Sensor 2 ..............................................................................................................................................
.................................. 20 N.m (200 kgf.cm, 14 ft.lbf)
Page 5403
2. Using 3 wire harness, wind the wire harness at least 2 times each around the bolts installed on
the left and right sides of the steering wheel pad.
CAUTION: Tightly wind the wire harness around the bolts so that there is no slack.
- If there is slack in the wire harness, the steering wheel pad may come loose due to the shock
when the airbag is deployed. This is highly dangerous.
3. Face the upper surface of the steering wheel pad upward.
Separately tie the left and right sides of the steering wheel pad to the disc wheel through the hub
nut holes. Position the steering wheel pad connector so that it hangs downward through a hub hole
in the disc wheel.
CAUTION: Make sure that the wire harness is tight. It is very dangerous when looseness in the wire harness
results in the steering wheel pad coming free through the shock from the airbag deploying.
- Always tie down the steering wheel pad with the pad side facing upward. It is very dangerous if
the steering wheel pad is tied down with the metal surface facing upward as the wire harness will
be cut by the shock from the airbag deploying and the steering wheel pad will be thrown into the
air.
NOTE: The disc wheel will be marked by airbag deployment, so when disposing of the airbag use a
redundant disc wheel.
Page 4510
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 5719
Instrument Panel
Connector Location
IA1 Engine Room Main and Cowl Wire (Left Kick Panel)
IA2 Engine Room Main and Cowl Wire (Left Kick Panel)
IA3 Engine Room Main and Cowl Wire (Left Kick Panel)
IA4 Engine Room Main and Cowl Wire (Left Kick Panel)
IB1 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IB2 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IB3 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IC1 Cowl Wire and Roof Wire (Left Side of Instrument Panel)
Instrument Panel
Connector Location
ID1 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH)
ID2 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH)
IE1 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IE2 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IE3 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IF1 Front Door RH Wire and Cowl Wire (Right Kick Panel)
IF2 Front Door RH Wire and Cowl Wire (Right Kick Panel)
IF3 Front Door RH Wire and Cowl Wire (Right Kick Panel)
Page 2531
^ 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 2184
Torque: 20.4 N.m (208 kgf.cm, 15 ft.lbf)
b. Connect the ECT sensor connector.
8. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS
a. Install a new gasket and the throttle body with the 2 bolts and 2 nuts.
Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)
b. Connect the accelerator cable to the throttle body.
9. REINSTALL INTAKE AIR CONNECTOR
10. REFILL WITH ENGINE COOLANT
11. REINSTALL THROTTLE BODY COVER
Page 1474
4. Match the axis of the connector with axis of the pipe, and push in the connector until the
connector makes a "click" sound. In case that the
connections is tight, apply small amount of fresh engine oil on the tip of the pipe.
5. After having finished the connection, check if the pipe and the connector are securely connected
by pulling them. 6. Check if there is any fuel leakage.
h. Observe these precautions when handling nylon tube.
1. Pay attention not to turn the connected part of the nylon tube and the quick connector by force
when connecting them. 2. Pay attention not to kink the nylon tube. 3. Do not remove the EPDM
protector from the outside of the nylon tube. 4. Must not close the piping with the nylon tube by
bending it.
i. Check that there is any fuel leak after maintenance anywhere on the fuel system. 1. Connect a
TOYOTA hand-held tester to the DLC3. 2. Turn the ignition switch ON and push the TOYOTA
hand-held tester main switch ON.
NOTE: Do not start the engine.
3. Select the ACTIVE TEST mode on the TOYOTA hand-held tester. 4. Please refer to the
TOYOTA hand-held tester operator's manual for further details.
Page 4765
Engine Room R/B
Details
Page 4025
(b) In this position. check the rear brake pressure
If the measured value is not within the standard, replace the valve body.
Page 5223
d. Remove the shims from the pressure palate.
2. REMOVE ROTOR
a. Using SST, remove the snap ring.
SST 95994-10020
NOTE: The snap ring should be installed so that beveled side faces up.
b. Using a plastic hammer, tap the rotor off the shaft.
NOTE: Be careful not to damage the pulley when tapping on the rotor.
3. REMOVE STATOR
Page 4101
21. 4WD:
Using the following SSTs and a press, install the bearing spacer.
SST P/N: 09950-60010 (09951-00650)
SST P/N: 09950-70010 (09951-07150)
22. 4WD:
Install new oil seal (inside).
A. Using the following SST and a plastic hammer, install a NEW oil seal (inside).
SST P/N: 09527-17011
NOTE:
Lightly strike the SST on its circumference evenly.
B. Coat MP grease to the oil seal lip.
23. Install steering knuckle.
A. 4WD:
Insert the drive shaft into the axle hub and temporarily tighten the nut.
NOTE:
Be careful not to damage the oil seal and drive shaft boot.
B. Connect the steering knuckle to the upper suspension arm.
C. Install the nut and a NEW cotter pin. If the holes for the cotter pin are not aligned, tighten the nut
further up to 600.
Torque: 105 N.m (1,100 kgf.cm, 77 ft.lbf)
24. Connect the lower ball joint to the steering knuckle with 4 bolts.
Locations
Supplemental Restraint System
Page 2289
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
Engine Controls - Bank 1/Bank 2 O2 Sensor identification
Oxygen Sensor: All Technical Service Bulletins Engine Controls - Bank 1/Bank 2 O2 Sensor
identification
ENGINE EG034-07
Title: ENGINE BANK 1 AND BANK 2 A/F AND O2 IDENTIFICATION
Models: '93 - '08 Applicable Models
June 28, 2007
The information contained in this TSB supercedes TSB No. EG037-04. TSB No. EG037-04 is now
obsolete and should be discarded.
Introduction
This service bulletin provides information on the proper identification of engine bank 1 and engine
bank 2 for correct A/F sensor and oxygen sensor replacement.
This bulletin contains information that identifies engine bank 1 and engine bank 2 on the following
engines: 1AZ-FE, 2AZ-FE, 2AZ-FE (PZEV), 1GR-FE, 2GR-FE, 2GR-FSE, 2JZ-GE, 1MZ-FE,
3MZ-FE, 1UR-FSE, 3UR-FE, 2UZ-FE, 3UZ-FE, 5VZ-FE, and 1ZZ-FE.
^ Bank 1 (B1) refers to the bank that includes cylinder No. 1.
^ Bank 2 (B2) refers to the bank opposite bank 1.
^ Sensor 1 (S1) refers to the sensor that is located before the catalytic converters.
^ Sensor 2 (S2) refers to the sensor that is located after the catalytic converters.
Warranty Information
Page 6280
Driver Side J/B And Integration Relay
Page 4644
Driver Side J/B And Integration Relay Inner Circuit
Page 898
Exhaust: N = T + (A - 0.30 mm (0.012 inch))
3. Select a new shim with thickness as close as possible to the calculated value.
HINT: Shims are available in 41 increments of 0.020 mm (0.0008 inch), from 2.00 mm (0.0787
inch) to 2.80 mm (0.1102 inch).
e. Place a new adjusting shim on the valve. f.
Place the valve lifter.
Page 4598
The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit
breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery
power is supplied to each system are explained. Since all System Circuit diagrams start from the
power source, the power source system must be fully understood.
Page 2208
Glossary Of Terms And Symbols (Part 1)
Page 1851
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
1. DRAIN ENGINE COOLANT
2. REMOVE THROTTLE BODY COVER
3. REMOVE INTAKE AIR CONNECTOR
4. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS
a. Disconnect the accelerator cable from the throttle body. b. Remove the 2 bolts and 2 nuts, and
disconnect the throttle body from the intake manifold. c. Remove the gasket
5. REMOVE ECT SENSOR
a. Disconnect the ECT sensor connector. b. Remove the ECT sensor and gasket.
6. REINSTALL ECT SENSOR
a. Install a new gasket and the ECT sensor.
Torque: 20.4 N.m (208 kgf.cm, 15 ft.lbf)
b. Connect the ECT sensor connector.
7. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS
a. Install a new gasket and the throttle body with the 2 bolts and 2 nuts.
Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)
b. Connect the accelerator cable to the throttle body.
8. REINSTALL INTAKE AIR CONNECTOR
9. REFILL WITH ENGINE COOLANT
10. REINSTALL THROTTLE BODY COVER
Page 3200
Spark Plug: Specifications Torque Specification
Spark Plug x Cylinder Head ................................................................................................................
......................................................................... 18 Nm
Page 2230
A. Test the CAN Interface Module (P/N 01002744) for continuity.
^ If there is no continuity, the CAN Interface Module needs to be replaced.
^ If there is continuity, the CAN Interface Module is OK. Re-check Cable Tests 1, 2, 3, and 4 while
wiggling and flexing the cables.
Page 5546
Front Seat Belt Extender Applications
Page 2733
A/F and 02 Sensor Identification
Page 393
BJ Inside of Rear Door LH
BK Inside of Rear Door RH
BL Surrounding of the Front of the Fuel Tank
Connector Location
BA1 Front Door LH Wire and Wire Harness (Connector Location)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel)
BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel)
BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel)
BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Page 1792
b. Push the secondary locking device or terminal retainer in to the full lock position.
5. CONNECT CONNECTOR
Disconnection of Male and Female Connectors
Disconnection of Male and Female Connectors
Disconnection Of Male And Female Connectors
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Page 6900
Brake Light Switch: Pinout Values and Diagnostic Parameters
ABS
A6, A7 ABS SPEED SENSOR FRONT LH, RH
1 - 2 : 1.40 - 1.80 kOhms (20°C, 68°F)
A19 ABS SPEED SENSOR REAR
1 - 2 : 0.89 - 1.29 kOhms (20°C, 68°F)
3 - 4 : 0.89 - 1.29 kOhms (20°C, 68°F)
A5 ABS ACTUATOR WITH ECU
6 - GROUND : 10 - 14 volts with ignition SW at ON or ST position
24 - GROUND : 10 - 14 volts with stop light SW on (Brake pedal depressed)
2, 18 - GROUND : Always continuity
S4 STOP LIGHT SW
2 - 1 : Closed with brake pedal depressed
Page 1992
CHART 22
Page 4812
Terminal Retainer
Push the terminal retainer down to the temporary lock position.
c. Release the locking lug from terminal and pull the terminal out from rear.
4. INSTALL TERMINAL TO CONNECTOR
a. Insert the terminal.
HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug
locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position.
Page 1082
Glossary Of Terms And Symbols (Part 1)
Page 2840
Oxygen Sensor: Mechanical Specifications
Torque: Sensor 1 .................................................................................................................................
...............................................
44 N.m (450 kgf.cm, 32 ft.lbf)
Sensor 2 ..............................................................................................................................................
.................................. 20 N.m (200 kgf.cm, 14 ft.lbf)
Page 95
B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(Connect the Relay) and SW 2 OFF (or Disconnect SW 2)
D. Disconnect and reconnect the connectors while watching the test light.
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
E. Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION:
a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals
are touched, the IC may be destroyed by
static electricity.)
b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact
with the terminals of leads from the IC, etc. of the replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
Special Tool
1. PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown.
2. DISCONNECT CONNECTOR
3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
a. Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the
secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
A: For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
Page 5343
- If the horn button contact plate of the steering wheel is deformed, never repair it. Always replace
the steering wheel assembly with a new one.
- There should be no interference between the steering wheel pad and steering wheel, and the
clearance should be uniform all the way around when the new steering wheel pad is installed on
the steering wheel.
REPLACEMENT REQUIREMENTS
CAUTION: Be sure to follow the correct procedure, for removal and installation of the steering
wheel pad.
AIRBAG HARNESS
INSPECTION
HINT: The SRS wire harness is integrated with the instrument panel wire harness assembly. All the
connectors in the system are a standard yellow color.
1. VEHICLES NOT INVOLVED IN COLLISION
Do a diagnostic system check. *
2. VEHICLES INVOLVED IN COLLISION
a. Do a diagnostic system check. * b. Check breaks in all wires of the SRS wire harness, and
exposed conductors. c. Check to see if the SRS wire harness connectors are cracked or chipped.
* Refer to SRS Warning Light Check, and How to Display and Read Diagnostic Codes.
AIRBAG SENSOR ASSEMBLY
VEHICLE NOT INVOLVED IN COLLISION
Check a diagnostic system.
VEHICLE INVOLVED IN COLLISION WITH AIRBAG NOT DEPLOYED
Check a diagnostic system. *
VEHICLE INVOLVED IN COLLISION WITH AIRBAG DEPLOYED
Replace the airbag sensor assembly. *
* Refer to SRS Warning Light Check, and How to Display and Read Diagnostic Trouble Codes.
REPLACEMENT REQUIREMENTS
In the following cases, replace the airbag sensor assembly.
- If the SRS has been deployed in a collision.
- If the airbag sensor assembly has been found to be faulty in troubleshooting.
- If the airbag sensor assembly has been dropped.
CAUTION: For removal and installation of the airbag sensor assembly. Be sure to follow the correct
procedure.
System Diagnosis
Air/Fuel Mixture: Testing and Inspection
INSPECTION
HINT: This check is used only to determine whether or not the idle CO/HC complies with
regulations.
1. INITIAL CONDITIONS
a. Engine at normal operating temperature b. Air cleaner installed c. All pipes and hoses of air
induction system connected d. All accessories switched OFF e. All vacuum lines properly
connected f.
SFI system wiring connectors fully plugged
g. Ignition timing checked correctly h. Transmission in neutral position i.
Tachometer and CO/HC meter calibrated by hand
2. START ENGINE 3. RACE ENGINE AT 2,500 RPM FOR APPROXIMATELY 180 SECONDS
4. INSERT CO/HC METER TESTING PROBE AT LEAST 40 cm (1.3 ft) INTO TAILPIPE DURING
IDLING 5. IMMEDIATELY CHECK CO/HC CONCENTRATION AT IDLE AND/OR 2,500 RPM
HINT: When performing the 2 mode (2,500 rpm and idle) test, follow the measurement orders are
prescribed by the applicable local regulations.
If the CO/HC concentration does not comply with regulations, perform troubleshooting in the order
given. a. Check the heated oxygen sensors operation.
b. See the table for possible causes, and then inspect and correct the applicable causes if
necessary.
Page 616
CHART 7
Page 476
Camshaft Position Sensor: Service and Repair
Camshaft Position Sensor
REMOVAL
1. DRAIN ENGINE COOLANT
2. REMOVE DRIVE BELT
3. REMOVE LH NO.3 TIMING BELT COVER
Page 840
Page 4511
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 3049
Fuel Supply Line: Testing and Inspection
INSPECTION
INSPECT FUEL TANK AND LINE
a. Check the fuel lines for cracks or leakage, and all connections for deformation. b. Check the fuel
tank vapor vent system hoses and connections for looseness, sharp bends or damage. c. Check
the fuel tank for deformation, cracks, fuel leakage or tank band looseness. d. Check the filler neck
for damage or fuel leakage.
e. Hose and pipe connections are as shown in the illustration.
If a problem is found, repair or replace the parts as necessary.
Page 1604
Engine Coolant Temperature (ECT) Sensor
Page 507
Knock Sensor: Description and Operation
P0325 - Knock Sensor 1 Circuit Malfunction (Bank 1) CIRCUIT DESCRIPTION
DTC Detection Condition
One of the knock sensors is fitted to the right bank and another to the left bank of the cylinder block
to detect the engine knocking. This sensor contains a piezoelectric element which generates
voltage when it becomes deformed. This occurs when the cylinder block vibrates due to knocking.
If the engine knocking occurs, ignition timing is retarded to suppress it.
Wiring Diagram
Page 1066
Engine Room R/B Fuse Applications (Part 2)
Engine Room Fuse Details
Locations
Upper Side Moulding / Trim: Locations
Roof Drip Side Finish Moulding
Page 2885
4. INSPECT THROTTLE POSITION SENSOR
a. Disconnect the throttle position sensor connector. b. Using an ohmmeter, measure the
resistance between terminals VC and E2.
Resistance: 1.25 - 2.35 kohms at 20 °C (68 °F)
If the resistance is not as specified, replace the throttle position sensor.
c. Reconnect the throttle position sensor connector.
5. INSPECT ACCELERATOR PEDAL POSITION SENSOR
a. Disconnect the pedal position sensor connector. b. Using an ohmmeter, measure the resistance
between terminals VC and E2.
Resistance: 1.64 - 3.28 kohms at 20 °C (68 °F)
If the resistance is not as specified, replace the accelerator pedal position sensor.
c. Reconnect the pedal position sensor connector.
6. REINSTALL THROTTLE BODY COVER
Testing and Inspection
Four Wheel Drive Indicator Lamp: Testing and Inspection
5VZ-FE: INSPECT "4Lo/4Hi", 4WD" INDICATOR LIGHT a. Disconnect the connectors from the
ADD actuator. b. "4WD" indicator: Ground terminal 3 on the wire harness side connector. c. Turn
the ignition switch ON, check that the warning light lights up.
If the warning light does not light up, inspect the bulb or wire harness.
2UZ-FE: INSPECT "4Lo/4Hi", "4WD" INDICATOR LIGHT a. Remove the center cluster finish
panel. b. Disconnect the connectors from the center cluster integration. c. "4Lo" indicator: Ground
terminal 3 on the wire harness side connector. d. "4Hi" indicator: Ground terminal 2 on the wire
harness side connector.
Testing and Inspection
Control Module: Testing and Inspection
For further information regarding this component and the system that it is a part of, please refer to
Four Wheel Drive Selector Relay; Testing and Inspection; Procedures.
Front Seat Cover - Damaged
Seat Cover: Customer Interest Front Seat Cover - Damaged
BODY
BO006-02
Title: FRONT SEAT COVER DAMAGE
Models: '00 - '02 Tundra & '01 - '02 Sequoia Equipped with Power Seats
March 1, 2002
Introduction
Due to the unique curvature of the front seat frames' outboard edge, the driver or passenger could
potentially wear a hole into the seat cover material during entry and exit of the vehicle. This
condition has been addressed and corrected in production. The instructions below will illustrate
how to properly repair vehicles with this condition.
Applicable Vehicles
2000 - 2002 model year Tundra vehicles equipped with power seats produced before the VIN
shown below.
2001 - 2002 model year Sequoia vehicles equipped with power seats produced before the VIN
shown below.
Production Change 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.
Page 4661
The ground points circuit diagram shows the connections from all major parts to the respective
ground points. When troubleshooting a faulty ground point, checking the system circuits which use
a common ground may help you identify the problem ground quickly. The relationship between
ground points (EA, IB and IC) can also be checked this way.
How to Read Power Source
HOW TO READ POWER SOURCE
Page 2022
Transmission Position Switch/Sensor: Service and Repair
ON-VEHICLE REPAIR
1. DISCONNECT OIL COOLER PIPE 2. REMOVE PARK/NEUTRAL POSITION SWITCH
a. Disconnect the connector. b. Pry off the lock washer and remove the nut. c. Remove the bolt and
park/neutral position switch.
3. INSTALL PARK/NEUTRAL POSITION SWITCH
a. Install the park/neutral position switch and bolt.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)
b. Install a new lock plate and the nut.
Torque: 3.9 Nm (40 kgf-cm, 35 inch lbs.)
c. Bend claws on the lock plate to fix the nut. d. Connect the connector. e. Check that the engine
can be started with the shift lever only in the N or P position, but not in other positions. If not as
stated, carry out the
adjustment procedure. See: Transmission and Drivetrain/Automatic
Transmission/Transaxle/Testing and Inspection/Initial Inspection and Diagnostic Overview
4. CONNECT OIL COOLER PIPE 5. FILL ATF AND CHECK FLUID LEVEL 6. TEST DRIVE
VEHICLE
ABS/TCS - Zero Point Calibration Information
Yaw Rate Sensor: Technical Service Bulletins ABS/TCS - Zero Point Calibration Information
T-SB-0020-08
March 25, 2008
Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment
Service Category Brake
Section Brake Control/Dynamic Control System
Market USA
Applicability
Introduction
The purpose of this TSB is to provide information on when and how to perform the zero point
calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting
the battery is a necessary step for performing the zero point calibration.
Warranty Information
Required Tools & Equipment
^ Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE).
^ The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the
service procedures listed in this bulletin.
Preliminary Information
Perform this procedure if any of these repairs have been performed on the vehicle:
^ Wheel alignment has been adjusted.
^ Any chassis components have been removed/installed or replaced.
Page 6370
Air Bag(s) Arming and Disarming: Service and Repair Release Method of Airbag Activation
Prevention Mechanism
RELEASE METHOD OF AIRBAG ACTIVATION PREVENTION MECHANISM
Page 4220
^ 09527-17011
B. Coat MP grease to the oil seal lip.
18. INSTALL NEW DUST COVER AND AXLE HUB TO STEERING KNUCKLE
A. Install the NEW dust cover to the steering knuckle with the 4 bolts.
Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)
B. Using the following SST and a press, install the axle hub to the steering knuckle.
^ 09649-17010
19. INSTALL ABS SPEED SENSOR ROTOR (W/ABS) OR SPACER (W/O ABS)
NOTE:
Take care not to scratch the serration of the speed sensor rotor.
20. 2WD: INSTALL NEW LOCK NUT
A. Using the following SST, install and torque a NEW lock nut to the axle hub.
^ 00002-00909 (09318-12010)
Torque: 274 N.m (2,800 kgf.cm, 203 ft.lbf)
NOTE:
Do NOT use air wrench.
B. Using a chisel and hammer, stake the lock nut.
21. 4WD: INSTALL BEARING SPACER
Page 4876
DISASSEMBLY
NOTICE: When using a vise, do not overtighten it.
Page 1764
E. Confirm the Diagnostic Tester has the appropriate software for the type of calibration file that
was downloaded.
NOTE:
The calibration type is specific to the software version loaded on your Diagnostic Tester. If you
selected the wrong version when downloading the calibration file, you will receive an error when
attempting to install the file on the Diagnostic Tester.
Page 3174
Camshaft Position Sensor: Service and Repair
Camshaft Position Sensor
REMOVAL
1. DRAIN ENGINE COOLANT
2. REMOVE DRIVE BELT
3. REMOVE LH NO.3 TIMING BELT COVER
Page 6522
The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit
breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery
power is supplied to each system are explained. Since all System Circuit diagrams start from the
power source, the power source system must be fully understood.
Page 6985
a. Remove the 4 screws and 2 sun visors. b. w/ Light:
Disconnect the connector.
5. REMOVE SUB-VISORS
Remove the 4 screws and 2 sub-visors.
6. REMOVE FRONT PERSONAL LIGHT
a. Using a screwdriver, remove the left side lens.
HINT: Tape the screwdriver tip before use.
b. Remove the 2 screws. c. Using a screwdriver, rotate the clip by 90 degrees and remove it.
HINT: Tape the screwdriver tip before use.
d. Remove the front personal light, then disconnect the connector.
7. REMOVE SUN VISOR HOLDERS
Remove the 2 screws and 2 sun visor holders.
8. REMOVE FRONT PART OF ROOF HEADLINING 9. REMOVE WIPER ARMS
a. Using a screwdriver, remove the 2 caps.
HINT: Tape the screwdriver tip before use.
b. Remove the 2 nuts and wiper arms.
10. REMOVE COWL LOUVER
Remove the 8 screws, 6 clips and cowl louver.
11. REMOVE FRONT PART OF ROOF SIDE RAIL WEATHERSTRIP LH AND RH
Pull the front part of roof side rail weatherstrip LH and RH to remove it.
12. REMOVE WINDSHIELD OUTSIDE MOULDING
Page 6867
Headlamp Relay: Testing and Inspection
POWER SOURCE
HEATER RELAY
1 - 2 : Closed with ignition SW on and heater blower SW on
HEAD RELAY
2 - 1 : Closed with light control SW at HEAD position or dimmer SW at FLASH position Closed with
engine running and parking brake lever released
(w/ daytime running light)
I23 IGNITION SW
2 - 3 : Closed with ignition key at ACC or ON position 2 - 4 : Closed with ignition key at ON or ST
position 7 - 6 : Closed with ignition key at ON or ST position
DIMMER RELAY (w/ DAYTIME RUNNING LIGHT)
4 - 3 : Closed with HEAD relay on and dimmer SW at HIGH or FLASH position
Specifications
Headliner: Specifications
Roof Headlining
Service and Repair
Fuel Pressure Release: Service and Repair
SFI SYSTEM
PRECAUTION
1. BEFORE WORKING ON FUEL SYSTEM, DISCONNECT NEGATIVE (-) TERMINAL CABLE
FROM BATTERY
HINT: Any diagnostic trouble code retained by the computer will be erased when the negative (-)
terminal cable is removed from the battery.
Therefore, if necessary, read the diagnosis before removing the negative (-) terminal cable from the
battery.
2. DO NOT SMOKE OR WORK NEAR AN OPEN FLAME WHEN WORKING ON THE FUEL
SYSTEM
3. KEEP GASOLINE AWAY FROM RUBBER OR LEATHER PARTS
4. FUEL SYSTEM
a. When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so
observe these procedures:
1. Disconnect the fuel pump connector. 2. Start the engine. After the engine has stopped on its
own, turn the ignition switch OFF.
3. Put a container under the connection. 4. Slowly loosen the connection. 5. Disconnect the
connection. 6. Plug the connection with a rubber plug. 7. Reconnect the fuel pump connector.
b. When connecting the union bolt (fuel pressure pulsation damper) on the high pressure pipe
union, observe these procedures:
1. Always use 2 new gaskets.
Front
Wheel Bearing: Service and Repair Front
Removal and Installation
REMOVAL
1. REMOVE FRONT WHEEL 2. REMOVE GREASE CAP
Using a screwdriver and hammer, remove the grease cap.
Diagram Information and Instructions
Vehicle Speed Sensor: Diagram Information and Instructions
Key to Diagrams
A: System Title
B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to
distinguish it from the J/B
Example: 1 Indicates Relay Block No.1
C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type,
or specification is different.
D: Indicates related system.
Page 741
Air Bag Deactivation Switch: Description and Operation
PASSENGER AIRBAG MANUAL ON-OFF SWITCH
Passenger airbag manual on-off switch is mounted on the center cluster finish panel. By turning the
passenger airbag manual on-0ff switch to OFF with the ignition key, the passenger airbag system
can be disabled. Also, in order to notify the passenger that the front passenger airbag is disabled,
OFF indicator inside the switch will light up.
Page 6231
Steps 1 - 2
INSPECTION PROCEDURE
Input Signal Check
INPUT SIGNAL CHECK BY USING TOYOTA HAND-HELD TESTER
a. Connect the TOYOTA hand-held tester to the DLC3. b. Check the control switch (CRUISE
ON-OFF, CANCEL, SET/COAST, RES/ACC).
ECM Terminal Values Using Toyota Break-Out-Box
ECM TERMINAL VALUES MEASUREMENT BY USING TOYOTA BREAK-OUT-BOX AND
TOYOTA HAND-HELD TESTER
a. Connect the TOYOTA break-out-box and TOYOTA hand-held tester to the vehicle. b. Read the
ECM input/output values by following the prompts on the tester screen. c. Please refer to the
TOYOTA hand-held tester which has a "Snapshot" function. This records the measured data and is
effective in the diagnosis of
intermittent problems.
Removal and Installation
Steering Wheel: Service and Repair Removal and Installation
Steering Wheel Pad And Spiral Cable
REMOVAL
1. REMOVE STEERING WHEEL PAD
2. REMOVE STEERING WHEEL
3. REMOVE UPPER AND LOWER COLUMN COVERS
4. REMOVE SPIRAL CABLE
INSTALLATION
Page 6490
Instrument Panel
Ground Location
IE Left Kick Panel
IF Left Kick Panel
IG Instrument Panel Brace RH
IH Right Kick Panel
II Right Kick Panel
Body
Ground Location (Access Cab)
Electrical - SRS And HV Wiring Repairs
Wiring Harness: Technical Service Bulletins Electrical - SRS And HV Wiring Repairs
TITLE: SRS & HV WIRING REPAIRS
SECTION: ELECTRICAL
BULLETIN # 156
MODELS: ALL TOYOTA LEXUS and SCION MODELS
DATE: AUGUST 2007
There are no approved repairs to Supplemental Restraint System (SRS) or High Voltage (HV)
wiring or connectors. SRS system wiring and connectors are color coded yellow and HV wiring is
orange however vehicle-specific wiring diagrams are the best source for identifying wiring in these
circuits. Wiring diagrams are available through the Technical Information System (TIS)
www.techinfo.toyota.com.
If SRS or HV wiring or connectors are suspected of damage they should be inspected thoroughly.
Damaged wiring and/or connectors require replacement of the affected harness. Follow all
precautions and procedures outlined in model-specific repair manuals for replacing SRS wiring or
components. Only Certified Hybrid Service Technicians are qualified to replace HV system wiring
and components.
Page 2525
A. Test the CAN Interface Module (P/N 01002744) for continuity.
^ If there is no continuity, the CAN Interface Module needs to be replaced.
^ If there is continuity, the CAN Interface Module is OK. Re-check Cable Tests 1, 2, 3, and 4 while
wiggling and flexing the cables.
Capacity Specifications
Refrigerant Oil: Capacity Specifications
When Replacing, Add:
Receiver 20 cc
Condenser 40 cc
Evaporator 40 to 50 cc
Page 133
Refer to Reset Procedure 2 for the vehicles with Electronically Controlled Automatic
Transmissions:
Reset Procedure 1
1. Connect the Toyota Diagnostic Tester to the vehicle.
2. Reset the ECM (PCM). Refer to the procedures below.
Page 3599
b. Connect the oil cooler pipe.
Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.)
c. Install the 3 clamps with the 3 bolts.
7. FILL ATF AND CHECK FLUID LEVEL
Page 573
CHART 27
Removal and Installation
Power Steering Pump: Service and Repair Removal and Installation
Page 3656
Page 6354
B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(Connect the Relay) and SW 2 OFF (or Disconnect SW 2)
D. Disconnect and reconnect the connectors while watching the test light.
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
E. Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION:
a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals
are touched, the IC may be destroyed by
static electricity.)
b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact
with the terminals of leads from the IC, etc. of the replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
Special Tool
1. PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown.
2. DISCONNECT CONNECTOR
3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
a. Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the
secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
A: For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
Page 2821
CHART 20
Page 1783
The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit
breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery
power is supplied to each system are explained. Since all System Circuit diagrams start from the
power source, the power source system must be fully understood.
ABS/TCS - Zero Point Calibration Information
Steering Angle Sensor: Technical Service Bulletins ABS/TCS - Zero Point Calibration Information
T-SB-0020-08
March 25, 2008
Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment
Service Category Brake
Section Brake Control/Dynamic Control System
Market USA
Applicability
Introduction
The purpose of this TSB is to provide information on when and how to perform the zero point
calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting
the battery is a necessary step for performing the zero point calibration.
Warranty Information
Required Tools & Equipment
^ Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE).
^ The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the
service procedures listed in this bulletin.
Preliminary Information
Perform this procedure if any of these repairs have been performed on the vehicle:
^ Wheel alignment has been adjusted.
^ Any chassis components have been removed/installed or replaced.
Page 4663
Glossary Of Terms And Symbols (Part 1)
Page 3954
Install the No.1 vehicle speed sensor with the bolt.
Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.)
6. CONNECT NO. I VEHICLE SPEED SENSOR CONNECTOR
Vehicle Speed Sensor NO.2
Vehicle speed Sensor NO.2 on-vehicle repair
1. DISCONNECT NO. 2 VEHICLE SPEED SENSOR CONNECTOR
2. REMOVE NO. 2 VEHICLE SPEED SENSOR
a. Remove the bolt and No. 2 vehicle speed sensor. b. Remove the O-ring from the No. 2 vehicle
speed sensor.
3. INSTALL NO. 2 VEHICLE SPEED SENSOR
a. Coat a new O-ring with ATF and install it to the No. 2 vehicle speed sensor. b. Install the No. 2
vehicle speed sensor with the bolt.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
4. CONNECT NO. 2 VEHICLE SPEED SENSOR CONNECTOR
Specifications
Knock Sensor: Specifications
SST 09816-30010
Torque: ................................................................................................................................................
................................. 45 N.m (450 kgf.cm, 33 ft.lbf)
Page 2195
2. REMOVE CRANKSHAFT POSITION SENSOR
a. Disconnect the crankshaft position sensor connector. b. Remove the bolt and crankshaft position
sensor.
INSTALLATION
1. INSTALL CRANKSHAFT POSITION SENSOR
a. Install the crankshaft position sensor with the bolt.
Torque: 6.5 N.m (65 kgf.cm, 58 in.lbf)
b. Connect the crankshaft position sensor connector.
2. INSTALL ENGINE UNDER COVER
Page 3280
An AC voltage is generated in the No.2 vehicle speed sensor coil as the rotor mounted on the
output shaft rotates, and this voltage is sent to the ECM.
The gear shift point and lock-up timing are controlled by the ECM based on the signals from this
vehicle speed sensor and the throttle position sensor signal.
If the No.2 vehicle speed sensor malfunctions, the ECM uses input signals from the No.1 vehicle
speed sensor as a back-up signal.
Testing and Inspection
Power Mirror Motor: Testing and Inspection
INSPECT MIRROR MOTOR OPERATION
a. Connect the positive (+) lead from the battery to terminal 3 and negative (-) lead to terminal 1.
Check that the mirror turns to left side.
b. Remove the polarity, check that the mirror turns to right side.
c. Connect the positive (+) lead from the battery to terminal 2 and the negative (-) lead to terminal
1. Check that the mirror turns upward.
d. Reverse the polarity, that the mirror turns downward.
If operation is not as specified, replace the mirror assembly.
Page 6362
1. PROBLEM NO.1
Troubleshooting No. 2
Step 2
2. PROBLEM NO.2
Page 4378
1. REMOVE FRONT WHEEL
2. 4WD: REMOVE GREASE CAP
Using a screwdriver and hammer remove the grease cap.
3. 4WD: DISCONNECT DRIVE SHAFT
A. Remove the cotter pin and lock cap.
B. While applying the brakes, remove the lock nut.
4. W/ABS DISCONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP FROM
STEERING KNUCKLE
Remove the 2 bolts and disconnect the ABS speed sensor and wire harness clamp from the
steering knuckle.
5. DISCONNECT BRAKE LINE
Using the SST, disconnect the brake line. Use a container to catch the brake fluid.
^ 09023-00100
6. REMOVE BRAKE,CALIPER AND DISC
Page 5046
Diagrams
Ignition Coil
Specifications
Firing Order: Specifications
Firing Order 1 - 8 - 4 - 3 - 6 - 5 - 7 - 2
Testing and Inspection
Fuel Gauge Sender: Testing and Inspection
INSPECT FUEL SENDER GAUGE RESISTANCE
Measure the resistance between terminals 1 and 2 for each float position. If resistance value is not
as specified, replace the main sender gauge.
INSPECT FUEL LEVEL WARNING SWITCH
a. Apply battery positive voltage between terminal 1 and 3, and through a 3.4 W test bulb, and
check that the bulb lights up.
HINT: It will take a short time for bulb to light up.
b. Submerge the switch in fuel, and check that the bulb goes out.
If operation is not as specified, replace the sender gauge.
Specifications
Connecting Rod Bearing: Specifications
Connecting Rod Bearing
Measure the Plastigage at its widest point.
Standard oil clearance: 0.027 - 0.053 mm (0.0011 - 0.0021 inch) Maximum oil clearance: 0.065 mm
(0.0026 inch)
If the oil clearance is greater than maximum, replace the bearings. If necessary, replace the
crankshaft.
HINT: If using a standard bearing, replace it with one having the same number. If the number of the
bearing cannot be determined, select the correct bearing by adding together the numbers imprinted
on the connecting rod cap and crankshaft, then selecting the bearing with the same number as the
total. There are 6 sizes of standard bearings, marked "2", "3", "4", "5", "6" and "7".
Reference
Connecting rod big end inside diameter
Page 5696
Service Precautions
Air Bag(s) Arming and Disarming: Service Precautions
SRS AIRBAG PRECAUTION
CAUTION: TOYOTA trucks are equipped with SRS, which comprises a driver airbag, front
passenger airbag and failure to carry out service operations in the correct sequence could cause
the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Further, if
a mistake is made in servicing the SRS, it is possible that the SRS may fail to operate when
required. Before performing servicing (including removal or installation of parts, inspection or
replacement), be sure to read the following items carefully, then follow the correct procedures
described.
Work must be started 90 seconds after the ignition switch is turned to the "LOCK" position and the
negative (-) terminal cable is disconnected from the battery.
The SRS is equipped with a back-up power source so that if work is started within 90 seconds from
disconnecting the negative (-) terminal cable of the battery, the SRS may be deployed.)
Do not expose the steering wheel pad, front passenger airbag assembly, airbag sensor assembly
or front airbag sensor directly to hot air or flames.
NOTE: Malfunction symptoms of the SRS are difficult to confirm, so the DTCs become the most
important source of information when troubleshooting. When troubleshooting the SRS, always
inspect the DTCs before disconnecting the battery.
Even in cases of a minor collision where the SRS does not deploy, the steering wheel pad, front
passenger airbag assembly, airbag sensor assembly and front airbag sensor should be inspected.
Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during
repairs.
Never use SRS parts from another vehicle. When replacing parts, replace them with new parts.
Never disassemble and repair the steering wheel pad, front passenger airbag assembly, airbag
sensor assembly or front airbag sensor, in order to reuse it.
If the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag
sensor, has been dropped, or if there are cracks, dents or other defects in the case, bracket or
connector, replace it with new one.
Use a volt/ohmmeter with high impedance (10 Kohms/V minimum) for troubleshooting the system's
electrical circuits.
Information labels are attached to the periphery of the SRS components. Follow the instructions on
the notices.
After work on the SRS is completed, check the SRS warning light check.
When the negative (-) terminal cable is disconnected from the battery, the memory of the clock and
audio system will be canceled. So before starting work, make a record of the contents memorized
in the audio memory system. When work is finished, reset the audio systems as they were before
and adjust the clock. To avoid erasing the memory in each memory system, never use a back-up
power supply from outside the vehicle.
If the vehicle is equipped with a mobile communication system, refer to the precaution.
Page 4787
Terminal Retainer
Push the terminal retainer down to the temporary lock position.
c. Release the locking lug from terminal and pull the terminal out from rear.
4. INSTALL TERMINAL TO CONNECTOR
a. Insert the terminal.
HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug
locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position.
Page 3486
Step 4
O/D OFF indicator light does not light up
Steps 1 - 2
O/D OFF indicator light remains ON
Page 6828
Wiring Harness Connector
E: Indicates the wiring harness and wiring harness connector. The wiring harness with male
terminal is shown with arrows.
Outside numerals are pin numbers.
The first letter of the code for each wiring harness and wiring harness connector(s) indicates the
component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and
Surrounding area, and "B" for the Body and Surrounding area.
When more than one code has the first and second letters in common, followed by numbers (e.g,
IH1, IH2), this indicates the same type of wiring harness and wiring harness connector.
F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in
parts position.
G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside
it). Junction Blocks are shaded to clearly separate
them from other parts.
H: When 2 parts both use one connector in common, the parts connector name used in wire
routing is shown in square brackets [ ].
Wiring Color
I: Indicates the wiring color.
Wire colors are indicated by an alphabetical code.
B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR =
Brown SB = Sky Blue LG = Light Green GR = Gray
The first letter indicates the basic wire color and the second letter indicates the color of the stripe.
Page 5123
Stabilizer Bar: Service and Repair
REMOVAL
1. DISCONNECT STABILIZER BAR LINKS
Remove the 2 nuts and disconnect the stabilizer bar links from the lower suspension arms.
HINT: If the ball joint turns together with the nut, use a hexagon (6 mm) wrench to hold the stud.
2. REMOVE STABILIZER BAR
a. Remove the 2 bolts, nuts and stabilizer bar with the cushions and brackets. b. Remove the 2
brackets and cushions from the stabilizer bar.
Page 2672
Camshaft Position Sensor: Service and Repair
Camshaft Position Sensor
REMOVAL
1. DRAIN ENGINE COOLANT
2. REMOVE DRIVE BELT
3. REMOVE LH NO.3 TIMING BELT COVER
Electrical Specifications
Alternator: Electrical Specifications
Testing - Voltage/Amperage
Testing - Voltage/Amperage
Regulating Voltage 13.2 to 14.8 V at 77 deg F
Rated - Voltage/Amperage
Rated - Voltage/Amperage
Rated Output 100 A at 12 V
Rotor Coil Resistance 2.1 to 2.5 ohms at 68 deg F
Interior - Seat Belt Extender Availability
Seat Belt Extension: Technical Service Bulletins Interior - Seat Belt Extender Availability
BODY BO017-02
September 30, 2002
Title: SEAT BELT EXTENDER
Models: '01 - '03 Model Year
Introduction
Toyota customers who find it necessary to increase the length of their seat belts may obtain Seat
Belt Extenders at no cost through their local Toyota dealer.
^ The extender is available in 6 inch, 9 inch, 12 inch, 15 inch and 18 inch lengths.
^ The extender is available only in black.
^ Owners are informed of the Seat Belt Extender availability through the Toyota Owner's Manual
included in each vehicle.
Page 1720
E. Confirm the Diagnostic Tester has the appropriate software for the type of calibration file that
was downloaded.
NOTE:
The calibration type is specific to the software version loaded on your Diagnostic Tester. If you
selected the wrong version when downloading the calibration file, you will receive an error when
attempting to install the file on the Diagnostic Tester.
Page 5721
Body
Connector Location (Standard Cab)
BA1 Front Door LH Wire and Speaker Tweeter Wire LH (Inside of Front Door LH)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Seat
Connector Location
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
BJ1 Seat No. 1 Wire and Seat No. 2 Wire (Under the Driver's Seat)
Page 4516
Required SSTs
Battery Inspection Procedure
All vehicles are to be inspected according to the procedures listed below using the Digital Battery
System Analyzer (P/N 00002-V8150-KIT) no more than 48 hours prior to customer vehicle delivery.
In hybrid vehicles, the Digital Battery System Analyzer (SST P/N 00002-V81 50-KIT) is to be used
ONLY on the AUXILIARY (12 volt) battery.
1. Connect test clamps to the battery. (If the analyzer does NOT power up automatically, press the
POWER button.)
2. Select the correct USER ID (if applicable) and press the NEXT soft key.
3. Enter USER PIN (if applicable) and press the NEXT soft key.
NOTE:
For details on defining USER ID or PIN, refer to the NVS-8150 Instruction Manual.
Page 3312
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 3002
Injector (Part 2)
Page 6593
Body
Connector Location (Standard Cab)
BA1 Front Door LH Wire and Speaker Tweeter Wire LH (Inside of Front Door LH)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Seat
Connector Location
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
BJ1 Seat No. 1 Wire and Seat No. 2 Wire (Under the Driver's Seat)
Page 885
Spark Plug: Application and ID
Recommended Spark Plugs
DENSO K20R-U
NGK BKR6EYA
Page 2539
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 675
Non-Waterproof Type Connector
"Case 1" Raise the terminal retainer up to the temporary lock position.
Non-Waterproof Type Connector
"Case 2" Open the secondary locking device.
Page 6611
Key Reminder Switch: Description and Operation
KEY REMINDER AND SEAT BELT WARNING
SYSTEM OUTLINE
Current always flows to TERMINAL (B) 5 of the combination meter through the DOME fuse.
1. SEAT BELT WARNING SYSTEM
When the ignition SW is turned on, current flows from the GAUGE fuse to TERMINAL (A) 7 of the
combination meter. This current activates the combination meter and the current flowing through
the seat belt warning light flows from TERMINAL (A) 12 to GROUND, causing the warning light to
light up. A buckle SW off signal is input to TERMINAL (B) 9 of the combination meter to TERMINAL
(A) 12 to GROUND, causing the warning light to light up. A buckle SW off signal is input to
TERMINAL (B) 9 of the combination meter, the current flowing to TERMINAL (B) 5 of the
combination meter flows from TERMINAL (A) 12 to GROUND and the seat belt warning buzzer
sounds. However, if the seat belt is put on during this period (While the buzzer is sounding), signal
input to TERMINAL (B) 9 of the combination meter stops and the current flow from TERMINAL (B)
5 of the combination meter to TERMINAL (A) 12 to GROUND is cut, causing the buzzer to stop.
2. KEY REMINDER SYSTEM
With the ignition key inserted in the key cylinder (Unlock warning SW on), the ignition SW still off
and driver's door open (Door courtesy SW on), when a signal is input to TERMINAL (B) 10 of the
combination meter, the combination meter operates, current flows from TERMINAL (B) 5 of the
combination meter to TERMINAL (A) 12 to GROUND and key reminder buzzer sounds.
Page 88
B: Junction Connector
Indicates a connector which is connected to a short terminal.
Junction connector in this include a short terminal which is connected to a number of wire
harnesses. Always perform inspection with the short terminal installed. (When installing the wire
harnesses, the harnesses can be connected to any position within the short terminal grouping.
Accordingly, in other vehicles, the same position in the short terminal may be connected to wire
harness from a different part.) Wire harness sharing the same short terminal grouping ha the same
color.
C: Parts Code
The first letter of the code is taken from the first letter of part, and the numbers indicates its order in
parts which start with the same letter.
D: Connector Color
Connectors not indicated are milky white in color.
How to Read Ground Points
HOW TO READ GROUND POINTS
Page 3185
2. REMOVE CRANKSHAFT POSITION SENSOR
a. Disconnect the crankshaft position sensor connector. b. Remove the bolt and crankshaft position
sensor.
INSTALLATION
1. INSTALL CRANKSHAFT POSITION SENSOR
a. Install the crankshaft position sensor with the bolt.
Torque: 6.5 N.m (65 kgf.cm, 58 in.lbf)
b. Connect the crankshaft position sensor connector.
2. INSTALL ENGINE UNDER COVER
Page 5567
Wiring Harness Connector
E: Indicates the wiring harness and wiring harness connector. The wiring harness with male
terminal is shown with arrows.
Outside numerals are pin numbers.
The first letter of the code for each wiring harness and wiring harness connector(s) indicates the
component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and
Surrounding area, and "B" for the Body and Surrounding area.
When more than one code has the first and second letters in common, followed by numbers (e.g,
IH1, IH2), this indicates the same type of wiring harness and wiring harness connector.
F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in
parts position.
G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside
it). Junction Blocks are shaded to clearly separate
them from other parts.
H: When 2 parts both use one connector in common, the parts connector name used in wire
routing is shown in square brackets [ ].
Wiring Color
I: Indicates the wiring color.
Wire colors are indicated by an alphabetical code.
B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR =
Brown SB = Sky Blue LG = Light Green GR = Gray
The first letter indicates the basic wire color and the second letter indicates the color of the stripe.
Page 2107
Fuel Pressure: Testing and Inspection
CHECK FUEL PRESSURE
a. Check the battery positive voltage is above 12 V. b. Disconnect the negative (-) terminal cable
from the battery. c. Remove the front fuel pipe from the LH delivery pipe.
d. Install the front fuel pipe and SST (pressure gauge) to the delivery pipe with 3 lower gaskets and
SST (adapter).
SST 09268-45014 (09268-1190, 90405-06167)
Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)
e. Wipe off any splattered gasoline. f.
Reconnect the negative (-) terminal cable to the battery.
g. Connect a TOYOTA hand-held tester to the DLC3. (See step 1 in check fuel pump operation (a)
to (e)) h. Measure the fuel pressure.
Fuel pressure: 265 - 304 kPa (2.7 - 3.1 kgf/sq.cm, 38 - 44 psi)
If pressure is high, replace the fuel pressure regulator. If pressure is low, check the fuel hoses and
connections, fuel pump, fuel filter and fuel pressure regulator.
i. Disconnect the TOYOTA hand-held tester from the DLC3.
j. Start the engine.
k. Measure the fuel pressure at idle.
Fuel pressure: 265 - 304 kPa (2.7 - 3.1 kgf/sq.cm, 38 - 44 psi)
l. Stop the engine.
m. Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped.
Fuel pressure: 147 kPa (1.5 kgf/sq.cm, 21 psi) or more
If pressure is not as specified, check the fuel pump, pressure regulator and/or injectors.
n. After checking fuel pressure, disconnect the negative (-) terminal cable from the battery and
carefully remove the SST to prevent gasoline from
splashing. SST 09268-45014
o. Reinstall the front fuel pipe to the LH delivery pipe. p. Reconnect the negative (-) terminal cable
to the battery. q. Check for fuel leaks.
Page 1489
Spark Plug: Testing and Inspection
ON-VEHICLE INSPECTION
NOTE: "Cold" and "Hot" in these sentences express the temperature of the coils themselves.
"Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F).
INSPECT SPARK PLUGS
a. Remove the ignition coils (with igniter).
b. Using a 16 mm plug wrench, remove the spark plugs.
c. Clean the spark plugs.
If the electrode has traces of wet carbon, allow it to dry and then clean with a spark plug cleaner.
Air pressure: Below 588 kPa (6 kgf/sq.cm, 85 psi)
Duration: 20 seconds or less
HINT: If there are traces of oil, remove it with gasoline before using the spark plug cleaner.
Recommended Spark Plug
Description and Operation
Throttle Position Sensor: Description and Operation
Throttle Position Sensor
Throttle position sensor is mounted on the throttle body and it has 2 sensors to detect the throttle
opening angle and a malfunction of the throttle position sensor's own.
Voltage applied to the terminals VTA and VTA2 of the ECM changes between 0 V and 5 V in
proportion to the opening angle of the throttle valve.
The ECM judges the current opening angle of the throttle valve from these signals output from
terminals VTA and VTA2, and the ECM controls the throttle motor to make the throttle valve
opening angle properly in accordance with the driving condition.
If this DTC is stored, the ECM cuts down the power for the throttle motor and the electromagnetic
clutch, and the throttle valve is fully closed by the return spring. However, the opening angle of the
throttle valve can be controlled by the accelerator pedal through the throttle cable.
Page 3079
Mass Air Flow Meter: Description and Operation
Mass Air Flow Meter
The mass air flow meter uses a platinum hot wire. The hot wire air flow meter consists of a
platinum hot wire, thermistor and a control circuit installed in a plastic housing. The hot wire air flow
meter works in principle that the hot wire and thermistor located in the intake air bypass of the
housing detect any changes in the intake air temperature.
The hot wire is maintained at the set temperature by controlling the current flow through the hot
wire. This current flow is then measured as an output voltage of the mass air flow meter.
The circuit is constructed so that the platinum hot wire and thermistor provide a bridge circuit, with
the power transistor, and controlled so that the potential of A and B remains equal in order to
maintain the set temperature.
Testing and Inspection
Fog/Driving Lamp Switch: Testing and Inspection
INSPECT FOG LIGHT SWITCH CONTINUITY If continuity is not as specified, replace the switch.
Engine Controls - MIL ON/DTC's P0135/P0155 Stored
Oxygen Sensor: Customer Interest Engine Controls - MIL ON/DTC's P0135/P0155 Stored
ENGINE EG019-02 REVISED
October 3, 2002
Title M.I.L. "ON" P0135 AND/OR P0155
Models: '00 - '02 Tundra (2UZ-FE) & '01 - '02 Sequoia
TSB REVISION NOTICE:
January 14, 2004: A Previous Part Number in the Parts Information table and one OFP number in
the Warranty Information table has been changed. All previous versions of this TSB should be
discarded.
Introduction
Certain 2000 - 2002 model year Tundra trucks (2UZ-FE) and 2001 - 2002 model year Sequoia
vehicles may exhibit a M.I.L. ON" condition with Diagnostic Trouble Code P0135 and/or P0155 in
the Engine Control Module (ECM)/SAE equivalent (PCM). The oxygen sensors have been
improved to correct this condition.
Applicable Vehicles ^
2000 - 2002 model year Tundra trucks with 2UZ-FE engines produced BEFORE the Production
Change Effective VINs listed below.
^ 2001 - 2002 model year Sequoia vehicles produced BEFORE the Production Change Effective
VINs listed below.
Production Change Information
Parts Information
Warranty Information
Applicable Warranty*:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36
months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Page 158
Page 2536
^ 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 194
Refer to Reset Procedure 2 for the vehicles with Electronically Controlled Automatic
Transmissions:
Reset Procedure 1
1. Connect the Toyota Diagnostic Tester to the vehicle.
2. Reset the ECM (PCM). Refer to the procedures below.
Page 3470
Transmission Mode Indicator - A/T: Electrical Diagrams
Electronically Controlled Transmission And A/T Indicator (Part 1)
Description and Operation
Brake Switch - TCC: Description and Operation
Stop Light Switch Signal
Engine
This signal is used to detect when the brakes have been applied. The STP signal voltage is the
same as the voltage supplied to the stop lights.
The STP signal is used mainly to control the fuel cut-off engine speed (The fuel cut-off engine
speed is reduced slightly when the vehicle is braking.).
Automatic Transaxle
The purpose of this circuit is to prevent the engine from stalling, while driving in lock-up condition,
when brakes are suddenly applied.
When the brake pedal is operated, this switch sends a signal to ECM. Then the ECM cancels
operation of the lock-up clutch while braking is in progress.
Page 4384
Using the following SSTs and a press, install the bearing spacer.
^ 09950-60010 (09951-00650)
^ 09950-70010 (09951-07150)
22. 4WD: INSTALL NEW OIL SEAL (INSIDE)
A. Using the following SST and a plastic hammer, install a NEW oil seal (inside).
^ 09527-17011
NOTE:
Lightly strike the SST on its circumference evenly.
B. Coat MP grease to the oil seal lip.
23. INSTALL STEERING KNUCKLE
A. 4WD: Insert the drive shaft into the axle hub and temporarily tighten the nut.
NOTE:
Be careful not to damage the oil seal and drive shaft boot.
B. Connect the steering knuckle to the upper suspension arm.
C. Install the nut and a NEW cotter pin. If the holes for the cotter pin are not aligned, tighten the nut
further up to 60°.
Torque: 105 N.m (1,100 kgf.cm, 77 ft.lbf)
24. CONNECT LOWER BALL JOINT
Connect the lower ball joint to the steering knuckle with 4 bolts.
Torque: 50 N.m (510 kgf.cm, 37 ft.lbf)
25. INSTALL SHOCK ABSORBER WITH COIL SPRING
A. Install the upper side of shock absorber to the chassis frame with the 3 nuts.
Page 4790
Driver Side J/B And Integration Relay
Page 2436
Page 2659
Mass Air Flow (MAF) Meter
Page 505
Knock Sensor: Locations
Knock Sensor (Part 1)
Page 3762
b. Push the secondary locking device or terminal retainer in to the full lock position.
5. CONNECT CONNECTOR
Disconnection of Male and Female Connectors
Disconnection of Male and Female Connectors
Disconnection Of Male And Female Connectors
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Page 4336
^ 09527-17011
B. Coat MP grease to the oil seal lip.
18. INSTALL NEW DUST COVER AND AXLE HUB TO STEERING KNUCKLE
A. Install the NEW dust cover to the steering knuckle with the 4 bolts.
Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)
B. Using the following SST and a press, install the axle hub to the steering knuckle.
^ 09649-17010
19. INSTALL ABS SPEED SENSOR ROTOR (W/ABS) OR SPACER (W/O ABS)
NOTE:
Take care not to scratch the serration of the speed sensor rotor.
20. 2WD: INSTALL NEW LOCK NUT
A. Using the following SST, install and torque a NEW lock nut to the axle hub.
^ 00002-00909 (09318-12010)
Torque: 274 N.m (2,800 kgf.cm, 203 ft.lbf)
NOTE:
Do NOT use air wrench.
B. Using a chisel and hammer, stake the lock nut.
21. 4WD: INSTALL BEARING SPACER
Testing and Inspection
Backup Lamp Switch: Testing and Inspection
INSPECT BACK-UP LIGHT SWITCH CONTINUITY If continuity is not as specified, replace the
switch.
Page 2997
Fuel Injector: Mechanical Specifications
Injector (Part 1)
Page 5371
Airbag Sensor Assembly: Description and Operation
AIRBAG SENSOR ASSEMBLY
The airbag sensor assembly is mounted on the floor inside the lower center cover. The airbag
sensor assembly consists of an airbag sensor, safing sensor, diagnosis circuit, ignition control and
drive circuit, etc. It receives signals from the airbag sensor and judges whether the SRS must be
activated or not.
Page 5220
Compressor And Magnetic Clutch (Part 2)
REMOVAL
1. RUN ENGINE AT IDLE SPEED WITH A/C ON FOR APPROX. 10 MINUTES
2. STOP ENGINE
3. DISCONNECT NEGATIVE (-) TERMINAL CABLE FROM BATTERY
4. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM
5. 5VZ-FE engine
REMOVE ENGINE UNDER COVER
6. 5VZ-FE engine
DISCONNECT DISCHARGE AND SUCTION HOSES Remove the 2 bolts and disconnect the both
hoses.
NOTE: Cap the open fitting immediately to keep moisture or dirt out of the system.
7. 2UZ-FE engine
DISCONNECT DISCHARGE AND SUCTION HOSES Remove the 2 nuts and disconnect the both
hoses.
NOTE: Cap the open fitting immediately to keep moisture or dirt out of the system.
8. REMOVE DRIVE BELT
9. 5VZ-FE engine
REMOVE COMPRESSOR a. Disconnect the connector. b. Remove the 4 bolts and compressor.
10. 2UZ-FE engine
REMOVE COMPRESSOR a. Disconnect the connector. b. Remove the 4 bolts and nut. c. Remove
the cooler bracket. d. Remove the compressor.
INSTALLATION
Page 5659
Impact Sensor: Service and Repair Airbag Sensor Connectors
DISCONNECTION
a. While holding both flank sides of the outer, slide the outer to the direction directed by an arrow.
b. Lock of the connectors is released, then disconnect the connectors.
HINT: Be sure to hold both flank sides of the outer. If holding the top or bottom sides, it will obstruct
disconnection.
CONNECTION
a. Align the male connector (on the side of sensor) and female connector in the same direction as
shown in the illustration and fit in them without
rubbing.
b. As they are fitted in, the outer slides rearward. Press it until the outer returns to its original
position again.
If fitting stops half way, connectors will separate.
c. Be sure to insert until they are locked. After fitting in, pull them slightly to check that they are
locked (When locked, make sure that the outer
returns to its original position and sound at the time of fitting in can be heard.).
HINT: Do not fit in while holding the outer.
- When fitting in, the outer slides. Do not touch it.
Page 6568
Seat Belt Reminder Lamp: Testing and Inspection
INSPECT DRIVER'S SEAT BELT WARNING LIGHT a. Disconnect the connector B from the
combination meter. b. Connect the negative (-) lead from the battery to terminal 9. c. Turn the
ignition switch ON and check that the warning light lights UP.
If the warning light does not light up, inspect the bulb or wire harness.
INSPECT PASSENGER SEAT BELT WARNING LIGHT a. Remove the center cluster finish panel.
b. Disconnect the connectors from the center cluster integration. c. Connect the positive (+) lead
from the battery to the terminal 4 and negative (-) lead terminal 16, and check that the warning light
lights UP.
If the warning light does not light up, inspect the bulb or wire harness
Page 224
The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit
breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery
power is supplied to each system are explained. Since all System Circuit diagrams start from the
power source, the power source system must be fully understood.
Specifications
Knock Sensor: Specifications
SST 09816-30010
Torque: ................................................................................................................................................
................................. 45 N.m (450 kgf.cm, 33 ft.lbf)
Page 188
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 6799
Horn: Splice Locations
Engine Compartment
Splice Location
E1 Engine Room Main Wire
E2 Engine Room Main Wire
E3 Engine Room Main Wire
E4 Engine No. 2 Wire
E5 Engine Wire
E6 Engine Wire
E7 Engine Wire
E8 Engine Wire
Instrument Panel
Keyless Entry - Remote Transmitter Programming Guide
Keyless Entry Transmitter: Technical Service Bulletins Keyless Entry - Remote Transmitter
Programming Guide
ELECTRICAL EL010-07 REVISED
Title: WIRELESS TRANSMITTER & PROGRAMMING GUIDE
Models: '90 - '08 Applicable Toyota
November 9, 2007
TSB REVISION NOTICE:
^ November 10, 2007: A TSB reference has been updated in the Programming column of the
Application Chart.
Previous versions of this TSB should be discarded.
TSB UPDATE NOTICE:
The information contained in this TSB supersedes TSB No. EL008-02. TSB No. EL008-02 is now
obsolete and should be discarded.
Introduction
Difficulties during Remote Keyless Entry (RKE) Transmitter Programming can arise due to
confusion between Toyota Factory Wireless systems and Toyota Port/Dealer installed systems.
This bulletin will assist in identifying the system/correct remote transmitters for each vehicle, and
provide the location of the most accurate programming procedure for each system.
Applicable Vehicles
^ 1990 - 2008 model year applicable Toyota vehicles.
Warranty Information
System Identification
The Application Chart contains all of the necessary information to correctly identify the type of
system installed, and where to go to get programming procedures for each vehicle.
Should a vehicle having both VIP and Factory systems available (as identified in the Application
Chart) be brought in without any remotes (or one non-working remote), use the following tips to
help determine which type of wireless system (O.E. or PIO/DIO) the vehicle has.
^ Look at the Trim Level of the vehicle. Higher-grade vehicles will tend to have O.E. systems, while
entry-grade vehicles will tend to have VIR For example, the 2001 Camry XLE has Factory WRKE,
but the LE and CE grades have VIR
^ Look for a "Status Monitor" with a glass breakage sensor and an LED externally installed into the
dashboard or on the center console. Most VIP systems will have this.
^ Locate the ECU (refer to the applicable vehicle VIP Manual installation instructions for location).
Once located, refer to the part label.
^ Attempt to perform the factory wireless programming procedure to get a response from the
vehicle. Select the "confirmation mode" and see if any "Lock/Unlock" response is received, if so,
the vehicle has a factory system.
Page 2029
Wiring Harness Connector
E: Indicates the wiring harness and wiring harness connector. The wiring harness with male
terminal is shown with arrows.
Outside numerals are pin numbers.
The first letter of the code for each wiring harness and wiring harness connector(s) indicates the
component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and
Surrounding area, and "B" for the Body and Surrounding area.
When more than one code has the first and second letters in common, followed by numbers (e.g,
IH1, IH2), this indicates the same type of wiring harness and wiring harness connector.
F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in
parts position.
G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside
it). Junction Blocks are shaded to clearly separate
them from other parts.
H: When 2 parts both use one connector in common, the parts connector name used in wire
routing is shown in square brackets [ ].
Wiring Color
I: Indicates the wiring color.
Wire colors are indicated by an alphabetical code.
B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR =
Brown SB = Sky Blue LG = Light Green GR = Gray
The first letter indicates the basic wire color and the second letter indicates the color of the stripe.
Page 5404
d. Check functioning of the SST.
CAUTION: When deploying the airbag, always use the specified SST: SRS Airbag Deployment
Tool.
SST 09082-00700
1. Connect the SST to the battery.
Connect the red clip of the SST to the battery positive (+) terminal and the black clip to the battery
negative (-) terminal.
HINT: Do not connect the yellow connector which will be connected with the supplemental restraint
system.
2. Check functioning of the SST.
Press the SST activation switch, and check that the LED of the SST activation switch lights up.
CAUTION: If the LED lights up when the activation switch is not being pressed, SST malfunction is
probable, so definitely do not use the SST.
3. Disconnect the SST from the battery.
Page 124
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 5463
Airbag Sensor Assembly: Service and Repair Removal and Installation
Airbag Sensor Assembly
REMOVAL
NOTE: Do not open the cover or the case of the ECU and various electrical devices unless
absolutely necessary (If the IC terminals are touched, the IC may be destroyed by static
electricity.).
1. REMOVE LOWER CENTER COVER
Remove the 2 clips and lower center cover.
Page 6518
Wiring Harness Connector
E: Indicates the wiring harness and wiring harness connector. The wiring harness with male
terminal is shown with arrows.
Outside numerals are pin numbers.
The first letter of the code for each wiring harness and wiring harness connector(s) indicates the
component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and
Surrounding area, and "B" for the Body and Surrounding area.
When more than one code has the first and second letters in common, followed by numbers (e.g,
IH1, IH2), this indicates the same type of wiring harness and wiring harness connector.
F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in
parts position.
G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside
it). Junction Blocks are shaded to clearly separate
them from other parts.
H: When 2 parts both use one connector in common, the parts connector name used in wire
routing is shown in square brackets [ ].
Wiring Color
I: Indicates the wiring color.
Wire colors are indicated by an alphabetical code.
B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR =
Brown SB = Sky Blue LG = Light Green GR = Gray
The first letter indicates the basic wire color and the second letter indicates the color of the stripe.
Locations
Page 1989
CHART 20
Page 1673
During ECU flash reprogramming, the Error screen shown may be displayed on the Diagnostic
Tester for one of the following reasons:
1. Immobilizer key not properly registered or auto-registration mode left open.
2. Ignition ON/OFF cycling not followed correctly during the flash reprogramming procedure.
3. The Diagnostic Tester cable is damaged, causing an open communication circuit.
NOTE:
The Diagnostic Tester may operate properly in other modes such as OBD, OBDII, or CARB, with a
damaged cable.
To eliminate the possibility of the first 2 reasons causing the error message, do the following:
1. Confirm the Immobilizer Transponder Master Key is properly registered and auto registration
mode is closed. Follow the appropriate Repair Manual procedure and consult TSB SS001-99,
"Scan tool Immobilizer key Code Utility
2. Conduct the ECU flash reprogramming process explicitly following key operation instructions.
Refer to TSB SS002-01, "ECU Flash Reprogramming Process, "for more details.
To determine if the Diagnostic Tester cable is damaged, follow the test procedures below to check
the electrical integrity of the cable. Conduct all continuity tests with an Ohm meter. For all five test
procedures, the resistance values must be below 6.0 ohms to pass.
Test CABLE TEST 1.
Page 2926
Canister Purge Solenoid: Testing and Inspection
VSV FOR EVAPORATIVE EMISSION (EVAP)
INSPECTION
1. REMOVE VSV
2. INSPECT VSV
a. Inspect the VSV for open circuit.
Using an ohmmeter, check that there is continuity between the terminals.
Resistance: 30 - 34 ohms at 20 °C (68 °F)
If there is no continuity, replace the VSV.
b. Inspect the VSV for ground.
Using an ohmmeter, check that there is no continuity between each terminal and the body. If there
is continuity, replace the VSV.
c. Inspect the VSV operation.
1. Check that air does not flow from ports.
Engine - Squealing Noise On Cold Start Up
Drive Belt: Customer Interest Engine - Squealing Noise On Cold Start Up
ENGINE EG003-05
Title: 2UZ-FE ACCESSORY DRIVE BELT NOISE
Models: '00 - '05 Tundra & '01 - '05 Sequoia
February 9, 2005
Introduction
Some customers may experience abnormal squeal noise from the engine accessory drive belt
area, usually during cold start-up. An improved accessory drive belt has been developed to correct
this condition.
Applicable Vehicles
^ 2000 - 2005 model year Tundra vehicles equipped with 2UZ-FE engine produced BEFORE the
Production Change Effective VIN shown below.
^ 2001 - 2005 model year Sequoia vehicles equipped with 2UZ-FE engine produced BEFORE the
Production Change Effective VIN shown below.
Production Change Information
Parts Information
Warranty Information
Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This
warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's
in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Repair Procedure
Replace the accessory drive belt with the improved part.
1. Remove existing accessory drive belt.
Testing and Inspection
Fuel Gauge Sender: Testing and Inspection
INSPECT FUEL SENDER GAUGE RESISTANCE
Measure the resistance between terminals 1 and 2 for each float position. If resistance value is not
as specified, replace the main sender gauge.
INSPECT FUEL LEVEL WARNING SWITCH
a. Apply battery positive voltage between terminal 1 and 3, and through a 3.4 W test bulb, and
check that the bulb lights up.
HINT: It will take a short time for bulb to light up.
b. Submerge the switch in fuel, and check that the bulb goes out.
If operation is not as specified, replace the sender gauge.
Page 1892
Applicable Vehicles
Page 412
Continuity And Resistance Check
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Continuity And Resistance Check
C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the
electrical circuit.
Finding A Short Circuit
Finding A Short Circuit
Finding A Short Circuit
A. Remove the blown fuse and disconnect all loads of the fuse.
Electrical Specifications
Resistance
Symptom Related Diagnostic Procedures
Problem Symptoms Table - Ignition Switch And Key Unlock Warning Switch
Specifications
Compressor Clutch: Specifications
Clearance 0.5 +/- 0.15 mm
Fuel Pump Relay
Fuel Pump Relay: Testing and Inspection Fuel Pump Relay
INSPECTION
1. REMOVE RELAY BOX COVER
2. REMOVE FUEL PUMP RELAY (Marking: FUEL PUMP)
3. INSPECT FUEL PUMP RELAY CONTINUITY
a. Using an ohmmeter, check that there is continuity between terminals 1 and 2.
If there is no continuity, replace the relay.
b. Check that there is continuity between terminals 3 and 4.
If there is no continuity, replace the relay.
4. INSPECT FUEL PUMP RELAY OPERATION
a. Apply battery positive voltage across terminals 1 and 2. b. Using an ohmmeter, check that there
is no continuity between terminals 3 and 4.
If there is continuity, replace the relay.
5. REINSTALL FUEL PUMP RELAY
6. REINSTALL RELAY BOX COVER
Page 4149
(b) Place the plate between the pistons and insert a pad at one side. (c) Use compressed air to
remove the pistons alternately from the cylinder.
CAUTION: Do not place your fingers in front of the pistons when using compressed air.
3. REMOVE PISTON SEALS
Using a screwdriver, remove the 4 piston seals from the cylinder.
INSPECTION
1. MEASURE PAD LINING THICKNESS
Using a ruler, measure the pad lining thickness. Standard thickness: 11.5 mm (0.453 inch)
Minimum thickness: 1.0 mm (0.039 inch) Replace the pad if the thickness is less than the minimum
(the 1.0 mm slit is no longer visible), or if it shows signs of uneven wear.
2. MEASURE DISC THICKNESS
Using a micrometer, measure the disc thickness. Standard thickness: 28.0 mm (1.102 inch)
Minimum thickness: 26.0 mm (1.024 inch) Replace the disc if the thickness of the disc is at the
minimum or less. Replace the disc or grind it on a lathe if it is scored or worn unevenly.
Page 6599
The ground points circuit diagram shows the connections from all major parts to the respective
ground points. When troubleshooting a faulty ground point, checking the system circuits which use
a common ground may help you identify the problem ground quickly. The relationship between
ground points (EA, IB and IC) can also be checked this way.
How to Read Power Source
HOW TO READ POWER SOURCE
Page 5748
Accessories - Hood Protector Replacement
Hood Bra: Technical Service Bulletins Accessories - Hood Protector Replacement
ACCESSORIES AX004-03
August 6, 2003
Title: ACCESSORY HOOD PROTECTOR
Models: '00 - '02 Tundra
Introduction
A new hood protector service replacement part is now available for 2000 through 2002 model year
Tundra vehicles. Replace the hood protector with the revised part when required.
Applicable Vehicles
^ 2000 - 2002 model year Tundra vehicles with the Toyota Genuine Accessory Hood Protector.
Parts Information
Repair Procedure
Refer to the installation instructions provided with the hood protector kit.
Warranty Information
Applicable Warranty **
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36
months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
** Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Page 3226
Body
Connector Location (Standard Cab)
BA1 Front Door LH Wire and Speaker Tweeter Wire LH (Inside of Front Door LH)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Seat
Connector Location
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
BJ1 Seat No. 1 Wire and Seat No. 2 Wire (Under the Driver's Seat)
Page 654
Throttle Position Sensor: Service and Repair
Refer to Fuel Delivery and Air Induction / Throttle Body / Service and Repair, for removal and
installation of this component.
Page 3519
An AC voltage is generated in the No.2 vehicle speed sensor coil as the rotor mounted on the
output shaft rotates, and this voltage is sent to the ECM.
The gear shift point and lock-up timing are controlled by the ECM based on the signals from this
vehicle speed sensor and the throttle position sensor signal.
If the No.2 vehicle speed sensor malfunctions, the ECM uses input signals from the No.1 vehicle
speed sensor as a back-up signal.
Page 5154
3. 2WD: REMOVE LOCK NUT AND ABS SPEED SENSOR ROTOR/SPACER
a. Using a chisel and hammer, loosen the staked part of the lock nut.
NOTICE: Be careful not to damage the bushing.
b. Using Special Service Tool (SST), remove the lock nut.
SST 09318-12010
c. Remove the ABS speed sensor rotor/spacer.
NOTICE: Take care not to scratch the serration of the speed sensor rotor.
4. REMOVE AXLE HUB FROM STEERING KNUCKLE
a. Remove the 4 bolts and shift the dust cover towards the hub side (outside). b. Using SST,
remove the axle hub from the steering knuckle.
SST 09710-30021 (09710-03051), 09950-40011 (09951-04020, 09952-04010, 09953-04020,
09954-04010, 09955-04031, 09957-04010, 09958-04011)
c. Remove the dust cover from the steering knuckle. d. 4WD: Remove the bearing spacer and ABS
speed sensor rotor (w/ABS)/spacer (w/o ABS).
NOTICE: Take care not to scratch the serration of the speed sensor rotor.
5. REMOVE OIL SEAL (OUTSIDE)
Using a screwdriver, remove the oil seal (outside) from the steering knuckle.
6. REMOVE BEARING FROM STEERING KNUCKLE
a. Using snap ring pliers, remove the snap ring. b. Using SST and a press, remove the bearing
from the steering knuckle.
SST 09950-60020 (09951-00810), 09950-70010 (09951-07150)
REASSEMBLY
Page 1770
Page 2837
CHART 30
Page 1233
2. Tighten the union bolt by hand.
3. Using SST, tighten the union bolt to the specified torque.
SST 09612-24014 (09617-24011)
Torque: 33 N.m (340 kgf.cm, 24 ft.lbf) for use with SST 39 N.m (400 kgf.cm, 29 ft.lbf)
HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
c. When connecting the flare nut on the high pressure pipe union, observe these procedures:
1. Apply a light coat of engine oil to the flare nut, and tighten the flare nut by hand. 2. Using SST,
tighten the flare nut to the specified torque.
SST 09023-38400
NOTE: Do not rotate the fuel filter outlet, when tightening the flare nut.
Torque: 28 N.m (285 kgf.cm, 21 ft.lbf) for use with SST 34.3 N.m (350 kgf.cm, 25 ft.lbf)
HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
d. Observe these precautions when removing and installing the injectors.
1. Never reuse the O-ring. 2. When placing a new O-ring on the injector, take care not to damage it
in any way. 3. Coat a new O-ring with spindle oil or gasoline before installing-never use engine,
gear or brake oil.
Engine/Transmission Controls - Resetting ECM Memory
Engine Control Module: All Technical Service Bulletins Engine/Transmission Controls - Resetting
ECM Memory
TRANSMISSION & CLUTCH TC002-03 REVISED
Title: ECM RESET MEMORY FUNCTION
Models: '00 - '05 All Models
June 10, 2003
TSB REVISION NOTICE:
^ December 20, 2004: Applicable Vehicles section has been updated - 2004 and 2005 model years
added, models and model years updated for various models; and Reset Procedure 2 has been
revised.
^ January 16, 2004: Tundra vehicles were added to the Applicable Vehicles chart.
^ December 17, 2003: T-100 vehicles were removed from the Applicable Vehicles chart.
Previous versions of this TSB should be discarded.
Introduction
Whenever an automatic transmission is replaced, overhauled or individual components are
replaced, use this procedure to clear Engine Control Module ( ECM, SAE term: Powertrain Control
Module, PCM) "Learned Values" to minimize subsequent performance concerns.
CAUTION:
Failure to follow the procedure below may lengthen the time to readjust the ECM "Learned Values,"
potentially resulting in performance concerns.
Required SSTs
Warranty Information
Applicable Vehicles
Page 2273
D. The Calibration Update Wizard (CUW) launches automatically when a calibration file link is
selected (or clicked). Verify that the CUW version is 6.0 or higher. If not, refer to the Note below.
The CUW will guide you through the steps to download the calibration file to the Diagnostic Tester
Program Card. Click NEXT on the first screen (Figure 7).
NOTE:
If the CUW does not launch, or the version is older than 6.0, install Diagnostic Software (TIS
Diagnostic Applications Installer). Specific installation instructions (Reprogramming with CUW 6.0)
are located under Diagnostics ECU Flash Reprogramming (Figure 6).
Page 6708
Brake Lamp: Splice Locations
Engine Compartment
Splice Location
E1 Engine Room Main Wire
E2 Engine Room Main Wire
E3 Engine Room Main Wire
E4 Engine No. 2 Wire
E5 Engine Wire
E6 Engine Wire
E7 Engine Wire
E8 Engine Wire
Instrument Panel
Page 3738
BJ Inside of Rear Door LH
BK Inside of Rear Door RH
BL Surrounding of the Front of the Fuel Tank
Connector Location
BA1 Front Door LH Wire and Wire Harness (Connector Location)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel)
BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel)
BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel)
BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Page 1064
Engine Compartment
Instrument Panel
Locations
Page 2341
Continuity And Resistance Check
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Continuity And Resistance Check
C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the
electrical circuit.
Finding A Short Circuit
Finding A Short Circuit
Finding A Short Circuit
A. Remove the blown fuse and disconnect all loads of the fuse.
Locations
Sound Proofing / Insulation: Locations
Page 2832
Page 1626
w/o Tachometer
HINT: Connect the test leads so that the current from the ohmmeter can flow according to the
above order. This circuit includes the diode.
If resistance value is not as specified, replace the receiver gauge.
Service Precautions
Air Bag(s) Arming and Disarming: Service Precautions
SRS AIRBAG PRECAUTION
CAUTION: TOYOTA trucks are equipped with SRS, which comprises a driver airbag, front
passenger airbag and failure to carry out service operations in the correct sequence could cause
the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Further, if
a mistake is made in servicing the SRS, it is possible that the SRS may fail to operate when
required. Before performing servicing (including removal or installation of parts, inspection or
replacement), be sure to read the following items carefully, then follow the correct procedures
described.
Work must be started 90 seconds after the ignition switch is turned to the "LOCK" position and the
negative (-) terminal cable is disconnected from the battery.
The SRS is equipped with a back-up power source so that if work is started within 90 seconds from
disconnecting the negative (-) terminal cable of the battery, the SRS may be deployed.)
Do not expose the steering wheel pad, front passenger airbag assembly, airbag sensor assembly
or front airbag sensor directly to hot air or flames.
NOTE: Malfunction symptoms of the SRS are difficult to confirm, so the DTCs become the most
important source of information when troubleshooting. When troubleshooting the SRS, always
inspect the DTCs before disconnecting the battery.
Even in cases of a minor collision where the SRS does not deploy, the steering wheel pad, front
passenger airbag assembly, airbag sensor assembly and front airbag sensor should be inspected.
Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during
repairs.
Never use SRS parts from another vehicle. When replacing parts, replace them with new parts.
Never disassemble and repair the steering wheel pad, front passenger airbag assembly, airbag
sensor assembly or front airbag sensor, in order to reuse it.
If the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag
sensor, has been dropped, or if there are cracks, dents or other defects in the case, bracket or
connector, replace it with new one.
Use a volt/ohmmeter with high impedance (10 Kohms/V minimum) for troubleshooting the system's
electrical circuits.
Information labels are attached to the periphery of the SRS components. Follow the instructions on
the notices.
After work on the SRS is completed, check the SRS warning light check.
When the negative (-) terminal cable is disconnected from the battery, the memory of the clock and
audio system will be canceled. So before starting work, make a record of the contents memorized
in the audio memory system. When work is finished, reset the audio systems as they were before
and adjust the clock. To avoid erasing the memory in each memory system, never use a back-up
power supply from outside the vehicle.
If the vehicle is equipped with a mobile communication system, refer to the precaution.
Locations
Relay Box: Locations
Driver Side J/B And Integration Relay
Page 6221
c. Output DTC using diagnosis check wire.
1. Turn the ignition switch ON. 2. Using SST connect terminals Tc and CG of DLC3.
SST 09843-18020
3. Read the DTC on the CRUISE MAIN indicator light.
HINT: If the DTC is not output, inspect the diagnosis circuit.
As an example, the blinking patterns for codes; normal 52 are shown in the illustration.
2. ECM TERMINAL VALUES MEASUREMENT BY USING TOYOTA BREAK-OUT-BOX AND
TOYOTA HAND-HELD TESTER
a. Connect the TOYOTA break-out-box and TOYOTA hand-held tester to the vehicle. b. Read the
ECM input/output values by following the prompts on the tester screen. c. Please refer to the
TOYOTA hand-held tester which has a "Snapshot" function. This records the measured data and is
effective in the diagnosis
of intermittent problems.
Page 697
If operation is not as specified, replace the MAF meter.
6. Turn the ignition switch OFF. 7. Disconnect the negative (-) terminal cable from the battery. 8.
Disconnect the MAF meter connector.
4. REINSTALL MAF METER
Install the MAF meter with the 2 screws.
5. RECONNECT MAF METER CONNECTOR
Service Precautions
Air Bag(s) Arming and Disarming: Service Precautions
SRS AIRBAG PRECAUTION
CAUTION: TOYOTA trucks are equipped with SRS, which comprises a driver airbag, front
passenger airbag and failure to carry out service operations in the correct sequence could cause
the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Further, if
a mistake is made in servicing the SRS, it is possible that the SRS may fail to operate when
required. Before performing servicing (including removal or installation of parts, inspection or
replacement), be sure to read the following items carefully, then follow the correct procedures
described.
Work must be started 90 seconds after the ignition switch is turned to the "LOCK" position and the
negative (-) terminal cable is disconnected from the battery.
The SRS is equipped with a back-up power source so that if work is started within 90 seconds from
disconnecting the negative (-) terminal cable of the battery, the SRS may be deployed.)
Do not expose the steering wheel pad, front passenger airbag assembly, airbag sensor assembly
or front airbag sensor directly to hot air or flames.
NOTE: Malfunction symptoms of the SRS are difficult to confirm, so the DTCs become the most
important source of information when troubleshooting. When troubleshooting the SRS, always
inspect the DTCs before disconnecting the battery.
Even in cases of a minor collision where the SRS does not deploy, the steering wheel pad, front
passenger airbag assembly, airbag sensor assembly and front airbag sensor should be inspected.
Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during
repairs.
Never use SRS parts from another vehicle. When replacing parts, replace them with new parts.
Never disassemble and repair the steering wheel pad, front passenger airbag assembly, airbag
sensor assembly or front airbag sensor, in order to reuse it.
If the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag
sensor, has been dropped, or if there are cracks, dents or other defects in the case, bracket or
connector, replace it with new one.
Use a volt/ohmmeter with high impedance (10 Kohms/V minimum) for troubleshooting the system's
electrical circuits.
Information labels are attached to the periphery of the SRS components. Follow the instructions on
the notices.
After work on the SRS is completed, check the SRS warning light check.
When the negative (-) terminal cable is disconnected from the battery, the memory of the clock and
audio system will be canceled. So before starting work, make a record of the contents memorized
in the audio memory system. When work is finished, reset the audio systems as they were before
and adjust the clock. To avoid erasing the memory in each memory system, never use a back-up
power supply from outside the vehicle.
If the vehicle is equipped with a mobile communication system, refer to the precaution.
Page 401
Body
Connector Location (Standard Cab)
BA1 Front Door LH Wire and Speaker Tweeter Wire LH (Inside of Front Door LH)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Seat
Connector Location
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
BJ1 Seat No. 1 Wire and Seat No. 2 Wire (Under the Driver's Seat)
Page 4563
Starter Motor: Testing and Inspection
INSPECTION
1. INSPECT COMMUTATOR FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity between the segments of the commutator. If
there is no continuity between any segment, replace the armature.
2. INSPECT COMMUTATOR FOR GROUND
Using an ohmmeter, check that there is no continuity between the commutator and armature coil
core. If there is continuity, replace the armature.
3. INSPECT COMMUTATOR FOR DIRTY AND BURNT SURFACE
If the surface is dirty or burnt, correct it with sandpaper (No.400) or on a lathe.
4. INSPECT COMMUTATOR CIRCLE RUNOUT
a. Place the commutator on V-blocks. b. Using a dial, indicate the circle runout.
Maximum circle runout: 0.05 mm (0.0020 in.)
If the circle runout is greater than maximum, correct it on a lathe.
5. INSPECT COMMUTATOR DIAMETER
Page 4366
11. 4WD:
REMOVE OIL SEAL (INSIDE)
A. Mount the axle hub in a soft jaw vise.
HINT:
Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further.
B. Using a screwdriver, remove the oil seal (inside).
12. 2WD:
REMOVE LOCK NUT AND ABS
SPEED SENSOR ROTOR (W/ABS) OR SPACER (W/O ABS) Using a chisel and hammer, loosen
the staked part of the lock nut.
NOTE:
Be careful not to damage the bushing.
A. Using the following SST, remove the lock nut. 00002-00909 (09318-12010)
NOTE:
Do NOT use air wrench.
B. Remove the ABS speed sensor rotor or spacer.
NOTE:
Take care not to scratch the serration of the speed sensor rotor.
13. REMOVE AXLE HUB FROM STEERING KNUCKLE
A. Remove the 4 bolts and shift the dust cover toward the hub side (outside).
B. Using the following SSTs, remove the axle hub from the steering knuckle.
Page 3307
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.
Testing and Inspection
Washer Fluid Level Switch: Testing and Inspection
INSPECT WASHER LEVEL SWITCH CONTINUITY a. Check that there is no continuity between
terminals with switch OFF (float up). b. Check that there is continuity between terminals with the
switch ON (float down).
If operation is not as specified, replace the switch.
Page 5241
5. INSPECT AIR INLET CONTROL SWITCH CONTINUITY
If operation is not as specified, replace integration circuit bulb
6. INSPECT AIR INLET INDICATOR OPERATION
a. Connect the positive (+) lead from the battery to terminal A4 and negative (-) lead to A1. b. Push
the air inlet button in and check that the air inlet indicator lights up.
If operation is not as specified, replace the integration circuit.
c. Connect the positive (+) lead from the battery to terminal A11 and negative (-) lead to terminal
A10, then check that the indicator dimes.
If operation is not as specified, replace the integration circuit.
Locations
Vehicle Speed Sensor: Locations
Vehicle Speed Sensor NO.1
Vehicle Speed Sensor NO.2
Vehicle Speed Sensor NO.1
Page 6152
INSPECT DOOR KEY LOCK AND UNLOCK SWITCH CONTINUITY
If continuity is not as specified, replace the switch.
INSPECT DOOR UNLOCK DETECTION SWITCH CONTINUITY
If continuity is not as specified, replace the switch.
Page 3278
Vehicle Speed Sensor NO.2
Page 3509
Step 4
O/D OFF indicator light does not light up
Steps 1 - 2
O/D OFF indicator light remains ON
Page 4583
- If the contact plate is not pressed down with the specified pressure, the contact plate may tilt due
to coil deformation or the tightening of the nut.
2. Using SST tighten the nuts to the specified torque.
SST 09810-38140
Torque: 17 N.m (170 kgf.cm, 13 ft.lbf)
NOTE: If the nut is over tightened, it may cause cracks on the inside of the insulator.
h. Clean contact surfaces of contact plate and plunger.
Clean the contact surfaces of the remaining contact plate and plunger with a dry shop rag.
i. Reinstall magnetic switch end cover. Install the plunger, new gasket, end cover and lead clamp
with the 3 bolts.
Torque: 1.4 kW type
: 2.5 N.m (25 kgf.cm, 22 in.lbf)
2.0 kW type : 3.6 N.m (37 kgf.cm, 32 in.lbf)
Page 6263
The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit
breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery
power is supplied to each system are explained. Since all System Circuit diagrams start from the
power source, the power source system must be fully understood.
Page 6432
Key Reminder And Seat Belt Warning
Page 2787
Engine Bank Identification
Page 4580
a. Using SST, remove the bearing.
SST 09286-46011
b. Using SST and a press, press in a new bearing.
NOTE: Be careful of the bearing installation direction.
SST 09820-00030
3. REPLACE MAGNETIC SWITCH TERMINAL KIT PARTS
a. Remove magnetic switch end cover.
Remove the 3 bolts, end cover, gasket and plunger.
b. Inspect contact plate for wear.
Using vernier calipers, measure the contact plate for depth of wear.
Page 2335
B: Junction Connector
Indicates a connector which is connected to a short terminal.
Junction connector in this include a short terminal which is connected to a number of wire
harnesses. Always perform inspection with the short terminal installed. (When installing the wire
harnesses, the harnesses can be connected to any position within the short terminal grouping.
Accordingly, in other vehicles, the same position in the short terminal may be connected to wire
harness from a different part.) Wire harness sharing the same short terminal grouping ha the same
color.
C: Parts Code
The first letter of the code is taken from the first letter of part, and the numbers indicates its order in
parts which start with the same letter.
D: Connector Color
Connectors not indicated are milky white in color.
How to Read Ground Points
HOW TO READ GROUND POINTS
Page 2237
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 1117
Non-Waterproof Type Connector
"Case 1" Raise the terminal retainer up to the temporary lock position.
Non-Waterproof Type Connector
"Case 2" Open the secondary locking device.
Page 5590
Seat Belt Reminder Lamp: Splice Locations
Engine Compartment
Splice Location
E1 Engine Room Main Wire
E2 Engine Room Main Wire
E3 Engine Room Main Wire
E4 Engine No. 2 Wire
E5 Engine Wire
E6 Engine Wire
E7 Engine Wire
E8 Engine Wire
Instrument Panel
Page 2306
Refer to Reset Procedure 1 for the vehicles with Electronically Controlled Automatic
Transmissions:
Page 618
CHART 10
Page 6605
B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(Connect the Relay) and SW 2 OFF (or Disconnect SW 2)
D. Disconnect and reconnect the connectors while watching the test light.
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
E. Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION:
a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals
are touched, the IC may be destroyed by
static electricity.)
b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact
with the terminals of leads from the IC, etc. of the replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
Special Tool
1. PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown.
2. DISCONNECT CONNECTOR
3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
a. Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the
secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
A: For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
Page 6758
Daytime Running Lamp Relay: Testing and Inspection
Terminal Identification
Connector Disconnected: INSPECT DAYTIME RUNNING LIGHT RELAY CIRCUIT Disconnect the
connector from the relay and inspect the connector on the wire harness side. If circuit is as
specified, perform inspections.
Connector Connected: INSPECT DAYTIME RUNNING LIGHT RELAY CIRCUIT Connect the wire
harness side connector to the relay and inspect wire harness side connector from the back side, as
shown. If circuit is not as specified, try replacing the relay with a new one.
Testing and Inspection
Washer Fluid Level Switch: Testing and Inspection
INSPECT WASHER LEVEL SWITCH CONTINUITY a. Check that there is no continuity between
terminals with switch OFF (float up). b. Check that there is continuity between terminals with the
switch ON (float down).
If operation is not as specified, replace the switch.
Page 2502
CHART 27
Page 5943
Page 2421
CHART 2
CHART 3
CHART 4
Page 1631
Thermostat: Service and Repair
REMOVAL
HINT: Removal of the thermostat would have an adverse effect, causing a lowering of cooling
efficiency. Do not remove the thermostat, even if the engine tends to overheat.
1. DRAIN ENGINE COOLANT
Service and Repair
Valve Seat: Service and Repair
For further information regarding this component and the system that it is a part of, please refer to
Cylinder Head Assembly; Service and Repair.
Specifications
Wheel Bearing: Specifications
On models with serviceable wheel bearings, use a Lithium Multipurpose Grease.
Page 3388
B. Continue to update the ECU calibration file following the screen flow (Figure 18). Details for
selected screens are shown in Figure 19.
NOTE:
^ Each flash calibration update will take approximately 15 to 45 minutes.
^ Screens E through J (Figure 18) will need to be repeated for each flash calibration update
(calibration ID number).
^ All updates must display "YES" to complete the entire calibration file update for the vehicle ECU.
^ Failure to complete all updates may result in PERMANENT ECU DAMAGE!
CONFIRM UPDATE
4. Confirm successful flash calibration update and affix calibration update sticker.
Follow these steps to confirm the calibration was reprogrammed to the ECU.
Page 966
Oil Filter: Service and Repair
For further information regarding this component and the system that it is a part of, please refer to
Oil; Service and Repair.
Page 87
Splice Point
J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel,
and "B" for the Body).
The Location of splice Point I5 is shaded.
K: Indicates a shielded cable.
L: Indicates the pin number of the connector.
The numbering system is different for female and male connectors.
M: Indicates a ground point.
The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for
the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body
and Surrounding area.
How to Read Connector List
HOW TO READ CONNECTOR LIST
A: Indicates connector to be connected to a part. (The numeral indicates the pin No.)
Page 2772
Page 4253
Brake Drum: Specifications
Brake Drum Standard Inside Diameter 295.0 mm
Maximum Inside Diameter 297.0 mm
Page 4071
Torque: 15 N.m (155 kgf.cm, 11 ft.lbf)
28. W/ABS:
CONNECTABS SPEED SENSOR AND WIRE HARNESS CLAMP
Connect the ABS speed sensor and wire harness clamp to the steering knuckle with the 2 bolts.
Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
29. 4WD:
INSTALL DRIVE SHAFT LOCK NUT
A. While applying the brakes, tighten the nut.
Torque: 235 N.m (2,400 kgf.cm, 173 ft.lbf)
B. Install the lock cap and a NEW cotter pin.
If the holes for the cotter pin are not aligned, tighten the nut further up to 600.
30. 2WD:
INSTALL GREASE CAP
31. INSTALL FRONT WHEEL
NOTE:
Do NOT use air wrench.
Torque: 110 N.m (1,150 kgf.cm, 83 ft.lbf)
32. DEPRESS BRAKE PEDAL SEVERAL TIMES
33. FILL THE BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM
34. CHECK ABS SPEED SENSOR SIGNAL (SEE REPAIR MANUAL)
Page 671
Glossary Of Terms And Symbols (Part 2)
Page 4046
Required SSTs
Diagnosis Procedure
1. Confirm the customer complaint.
2. Determine if vibration is from front or rear (while brakes are still warm from confirmation test
driving).
The following procedure will isolate the drum brakes from the rest of the hydraulic system by using
the parking brake (PKB).
A. Drive the Tundra along a smooth, level section of road at approximately 40 mph - 50 mph.
Page 3317
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.
Testing and Inspection
Overdrive Indicator Lamp: Testing and Inspection
O/D Main Switch & O/D OFF Indicator Light Circuit
CIRCUIT DESCRIPTION
The O/D main switch contacts go open when the switch is pushed in and go closed when it is
pushed out.
If O/D main switch is at OFF position, the O/D OFF indicator light lights up, and the ECM prohibits
shifting O/D.
Wiring Diagram
INSPECTION PROCEDURE
Page 2399
Applicable Vehicles
Page 6687
Transmission Mode Indicator - A/T: Description and Operation
ELECTRONICALLY CONTROLLED TRANSMISSION AND A/T INDICATOR
SYSTEM OUTLINE
The electronically controlled transmission electrically controls the, throttle pressure, lock-up
pressure, and accumulator pressure etc. through the solenoid valve.
The electronically controlled transmission is a system which precisely controls the gear shift timing
and lock-up timing in response to the vehicle's driving conditions and the engine condition detected
by various sensors. It makes smooth driving possible by shift selection of the gear which is the
most appropriate to the driving conditions at that time, and by preventing downing, squat and gear
shift shock when starting off.
1. GEAR SHIFT OPERATION
When driving, the engine warm up condition is input as a control signal from the engine coolant
temperature sensor to TERMINAL THW of the engine control module, and the vehicle speed is
input to TERMINAL SP2+ of the engine control module from the vehicle speed sensor. At the same
time, the throttle valve opening signal from the throttle position sensor is input to TERMINALS VTA,
VTA2 of the engine control module as a throttle angle signal. Based on these signals, the engine
control module selects the best shift position for the driving conditions and sends current to the
electronically controlled transmission solenoid.
2. LOCK-UP OPERATION
When the engine control module decides based on each signal that the lock-up condition has been
met, the current flows from the engine control module TERMINAL SL to TERMINAL 7 of the
electronically controlled transmission solenoid to GROUND.
3. STOP LIGHT SW CIRCUIT
If the brake pedal is depressed (Stop light SW on) when driving in lock-up position, a signal is input
to TERMINAL STP of the engine control module. As a result, the engine control module cuts the
current to the solenoid to release the lock-up.
4. OVERDRIVE CIRCUIT
- O/D main SW on When the O/D main SW is switched to ON position, a signal is input to
TERMINAL ODMS of the engine control module, and enables shift change to the overdrive range,
through the control of the engine control module.
- O/D main SW off When the O/D main SW is switched to OFF position, a signal is input to
TERMINAL ODMS of the engine control module, and prohibits shift change to the overdrive range
through the control of the engine control module. When in the overdrive range already, shift down
is made.
Page 6249
Audible Warning Device: Splice Locations
Engine Compartment
Splice Location
E1 Engine Room Main Wire
E2 Engine Room Main Wire
E3 Engine Room Main Wire
E4 Engine No. 2 Wire
E5 Engine Wire
E6 Engine Wire
E7 Engine Wire
E8 Engine Wire
Instrument Panel
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 5300
Hose/Line HVAC: Testing and Inspection
REFRIGERANT LINE
ON-VEHICLE INSPECTION
1. INSPECT HOSE AND TUBE CONNECTIONS FOR LOOSENESS
2. INSPECT HOSES AND TUBES FOR LEAKAGE
Using a gas leak detector, check for leakage of refrigerant.
Page 2760
CHART 15
Page 3765
Electronically Controlled Transmission And A/T Indicator (Part 3)
Page 5106
Page 2455
Engine Controls - Error When Reprogramming ECU
Engine Control Module: Customer Interest Engine Controls - Error When Reprogramming ECU
SPECIAL SERVICE TOOLS SS004-01 REVISED
May 25, 2001
Title: ECU FLASH REPROGRAMMING ERROR MESSAGE
Models: Applicable Models
TSB REVISION NOTICE:
September 23, 2003: Models added - 2002 (and later) Solara, 2003 (and later) Corolla and Matrix,
and 2004 models; Test Procedures updated for new CAN Interface Module. The previous TSB
should be discarded.
Introduction
During ECU flash reprogramming, an error message may be displayed on the Diagnostic Tester
that will not allow ECU flash reprogramming to complete. This bulletin provides test procedures to
determine the cause for the error message.
Applicable Vehicles ^
2001 (and later) model year 4Runner, Highlander, Land Cruiser, RAV4, Sequoia and Tundra
vehicles.
^ 2002 (and later) model year Camry, Solara and Tacoma vehicles.
^ 2003 (and later) model year Corolla and Matrix vehicles.
^ All 2004 (and later) model year Toyota vehicles except Celica, MR2 Spyder, Avalon, and Tacoma
(3RZ-FE engine)
Required SSTs
NOTE:
Additional Diagnostic Tester Kits, CAN Interface Modules, Program Cards or other SSTs may be
ordered by calling SPX/OTC at 1-800-933-8335.
Warranty Information
Test Procedure
Page 2366
Knock Sensor: Testing and Inspection
INSPECTION
1. REMOVE THROTTLE BODY COVER
2. REMOVE INTAKE AIR CONNECTOR
3. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS
4. REMOVE UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY
5. INSPECT KNOCK SENSOR 1,2
a. Disconnect the knock sensor connectors. b. Using an ohmmeter, check that there is no
continuity between the terminal and body.
If there is continuity, replace the sensor with SST. SST 09816-30010
Torque: 45 N.m (450 kgf.cm, 33 ft.lbf)
c. Reconnect the knock sensor connectors.
6. REINSTALL UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY
7. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS
8. REINSTALL INTAKE AIR CONNECTOR
9. REINSTALL THROTTLE BODY COVER
Page 3752
The ground points circuit diagram shows the connections from all major parts to the respective
ground points. When troubleshooting a faulty ground point, checking the system circuits which use
a common ground may help you identify the problem ground quickly. The relationship between
ground points (EA, IB and IC) can also be checked this way.
How to Read Power Source
HOW TO READ POWER SOURCE
Page 1371
Intake Manifold: Testing and Inspection
For further information regarding this component and the system that it is a part of, please refer to
Cylinder Head Assembly; Service and Repair.
Page 4453
Parking Brake Pedal: Testing and Inspection
ON-VEHICLE INSPECTION
1. CHECK PARKING BRAKE PEDAL TRAVEL
Depress the parking brake pedal all the way and count the number of clicks. Parking brake pedal
travel at 294 N (30 kgf, 66 lbs.): 6 - 9 clicks If incorrect, adjust the parking brake.
2. IF NECESSARY, ADJUST PARKING BRAKE PEDAL TRAVEL
HINT: Before adjusting the parking brake, make sure that the rear brake shoe clearance has been
adjusted. For shoe clearance adjustment, see step 3.
(a) Remove the scuff plate LH. (b) Remove the cowl side trim LH. (c) Remove the lower finish
panel. (d) Remove the No. 2 heater to register duct. (e) Loosen the lock nut and turn the adjusting
nut until the pedal travel is correct. (f) Tighten the lock nut.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
(g) Install the removed parts.
Description and Operation
Throttle Position Sensor: Description and Operation
Throttle Position Sensor
Throttle position sensor is mounted on the throttle body and it has 2 sensors to detect the throttle
opening angle and a malfunction of the throttle position sensor's own.
Voltage applied to the terminals VTA and VTA2 of the ECM changes between 0 V and 5 V in
proportion to the opening angle of the throttle valve.
The ECM judges the current opening angle of the throttle valve from these signals output from
terminals VTA and VTA2, and the ECM controls the throttle motor to make the throttle valve
opening angle properly in accordance with the driving condition.
If this DTC is stored, the ECM cuts down the power for the throttle motor and the electromagnetic
clutch, and the throttle valve is fully closed by the return spring. However, the opening angle of the
throttle valve can be controlled by the accelerator pedal through the throttle cable.
Page 2788
A/F and 02 Sensor Identification
Page 1725
^ Confirm cable connections between the vehicle and Diagnostic Tester are secure. (Reference
TSB No. SS004-01, "ECU Flash Reprogramming Error Message.")
^ Do not disconnect or turn off the Diagnostic Tester or the vehicle ignition during reprogramming.
^ Set the parking brake.
^ Complete ALL flash calibration updates provided for each ECU.
If the battery's state of charge or capacity are in question, test with SST No. 00002-MP815-T,
"Midtronics Battery Tester," and follow TSB No. PG017-02, "Battery Maintenance for In-Stock
Vehicles & Pre-Delivery."
To ensure stable battery voltage, a battery charger may be connected during reprogramming if:
^ Voltage does not fall below 11.4 volts.
^ Voltage does not rise above 16.0 volts.
^ Setting is on SLOW charge and not BOOST.
A. Connect the Diagnostic Tester to the vehicle and select CURRENT ECU CAL from the ECU
REPROGRAM MAIN MENU. Determine the vehicle's current ECU calibration. (See Figure 17.)
NOTE:
The vehicle may contain up to 3 separate calibration ID numbers. In the example shown, the
vehicle ECU contains only 2 calibration IDs.
Page 1173
9. Apply a light coat of engine oil on the threads and under the heads (D and E) of the bearing cap
bolts.
HINT: Do not apply engine oil under the heads of the bearing cap bolt (A), (B)and (C).
10. Install the oil feed pipe and 22 bearing cap bolts as shown.
HINT: Each bolt length is indicated in the illustration.
Bolt length:
25 mm (0.98 inch) for A 38 mm (1.50 inch) for B 52 mm (2.05 inch) for C 72 mm (2.83 inch) for D
94 mm (3.70 inch) for E
11. Uniformly tighten the 22 bearing cap bolts in several passes, in the sequence shown.
Torque:
Bolt A: 7.5 Nm (80 kgf-cm, 69 inch lbs.) Others 16 Nm (160 kgf-cm, 12 ft. lbs.)
12. Boring the service bolt installed in the driven sub-gear upward by turning the hexagon wrench
head portion of the camshaft with a wrench. 13. Remove the service bolt.
Page 3131
4. REMOVE CAMSHAFT POSITION SENSOR
Remove the bolt, stud bolt and camshaft position sensor.
INSTALLATION
1. INSTALL CAMSHAFT POSITION SENSOR
Install the camshaft position sensor with the bolt and stud bolt Torque: 7.5 N.m (80 kgf.cm, 66
in.lbf)
2. INSTALL LH NO.3 TIMING BELT COVER
3. INSTALL DRIVE BELT
4. FILL ENGINE COOLANT
5. CHECK ENGINE COOLANT FOR LEAKS
6. CHECK IGNITION TIMING
Page 4666
Continuity And Resistance Check
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Continuity And Resistance Check
C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the
electrical circuit.
Finding A Short Circuit
Finding A Short Circuit
Finding A Short Circuit
A. Remove the blown fuse and disconnect all loads of the fuse.
Page 652
If you have no TOYOTA hand-held tester, measure voltage between terminals VPA and E2 of the
ECM connector.
d. Inspect the air assist system.
1. Start the engine and check that the MIL does not light up. 2. Allow the engine to warm up to
normal operating temperature. 3. Turn the A/C compressor ON to OFF, and check the idle speed.
Idle speed (Transmission in neutral): 700 ± 50 rpm
NOTE: Perform inspection under condition without electrical load.
e. After checking the above (b) to (d), perform the driving test and check that there is no sense of
incongruity.
3. INSPECT THROTTLE CONTROL MOTOR
a. Disconnect the throttle control motor connector. b. Using an ohmmeter, measure the motor
resistance between terminal 1 (M+) and 2 (M-).
Motor resistance: 0.3 - 100 ohms at 20 °C (68 °F)
If the resistance is not as specified, replace the throttle control motor.
c. Using an ohmmeter, measure the clutch resistance between terminal 3 (CL-) and 4 (CL+).
Clutch resistance: 4.2 - 5.2 ohms at 20 °C (68 °F)
If the resistance is not as specified, replace the throttle control motor.
d. Reconnect the throttle control motor connector.
Page 5496
CAUTION
For this procedure, do not use pliers. They may damage the webbing.
C. Tighten the c-clamp until the space between its jaws are 4.5 - 5.0 mm (0.18 in. -0.20 in.) Figures
5&6
Page 5960
II. Identification of Affected Vehicles
Page 3804
Transmission Speed Sensor: Description and Operation
Vehicle Speed Sensor NO.1
Vehicle Speed Sensor NO.1 Circuit Description
The vehicle speed sensor outputs a 4-pulse signal for every revolution of the rotor shaft, which is
rotated by the transmission output shaft via the driven gear. After this signal is converted into a
more precise rectangular waveform by the waveform shaping circuit inside the combination meter,
it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency
of these pulse signals.
Vehicle Speed Sensor NO.2
Vehicle Speed Sensor NO.2 Circuit Description
The No.2 vehicle speed sensor detects the rotation speed of the transmission output shaft and
sends signals to the ECM. The ECM determines the vehicle speed based on these signals.
Page 5044
Page 6218
a. Inspect the SET switch.
1. Push the main switch ON. 2. Drive at a desired speed (40 km/h (25 mph) or higher). 3. Push the
control switch downward for the SET/COAST. 4. After releasing the switch, check that the vehicle
cruises at the desired speed.
b. Inspect the ACC (acceleration) switch.
1. Push the main switch ON. 2. Drive at a desired speed (40 km/h (25 mph) or higher). 3. Check
that the vehicle speed increases while the control switch is turned to RES/ACC, and that the
vehicle cruises at the set speed when the
switch is released.
4. Momentarily push the control switch upward in the RES/ACC direction and then immediately
release it. Check that the vehicle speed increases
by about 1.5 km/h (Tap-up function).
c. Inspect the COAST switch.
1. Push the main switch ON. 2. Drive at a desired speed (40 km/h (25 mph) or higher). 3. Check
that the vehicle speed decreases while the control switch is turned to SET/COAST; and the vehicle
cruises at the set speed when the
switch is released.
4. Momentarily push the control switch downward for the SET/COAST, and then immediately
release it. Check that the vehicle speed decreases
by about 1.5 km/h (Tap-down function).
d. Inspect the CANCEL switch.
1. Push the main switch ON. 2. Drive at a desired speed (40 km/h (25 mph) or higher). 3. When
operating one of the followings, check that the cruise control system is cancelled and that the
normal driving mode is reset.
- Depress the brake pedal.
- Shift into except D position.
- Push the main switch OFF.
- Pull the cruise control switch for CANCEL.
Page 5653
Impact Sensor: Description and Operation
FRONT AIRBAG SENSOR
The front airbag sensor is mounted inside each of the aprons. The sensor unit is a mechanical
type. When the sensor detects deceleration force above a predetermined limit, contact is made in
the sensor, sending a signal to the airbag sensor assembly. The sensor cannot be disassembled.
Page 1791
Terminal Retainer
Push the terminal retainer down to the temporary lock position.
c. Release the locking lug from terminal and pull the terminal out from rear.
4. INSTALL TERMINAL TO CONNECTOR
a. Insert the terminal.
HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug
locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position.
Page 5074
Page 6310
Body
Connector Location (Standard Cab)
BA1 Front Door LH Wire and Speaker Tweeter Wire LH (Inside of Front Door LH)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Seat
Connector Location
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
BJ1 Seat No. 1 Wire and Seat No. 2 Wire (Under the Driver's Seat)
Page 4099
A. Using snap ring pliers, remove the snap ring.
B. Using the following SSTs and a press, remove the bearing from the steering knuckle.
SST P/N: 09950-60020
(09951-00810)
SST P/N: 09950-70010
(09951-07150)
16. Install new bearing.
A. Using the following SSTs and a press, install a NEW bearing to the steering knuckle.
SST P/N: 09527-17011
SST P/N: 09950-60020 (09951-00910)
B. Using snap ring pliers, install a NEW snap ring.
17. Install new oil seal (outside).
A. Using the following SSTs and a plastic hammer, install a NEW oil seal (outside).
SST P/N: 09223-15030
Page 1874
Knock Sensor: Testing and Inspection
INSPECTION
1. REMOVE THROTTLE BODY COVER
2. REMOVE INTAKE AIR CONNECTOR
3. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS
4. REMOVE UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY
5. INSPECT KNOCK SENSOR 1,2
a. Disconnect the knock sensor connectors. b. Using an ohmmeter, check that there is no
continuity between the terminal and body.
If there is continuity, replace the sensor with SST. SST 09816-30010
Torque: 45 N.m (450 kgf.cm, 33 ft.lbf)
c. Reconnect the knock sensor connectors.
6. REINSTALL UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY
7. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS
8. REINSTALL INTAKE AIR CONNECTOR
9. REINSTALL THROTTLE BODY COVER
Page 3183
Crankshaft Position Sensor: Testing and Inspection
INSPECTION
NOTE: "Cold" and "Hot" in these sentences express the temperature of the coils themselves.
"Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F).
INSPECT CRANKSHAFT POSITION SENSOR
Resistance
Using an ohmmeter, measure the resistance between the terminals.
If the resistance is not as specified, replace the crankshaft position sensor.
Page 116
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 2512
Oxygen Sensor: Testing and Inspection
HEATED OXYGEN SENSOR
INSPECTION
1. INSPECT HEATER RESISTANCE OF HEATED OXYGEN SENSORS
a. Disconnect the oxygen sensor connector.
Resistance
b. Using an ohmmeter, measure the resistance between terminals +B and HT.
If the resistance is not as specified, replace the sensor.
Torque: 44 N.m (450 kgf.cm, 32 ft.lbf) for sensor 1 20 N.m (200 kgf.cm, 14 ft.lbf) for sensor 2
c. Reconnect the oxygen sensor connector.
2. INSPECT OPERATION OF HEATED OXYGEN SENSORS
Page 3210
Steps 1 - 2
Page 1087
Non-Waterproof Type Connector
"Case 1" Raise the terminal retainer up to the temporary lock position.
Non-Waterproof Type Connector
"Case 2" Open the secondary locking device.
Page 1555
Heater Control Valve: Service and Repair
WATER VALVE
REMOVAL
1. DRAIN ENGINE COOLANT FROM RADIATOR
HINT: It is not necessary to drain out all the coolant.
2. DISCONNECT WATER VALVE CONTROL CABLE FROM WATER VALVE
HINT: At the time of installation, please refer to the following item. After connection, adjust the
control cable.
3. DISCONNECT WATER HOSES
a. Using pliers, grip the claws of the hose clip and slide the hose clip along the hose. b. Disconnect
the water hoses.
HINT: At the time of installation, please refer to the following item. Heater radiator pipe: Push the water hose onto the heater radiator pipe as far as second ridge on
the pipe.
- Water valve: Push the water hose onto the water valve pipe as far as water valve.
- Install the hose clip in a position, as shown in the illustration.
Page 6564
b. Push the secondary locking device or terminal retainer in to the full lock position.
5. CONNECT CONNECTOR
Disconnection of Male and Female Connectors
Disconnection of Male and Female Connectors
Disconnection Of Male And Female Connectors
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Page 4318
8. DISCONNECT LOWER BALL JOINT
Remove the 4 bolts and disconnect the lower ball joint.
9. REMOVE STEERING KNUCKLE
A. Remove the cotter pin and loosen the nut.
B. Using the following SSTs, disconnect the steering knuckle.
09950-40011(09951-04010, 09952-04010, 09553-04020, 09554-04010, 09955-04031,
09958-04011)
C. Remove the nut and steering knuckle.
NOTE:
4WD:
Be careful not to damage the oil seal and drive shaft boot.
HINT: 4WD:
When it is difficult to disconnect the drive shaft, tap the tip of the drive shaft with a plastic hammer.
10. 2WD:
REMOVE GREASE CAP
A. Mount the axle hub in a soft jaw vise.
HINT:
Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further.
B. Using a screwdriver, remove the grease cap.
HINT:
Be careful not to damage the grease cap.
Page 4981
Steering Wheel: Service and Repair Air Bag - Deployment and Disposal
Deployment When Disposing of Steering Wheel Pad Only
DISPOSAL
HINT: When scrapping vehicle equipped with an SRS or disposing of a steering wheel pad (with
airbag), always first deploy the air-bag in accordance with the procedure described below. If any
abnormality occurs with the airbag deployment, contact the SERVICE DEPT of TOYOTA MOTOR
SALES, U.S.A., INC.
CAUTION:
- Never dispose of a steering wheel pad which has an undeployed airbag.
- The airbag produces a sizeable exploding sound when it deploys, so perform the operation
out-of-doors and where it will not create a nuisance to nearby residents.
- When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool)
Perform the operation in a place away from electrical noise. SST 09082-00700
- When deploying an airbag, perform the operation at least 10 m (33 ft) away from the steering
wheel pad.
- The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30
minutes after deployment.
- Use gloves and safety glasses when handling a steering wheel pad with the deployed airbag.
- Always wash your hands with water after completing the operation.
- Do not apply water, etc. to a steering wheel pad with the deployed airbag.
DEPLOYMENT WHEN DISPOSING OF STEERING WHEEL PAD ONLY
NOTE:
- When disposing of the steering wheel pad (with air-bag) only, never use the customers vehicle to
deploy the airbag.
- Be sure to follow the procedure given below when deploying the airbag.
HINT: Have a battery ready as the power source to deploy the airbag.
a. Remove the steering wheel pad.
CAUTION: When removing the steering wheel pad, work must be started 90 seconds after the ignition switch
is turned to the "LOCK" position and the negative (-) terminal cable is disconnected from the
battery.
- When storing the steering wheel pad, keep the upper surface of the pad facing upward.
b. Remove the connector on the steering wheel pad rear surface.
Page 2462
Applicable Vehicles
Page 4956
6. REMOVE RACK GUIDE SPRING CAP LOCK NUT
Using SST, remove the lock nut. SST 09922-10010
NOTICE: Use SST 09922-10010 in the direction shown in the illustration.
7. REMOVE RACK GUIDE SPRING CAP, RACK GUIDE SPRING AND RACK GUIDE
a. Using a hexagon wrench, remove the rack guide spring cap. b. Remove the rack guide spring
and rack guide.
8. REMOVE RACK HOUSING CAP
Using SST, remove the rack housing cap. SST 09816-30010
9. REMOVE SELF-SOCKING NUT
Using SST to stop the control valve shaft rotating, remove the nut. SST 09616-00011
10. REMOVE DUST COVER
11. REMOVE CONTROL VALVE HOUSING WITH CONTROL VALVE ASSEMBLY
a. Place matchmarks on the control valve housing and rack housing. b. Remove the 2 bolts and
control valve housing with control valve assembly. c. Remove the gasket from the rack housing.
Page 6430
Terminal Retainer
Push the terminal retainer down to the temporary lock position.
c. Release the locking lug from terminal and pull the terminal out from rear.
4. INSTALL TERMINAL TO CONNECTOR
a. Insert the terminal.
HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug
locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position.
Page 4619
Interior Panel Fuse Details
Page 1887
A/F and 02 Sensor Identification
Page 3157
Step 1
Service and Repair
Transmission Temperature Sensor/Switch: Service and Repair
ON-VEHICLE REPAIR
1. 5VZ-FE:
DISCONNECT OIL COOLER PIPE
a. Remove the 3 bolts and clamps.
b. Disconnect the oil cooler pipe. c. Remove the elbow from the transmission.
2. DISCONNECT ATF TEMPERATURE SENSOR CONNECTOR 3. REMOVE ATF
TEMPERATURE SENSOR
a. Remove the ATF temperature sensor. b. Remove the O-ring from the ATF temperature sensor.
4. INSTALL ATF TEMPERATURE SENSOR
a. Coat a new O-ring with ATF and install it to the ATF temperature sensor. b. Install the ATF
temperature sensor.
Torque: 15 Nm (150 kgf-cm, 11 ft. lbs.)
5. CONNECT ATF TEMPERATURE SENSOR CONNECTOR
NOTICE: Be careful not to twist the wire harness.
6. CONNECT OIL COOLER PIPE
a. Install the elbow to the transmission.
Page 6072
Page 5374
Airbag Sensor Assembly: Testing and Inspection Replacement Requirements
REPLACEMENT REQUIREMENTS
In the following cases, replace the airbag sensor assembly.
- If the SRS has been deployed in a collision.
- If the airbag sensor assembly has been found to be faulty in troubleshooting.
- If the airbag sensor assembly has been dropped.
CAUTION: For removal and installation of the airbag sensor assembly. Be sure to follow the correct
procedure.
Page 2207
The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit
breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery
power is supplied to each system are explained. Since all System Circuit diagrams start from the
power source, the power source system must be fully understood.
Specifications
Valve Clearance: Specifications
Valve Clearance (Cold)
Intake ...................................................................................................................................................
.......................................................... 0.15 - 0.25 mm Exhaust ...........................................................
............................................................................................................................................... 0.25 0.35 mm
Diagrams
Back Window Glass
Page 3611
12. INSTALL DETENT SPRING
Install the detent spring and spring plate with the bolt. Torque: 10 Nm (100 kgf-cm, 7 ft. lbs.)
13. MAKE SURE MANUAL VALVE MOVES SMOOTHLY
Page 1701
Refer to Reset Procedure 2 for the vehicles with Electronically Controlled Automatic
Transmissions:
Reset Procedure 1
1. Connect the Toyota Diagnostic Tester to the vehicle.
2. Reset the ECM (PCM). Refer to the procedures below.
Page 4575
4. DISCONNECT THROTTLE BODY ASSEMBLY FROM INTAKE MANIFOLD
5. REMOVE INTAKE MANIFOLD ASSEMBLY
6. REMOVE STARTER
a. Remove the 2 bolts holding the starter to the cylinder block. b. Disconnect the starter from the
cylinder block.
c. Disconnect the starter connector. d. Remove the nut, bolt and disconnect the starter wire. e.
Remove the bolt, and disconnect the engine wire protector from the starter. f.
Remove the starter.
INSTALLATION
1. INSTALL STARTER
a. Install the engine wire protector to the starter with the bolt.
Torque: 9.81 N.m (100 kgf.cm, 84 in.lbf)
b. Connect the starter wire with the nut.
Torque: 9.81 N.m (100 kgf.cm, 84 in.lbf)
c. Connect the starter connector. d. Connect the starter to the cylinder block.
Page 590
Engine Controls - O2 Sensor Monitor Threshold Values
Oxygen Sensor: All Technical Service Bulletins Engine Controls - O2 Sensor Monitor Threshold
Values
SPECIAL SERVICE TOOLS SS002-03
December 17, 2003
Title O2S TEST RESULTS (MODE 05)
Models All '96 - '03, '04 Corolla, ECHO, Matrix, Sienna & Scion xA & xB
Introduction
This Service Bulletin contains Oxygen Sensor (O2S) Monitor threshold values for all models from
1996 to 2003 and some 2004 models. Starting in 2004, the O2S Monitor threshold values can be
found in the repair manual. These values are used when analyzing the O2S test results to
determine the O2S condition.
Applicable Vehicles ^
All 1996 - 2003 model year Toyota vehicles.
^ 2004 model year Corolla, ECHO, Matrix and Sienna vehicles.
^ 2004 model year Scion xA and xB vehicles.
Function Description
Checking O2S Test Results
To view O2S test results, the O2S Monitor must be completed and the test results must be
checked within the same key cycle. If the ignition key is cycled OFF, the O2S test results will be set
to the minimum or maximum limits, and all test results will be erased. The O2S test results are
stored in the ECU (SAE term: Powertrain Control Module/PCM) when the monitor is completed.
The test results are static and will not change once the monitor is complete.
The process for checking 02S test results is described in the following three basic steps:
1. Completing the O2S Readiness Monitor.
2. Accessing O2S Test Results.
3. Comparing O2S Test Results to Failure Thresholds.
Required SSTs
NOTE:
Additional Diagnostic Tester Kits, Program Cards or other SSTs may be ordered by calling
SPX-OTC at 1-800-933-8335.
Warranty Information
Completing O2S Readiness Monitor
1. Clear any stored Diagnostic Trouble Codes (DTCs) using the Toyota Diagnostic Tester.
Page 3175
4. REMOVE CAMSHAFT POSITION SENSOR
Remove the bolt, stud bolt and camshaft position sensor.
INSTALLATION
1. INSTALL CAMSHAFT POSITION SENSOR
Install the camshaft position sensor with the bolt and stud bolt Torque: 7.5 N.m (80 kgf.cm, 66
in.lbf)
2. INSTALL LH NO.3 TIMING BELT COVER
3. INSTALL DRIVE BELT
4. FILL ENGINE COOLANT
5. CHECK ENGINE COOLANT FOR LEAKS
6. CHECK IGNITION TIMING
Page 2908
Waterproof Type Connector
B: For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White
: Gray
Black or White : Dark Gray
Gray or White : Black
Waterproof Type Connector
"Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up
to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Waterproof Type Connector
"Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 1490
d. Check the spark plug for thread damage and insulator damage.
If abnormal, replace the spark plug.
e. Adjust the spark plug electrode gap.
Electrode gap: 0.8 mm (0.031 in.)
f. Using a 16 mm plug wrench, install the spark plugs. Torque: 17.5 N.m (180 kgf.cm, 13 ft.lbf)
g. Reinstall the ignition coils (with igniter).
Page 6965
a. Using a knife, cut away any rough areas on the body.
HINT: Leave as much of the adhesive on the body as possible.
b. Clean the cutting surface of the adhesive with a piece of shop rag saturated in cleaner.
2. POSITION GLASS
a. Place the glass in the correct position. b. Check that all contacting parts of the glass rim are
perfectly even. c. Place reference marks between the glass and body. d. Remove the glass.
3. COAT CONTACT SURFACE OF BODY WITH PRIMER "M"
Using a brush, coat Primer M to the exposed part of body on the vehicle side.
NOTE: Let the primer coating dry for 3 minutes or more.
- Do not coat Primer M to the adhesive.
- Do not keep any of the opened Primer M for later use.
4. Fixed type:
COAT CONTACT SURFACE OF GLASS WITH PRIMER "G"
Page 2322
L. The calibration file will now be downloaded to the Diagnostic Tester Program Card. This process
takes approximately 2-6 minutes (see Figure 15).
M. The CUW will prompt when the calibration file is completely downloaded. Click OK to close the
CUW (Figure 16).
NOTE:
With the calibration file loaded on the Diagnostic Tester Program Card, it is not necessary to repeat
the above steps to reprogram a different vehicle needing the same calibration file. The steps above
are only required when a new calibration file must be loaded onto the Diagnostic Tester Program
Card.
The Diagnostic Tester now has the calibration file stored and you may proceed to the next step to
reprogram the vehicle ECU.
REPROGRAM ECU WITH TESTER
3. Reprogram the vehicle ECU with the Diagnostic Tester.
NOTICE:
Errors during the flash reprogramming process can permanently damage the vehicle ECU.
Minimize the risks by following the steps below.
^ Battery voltage MUST NOT FALL BELOW 11.4 volts during reprogramming.
^ Confirm battery voltage is higher than 11.4 volts, but be sure voltage DOES NOT RISE ABOVE
16.0 volts during reprogramming.
^ Turn off all electrical accessories (e.g. Audio system, A/C, interior lights, DRL, etc.).
^ Do not add to or significantly change the vehicle's electrical load while reprogramming.
^ Confirm the hood is open and ensure under hood temperatures do not exceed 158°F.
Page 850
Wheel turning angle:
If the right and left wheel turning angles differ from the specified value, readjust the toe-in and
wheel angle within the specified value. At this time, make sure that the lengths of the right and left
rack ends are the same. Rack end length difference: 1.5 mm (0.059 inch) or less
Page 1091
Fuse Block: Connector Views
Engine Room R/B
Page 4188
^ 09527-17011
B. Coat MP grease to the oil seal lip.
18. INSTALL NEW DUST COVER AND AXLE HUB TO STEERING KNUCKLE
A. Install the NEW dust cover to the steering knuckle with the 4 bolts.
Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)
B. Using the following SST and a press, install the axle hub to the steering knuckle.
^ 09649-17010
19. INSTALL ABS SPEED SENSOR ROTOR (W/ABS) OR SPACER (W/O ABS)
NOTE:
Take care not to scratch the serration of the speed sensor rotor.
20. 2WD: INSTALL NEW LOCK NUT
A. Using the following SST, install and torque a NEW lock nut to the axle hub.
^ 00002-00909 (09318-12010)
Torque: 274 N.m (2,800 kgf.cm, 203 ft.lbf)
NOTE:
Do NOT use air wrench.
B. Using a chisel and hammer, stake the lock nut.
21. 4WD: INSTALL BEARING SPACER
Page 610
Testing and Inspection
Power Door Lock Switch: Testing and Inspection
Master switch
INSPECT DRIVER'S DOOR LOCK CONTROL SWITCH CONTINUITY
If continuity is not as specified, replace the switch.
INSPECT PASSENGER'S DOOR LOCK CONTROL SWITCH CONTINUITY
If continuity is not as specified, replace the switch.
Page 5932
Page 2488
CHART 16
CHART 17
Page 4525
Battery: Specifications
Parasitic Draw: Information not supplied by the manufacturer.
Page 6337
Body
Splice Location (Standard Cab)
B1 Speaker Tweeter Wire LH
B2 Front Door LH Wire
B3 Front Door LH Wire
B4 Roof Wire
B5 Speaker Tweeter Wire RH
B6 B7
Front Door RH Wire
B10 Frame Wire
Seat
Page 4154
Brake Pad: Service and Repair
REPLACEMENT
1. REMOVE FRONT WHEEL
2. INSPECT PAD LINING THICKNESS
Check the pad thickness and replace pads if not within specification. Minimum thickness: 1.0 mm
(0.039 inch)
3. REMOVE CLIP, 2 PINS AND ANTI-RATTLE SPRING 4. REMOVE 2 PADS AND 4
ANTI-SQUEAL SHIMS
NOTICE: The anti-rattle spring and clip can be used again provided that they have sufficient
rebound, no deformation, cracks or wear, and have had all rust, dirt and foreign particles cleaned
off.
5. CHECK DISC THICKNESS AND RUNOUT
Page 5707
Required SSTs
Repair Procedure
1. Make sure the vehicle is stationary during the test.
2. Insert a compact disc (NOT the Toyota Master CD) to make sure the radio can accept and eject
the disc without damaging it.
3. Check the Toyota Master CD for any unintended scratches or dirt. Wipe away dirt using a glass
cleaning cloth. If the disc is damaged, order a replacement master CD.
4. Insert the Toyota Master CD and change to track number 9.
5. Play the track for one minute.
A. If skips are heard, replace the CD player.
B. If NO skips are heard, the CD player is working normally. Check the customer's CDs for
scratches or other damage to the discs. Confirm that the customer is using a pre-recorded CD,
NOT CD-Rs or CD-RWs as they may NOT have been burned properly.
NOTE:
^ Tracks 1 - 8 and 11 - 14 are reference tracks. They can be used, but the conditions are less
severe than track 9. Do NOT use tracks 10 and 15.
^ Track 9 (0.8 mm scratch) is much more severe than the Toyota engineering specification in order
to ensure customer satisfaction. If the customer's radio passes this test, a replacement radio will
NOT improve the performance.
^ This disc has been specially manufactured with a physical defect for the purposes of testing the
CD player's performance. It is NOT possible to make copies of this disc that can be used to test the
CD player's performance.
Page 2593
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 1795
Engine Control Module: Description and Operation
DESCRIPTION
The Engine Control Module (ECM) controls all phases of electrical engine operation. In order to
accomplish this control, the ECM relies on the input from a variety of engine operation sensors.
The ECM compares input signals with those stored in memory to determine what steps should be
taken to achieve maximum performance, fuel economy, and meet emission standards. The ECM
outputs the necessary signals to the fuel system, ignition system, emission control systems, etc..
Page 2499
Page 5636
3. Using a screwdriver, remove the roof side rail garnish.
HINT: Tape the screwdriver tip before use.
f. Remove the front door rear scuff plate and cover. 1. Remove the clip cover. 2. Remove the clip
and front door rear scuff plate.
g. Remove the retractor of front seat outer belt.
CAUTION: Never disassemble the front seat outer belt.
NOTE: When removing the retractor of front seat outer belt, take care not to pull the seat belt
pretensioner wire harness.
1. Disconnect the pretensioner connector as shown in the illustration.
CAUTION: When removing the seat belt pretensioner, work must be started 90 seconds after the
ignition switch is turned to the "LOCK" position and the negative (-) terminal cable is disconnected
from the battery.
2. Remove the bolt and retractor of front seat outer belt.
REPLACEMENT
REPLACE REQUIREMENTS In the following cases, replace the seat belt pretensioner. If the seat
belt pretensioner has been activated.
- If the seat belt pretensioner has been found to be faulty in troubleshooting.
- If the front seat outer belt has been found to be faulty during checking items 1-(b) or 2-(b).
- If the front seat outer belt has been dropped.
CAUTION: For removal and installation of the seat belt pretensioner. Be sure to follow the correct
procedure.
INSTALLATION
NOTE:
- Never use seat belt pretensioner from another vehicle. When replacing parts, replace them with
new parts.
- Make sure that the front seat outer belt is installed with the specified torque.
- If the front seat outer belt has been dropped, or there are cracks, dents or other defects in the
case or connector, replace the front seat outer belt with a new one.
- When installing the front seat outer belt, take care that the wiring does not interfere with other
parts and is not pinched between other parts.
1. Access cab:
INSTALL FRONT SEAT OUTER BELT
Diagrams
Blower Unit
Front
Wheel Bearing: Service and Repair Front
Removal and Installation
REMOVAL
1. REMOVE FRONT WHEEL 2. REMOVE GREASE CAP
Using a screwdriver and hammer, remove the grease cap.
Ground Locations
Seat Belt Reminder Buzzer: Ground Locations
Engine Compartment
Ground Location
EA Front Left Fender
EB Rear Bank of Right Cylinder
EC Rear Bank of Left Cylinder
Connector Location
EA1 Cowl Wire Harness and Wire Harness (Connector Location)
EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B)
EC1 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC2 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC3 Engine No. 2 Wire and Engine Wire (Near the Starter)
ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission)
Testing and Inspection
Power Mirror Switch: Testing and Inspection
Left side
INSPECT MIRROR SWITCH INSPECTION
Right side
INSPECT MIRROR SWITCH INSPECTION
If continuity is not as specified, replace the switch.
Page 1927
CHART 21
Diagrams
Heater Unit
Page 3530
Shifter A/T: Service and Repair
Page 4549
e. To loosen the pulley nut, turn SST (A) in the direction shown in the illustration.
NOTE: To prevent damage to the rotor shaft, do not loosen the pulley nut more than one-half of a
turn.
f. Remove the generator from SST (C).
g. Turn SST (B), and remove SST (A and B). h. Remove the pulley nut and pulley.
6. REMOVE RECTIFIER END FRAME
a. Remove the 3 nuts.
b. Using SST, remove the rectifier end frame.
SST 09286-46011
c. Remove the generator washer from the rectifier end frame.
7. REMOVE ROTOR FROM DRIVE END FRAME
REASSEMBLY
Page 4921
B: Junction Connector
Indicates a connector which is connected to a short terminal.
Junction connector in this include a short terminal which is connected to a number of wire
harnesses. Always perform inspection with the short terminal installed. (When installing the wire
harnesses, the harnesses can be connected to any position within the short terminal grouping.
Accordingly, in other vehicles, the same position in the short terminal may be connected to wire
harness from a different part.) Wire harness sharing the same short terminal grouping ha the same
color.
C: Parts Code
The first letter of the code is taken from the first letter of part, and the numbers indicates its order in
parts which start with the same letter.
D: Connector Color
Connectors not indicated are milky white in color.
How to Read Ground Points
HOW TO READ GROUND POINTS
Page 6728
Non-Waterproof Type Connector
"Case 1" Raise the terminal retainer up to the temporary lock position.
Non-Waterproof Type Connector
"Case 2" Open the secondary locking device.
Page 59
Splice Point
J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel,
and "B" for the Body).
The Location of splice Point I5 is shaded.
K: Indicates a shielded cable.
L: Indicates the pin number of the connector.
The numbering system is different for female and male connectors.
M: Indicates a ground point.
The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for
the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body
and Surrounding area.
How to Read Connector List
HOW TO READ CONNECTOR LIST
A: Indicates connector to be connected to a part. (The numeral indicates the pin No.)
Page 4805
Glossary Of Terms And Symbols (Part 1)
Page 3363
^ 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
Locations
Page 6479
Step 4
O/D OFF indicator light does not light up
Steps 1 - 2
O/D OFF indicator light remains ON
Page 1685
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 4282
HINT: The brake pedal should not be depressed twice and/or returned while setting to the specified
pressure. Read the value of rear brake pressure after holding the specified fluid pressure for 2
seconds. If the brake pressure is incorrect, adjust the fluid pressure.
4. IF NECESSARY, ADJUST FLUID PRESSURE
(a) Loosen the lock nut.
(b) Adjust the length of the shackle No. 2.
Low pressure: Lengthen A High pressure: Shorten A Initial set: 120 mm (4.72 inch) Adjustment
range: 112 - 128 mm (4.41 - 5.04 inch)
HINT: One turn of the nut changes the fluid pressure as shown in the following specification.
7.4 kPa (0.76 kgf/cm, 11 psi)
(c) Torque the lock nut.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)
(d) If the pressure cannot be adjusted by the shackle No. 2, raise or lower the valve body.
Low pressure-Lower body High pressure-Raise body
(e) Torque the nuts.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.) Adjust the length of the shackle No. 2 again. If it cannot be
adjusted, inspect the valve body.
5. IF NECESSARY, CHECK VALVE BODY
(a) Assemble the valve body in the uppermost position.
HINT: When the brakes are applied, the piston will move down about 0.8 mm (0.03 inch). Even at
this time, the piston should not make contact with the load sensing spring or move it.
Page 5777
B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(Connect the Relay) and SW 2 OFF (or Disconnect SW 2)
D. Disconnect and reconnect the connectors while watching the test light.
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
E. Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION:
a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals
are touched, the IC may be destroyed by
static electricity.)
b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact
with the terminals of leads from the IC, etc. of the replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
Special Tool
1. PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown.
2. DISCONNECT CONNECTOR
3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
a. Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the
secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
A: For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
Page 1306
12. Install the NEW A/C compressor mounting bracket and hand tighten bolts 1 and 2 while holding
the bracket forward (refer to illustration).
13. While holding the bracket forward, tighten the A/C compressor mounting bolts in the following
sequence: bolt 2, bolt 1, bolt 3.
Torque: 47 N.m (475 kgf.cm, 34 ft.lbf)
14. Remove the accessory drive belt tensioner.
15. Install the NEW accessory drive belt tensioner.
16. Reassemble in the reverse order of disassembly.
17. Refill cooling system.
Page 1533
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
1. DRAIN ENGINE COOLANT
2. REMOVE THROTTLE BODY COVER
3. REMOVE INTAKE AIR CONNECTOR
4. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS
a. Disconnect the accelerator cable from the throttle body. b. Remove the 2 bolts and 2 nuts, and
disconnect the throttle body from the intake manifold. c. Remove the gasket
5. REMOVE ECT SENSOR
a. Disconnect the ECT sensor connector. b. Remove the ECT sensor and gasket.
6. REINSTALL ECT SENSOR
a. Install a new gasket and the ECT sensor.
Torque: 20.4 N.m (208 kgf.cm, 15 ft.lbf)
b. Connect the ECT sensor connector.
7. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS
a. Install a new gasket and the throttle body with the 2 bolts and 2 nuts.
Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)
b. Connect the accelerator cable to the throttle body.
8. REINSTALL INTAKE AIR CONNECTOR
9. REFILL WITH ENGINE COOLANT
10. REINSTALL THROTTLE BODY COVER
Brakes - Front Brakes Vibrate Upon Application
Technical Service Bulletin # BR004R-02 Date: 050404
Brakes - Front Brakes Vibrate Upon Application
BRAKES BR004-02 REVISED
Title: FRONT BRAKE VIBRATION
Models: '00 - '05 Tundra
September 12, 2002
TSB REVISION NOTICE:
^ April 4, 2005: Applicable Vehicles has been updated to include 2003 - 2005 model years. The
following sections have been updated, expanded, or added: Introduction, Warranty Information,
Production Change Information, Parts Information, Required SSTs, Diagnosis Procedure, Repair
Procedure No.1, and Repair Procedure No.2. PLEASE READ ENTIRE TSB.
^ September 24, 2004: A note has been added, step 26.
^ March 5, 2004: A torque specification in step 24, was changed.
^ September 8, 2003: A torque specification in step 28, was changed.
Previous versions of this TSB should be discarded.
Introduction
Under certain usage conditions, some Tundra trucks may exhibit front brake vibration.
Improvements have been made to various brake components to help improve this condition.
Applicable Vehicles
^ 2000 - 2005 model year Tundra vehicles produced BEFORE the Production Change Effective
VINs shown.
Production Change Information
System Diagnosis
Air/Fuel Mixture: Testing and Inspection
INSPECTION
HINT: This check is used only to determine whether or not the idle CO/HC complies with
regulations.
1. INITIAL CONDITIONS
a. Engine at normal operating temperature b. Air cleaner installed c. All pipes and hoses of air
induction system connected d. All accessories switched OFF e. All vacuum lines properly
connected f.
SFI system wiring connectors fully plugged
g. Ignition timing checked correctly h. Transmission in neutral position i.
Tachometer and CO/HC meter calibrated by hand
2. START ENGINE 3. RACE ENGINE AT 2,500 RPM FOR APPROXIMATELY 180 SECONDS
4. INSERT CO/HC METER TESTING PROBE AT LEAST 40 cm (1.3 ft) INTO TAILPIPE DURING
IDLING 5. IMMEDIATELY CHECK CO/HC CONCENTRATION AT IDLE AND/OR 2,500 RPM
HINT: When performing the 2 mode (2,500 rpm and idle) test, follow the measurement orders are
prescribed by the applicable local regulations.
If the CO/HC concentration does not comply with regulations, perform troubleshooting in the order
given. a. Check the heated oxygen sensors operation.
b. See the table for possible causes, and then inspect and correct the applicable causes if
necessary.
Page 4746
B: Junction Connector
Indicates a connector which is connected to a short terminal.
Junction connector in this include a short terminal which is connected to a number of wire
harnesses. Always perform inspection with the short terminal installed. (When installing the wire
harnesses, the harnesses can be connected to any position within the short terminal grouping.
Accordingly, in other vehicles, the same position in the short terminal may be connected to wire
harness from a different part.) Wire harness sharing the same short terminal grouping ha the same
color.
C: Parts Code
The first letter of the code is taken from the first letter of part, and the numbers indicates its order in
parts which start with the same letter.
D: Connector Color
Connectors not indicated are milky white in color.
How to Read Ground Points
HOW TO READ GROUND POINTS
Page 3424
Fluid - A/T: Testing and Inspection
FLUID INSPECTION
1. Check fluid level, as follows:
NOTE:
Drive the vehicle so that the engine and transaxle are at normal operating temperature. ATF
temperature: 70 - 80°C (158 - 176°F). Only use the COOL range on the dipstick as a rough
reference when the fluid is replaced or the engine does not run.
a. Park the vehicle on a level surface and set the parking brake.
b. With the engine idling and the brake pedal depressed, shift the shift lever into all positions from
the Park (P) to Low (L) position and return to
the P position.
c. Pull out the oil level gauge and wipe it clean. d. Push it back fully into the pipe.
e. Pull it out and check that the fluid level is in the HOT range. If the level is at the low side, add
new Automatic Transmission Fluid.
Fluid type: ATF D-II or DEXRON III (DEXRON II)
NOTICE: Do not overfill.
2. Check fluid condition. If the fluid smells burnt or is black, replace fluid.
Page 3449
Splice Location
B11
Page 3041
Fuel Tank And Line
Page 4913
Key Reminder Switch: Harness Locations
Engine Compartment
Connector Location
EA1 Cowl Wire Harness and Wire Harness (Connector Location)
EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B)
EC1 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC2 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC3 Engine No. 2 Wire and Engine Wire (Near the Starter)
ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission)
Page 3806
Transmission Speed Sensor: Service and Repair
Vehicle Speed Sensor NO.1
1. DISCONNECT NO. 1 VEHICLE SPEED SENSOR CONNECTOR
2. REMOVE NO. 1 VEHICLE SPEED SENSOR
Remove the bolt and No.1 vehicle speed sensor.
3. DISASSEMBLE NO. 1 VEHICLE SPEED SENSOR
a. Remove the O-ring from the speedometer driven gear assembly. b. Remove the clip and
speedometer driven gear from the speedometer driven gear sleeve.
4. ASSEMBLE NO. 1 VEHICLE SPEED SENSOR
a. Install the speedometer driven gear and clip to the speedometer driven gear sleeve. b. Coat a
new O-ring with ATF. c. Install the O-ring to the speedometer driven gear assembly.
5. INSTALL NO. 1 VEHICLE SPEED SENSOR
Removal and Installation
Alternator: Service and Repair Removal and Installation
Generator (Part 1)
Page 5904
Locations
Engine Room R/B
Page 4204
A. Using snap ring pliers, remove the snap ring.
B. Using the following SSTs and a press, remove the bearing from the steering knuckle.
SST P/N: 09950-60020
(09951-00810)
SST P/N: 09950-70010
(09951-07150)
16. Install new bearing.
A. Using the following SSTs and a press, install a NEW bearing to the steering knuckle.
SST P/N: 09527-17011
SST P/N: 09950-60020 (09951-00910)
B. Using snap ring pliers, install a NEW snap ring.
17. Install new oil seal (outside).
A. Using the following SSTs and a plastic hammer, install a NEW oil seal (outside).
SST P/N: 09223-15030
Page 3820
STANDARD VALUE OF ECU TERMINAL
Page 1279
12. Install the NEW A/C compressor mounting bracket and hand tighten bolts 1 and 2 while holding
the bracket forward (refer to illustration).
13. While holding the bracket forward, tighten the A/C compressor mounting bolts in the following
sequence: bolt 2, bolt 1, bolt 3.
Torque: 47 N.m (475 kgf.cm, 34 ft.lbf)
14. Remove the accessory drive belt tensioner.
15. Install the NEW accessory drive belt tensioner.
16. Reassemble in the reverse order of disassembly.
17. Refill cooling system.
Page 6710
Body
Splice Location (Standard Cab)
B1 Speaker Tweeter Wire LH
B2 Front Door LH Wire
B3 Front Door LH Wire
B4 Roof Wire
B5 Speaker Tweeter Wire RH
B6 B7
Front Door RH Wire
B10 Frame Wire
Seat
Page 6877
Glossary Of Terms And Symbols (Part 1)
Page 2227
During ECU flash reprogramming, the Error screen shown may be displayed on the Diagnostic
Tester for one of the following reasons:
1. Immobilizer key not properly registered or auto-registration mode left open.
2. Ignition ON/OFF cycling not followed correctly during the flash reprogramming procedure.
3. The Diagnostic Tester cable is damaged, causing an open communication circuit.
NOTE:
The Diagnostic Tester may operate properly in other modes such as OBD, OBDII, or CARB, with a
damaged cable.
To eliminate the possibility of the first 2 reasons causing the error message, do the following:
1. Confirm the Immobilizer Transponder Master Key is properly registered and auto registration
mode is closed. Follow the appropriate Repair Manual procedure and consult TSB SS001-99,
"Scan tool Immobilizer key Code Utility
2. Conduct the ECU flash reprogramming process explicitly following key operation instructions.
Refer to TSB SS002-01, "ECU Flash Reprogramming Process, "for more details.
To determine if the Diagnostic Tester cable is damaged, follow the test procedures below to check
the electrical integrity of the cable. Conduct all continuity tests with an Ohm meter. For all five test
procedures, the resistance values must be below 6.0 ohms to pass.
Test CABLE TEST 1.
Page 4144
Brake Caliper: Specifications
Caliper Anchor Bolts 123 Nm
Bleeder Screw 11 Nm
Hydraulic Brake Line 15 Nm
Keyless Entry - Remote Transmitter Programming Guide
Keyless Entry Transmitter: Technical Service Bulletins Keyless Entry - Remote Transmitter
Programming Guide
ELECTRICAL EL010-07 REVISED
Title: WIRELESS TRANSMITTER & PROGRAMMING GUIDE
Models: '90 - '08 Applicable Toyota
November 9, 2007
TSB REVISION NOTICE:
^ November 10, 2007: A TSB reference has been updated in the Programming column of the
Application Chart.
Previous versions of this TSB should be discarded.
TSB UPDATE NOTICE:
The information contained in this TSB supersedes TSB No. EL008-02. TSB No. EL008-02 is now
obsolete and should be discarded.
Introduction
Difficulties during Remote Keyless Entry (RKE) Transmitter Programming can arise due to
confusion between Toyota Factory Wireless systems and Toyota Port/Dealer installed systems.
This bulletin will assist in identifying the system/correct remote transmitters for each vehicle, and
provide the location of the most accurate programming procedure for each system.
Applicable Vehicles
^ 1990 - 2008 model year applicable Toyota vehicles.
Warranty Information
System Identification
The Application Chart contains all of the necessary information to correctly identify the type of
system installed, and where to go to get programming procedures for each vehicle.
Should a vehicle having both VIP and Factory systems available (as identified in the Application
Chart) be brought in without any remotes (or one non-working remote), use the following tips to
help determine which type of wireless system (O.E. or PIO/DIO) the vehicle has.
^ Look at the Trim Level of the vehicle. Higher-grade vehicles will tend to have O.E. systems, while
entry-grade vehicles will tend to have VIR For example, the 2001 Camry XLE has Factory WRKE,
but the LE and CE grades have VIR
^ Look for a "Status Monitor" with a glass breakage sensor and an LED externally installed into the
dashboard or on the center console. Most VIP systems will have this.
^ Locate the ECU (refer to the applicable vehicle VIP Manual installation instructions for location).
Once located, refer to the part label.
^ Attempt to perform the factory wireless programming procedure to get a response from the
vehicle. Select the "confirmation mode" and see if any "Lock/Unlock" response is received, if so,
the vehicle has a factory system.
Page 4723
Terminal Retainer
Push the terminal retainer down to the temporary lock position.
c. Release the locking lug from terminal and pull the terminal out from rear.
4. INSTALL TERMINAL TO CONNECTOR
a. Insert the terminal.
HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug
locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position.
Page 4352
A. Using snap ring pliers, remove the snap ring.
B. Using the following SSTs and a press, remove the bearing from the steering knuckle.
SST P/N: 09950-60020
(09951-00810)
SST P/N: 09950-70010
(09951-07150)
16. Install new bearing.
A. Using the following SSTs and a press, install a NEW bearing to the steering knuckle.
SST P/N: 09527-17011
SST P/N: 09950-60020 (09951-00910)
B. Using snap ring pliers, install a NEW snap ring.
17. Install new oil seal (outside).
A. Using the following SSTs and a plastic hammer, install a NEW oil seal (outside).
SST P/N: 09223-15030
Page 987
Coolant: Fluid Type Specifications
Coolant Type "Toyota Long Life Coolant" or Equivelant Ethylene-Glycol Coolant
Do Not use alcohol type antifreezs or plain water alone.
Page 418
Key Reminder And Seat Belt Warning
Specifications
Valve Body
Valve Body: Service and Repair Valve Body
DISASSEMBLY
NOTICE: Disassembling and reassembling should be conducted on a clean vinyl sheet or mat, or aluminum
tray.
- Make the valve slide through the valve hole by its own weight. Do not forcibly pull out the valve
using needle-nose pliers. When having difficulty in removing it, slant and shake the valve body or
use a magnet hand.
- Do not place the disassembled parts directly on metal work bench or waste cloth.
- Do not use dropped parts.
- Make sure that no burr is identified before assembling.
Page 4198
Required SSTs
Diagnosis Procedure
1. Confirm the customer complaint.
2. Determine if vibration is from front or rear (while brakes are still warm from confirmation test
driving).
The following procedure will isolate the drum brakes from the rest of the hydraulic system by using
the parking brake (PKB).
A. Drive the Tundra along a smooth, level section of road at approximately 40 mph - 50 mph.
Page 6545
Seat Belt Reminder Lamp: Harness Locations
Engine Compartment
Connector Location
EA1 Cowl Wire Harness and Wire Harness (Connector Location)
EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B)
EC1 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC2 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC3 Engine No. 2 Wire and Engine Wire (Near the Starter)
ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission)
Page 2584
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 3247
Transmission Mode Indicator - A/T: Testing and Inspection
ELECTRONICALLY CONTROLLED TRANSMISSION AND A/T INDICATOR
E1 ELECTRONICALLY CONTROLLED TRANSMISSION SOLENOID
4, 7, 8 - GROUND : Approx. 13 Ohms
O4 O/D MAIN SW
3 - 1 : Open with O/D main SW at ON position
Closed with O/D main SW at OFF position
S4 STOP LIGHT SW
1 - 2 : Closed with brake pedal depressed
E3 (A) E4 (B), E5 (C), E6 (D), E7 (E) ENGINE CONTROL MODULE
S1 - E1 : 9 - 14 volts with vehicle not move and shift lever in D position
S2, SL - E1 : 0 - 1.5 volts with vehicle not move
STP - E1 : 7.5 - 14 volts with brake pedal depressed 0 - 1.5 volts with brake pedal released
THW - E1 : 0.2 - 1.0 volts with idling, engine coolant temperature 60 °C (140 °F) -120 °C (248 °F)
OIL - E1 : Below 1.0 volts with fluid temperature 110 °C (230 °F)
VTA - E1 : 0.4 - 1.0 volts with ignition SW on and throttle valve fully closed : 3.2 - 4.8 volts with
ignition SW on and throttle valve fully open
VC - E1 : 4.5 - 5.5 volts with ignition SW at ON or ST position
ODMS - E1 : 9 - 14 volts with O/D main SW turned on : 0 - 3 volts with 0/D main SW turned off
SPD - E1 : Pulse generation with vehicle moving
2 - E1 : 7.5 - 14 volts with shift lever at 2 position : 0 - 1.5 volts with shift lever at except 2 position
L - E1 : 7.5 - 14 volts with shift lever at L position : 0 - 1.5 volts with shift lever at except L position
+B - E1 : 9 - 14 volts with ignition SW at ON or ST position
BATT - E1 : Always 9 - 14 volts
P1 A/T INDICATOR SW [PARK/NEUTRAL POSITION SW]
3 - 1 : Closed with shift lever in P position 3 - 2 : Closed with shift lever in R position 3 - 5 : Closed
with shift lever in N position 3 - 7 : Closed with shift lever in D position 3 - 4 : Closed with shift lever
in 2 position 3 - 8 : Closed with shift lever in L position
Page 2596
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.
Electrical Specifications
Page 5104
A. AFFECTED VIN RANGE
III. Preparation
A. PARTS
^ No parts are required for the inspection.
B. EQUIPMENT & MATERIALS
^ Protective eyewear
^ Standard heater core hose
Page 5176
3. 2WD: REMOVE LOCK NUT AND ABS SPEED SENSOR ROTOR/SPACER
a. Using a chisel and hammer, loosen the staked part of the lock nut.
NOTICE: Be careful not to damage the bushing.
b. Using Special Service Tool (SST), remove the lock nut.
SST 09318-12010
c. Remove the ABS speed sensor rotor/spacer.
NOTICE: Take care not to scratch the serration of the speed sensor rotor.
4. REMOVE AXLE HUB FROM STEERING KNUCKLE
a. Remove the 4 bolts and shift the dust cover towards the hub side (outside). b. Using SST,
remove the axle hub from the steering knuckle.
SST 09710-30021 (09710-03051), 09950-40011 (09951-04020, 09952-04010, 09953-04020,
09954-04010, 09955-04031, 09957-04010, 09958-04011)
c. Remove the dust cover from the steering knuckle. d. 4WD: Remove the bearing spacer and ABS
speed sensor rotor (w/ABS)/spacer (w/o ABS).
NOTICE: Take care not to scratch the serration of the speed sensor rotor.
5. REMOVE OIL SEAL (OUTSIDE)
Using a screwdriver, remove the oil seal (outside) from the steering knuckle.
6. REMOVE BEARING FROM STEERING KNUCKLE
a. Using snap ring pliers, remove the snap ring. b. Using SST and a press, remove the bearing
from the steering knuckle.
SST 09950-60020 (09951-00810), 09950-70010 (09951-07150)
REASSEMBLY
Page 2236
^ 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 3942
Step 4
O/D OFF indicator light does not light up
Steps 1 - 2
O/D OFF indicator light remains ON
Page 3203
d. Check the spark plug for thread damage and insulator damage.
If abnormal, replace the spark plug.
e. Adjust the spark plug electrode gap.
Electrode gap: 0.8 mm (0.031 in.)
f. Using a 16 mm plug wrench, install the spark plugs. Torque: 17.5 N.m (180 kgf.cm, 13 ft.lbf)
g. Reinstall the ignition coils (with igniter).
Page 904
Part 2 of 4
Part 3 of 4
Page 6958
INSPECT PASSENGER'S DOOR POWER WINDOW SWITCH CONTINUITY
If continuity is not as specified, replace the switch.
INSPECT POWER WINDOW MASTER SWITCH CIRCUIT
Disconnect the connector from the master switch and inspect the connector on the wire harness
side.
* Exceptions: During 60 seconds after the ignition switch is turned ON to OFF (ACC) or until driver
or a passenger's door is opened after the ignition switch is turned ON to OFF (ACC).
If the circuit is not as specified, inspect the circuits connected to other parts.
Page 1747
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 4827
Repair Procedure
1. Disconnect the cable from the negative (-) battery terminal for MORE THAN two (2) seconds.
2. Reconnect the cable to the negative (-) battery terminal.
3. Perform the applicable zero point calibration of the yaw rate sensor and/or the steering angle
sensor.
HINT Refer to the applicable TSB or Repair Manual for the zero point calibration procedure.
4. Re-initialize all applicable systems available on the vehicle (power window sunroof power lift
door etc.).
Page 2444
CHART 27
Testing and Inspection
Washer Fluid Level Switch: Testing and Inspection
INSPECT WASHER LEVEL SWITCH CONTINUITY a. Check that there is no continuity between
terminals with switch OFF (float up). b. Check that there is continuity between terminals with the
switch ON (float down).
If operation is not as specified, replace the switch.
Page 6314
Splice Point
J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel,
and "B" for the Body).
The Location of splice Point I5 is shaded.
K: Indicates a shielded cable.
L: Indicates the pin number of the connector.
The numbering system is different for female and male connectors.
M: Indicates a ground point.
The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for
the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body
and Surrounding area.
How to Read Connector List
HOW TO READ CONNECTOR LIST
A: Indicates connector to be connected to a part. (The numeral indicates the pin No.)
Page 5938
Locations
Engine Room R/B
Page 5812
Terminal Retainer
Push the terminal retainer down to the temporary lock position.
c. Release the locking lug from terminal and pull the terminal out from rear.
4. INSTALL TERMINAL TO CONNECTOR
a. Insert the terminal.
HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug
locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position.
Locations
Daytime Running Lamp Relay: Locations
Instrument Panel
Page 4964
a. To prevent oil seal lip damage, wind vinyl tape on the serrated part of the valve shaft. b. Coat the
teflon rings with power steering fluid. c. Install the valve assembly into the valve housing.
NOTICE: Be careful not to damage the teflon rings and oil seal.
8. INSTALL OIL SEAL
a. Coat a new oil seal lip with power steering fluid. b. Using SST, press in the oil seal.
SST 09612-22011
NOTICE: Make sure to install the oil seal facing in the correct direction.
9. INSTALL CONTROL VALVE HOUSING WITH CONTROL VALVE ASSEMBLY
a. Place a new gasket on the rack housing. b. Align the matchmarks on the control valve housing
with control valve assembly and rack housing. c. Install the 2 bolts.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)
10. INSTALL SELF-LOCKING NUT
Using SST to stop the control valve shaft rotating, install a new nut. SST 09616-00011 Torque: 30
Nm (300 kgf-cm, 22 ft. lbs.)
11. INSTALL DUST COVER 12. INSTALL RACK HOUSING CAP
a. Apply sealant to 2 or 3 threads of the rack housing cap.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
b. Using SST, install the rack housing cap.
SST 09816-30010 Torque: 59 Nm (600 kgf-cm, 43 ft. lbs.)
Page 3702
Page 2106
Fuel Pressure: Specifications Volume Specification
Information not supplied by the manufacturer.
Page 4965
c. Using a punch and hammer, stake the 2 parts of the cap.
13. INSTALL RACK GUIDE, RACK GUIDE SPRING AND RACK GUIDE SPRING CAP
a. Install the rack guide and rack guide spring. b. Apply sealant to 2 or 3 threads of the rack guide
spring cap.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
c. Temporarily install the rack guide spring cap.
14. ADJUST TOTAL PRELOAD
a. To prevent the steering rack teeth from damaging the oil seal lip, temporarily install the
Right-Hand and Left-Hand rack ends. b. Using a hexagon wrench, install the rack guide spring cap.
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)
c. Using a hexagon wrench, return the rack guide spring cap 12°.
d. Using SST, turn the control valve shaft right and left 1 or 2 times.
SST 09616-00011
e. Using a hexagon wrench, loosen the rack guide spring cap until the rack guide spring is not
functioning.
f. Using SST, torque wrench and hexagon wrench, tighten the rack guide spring cap until the
preload is within specification. SST 09616-00011 Preload (turning): 1.0 - 1.45 Nm (10 - 14.5
kgf-cm, 8.7 - 12.6 inch lbs.)
Page 5364
Wire Harness And Connector
Page 930
1. Remove the engine under cover.
2. Drain the engine coolant.
3. Remove the intake air connector assembly.
4. Remove the radiator fan shroud.
5. Remove the drive belt, fan, fluid coupling, and fan pulley.
6. Without disconnecting the power steering fluid lines, remove the power steering pump.
HINT: Suspend the power steering pump securely.
7. Remove the drive belt idler pulley.
8. Remove the right hand (RH) No. 3 timing belt cover.
9. Remove the No.2 timing belt cover.
10. Without disconnecting the A/C refrigerant lines, remove the A/C compressor from the mounting
bracket.
HINT: Suspend the A/C compressor securely.
11. Disconnect the A/C compressor mounting bracket.
Page 3387
Page 619
CHART 11
Page 6413
Instrument Panel
Connector Location
IA1 Engine Room Main and Cowl Wire (Left Kick Panel)
IA2 Engine Room Main and Cowl Wire (Left Kick Panel)
IA3 Engine Room Main and Cowl Wire (Left Kick Panel)
IA4 Engine Room Main and Cowl Wire (Left Kick Panel)
IB1 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IB2 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IB3 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IC1 Cowl Wire and Roof Wire (Left Side of Instrument Panel)
Instrument Panel
Connector Location
ID1 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH)
ID2 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH)
IE1 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IE2 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IE3 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IF1 Front Door RH Wire and Cowl Wire (Right Kick Panel)
IF2 Front Door RH Wire and Cowl Wire (Right Kick Panel)
IF3 Front Door RH Wire and Cowl Wire (Right Kick Panel)
Page 1520
Coolant: Fluid Type Specifications
Coolant Type "Toyota Long Life Coolant" or Equivelant Ethylene-Glycol Coolant
Do Not use alcohol type antifreezs or plain water alone.
Locations
Fuse Block: Locations
Driver Side J/B And Integration Relay
Page 83
Engine Compartment
Instrument Panel
Locations
Testing and Inspection
Dimmer Switch: Testing and Inspection
INSPECT LIGHT CONTROL RHEOSTAT
a. Connect terminals 1 and 3 through a 3.4 W test bulb. b. Connect the positive (+) lead from the
battery to terminal 1 and the negative (-) lead to terminal 2. c. Turn the rheostat knob to fully
counterclockwise, check that the test bulb goes out. d. Gradually turn the rheostat knob to
clockwise, check that the test bulb brightness changes from dark to bright.
If operation is not as specified, replace the rheostat.
ABS/TCS - Zero Point Calibration Information
Steering Angle Sensor: Technical Service Bulletins ABS/TCS - Zero Point Calibration Information
T-SB-0020-08
March 25, 2008
Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment
Service Category Brake
Section Brake Control/Dynamic Control System
Market USA
Applicability
Introduction
The purpose of this TSB is to provide information on when and how to perform the zero point
calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting
the battery is a necessary step for performing the zero point calibration.
Warranty Information
Required Tools & Equipment
^ Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE).
^ The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the
service procedures listed in this bulletin.
Preliminary Information
Perform this procedure if any of these repairs have been performed on the vehicle:
^ Wheel alignment has been adjusted.
^ Any chassis components have been removed/installed or replaced.
Ground Locations
Cigarette Lighter: Ground Locations
Engine Compartment
Ground Location
EA Front Left Fender
EB Rear Bank of Right Cylinder
EC Rear Bank of Left Cylinder
Connector Location
EA1 Cowl Wire Harness and Wire Harness (Connector Location)
EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B)
EC1 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC2 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC3 Engine No. 2 Wire and Engine Wire (Near the Starter)
ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission)
Page 844
Page 5205
Blower Motor Relay: Testing and Inspection
HEATER MAIN RELAY
INSPECTION
1. REMOVE HEATER MAIN RELAY FROM NO.2 RELAY BLOCK
2. INSPECT HEATER MAIN RELAY (Making: HTR) CONTINUITY
If continuity is not as specified, replace the relay.
Page 4750
Glossary Of Terms And Symbols (Part 2)
Testing and Inspection
Brake Warning Indicator: Testing and Inspection
INSPECT BRAKE WARNING LIGHT
a. Disconnect the connector from the brake fluid warning switch b. Release the parking brake
pedal. c. Connect the terminals on the harness side of the level Warning switch connector. d. Start
the engine, check that the warning light lights up.
If warning light does not light up, test the bulb or wire harness.
Testing and Inspection
Tail Lamp Relay: Testing and Inspection
w/ Daytime running light: INSPECT TAILLIGHT DIMMER RELAY CONTINUITY If continuity is not
as specified, replace the relay.
Diagrams
Starter Motor: Diagrams
Starter (Part 1)
Locations
Fuse: Locations
Driver Side J/B And Integration Relay
Page 6830
B: Junction Connector
Indicates a connector which is connected to a short terminal.
Junction connector in this include a short terminal which is connected to a number of wire
harnesses. Always perform inspection with the short terminal installed. (When installing the wire
harnesses, the harnesses can be connected to any position within the short terminal grouping.
Accordingly, in other vehicles, the same position in the short terminal may be connected to wire
harness from a different part.) Wire harness sharing the same short terminal grouping ha the same
color.
C: Parts Code
The first letter of the code is taken from the first letter of part, and the numbers indicates its order in
parts which start with the same letter.
D: Connector Color
Connectors not indicated are milky white in color.
How to Read Ground Points
HOW TO READ GROUND POINTS
Page 2647
Terminals Of ECU - Connector Pinouts (Part 2)
INSPECTION
1. REMOVE ECM
2. INSPECT ECM
3. REINSTALL ECM
Page 4939
Key Reminder Switch: Pinout Values and Diagnostic Parameters
KEY REMINDER AND SEAT BELT WARNING
B7 (A), (B) BUCKLE SW LH
(A) 1 - (A) 2, (B) 2 - (B) 1 : Closed with driver's seat belt in use
D16 DOOR COURTESY SW FRONT LH
1 - GROUND : Closed with front LH door open
U1 UNLOCK WARNING SW
1 - 2 : Closed with ignition key in cylinder
C11 (A), C12 (B), C13 (C) COMBINATION METER
(A) 12, (B) 15 - GROUND : Always continuity (B) 10 - GROUND
: Continuity with the front LH door open (Standard cab) : Continuity with the each LH door open
(Access cab)
(C) 1 - GROUND : Continuity with the ignition key in cylinder
(B) 9 - GROUND : Continuity with the driver's seat belt in use
(B) 5 - GROUND : Always approx. 12 volts
(A) 7 - GROUND : Approx. 12 volts with the ignition SW at ON or ST position
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 4643
Driver Side J/B And Integration Relay
Instruments - Oil Pressure Gauge Reads Abnormally Low
Oil Pressure Sender: All Technical Service Bulletins Instruments - Oil Pressure Gauge Reads
Abnormally Low
ELECTRICAL EL017-03
December 23, 2503
Title OIL PRESSURE GAUGE READS LOW
Models '01 - '04 Sequoia & '00 - '02 Tundra
TSB UPDATE NOTICE:
This TSB updates EL006-03. TSB EL006-03 is now obsolete and should be discarded.
Introduction
Some customers with Sequoia or Tundra vehicles may encounter an oil pressure gauge that reads
abnormally low at idle. An updated oil pressure sender has been created to address this condition.
Applicable Vehicles ^
2001 - 2004 model year Sequoia vehicles produced BEFORE the Production Change Effective
VINs shown below.
^ 2000 - 2002 model year Tundra vehicles produced BEFORE the Production Change Effective
VIN shown below.
Production Change Information
Parts Information
Repair Procedure
1. Replace the Oil Pressure Sender.
2. Verify proper operation of the Oil Pressure Gauge.
Warranty Information
Applicable Warranty*:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36
months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Page 1209
Harmonic Balancer - Crankshaft Pulley: Service and Repair
For further information regarding this component and the system that it is a part of, please refer to
Timing Belt; Service and Repair.
Page 353
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
1. DRAIN ENGINE COOLANT
2. REMOVE THROTTLE BODY COVER
3. REMOVE INTAKE AIR CONNECTOR
4. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS
a. Disconnect the accelerator cable from the throttle body. b. Remove the 2 bolts and 2 nuts, and
disconnect the throttle body from the intake manifold. c. Remove the gasket
5. REMOVE ECT SENSOR
a. Disconnect the ECT sensor connector. b. Remove the ECT sensor and gasket.
6. REINSTALL ECT SENSOR
a. Install a new gasket and the ECT sensor.
Torque: 20.4 N.m (208 kgf.cm, 15 ft.lbf)
b. Connect the ECT sensor connector.
7. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS
a. Install a new gasket and the throttle body with the 2 bolts and 2 nuts.
Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)
b. Connect the accelerator cable to the throttle body.
8. REINSTALL INTAKE AIR CONNECTOR
9. REFILL WITH ENGINE COOLANT
10. REINSTALL THROTTLE BODY COVER
ABS/TCS - Zero Point Calibration Information
Steering Angle Sensor: Technical Service Bulletins ABS/TCS - Zero Point Calibration Information
T-SB-0020-08
March 25, 2008
Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment
Service Category Brake
Section Brake Control/Dynamic Control System
Market USA
Applicability
Introduction
The purpose of this TSB is to provide information on when and how to perform the zero point
calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting
the battery is a necessary step for performing the zero point calibration.
Warranty Information
Required Tools & Equipment
^ Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE).
^ The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the
service procedures listed in this bulletin.
Preliminary Information
Perform this procedure if any of these repairs have been performed on the vehicle:
^ Wheel alignment has been adjusted.
^ Any chassis components have been removed/installed or replaced.
Testing and Inspection
Headlamp Dimmer Switch: Testing and Inspection
INSPECT LIGHT CONTROL SWITCH CONTINUITY
If continuity is not as specified, replace the switch.
INSPECT HEADLIGHT DIMMER SWITCH CONTINUITY
If continuity is not as specified, replace the switch.
Page 4696
b. Push the secondary locking device or terminal retainer in to the full lock position.
5. CONNECT CONNECTOR
Disconnection of Male and Female Connectors
Disconnection of Male and Female Connectors
Disconnection Of Male And Female Connectors
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Page 3559
Transmission Mode Indicator - A/T: Harness Locations
Engine Compartment
Connector Location
EA1 Cowl Wire Harness and Wire Harness (Connector Location)
EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B)
EC1 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC2 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC3 Engine No. 2 Wire and Engine Wire (Near the Starter)
ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission)
Page 2827
Page 3740
Splice Location
I1 Cowl Wire
I2 Cowl Wire
I3 Cowl Wire
I4 Cowl Wire
I5 Cowl Wire
I6 Cowl Wire
I7 Engine Wire
I8 Engine Wire
I9 Engine Wire
I10 Engine Wire
I11 Engine Wire
I12 Engine Wire
I13 Engine Wire
I14 Engine Wire
I15 Engine Wire
I16 Cowl Wire
Body
Splice Location (Access Cab)
B1 Speaker Tweeter Wire LH
B2 Front Door LH Wire
B3 Front Door LH Wire
B4 Roof Wire
B5 Speaker Tweeter Wire RH
B6 B7
Front Door RH Wire
B8 Front Door RH Wire
B9 Rear Door No. 1 Wire RH
B10 Frame Wire
Page 1109
B: Junction Connector
Indicates a connector which is connected to a short terminal.
Junction connector in this include a short terminal which is connected to a number of wire
harnesses. Always perform inspection with the short terminal installed. (When installing the wire
harnesses, the harnesses can be connected to any position within the short terminal grouping.
Accordingly, in other vehicles, the same position in the short terminal may be connected to wire
harness from a different part.) Wire harness sharing the same short terminal grouping ha the same
color.
C: Parts Code
The first letter of the code is taken from the first letter of part, and the numbers indicates its order in
parts which start with the same letter.
D: Connector Color
Connectors not indicated are milky white in color.
How to Read Ground Points
HOW TO READ GROUND POINTS
Description and Operation
Throttle Position Sensor: Description and Operation
Throttle Position Sensor
Throttle position sensor is mounted on the throttle body and it has 2 sensors to detect the throttle
opening angle and a malfunction of the throttle position sensor's own.
Voltage applied to the terminals VTA and VTA2 of the ECM changes between 0 V and 5 V in
proportion to the opening angle of the throttle valve.
The ECM judges the current opening angle of the throttle valve from these signals output from
terminals VTA and VTA2, and the ECM controls the throttle motor to make the throttle valve
opening angle properly in accordance with the driving condition.
If this DTC is stored, the ECM cuts down the power for the throttle motor and the electromagnetic
clutch, and the throttle valve is fully closed by the return spring. However, the opening angle of the
throttle valve can be controlled by the accelerator pedal through the throttle cable.
Page 5612
Terminal Retainer
Push the terminal retainer down to the temporary lock position.
c. Release the locking lug from terminal and pull the terminal out from rear.
4. INSTALL TERMINAL TO CONNECTOR
a. Insert the terminal.
HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug
locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position.
Page 6478
Step 3
Page 1119
Terminal Retainer
Push the terminal retainer down to the temporary lock position.
c. Release the locking lug from terminal and pull the terminal out from rear.
4. INSTALL TERMINAL TO CONNECTOR
a. Insert the terminal.
HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug
locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position.
Page 3060
Page 6664
Transmission Mode Indicator - A/T: Harness Locations
Engine Compartment
Connector Location
EA1 Cowl Wire Harness and Wire Harness (Connector Location)
EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B)
EC1 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC2 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC3 Engine No. 2 Wire and Engine Wire (Near the Starter)
ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission)
Page 2491
Page 799
Transmission Speed Sensor: Description and Operation
Vehicle Speed Sensor NO.1
Vehicle Speed Sensor NO.1 Circuit Description
The vehicle speed sensor outputs a 4-pulse signal for every revolution of the rotor shaft, which is
rotated by the transmission output shaft via the driven gear. After this signal is converted into a
more precise rectangular waveform by the waveform shaping circuit inside the combination meter,
it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency
of these pulse signals.
Vehicle Speed Sensor NO.2
Vehicle Speed Sensor NO.2 Circuit Description
The No.2 vehicle speed sensor detects the rotation speed of the transmission output shaft and
sends signals to the ECM. The ECM determines the vehicle speed based on these signals.
Page 4906
Key Reminder Switch: Ground Locations
Engine Compartment
Ground Location
EA Front Left Fender
EB Rear Bank of Right Cylinder
EC Rear Bank of Left Cylinder
Connector Location
EA1 Cowl Wire Harness and Wire Harness (Connector Location)
EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B)
EC1 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC2 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC3 Engine No. 2 Wire and Engine Wire (Near the Starter)
ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission)
Collision / Non-Collision Inspections
Airbag Sensor Assembly: Testing and Inspection Collision / Non-Collision Inspections
VEHICLE NOT INVOLVED IN COLLISION
Check a diagnostic system.
VEHICLE INVOLVED IN COLLISION WITH AIRBAG NOT DEPLOYED
Check a diagnostic system. *
VEHICLE INVOLVED IN COLLISION WITH AIRBAG DEPLOYED
Replace the airbag sensor assembly. *
* Refer to SRS Warning Light Check, and How to Display and Read Diagnostic Trouble Codes.
See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Displaying & Reading
Trouble Codes
Page 1099
Engine Compartment
Instrument Panel
Locations
Page 843
Page 6185
Instrument Panel
Ground Location
IE Left Kick Panel
IF Left Kick Panel
IG Instrument Panel Brace RH
IH Right Kick Panel
II Right Kick Panel
Body
Ground Location (Access Cab)
Page 4731
Engine Compartment
Instrument Panel
Locations
Page 6815
Glossary Of Terms And Symbols (Part 2)
Service and Repair
Front Crankshaft Seal: Service and Repair
For further information regarding this component and the system that it is a part of, please refer to
Oil Pump; Service and Repair.
Page 1145
6. 4WD: INSTALL BEARING SPACER
Using SST and a press, install the bearing spacer. SST 09950-60010 (09951-00650), 09950-70010
(09951-07150)
7. 2WD: INSTALL GREASE CAP
8. 4WD: INSTALL NEW OIL SEAL (INSIDE)
a. Using SST and a plastic hammer, install a new oil seal (inside).
SST 09527-17011
HINT: Lightly strike the SST on its circumference evenly.
b. Coat MP grease to the oil seal lip.
Page 5758
Trailer Connector: Splice Locations
Engine Compartment
Splice Location
E1 Engine Room Main Wire
E2 Engine Room Main Wire
E3 Engine Room Main Wire
E4 Engine No. 2 Wire
E5 Engine Wire
E6 Engine Wire
E7 Engine Wire
E8 Engine Wire
Instrument Panel
Page 2248
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.
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 396
Body
Splice Location (Standard Cab)
B1 Speaker Tweeter Wire LH
B2 Front Door LH Wire
B3 Front Door LH Wire
B4 Roof Wire
B5 Speaker Tweeter Wire RH
B6 B7
Front Door RH Wire
B10 Frame Wire
Seat
Page 4166
Required SSTs
Diagnosis Procedure
1. Confirm the customer complaint.
2. Determine if vibration is from front or rear (while brakes are still warm from confirmation test
driving).
The following procedure will isolate the drum brakes from the rest of the hydraulic system by using
the parking brake (PKB).
A. Drive the Tundra along a smooth, level section of road at approximately 40 mph - 50 mph.
Engine Controls - Bank 1/Bank 2 O2 Sensor identification
Oxygen Sensor: All Technical Service Bulletins Engine Controls - Bank 1/Bank 2 O2 Sensor
identification
ENGINE EG034-07
Title: ENGINE BANK 1 AND BANK 2 A/F AND O2 IDENTIFICATION
Models: '93 - '08 Applicable Models
June 28, 2007
The information contained in this TSB supercedes TSB No. EG037-04. TSB No. EG037-04 is now
obsolete and should be discarded.
Introduction
This service bulletin provides information on the proper identification of engine bank 1 and engine
bank 2 for correct A/F sensor and oxygen sensor replacement.
This bulletin contains information that identifies engine bank 1 and engine bank 2 on the following
engines: 1AZ-FE, 2AZ-FE, 2AZ-FE (PZEV), 1GR-FE, 2GR-FE, 2GR-FSE, 2JZ-GE, 1MZ-FE,
3MZ-FE, 1UR-FSE, 3UR-FE, 2UZ-FE, 3UZ-FE, 5VZ-FE, and 1ZZ-FE.
^ Bank 1 (B1) refers to the bank that includes cylinder No. 1.
^ Bank 2 (B2) refers to the bank opposite bank 1.
^ Sensor 1 (S1) refers to the sensor that is located before the catalytic converters.
^ Sensor 2 (S2) refers to the sensor that is located after the catalytic converters.
Warranty Information
Page 3645
5. REMOVE OIL SEAL AND OIL SLINGER
a. Using SST, remove the oil seal.
SST 09308-10010
b. Remove the oil slinger.
6. REMOVE REAR BEARING AND BEARING SPACER
a. Using SST, remove the rear bearing from the drive pinion.
SST 09556-22010
b. Remove the bearing spacer.
7. INSTALL BEARING SPACER, REAR BEARING AND OIL SLINGER
a. Install a new bearing spacer and place the rear bearing and oil slinger. b. Using SST and the
companion flange, install the rear bearing, then remove the companion flange.
SST 09950-30011 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020)
8. INSTALL OIL SEAL
a. Coat a new oil seal lip with MP grease. b. Using SST and a hammer, install the oil seal.
SST 09554-22010 Oil seal drive in depth: 4.5 ± 0.3 mm (0.177 ± 0.012 inch)
Page 1514
b. Apply seal packing to the sealing groove of water inlet housing as shown in the illustration.
Seal packing: Part No. 08826-00100 or equivalent ^
Install a nozzle that has been cut to a 2 - 3 mm (0.08 - 0.12 inch) opening.
^ Parts must be assembled within 5 minutes of application. Otherwise the material must be
removed and reapplied.
^ Immediately remove nozzle from the tube and reinstall cap.
c. Install a new O-ring to the water inlet housing. d. Apply soapy water on the O-ring. e. Attach the
water inlet housing end to the front water bypass joint hole.
f. Install the water inlet and housing assembly with the 2 bolts. Alternately tighten the bolts. Torque:
18 Nm (185 kgf-cm, 13 ft. lbs.)
HINT: Each bolt length is indicated in the illustration.
Bolt length:
76 mm (3.00 inch) for A 22 mm (0.87 inch) for B
g. Connect the water bypass hose to the water inlet housing.
3. INSTALL NO.2 IDLER PULLEY 4. INSTALL TIMING BELT 5. FILL WITH ENGINE COOLANT 6.
START ENGINE AND CHECK FOR ENGINE COOLANT LEAKS 7. RECHECK ENGINE
COOLANT LEVEL
Page 3686
8. REMOVE STEERING KNUCKLE
a. Remove the coffer pin and loosen the nut. b. Using Special Service Tool (SST), disconnect the
steering knuckle.
SST 09950-40011 (09951-04010, 09952-04010, 09553-04020, 09554-04010, 09955-04031,
09958-04011)
c. Remove the nut and steering knuckle.
NOTICE: 4WD: Be careful not to damage the oil seal and drive shaft boot.
HINT: 4WD: When it is difficult to disconnect the drive shaft, tap the tip of the drive shaft with a
plastic hammer.
INSTALLATION
1. INSTALL STEERING KNUCKLE
a. 4WD: Insert the drive shaft into the axle hub and temporarily tighten the nut.
NOTICE: Be careful not to damage the oil seal and drive shaft boot.
b. Connect the steering knuckle to the upper suspension arm. c. Install the nut and a new cotter
pin.
If the holes for the cotter pin are not aligned, tighten the nut further up to 60°. Torque: 105 Nm
(1,100 kgf-cm, 77 ft. lbs.)
2. CONNECT LOWER BALL JOINT
Connect the lower ball joint to the steering knuckle with 4 bolts. Torque: 80 Nm (820 kgf-cm, 59 ft.
lbs.)
3. INSTALL SHOCK ABSORBER 4. INSTALL BRAKE CALIPER
a. Install the disc, brake caliper and 2 bolts.
Torque: 123 Nm (1,250 kgf-cm, 90 ft. lbs.)
b. Install the brake line clamp to the steering knuckle with bolt.
Torque: 28 Nm (285 kgf-cm, 21 ft. lbs.)
5. w/ ABS: CONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP
Connect the ABS speed sensor and wire harness clamp to the steering knuckle with 2 bolts.
Torque: 8.0 Nm (82 kgf-cm, 71 ft. lbs.)
6. 4WD: INSTALL DRIVE SHAFT LOCK NUT
a. While applying the brakes, tighten the nut.
Torque: 235 Nm (2,400 kgf-cm, 173 ft. lbs.)
b. Install the lock cap and a new cotter pin.
If the holes for the cotter pin are not aligned, tighten the nut further up to 60°.
7. INSTALL GREASE CAP 8. INSTALL FRONT WHEEL
Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.)
9. DEPRESS BRAKE PEDAL SEVERAL TIMES
10. CHECK FRONT WHEEL ALIGNMENT 11. CHECK ABS SPEED SENSOR SIGNAL
Disassembly and Reassembly
Page 5266
9. REMOVE NO.4 HEATER TO REGISTER DUCT
10. REMOVE COOLING UNIT
a. Disconnect the connectors. b. Remove the 3 screws, bolt and the cooling unit.
INSTALLATION
Installation is in the reverse order of removal.
Page 1900
Required Tools & Material
NOTE:
Additional Diagnostic Tester Kits, Program Cards or SSTs may be ordered by calling SPX-OTC at
1-800-933-8335.
Repair Procedure
Using the chart, refer to the Diagnostic Section (DI-###) in the appropriate Repair Manual and
follow the diagnostic procedure for the specific DTC.
Locations
EFI Main Relay: Locations
Engine Room R/B
Page 1765
F. Confirm the Diagnostic Tester software version and connections to the TIS workstation are
correct.
* NOTE:
This screen displays the required version of Diagnostic Tester software that is compatible with the
selected calibration file, and the other required steps to properly connect the Diagnostic Tester to
your PC.
^ Type I calibration files are only compatible with software version 10.1a and older versions.
^ Type II calibration files are only compatible with software version 10.2a and newer versions.
G. Place the Diagnostic Tester in the "GET CAL FROM PC" mode to receive the calibration file
(Figure 10).
Click NEXT on the TIS workstation. Once communications begin between the PC and the
Diagnostic Tester, the Diagnostic Tester display will flash CONNECTED.
H. The CUW determines if there is enough memory to store the calibration file on the Diagnostic
Tester Program Card. If there is insufficient
Page 6222
3. MONITOR ECM DATA BY USING TOYOTA HAND-HELD TESTER
a. Connect the TOYOTA hand-held tester to the DLC3. b. Monitor the ECM data by following the
prompts on the tester screen.
HINT: TOYOTA hand-held tester has a "Snapshot" function which records the monitored data.
Please refer to the TOYOTA hand-held tester operator's manual for further details.
Page 564
CHART 22
Page 4197
Parts Information
Engine Controls - Bank 1/Bank 2 O2 Sensor identification
Oxygen Sensor: All Technical Service Bulletins Engine Controls - Bank 1/Bank 2 O2 Sensor
identification
ENGINE EG034-07
Title: ENGINE BANK 1 AND BANK 2 A/F AND O2 IDENTIFICATION
Models: '93 - '08 Applicable Models
June 28, 2007
The information contained in this TSB supercedes TSB No. EG037-04. TSB No. EG037-04 is now
obsolete and should be discarded.
Introduction
This service bulletin provides information on the proper identification of engine bank 1 and engine
bank 2 for correct A/F sensor and oxygen sensor replacement.
This bulletin contains information that identifies engine bank 1 and engine bank 2 on the following
engines: 1AZ-FE, 2AZ-FE, 2AZ-FE (PZEV), 1GR-FE, 2GR-FE, 2GR-FSE, 2JZ-GE, 1MZ-FE,
3MZ-FE, 1UR-FSE, 3UR-FE, 2UZ-FE, 3UZ-FE, 5VZ-FE, and 1ZZ-FE.
^ Bank 1 (B1) refers to the bank that includes cylinder No. 1.
^ Bank 2 (B2) refers to the bank opposite bank 1.
^ Sensor 1 (S1) refers to the sensor that is located before the catalytic converters.
^ Sensor 2 (S2) refers to the sensor that is located after the catalytic converters.
Warranty Information
Service and Repair
Fuel Pressure Release: Service and Repair
SFI SYSTEM
PRECAUTION
1. BEFORE WORKING ON FUEL SYSTEM, DISCONNECT NEGATIVE (-) TERMINAL CABLE
FROM BATTERY
HINT: Any diagnostic trouble code retained by the computer will be erased when the negative (-)
terminal cable is removed from the battery.
Therefore, if necessary, read the diagnosis before removing the negative (-) terminal cable from the
battery.
2. DO NOT SMOKE OR WORK NEAR AN OPEN FLAME WHEN WORKING ON THE FUEL
SYSTEM
3. KEEP GASOLINE AWAY FROM RUBBER OR LEATHER PARTS
4. FUEL SYSTEM
a. When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so
observe these procedures:
1. Disconnect the fuel pump connector. 2. Start the engine. After the engine has stopped on its
own, turn the ignition switch OFF.
3. Put a container under the connection. 4. Slowly loosen the connection. 5. Disconnect the
connection. 6. Plug the connection with a rubber plug. 7. Reconnect the fuel pump connector.
b. When connecting the union bolt (fuel pressure pulsation damper) on the high pressure pipe
union, observe these procedures:
1. Always use 2 new gaskets.
Page 5735
Waterproof Type Connector
B: For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White
: Gray
Black or White : Dark Gray
Gray or White : Black
Waterproof Type Connector
"Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up
to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Waterproof Type Connector
"Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 5736
Terminal Retainer
Push the terminal retainer down to the temporary lock position.
c. Release the locking lug from terminal and pull the terminal out from rear.
4. INSTALL TERMINAL TO CONNECTOR
a. Insert the terminal.
HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug
locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position.
Page 1831
Mass Air Flow Meter: Service and Repair
MASS AIR FLOW (MAF) METER
1. DISCONNECT MAF METER CONNECTOR
2. REMOVE MAF METER
Remove the 2 screws and MAF meter.
3. REINSTALL MAF METER
Install the MAF meter with the 2 screws.
4. RECONNECT MAF METER CONNECTOR
Page 1081
The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit
breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery
power is supplied to each system are explained. Since all System Circuit diagrams start from the
power source, the power source system must be fully understood.
Service and Repair
Crankshaft Main Bearing Seal: Service and Repair
For further information regarding this component and the system that it is a part of, please refer to
Cylinder Block Assembly; Service and Repair.
Testing and Inspection
Overdrive Switch: Testing and Inspection
O/D Main Switch & O/D OFF Indicator Light Circuit
CIRCUIT DESCRIPTION
The O/D main switch contacts go open when the switch is pushed in and go closed when it is
pushed out.
If O/D main switch is at OFF position, the O/D OFF indicator light lights up, and the ECM prohibits
shifting O/D.
Wiring Diagram
INSPECTION PROCEDURE
Testing and Inspection
Power Window Switch: Testing and Inspection
Driver's Switch
Passenger's Switch : Window Unlock
Passenger's Switch : Window Lock
INSPECT POWER WINDOW MASTER SWITCH CONTINUITY
If continuity is not as specified, replace the switch.
Page 2803
A. The Diagnostic Tester displays 17" as a value of the Time $81" (see illustration).
B. Find the Conversion Factor value of Time $81" in the O2S Failure Threshold chart. 0.3906 is
specified for Time $81 in this chart.
C. Multiply "17" in step "A" by 0.3906 (Conversion Factor) in step "B."
17 x 0.3906 = 6.6%
D. If the answer is within the Standard Value of TEST LIMIT, the Time $81" can be confirmed to be
normal.
NOTE:
^ "LOW SW V" indicates the O2S voltage when the O2S status changes from rich to lean.
^ "HIGH SW V" indicates the O2S voltage when the O2S status changes from lean to rich.
^ If the O2S voltage is lower than "LOW SW V," the O2S status is lean.
^ If the O2S voltage is higher than "HIGH SW V," the O2S status is rich.
NOTE:
Before the O2S Monitor completes or after the ignition switch is turned OFF, the Diagnostic Tester
displays the viewable upper limit or a lower limit of the test value (example: 0 V, 1.275 V, Os
[seconds], 10.2s, 0 and 255).
Page 1120
b. Push the secondary locking device or terminal retainer in to the full lock position.
5. CONNECT CONNECTOR
Disconnection of Male and Female Connectors
Disconnection of Male and Female Connectors
Disconnection Of Male And Female Connectors
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Engine - Squealing Noise On Cold Start Up
Drive Belt: All Technical Service Bulletins Engine - Squealing Noise On Cold Start Up
ENGINE EG003-05
Title: 2UZ-FE ACCESSORY DRIVE BELT NOISE
Models: '00 - '05 Tundra & '01 - '05 Sequoia
February 9, 2005
Introduction
Some customers may experience abnormal squeal noise from the engine accessory drive belt
area, usually during cold start-up. An improved accessory drive belt has been developed to correct
this condition.
Applicable Vehicles
^ 2000 - 2005 model year Tundra vehicles equipped with 2UZ-FE engine produced BEFORE the
Production Change Effective VIN shown below.
^ 2001 - 2005 model year Sequoia vehicles equipped with 2UZ-FE engine produced BEFORE the
Production Change Effective VIN shown below.
Production Change Information
Parts Information
Warranty Information
Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This
warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's
in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Repair Procedure
Replace the accessory drive belt with the improved part.
1. Remove existing accessory drive belt.
Page 2068
4. INSPECT THROTTLE POSITION SENSOR
a. Disconnect the throttle position sensor connector. b. Using an ohmmeter, measure the
resistance between terminals VC and E2.
Resistance: 1.25 - 2.35 kohms at 20 °C (68 °F)
If the resistance is not as specified, replace the throttle position sensor.
c. Reconnect the throttle position sensor connector.
5. INSPECT ACCELERATOR PEDAL POSITION SENSOR
a. Disconnect the pedal position sensor connector. b. Using an ohmmeter, measure the resistance
between terminals VC and E2.
Resistance: 1.64 - 3.28 kohms at 20 °C (68 °F)
If the resistance is not as specified, replace the accelerator pedal position sensor.
c. Reconnect the pedal position sensor connector.
6. REINSTALL THROTTLE BODY COVER
Page 6555
The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit
breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery
power is supplied to each system are explained. Since all System Circuit diagrams start from the
power source, the power source system must be fully understood.
Page 1111
The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit
breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery
power is supplied to each system are explained. Since all System Circuit diagrams start from the
power source, the power source system must be fully understood.
Page 4698
Driver Side J/B And Integration Relay
Page 1459
Fuel Pressure: Specifications Volume Specification
Information not supplied by the manufacturer.
Page 669
The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit
breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery
power is supplied to each system are explained. Since all System Circuit diagrams start from the
power source, the power source system must be fully understood.
Page 6239
Step 4
INSPECTION PROCEDURE
HINT: Troubleshoot in accordance with the chart for each trouble symptom.
Page 5596
Body
Connector Location (Access Cab)
BA1 Front Door LH Wire and Wire Harness (Connector Location)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel)
BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel)
BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel)
BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Page 4680
Engine Compartment
Instrument Panel
Locations
Page 1956
A/F and 02 Sensor Identification
Replacement Requirements
Impact Sensor: Service and Repair Replacement Requirements
REPLACEMENT REQUIREMENTS
In the following cases, replace the front airbag sensor.
- If the SRS has been deployed in a collision. (Replace both the left and right airbag sensors.)
- If the front airbag sensor has been found to be faulty in troubleshooting.
- If the front airbag sensor has been found to be faulty during checking items.
- If the front airbag sensor has been dropped.
CAUTION: Be sure to follow the correct procedure for removal and installation of the front airbag
sensor.
Page 5621
Seat Belt Tensioner: Description and Operation
SEAT BELT PRETENSIONER
The seat belt pretensioner system is a component of the front seat outer belt. The pretensioner
operates in the event of a frontal collision. The seat belt pretensioner cannot be disassembled.
Page 5448
Step 4
Page 208
J. The top half of the CUW screen displays the calibrations currently stored on the Diagnostic
Tester Program Card. The bottom half of the screen displays the new calibration to be loaded onto
the Diagnostic Tester Program Card (see Figure 13). Click NEXT to continue the process.
K. Confirm the calibration file to be sent to the Diagnostic Tester Program Card (Figure 14). Click
SEND.
Page 6400
- Do not release the airbag activation prevention mechanism unless specifically directed by the
troubleshooting procedure.
- If the inserted paper is too thick the terminal and short spring may be damaged, so always use
paper with the same thickness as the male terminal.
Page 5124
3. REMOVE STABILIZER BAR LINKS
a. Hold the stabilizer bar link, remove the nut. b. Remove the stabilizer bar link, 2 retainers and
bushings from the stabilizer bar. c. Employ the same manner described to the other side.
INSPECTION
1. INSPECT STABILIZER BAR LINK BALL JOINT BOOT FOR DAMAGE
2. INSPECT STABILIZER BAR LINK BALL JOINT FOR ROTATION CONDITION
a. As shown in the illustration, flip the ball joint stud back and forth 5 times before installing the nut.
b. Using a torque wrench, turn the nut continuously 1 turn per 2 - 4 seconds and take the torque
reading on the 5th turn.
Turning torque: 0.05 - 2.0 Nm (0.5 - 20 kgf-cm, 0.4 - 17 inch lbs.)
INSTALLATION
1. INSTALL STABILIZER BAR LINKS
a. Install the 2 bushings, retainers and stabilizer bar link to the stabilizer bar. b. Hold the stabilizer
bar link, install the nut.
Torque: 19 Nm (190 kgf-cm, 14 ft. lbs.)
c. Employ the same manner described to the other side.
2. INSTALL STABILIZER BAR
a. Install the 2 bushings with their cutout facing to the rearward to the stabilizer bar. b. Install the
stabilizer bar and 2 brackets with nut and bolts.
Torque: 37 Nm (375 kgf-cm, 27 ft. lbs.)
3. CONNECT STABILIZER BAR LINKS TO LOWER SUSPENSION ARM
Torque: 69 Nm (700 kgf-cm, 51 ft. lbs.)
HINT: If the ball joint turns together with the nut, use a hexagon (6 mm) wrench to hold the nut.
Page 1094
Driver Side J/B And Integration Relay Inner Circuit
Page 2678
Coolant Temperature Sensor/Switch (For Computer): Mechanical Specifications
New gasket and the ECT sensor. Torque: ..........................................................................................
.................................................................................... 20.4 N.m (208 kgf.cm, 15 ft.lbf)
New gasket and the throttle body with the 2 bolts and 2 nuts. Torque: ...............................................
.................................................................................................................................. 18 N.m (185
kgf.cm, 13 ft.lbf)
Page 5086
Page 6506
Instrument Panel
Ground Location
IE Left Kick Panel
IF Left Kick Panel
IG Instrument Panel Brace RH
IH Right Kick Panel
II Right Kick Panel
Body
Ground Location (Access Cab)
Page 638
Page 3282
Install the No.1 vehicle speed sensor with the bolt.
Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.)
6. CONNECT NO. I VEHICLE SPEED SENSOR CONNECTOR
Vehicle Speed Sensor NO.2
Vehicle speed Sensor NO.2 on-vehicle repair
1. DISCONNECT NO. 2 VEHICLE SPEED SENSOR CONNECTOR
2. REMOVE NO. 2 VEHICLE SPEED SENSOR
a. Remove the bolt and No. 2 vehicle speed sensor. b. Remove the O-ring from the No. 2 vehicle
speed sensor.
3. INSTALL NO. 2 VEHICLE SPEED SENSOR
a. Coat a new O-ring with ATF and install it to the No. 2 vehicle speed sensor. b. Install the No. 2
vehicle speed sensor with the bolt.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
4. CONNECT NO. 2 VEHICLE SPEED SENSOR CONNECTOR
Testing and Inspection
Positive Crankcase Ventilation: Testing and Inspection
INSPECTION
1. REMOVE THROTTLE BODY COVER
2. INSPECT PCV VALVE
a. Remove the PCV valve.
b. Install a clean hose to the PCV valve.
c. Inspect the PCV valve operation.
1. Blow air into the cylinder head side, and check that air passes through easily.
CAUTION: Do not suck air through the valve. Petroleum substances inside the valve are harmful.
2. Blow air into the intake manifold side, and check that air passes through with difficulty.
If operation is not as specified, replace the PCV valve.
d. Remove the clean hose from the PCV valve. e. Reinstall the PCV valve.
3. INSPECT HOSES, CONNECTIONS AND GASKETS
Visually check for cracks, leaks or damage.
4. REINSTALL THROTTLE BODY COVER
Diagram Information and Instructions
Vehicle Speed Sensor: Diagram Information and Instructions
Key to Diagrams
A: System Title
B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to
distinguish it from the J/B
Example: 1 Indicates Relay Block No.1
C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type,
or specification is different.
D: Indicates related system.
Page 2903
Glossary Of Terms And Symbols (Part 2)
Page 2757
CHART 11
Page 4950
7. POSITION FRONT WHEEL FACING STRAIGHT AHEAD
HINT: Do it with the front of the vehicle jacked up.
8. CENTER SPIRAL CABLE 9. INSTALL STEERING WHEEL
a. Align the matchmarks on the wheel and steering column main shaft. b. Temporarily tighten the
wheel set nut. c. Connect the connector.
10. BLEED POWER STEERING SYSTEM 11. CHECK STEERING WHEEL CENTER POINT 12.
TORQUE STEERING WHEEL SET NUT
Torque: 50 Nm (500 kgf-cm, 35 ft. lbs.)
13. INSTALL STEERING WHEEL PAD 14. CHECK FRONT WHEEL ALIGNMENT
Engine/Transmission Controls - Resetting ECM Memory
Engine Control Module: All Technical Service Bulletins Engine/Transmission Controls - Resetting
ECM Memory
TRANSMISSION & CLUTCH TC002-03 REVISED
Title: ECM RESET MEMORY FUNCTION
Models: '00 - '05 All Models
June 10, 2003
TSB REVISION NOTICE:
^ December 20, 2004: Applicable Vehicles section has been updated - 2004 and 2005 model years
added, models and model years updated for various models; and Reset Procedure 2 has been
revised.
^ January 16, 2004: Tundra vehicles were added to the Applicable Vehicles chart.
^ December 17, 2003: T-100 vehicles were removed from the Applicable Vehicles chart.
Previous versions of this TSB should be discarded.
Introduction
Whenever an automatic transmission is replaced, overhauled or individual components are
replaced, use this procedure to clear Engine Control Module ( ECM, SAE term: Powertrain Control
Module, PCM) "Learned Values" to minimize subsequent performance concerns.
CAUTION:
Failure to follow the procedure below may lengthen the time to readjust the ECM "Learned Values,"
potentially resulting in performance concerns.
Required SSTs
Warranty Information
Applicable Vehicles
Page 4187
14. REMOVE OIL SEAL (OUTSIDE)
Using a screwdriver, remove the oil seal (outside) from the steering knuckle.
15. REMOVE BEARING FROM STEERING KNUCKLE
A. Using snap ring pliers, remove the snap ring.
B. Using the following SSTs and a press, remove the bearing from the steering knuckle.
^ 09950-60020 (09951-00810)
^ 09950-70010 (09951-07150)
16. INSTALL NEW BEARING
A. Using the following SSTs and a press, install a NEW bearing to the steering knuckle.
^ 09527-17011
^ 09950-60020 (09951-00910)
B. Using Snap ring pliers, install a NEW snap ring.
17. INSTALL NEW OIL SEAL (OUTSIDE)
A. Using the following SSTs and a plastic hammer, install a NEW oil seal (outside).
^ 09223-15030
Page 2314
The calibration file contains the Calibration ID number(s) for a specific vehicle ECU (see Figure 1).
NOTE:
The total number of Calibration ID numbers corresponds to the number of reprogrammable
processors in the ECU (see Figure 2).
Operation Procedure
LOCATE CALIBRATION FILE
The following steps in this bulletin describe how to properly flash reprogram an ECU.
1. Locate calibration file on TIS.
Calibration files may be found in two areas (see Figure 3):
A. Search by model and year for a Technical Service Bulletin addressing a specific Product issue.
^ Within the TSB, click on the link for the calibration file.
B. Search by model under the ECU Flash Reprogramming Section.
^ Under the ECU Flash Reprogramming section on TIS, a drop-down list of the latest calibration
files will be displayed.
C. Proceed to step 2 for instructions on how to download the calibration file from TIS to the
Diagnostic Tester Program Card.
Page 411
Key Reminder Switch: Diagnostic Aids
Voltage Check
Voltage Check
Voltage Check
A. Establish conditions in which voltage is present at the check point.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(SW 2 OFF)
B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or
component terminal. This check can be done with a test light instead of a voltmeter.
Continuity and Resistance Check
Continuity and Resistance Check
Continuity And Resistance Check
A. Disconnect the battery terminal or wire so there is no voltage between the check points. B.
Contact the two leads of an ohmmeter to each of the check points.
Testing and Inspection
Idle Up Control Valve: Testing and Inspection
INSPECTION
1. TURN AIR CONDITIONING SWITCH OFF
2. CHECK IDLE-UP
a. Start the engine and run it at idle. b. Fully turn the steering wheel. c. Check that the engine
rotations decrease when the vacuum hose of the air control valve is pinched. d. Check that the
engine rotations increase when the hose is released.
Page 2834
Page 1999
CHART 26
Page 2681
Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
INSPECTION
1. DRAIN ENGINE COOLANT
2. REMOVE THROTTLE BODY COVER
3. REMOVE INTAKE AIR CONNECTOR
4. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS
a. Disconnect the accelerator cable from the throttle body. b. Remove the 2 bolts and 2 nuts, and
disconnect the throttle body from the intake manifold. c. Remove the gasket
5. REMOVE ECT SENSOR
a. Disconnect the ECT sensor connector. b. Remove the ECT sensor and gasket.
6. INSPECT ECT SENSOR
Using an ohmmeter, measure the resistance between the terminals.
Resistance: Refer to the graph
If the resistance is not as specified, replace the ECT sensor.
7. REINSTALL ECT SENSOR
a. Install a new gasket and the ECT sensor.
Page 495
Crankshaft Position Sensor: Testing and Inspection
INSPECTION
NOTE: "Cold" and "Hot" in these sentences express the temperature of the coils themselves.
"Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F).
INSPECT CRANKSHAFT POSITION SENSOR
Resistance
Using an ohmmeter, measure the resistance between the terminals.
If the resistance is not as specified, replace the crankshaft position sensor.
Testing and Inspection
Overdrive Indicator Lamp: Testing and Inspection
O/D Main Switch & O/D OFF Indicator Light Circuit
CIRCUIT DESCRIPTION
The O/D main switch contacts go open when the switch is pushed in and go closed when it is
pushed out.
If O/D main switch is at OFF position, the O/D OFF indicator light lights up, and the ECM prohibits
shifting O/D.
Wiring Diagram
INSPECTION PROCEDURE
Diagram Information and Instructions
Transmission Mode Indicator - A/T: Diagram Information and Instructions
Key to Diagrams
A: System Title
B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to
distinguish it from the J/B
Example: 1 Indicates Relay Block No.1
C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type,
or specification is different.
D: Indicates related system.
Page 2032
The ground points circuit diagram shows the connections from all major parts to the respective
ground points. When troubleshooting a faulty ground point, checking the system circuits which use
a common ground may help you identify the problem ground quickly. The relationship between
ground points (EA, IB and IC) can also be checked this way.
How to Read Power Source
HOW TO READ POWER SOURCE
Page 5080
- Length: 6 in.
^ Ratcheting tie down strap (quantity 1)
- Minimum Width & Length: 1 in. x 6 ft.
^ Bicycle Cable Lock (quantity 1)
- Minimum Width & Length: 3/8 in. x 5 ft.
- Built-in lock with key
- Bell: P/N 1002107, Master Lock: P/N 8126D, Kryptonite: P/N 999782 or equivalent
IV. Background
On certain 2000 through 2003 model year Tundra vehicles operated in cold climate areas with high
road salt use (Severe Cold Climate States) excessive corrosion may be exhibited on the rear frame
cross-member. In the worst case the spare tire stowed under the truck bed may become separated
from the rear cross-member. Eventually excessive corrosion of the rear cross-member may also
affect the functionality of the brake system Load Sensing Proportioning & By-Pass Valve and/or
associated brake lines.
Locations
Engine Room R/B
Page 2533
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 5600
Wiring Harness Connector
E: Indicates the wiring harness and wiring harness connector. The wiring harness with male
terminal is shown with arrows.
Outside numerals are pin numbers.
The first letter of the code for each wiring harness and wiring harness connector(s) indicates the
component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and
Surrounding area, and "B" for the Body and Surrounding area.
When more than one code has the first and second letters in common, followed by numbers (e.g,
IH1, IH2), this indicates the same type of wiring harness and wiring harness connector.
F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in
parts position.
G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside
it). Junction Blocks are shaded to clearly separate
them from other parts.
H: When 2 parts both use one connector in common, the parts connector name used in wire
routing is shown in square brackets [ ].
Wiring Color
I: Indicates the wiring color.
Wire colors are indicated by an alphabetical code.
B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR =
Brown SB = Sky Blue LG = Light Green GR = Gray
The first letter indicates the basic wire color and the second letter indicates the color of the stripe.
Page 3592
Transmission Speed Sensor: Description and Operation
Vehicle Speed Sensor NO.1
Vehicle Speed Sensor NO.1 Circuit Description
The vehicle speed sensor outputs a 4-pulse signal for every revolution of the rotor shaft, which is
rotated by the transmission output shaft via the driven gear. After this signal is converted into a
more precise rectangular waveform by the waveform shaping circuit inside the combination meter,
it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency
of these pulse signals.
Vehicle Speed Sensor NO.2
Vehicle Speed Sensor NO.2 Circuit Description
The No.2 vehicle speed sensor detects the rotation speed of the transmission output shaft and
sends signals to the ECM. The ECM determines the vehicle speed based on these signals.
Page 6192
Instrument Panel
Connector Location
IA1 Engine Room Main and Cowl Wire (Left Kick Panel)
IA2 Engine Room Main and Cowl Wire (Left Kick Panel)
IA3 Engine Room Main and Cowl Wire (Left Kick Panel)
IA4 Engine Room Main and Cowl Wire (Left Kick Panel)
IB1 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IB2 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IB3 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IC1 Cowl Wire and Roof Wire (Left Side of Instrument Panel)
Instrument Panel
Connector Location
ID1 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH)
ID2 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH)
IE1 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IE2 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IE3 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IF1 Front Door RH Wire and Cowl Wire (Right Kick Panel)
IF2 Front Door RH Wire and Cowl Wire (Right Kick Panel)
IF3 Front Door RH Wire and Cowl Wire (Right Kick Panel)
Service and Repair
Parking Pawl: Service and Repair
ON-VEHICLE REPAIR
1. REMOVE VALVE BODY
2. REMOVE PARKING LOCK PAWL BRACKET
Remove the 3 bolts and parking lock pawl bracket.
3. REMOVE SPRING FROM PARKING LOCK PAWL SHAFT
4. REMOVE PARKING LOCK PAWL AND SHAFT 5. INSTALL PARKING LOCK PAWL AND
SHAFT
6. INSTALL SPRING TO PARKING LOCK PAWL SHAFT
A/C - Insufficient Cabin Cooling
Heater Control Valve: All Technical Service Bulletins A/C - Insufficient Cabin Cooling
HEATING & AIR CONDITIONING AC004-04
May 20, 2004
Title: POOR PERFORMANCE OF A/C SYSTEM
Models: '01 - '04 Sequoia & '00 - '04 Tundra
May 20, 2004
Introduction Some Sequoia and Tundra vehicles may exhibit a condition where the air conditioning
system does not sufficiently cool the cabin. Adjustment of the water control valve is necessary to
correct the condition.
Applicable ^
2001 - 2004 model year Sequoia vehicles produced BEFORE the Production Vehicles Change
Effective VINs shown below.
^ 2000 - 2004 model year Tundra vehicles produced BEFORE the Production Change Effective
VINs shown below.
Production Change Information
Warranty Information
Applicable Warranty*:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36
months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Repair Procedure
Page 6237
ABS Light: Testing and Inspection
CIRCUIT DESCRIPTION
If the ECU detects a trouble, the ABS warning light comes on while the ABS control is prohibited
and at the same time, the ECU records a DTC in memory.
After removing the short pin of the DLC3, connect terminals Tc and CG of the DLC3 to make the
ABS warning light blink and to output the DTC.
Wiring Diagram
Page 1440
3. TEMPORARILY INSTALL TIMING BELT
NOTICE: The engine should be cold.
a. Remove any oil or water on the crankshaft pulley, oil pump pulley, water pump pulley, No.1 idler
pulley and No.2 idler pulley, and keep them
clean.
NOTICE: Only wipe the pulleys; do not use any cleansing agent.
b. Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley.
c. Install the timing belt on the crankshaft timing pulley, No.1 idler pulley and No.2 idler pulley.
4. INSTALL TIMING BELT COVER SPACER
a. Install the gasket to the cover spacer. b. Install the cover spacer.
5. INSTALL TIMING BELT GUIDE
Install the belt guide, facing the cup side outward.
6. INSTALL NO.1TIMING BELT COVER
Install the timing belt cover with the 4 bolts.
7. INSTALL CRANKSHAFT PULLEY
a. Align the pulley set key with the key groove of the crankshaft pulley. b. Using SST and a
hammer, tap in the crankshaft pulley.
SST 09223-46011
8. INSTALL DRIVE BELT TENSIONER
Install the belt tensioner with the bolt and 2 nuts. Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.)
HINT: Use a bolt 106 mm (4.18 inch) in length.
9. INSTALL GENERATOR
Page 5548
Owner Instructions
Failure to follow the recommendations indicated below could result in reduced effectiveness of the
seat belt restraint system in case of vehicle collision, causing personal injury.
The Seat Belt Extender must not be used:
a. By anyone other than for whom it was provided (name recorded on seat belt extender).
b. In any vehicle and/or seat position other than the one for which it was provided.
c. When the Seat Belt Extender is provided for rear seat positions (with automatic locking
retractor), make sure the retractor is locked when in use.
If your seat belt cannot be fastened securely because it is not long enough, a personalized Seat
Belt Extender is available from your Toyota dealer free of charge.
Please contact your local Toyota dealer so that the dealer can order the proper required length for
the extender. Bring the heaviest coat you expect to wear for proper measurement and selection of
length. Additional ordering information is available at your Toyota dealer.
CAUTION:
When using the Seat Belt Extender, observe the following. Failure to follow these instructions could
result in reduced effectiveness of the seat belt restraint system in case of vehicle accident,
increasing the chance of personal injury.
^ Never use the Seat Belt Extender if you can COMFORTABLY fasten the seat belt without it.
^ The Seat Belt Extender must never be used with any child safety seats.
^ Remember that the extender provided for you may not be safe when used on a; different vehicle,
or for another person or at a different seating position than the one originally intended for.
To connect the extender to the seat belt, insert the tab into the seat belt buckle so that the
"PRESS" signs on the buckle-release buttons of the extender
Page 6500
Audible Warning Device Control Module: Testing and Inspection
LIGHT AUTO TURN OFF
HEAD RELAY
2 - 1 : Closed with the light control SW at HEAD position or the dimmer SW at FLASH position.
Closed with the engine running and the parking brake lever released (w/ daytime running light)
C15 LIGHT CONTROL SW [COMB. SW]
13 - 16 : Closed with light control SW at HEAD position
14 - 16 : Closed with light control SW at TAIL or HEAD position
D16 DOOR COURTESY SW FRONT LH
1 - GROUND : Continuity with the front LH door open
INTEGRATION RELAY
9 - GROUND : Approx. 12 volts with the ignition SW at ON position
14 - GROUND : Continuity with the front LH door open
3, 6 - GROUND : Always approx. 12 volts
8 - GROUND : Always continuity
POWER WINDOW
D16, D17 DOOR COURTESY SW LH, RH
1 - GROUND : Continuity with door open
INTEGRATION RELAY
9 - GROUND : Approx. 12 volts with ignition SW at ON position
3 - GROUND : Always approx. 12 volts
14 - GROUND : Continuity with front LH door open (Standard cab)
14 - GROUND : Continuity with each LH door open (Access cab)
15 - GROUND : Continuity with front RH door open (Standard cab)
15 - GROUND : Continuity with each RH door open (Access cab)
P9 POWER WINDOW CONTROL SW RH
4 - GROUND : Approx. 12 volts with ignition SW on and stays at 12 volts for 41.5 - 44.5 seconds
after the ignition SW is turned off, but if a door is
open in the 45 seconds period, voltage will drop to 0 volts
P10 POWER WINDOW MASTER SW 1 - GROUND : Always continuity 9 - GROUND : Approx. 12
volts with ignition SW on and stays at 12 volts for 41.5 - 44.5 seconds after the ignition SW is
turned off, but if a door is
opened in this 41.5 - 44.5 seconds period, voltage will drop to 0 volts
3 - GROUND : Approx. 12 volts with ignition SW at ON position and master SW at UP position 4 GROUND : Approx. 12 volts with ignition SW at ON position and master SW at DOWN or AUTO
DOWN position
WINDOW LOCK SW
Open with window lock SW at LOCK position
DOOR LOCK CONTROL
INTEGRATION RELAY
8 - GROUND : Always continuity
3 - GROUND : Always approx. 12 volts
Page 5111
Page 1973
Page 5052
FOR
SPECIAL SERVICE CAMPAIGN
REAR FRAME CROSS MEMBER &
LOAD SENSING PROPORTIONING & BY-PASS VALVE INSPECTION
2000-2003 MODEL YEAR TUNDRA
Lower
Control Arm: Service and Repair Lower
REMOVAL
1. REMOVE RH AND LH FRONT WHEELS
Locations
Engine Room R/B
Page 1726
Page 4792
Driver Side J/B And Integration Relay Inner Circuit
Page 3369
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 665
Wiring Harness Connector
E: Indicates the wiring harness and wiring harness connector. The wiring harness with male
terminal is shown with arrows.
Outside numerals are pin numbers.
The first letter of the code for each wiring harness and wiring harness connector(s) indicates the
component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and
Surrounding area, and "B" for the Body and Surrounding area.
When more than one code has the first and second letters in common, followed by numbers (e.g,
IH1, IH2), this indicates the same type of wiring harness and wiring harness connector.
F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in
parts position.
G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside
it). Junction Blocks are shaded to clearly separate
them from other parts.
H: When 2 parts both use one connector in common, the parts connector name used in wire
routing is shown in square brackets [ ].
Wiring Color
I: Indicates the wiring color.
Wire colors are indicated by an alphabetical code.
B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR =
Brown SB = Sky Blue LG = Light Green GR = Gray
The first letter indicates the basic wire color and the second letter indicates the color of the stripe.
Engine Controls - O2 Sensor Monitor Threshold Values
Oxygen Sensor: All Technical Service Bulletins Engine Controls - O2 Sensor Monitor Threshold
Values
SPECIAL SERVICE TOOLS SS002-03
December 17, 2003
Title O2S TEST RESULTS (MODE 05)
Models All '96 - '03, '04 Corolla, ECHO, Matrix, Sienna & Scion xA & xB
Introduction
This Service Bulletin contains Oxygen Sensor (O2S) Monitor threshold values for all models from
1996 to 2003 and some 2004 models. Starting in 2004, the O2S Monitor threshold values can be
found in the repair manual. These values are used when analyzing the O2S test results to
determine the O2S condition.
Applicable Vehicles ^
All 1996 - 2003 model year Toyota vehicles.
^ 2004 model year Corolla, ECHO, Matrix and Sienna vehicles.
^ 2004 model year Scion xA and xB vehicles.
Function Description
Checking O2S Test Results
To view O2S test results, the O2S Monitor must be completed and the test results must be
checked within the same key cycle. If the ignition key is cycled OFF, the O2S test results will be set
to the minimum or maximum limits, and all test results will be erased. The O2S test results are
stored in the ECU (SAE term: Powertrain Control Module/PCM) when the monitor is completed.
The test results are static and will not change once the monitor is complete.
The process for checking 02S test results is described in the following three basic steps:
1. Completing the O2S Readiness Monitor.
2. Accessing O2S Test Results.
3. Comparing O2S Test Results to Failure Thresholds.
Required SSTs
NOTE:
Additional Diagnostic Tester Kits, Program Cards or other SSTs may be ordered by calling
SPX-OTC at 1-800-933-8335.
Warranty Information
Completing O2S Readiness Monitor
1. Clear any stored Diagnostic Trouble Codes (DTCs) using the Toyota Diagnostic Tester.
Capacity Specifications
Refrigerant Oil: Capacity Specifications
When Replacing, Add:
Receiver 20 cc
Condenser 40 cc
Evaporator 40 to 50 cc
Page 5539
Warranty Information
Procedure
1. Owner requests a Seat Belt Extender from dealer.
2. Dealer verifies the need for a Seat Belt Extender and obtains a current copy of this TSB and
copies the Worksheet.
3. Dealer measures the customer and completes the Worksheet. Dealer determines the correct
part number and places a Critical Order for the part through the TDN Parts Network or Dealer
Daily.
4. Dealer receives Seat Belt Extender and calls the customer in to check fit of the part.
5. If the Seat Belt Extender fit is good, dealership personnel completes the Customer Information
Label on the part, explains usage of the part, and gives the customer a copy of the completed
Worksheet.
6. Dealer places copy of the completed Worksheet in the customer's records.
Sample Seat Belt Extender Customer Information Label
Page 5797
Body
Connector Location (Standard Cab)
BA1 Front Door LH Wire and Speaker Tweeter Wire LH (Inside of Front Door LH)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Seat
Connector Location
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
BJ1 Seat No. 1 Wire and Seat No. 2 Wire (Under the Driver's Seat)
Locations
EFI Main Relay: Locations
Engine Room R/B
A/T - Fluid Requirements
Fluid - CVT: Technical Service Bulletins A/T - Fluid Requirements
TRANSMISSION & CLUTCH TC001-02
May 24, 2002
Title: AUTOMATIC TRANSMISSION FLUID REQUIREMENTS
Models: All '00 - '02 Models & '03 Corolla & Matrix
Introduction
Please refer to the table for correct application of Dexron(R) III (Dexron(R) II) and Toyota Type T-IV
Automatic Transmission Fluids or equivalent.
Parts Information
Warranty Information
Page 4534
Alternator: Mechanical Specifications
STD Minimum
Slip Ring Diameter 14.2 to 14.4 mm 12.8 mm
Brush Exposed Length 10.5 mm 1.5 mm
Page 903
Timing Belt: Diagrams
TIMING BELT REPLACEMENT W/ RELATED COMPONENTS
Part 1 of 4
Page 5510
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for
36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Parts Information
Repair Procedure
1. Shift the tongue plate to the upper portion of the tongue plate stopper and temporarily hold it with
a clip or tape.
2. Remove any pieces of the original tongue plate stopper in the webbing with a pair of diagonal
pliers.
NOTE
Be careful not to damage the webbing, since this may compromise the safety of this seatbelt.
CAUTION
Damaged or weakened seat belts may break in an accident and injure the occupant. The seat belt
assembly MUST be replaced if:
^ The webbing is cut, frayed, worn, or damaged.
^ It has been used during a severe impact (inspect the label to ensure no impact damage has
occurred)
Specifications
Knock Sensor: Specifications
SST 09816-30010
Torque: ................................................................................................................................................
................................. 45 N.m (450 kgf.cm, 33 ft.lbf)
Page 7017
Windshield Washer Spray Nozzle: Adjustments
FRONT WIPER AND WASHER ADJUSTMENT
ADJUST WASHER NOZZLE
Using a tool like the one shown in the illustration, change the direction of the nozzle hole to adjust
the point where washer fluid hits the windshield.
Page 60
B: Junction Connector
Indicates a connector which is connected to a short terminal.
Junction connector in this include a short terminal which is connected to a number of wire
harnesses. Always perform inspection with the short terminal installed. (When installing the wire
harnesses, the harnesses can be connected to any position within the short terminal grouping.
Accordingly, in other vehicles, the same position in the short terminal may be connected to wire
harness from a different part.) Wire harness sharing the same short terminal grouping ha the same
color.
C: Parts Code
The first letter of the code is taken from the first letter of part, and the numbers indicates its order in
parts which start with the same letter.
D: Connector Color
Connectors not indicated are milky white in color.
How to Read Ground Points
HOW TO READ GROUND POINTS
Page 3884
Step 4
O/D OFF indicator light does not light up
Steps 1 - 2
O/D OFF indicator light remains ON
Component Locations
Ignition Switch And Key Unlock Warning Switch
Page 6213
Cruise Control (Part 2)
Page 5569
B: Junction Connector
Indicates a connector which is connected to a short terminal.
Junction connector in this include a short terminal which is connected to a number of wire
harnesses. Always perform inspection with the short terminal installed. (When installing the wire
harnesses, the harnesses can be connected to any position within the short terminal grouping.
Accordingly, in other vehicles, the same position in the short terminal may be connected to wire
harness from a different part.) Wire harness sharing the same short terminal grouping ha the same
color.
C: Parts Code
The first letter of the code is taken from the first letter of part, and the numbers indicates its order in
parts which start with the same letter.
D: Connector Color
Connectors not indicated are milky white in color.
How to Read Ground Points
HOW TO READ GROUND POINTS
Page 310
INSPECT POWER SEAT SWITCH CIRCUIT
a. Disconnect the switch connector and connect the seat wire harness to the floor wire harness. b.
Inspect the connector on the wire harness side.
If circuit is not as specified, inspect the circuits connected to other parts.
INSPECT LUMBAR SUPPORT SWITCH CONTINUITY
If continuity is not as specified, replace the switch.
INSPECT LUMBAR SUPPORT SWITCH CIRCUIT
a. Disconnect the switch connector and connect the seat wire harness to the floor wire harness.
Page 4807
Relay Box: Diagnostic Aids
Voltage Check
Voltage Check
Voltage Check
A. Establish conditions in which voltage is present at the check point.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(SW 2 OFF)
B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or
component terminal. This check can be done with a test light instead of a voltmeter.
Continuity and Resistance Check
Continuity and Resistance Check
Continuity And Resistance Check
A. Disconnect the battery terminal or wire so there is no voltage between the check points. B.
Contact the two leads of an ohmmeter to each of the check points.
Page 2036
Vehicle Speed Sensor: Diagnostic Aids
Voltage Check
Voltage Check
Voltage Check
A. Establish conditions in which voltage is present at the check point.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(SW 2 OFF)
B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or
component terminal. This check can be done with a test light instead of a voltmeter.
Continuity and Resistance Check
Continuity and Resistance Check
Continuity And Resistance Check
A. Disconnect the battery terminal or wire so there is no voltage between the check points. B.
Contact the two leads of an ohmmeter to each of the check points.
Page 1709
A. Test J1962 OBDIII CAN Interface Module (P/N 01002744) for continuity.
^ If there is continuity, the cable and CAN Interface Module are OK. Re-check Cable Tests 1, 2,
and 3 while wiggling and flexing the cables.
^ If there is no continuity, proceed to CABLE TEST 4.
CABLE TEST 4.
A. Disconnect the CAN Interface Module (P/N 01002744) from the J1962 OBDII cable using a
Phillips screwdriver.
B. Test J1962 OBDII cable (P/N 02003180) for continuity.
^ If there is no continuity, the cable needs to be replaced.
^ If there is continuity, proceed to CAN Interface Module Test 5.
CAN INTERFACE MODULE TEST 5.
Page 3518
Transmission Speed Sensor: Description and Operation
Vehicle Speed Sensor NO.1
Vehicle Speed Sensor NO.1 Circuit Description
The vehicle speed sensor outputs a 4-pulse signal for every revolution of the rotor shaft, which is
rotated by the transmission output shaft via the driven gear. After this signal is converted into a
more precise rectangular waveform by the waveform shaping circuit inside the combination meter,
it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency
of these pulse signals.
Vehicle Speed Sensor NO.2
Vehicle Speed Sensor NO.2 Circuit Description
The No.2 vehicle speed sensor detects the rotation speed of the transmission output shaft and
sends signals to the ECM. The ECM determines the vehicle speed based on these signals.
Page 6991
c. Correct insufficient or protruded adhesive agent using a spatula.
HINT: Apply the adhesive agent up to the windshield glass edge.
d. Install a new windshield outside upper moulding to the windshield glass before the adhesive
agent hardens. e. Using a scraper, remove any excessive adhesive agent before it hardens. f.
Hold the glass and moulding in place securely with a protective tape or equivalent until the
adhesive hardened.
NOTE: Take care not to drive the vehicle during the time described in the table.
11. INSPECT FOR LEAKAGE AND REPAIR
NOTE: Conduct a leak test after the hardening time has elapsed.
12. INSTALL WINDSHIELD OUTSIDE MOULDING
a. Install the 4 screws and windshield outside moulding. b. Employ the same manner described
above to the other side.
13. INSTALL FRONT PART OF ROOF SIDE RAIL WEATHERSTRIP LH AND RH
Install the front part of roof side rail weatherstrip LH and RH.
14. INSTALL COWL LOUVER
Diagram Information and Instructions
Relay Box: Diagram Information and Instructions
Key to Diagrams
A: System Title
B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to
distinguish it from the J/B
Example: 1 Indicates Relay Block No.1
C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type,
or specification is different.
D: Indicates related system.
Page 4938
d. Disconnect the negative (-) lead from the body ground to terminal 1 or 10. e. Check that the
buzzer stops sounding.
If operation is not as specified, replace the combination meter.
4. INSPECT COMBINATION METER CIRCUIT
Page 6445
Malfunction Indicator Lamp: Description and Operation
Malfunction Indicator Lamp (MIL)
OBD II regulations require that the vehicle's on-board computer lights up the Malfunction Indicator
Lamp (MIL) on the instrument panel when the computer detects a malfunction in the emission
control system/components or in the powertrain control components which affect vehicle
emissions, or a malfunction in the computer. In addition to the MIL lighting up when a malfunction is
detected, the applicable Diagnostic Trouble Codes (DTCs) prescribed by SAE J2012 are recorded
in the ECM memory.
If the malfunction does not reoccur in 3 consecutive trips, the MIL goes off automatically but the
DTCs remain recorded in the ECM memory.
Page 3803
Vehicle Speed Sensor NO.2
Testing and Inspection
Receiver Dryer: Testing and Inspection
RECEIVER
ON-VEHICLE INSPECTION
INSPECT FITTINGS FOR LEAKAGE Using a gas leak detector, check for leakage. If there is
leakage, check the tightening torque at the joints.
Page 4427
1. INSTALL LSP & BV ASSEMBLY TO FRAME
Install the LSP & BV assembly and 2 valve bracket mounting bolts. Torque: 29 Nm (300 kgf-cm, 22
ft. lbs.)
2. CONNECT BRAKE LINE
Using SST, connect the 3 brake lines. Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.) SST 09751-36011
3. CONNECT SHACKLE NO. 2 BRACKET
(a) Set dimension A and torque the lock nut.
Initial set: 120 mm (4.72 inch) Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)
(b) Install the shackle bracket and 2 bolts.
Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.)
(c) Connect the 2 bushings, collar and shackle No. 2 to the shackle bracket.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)
(d) Install the cushion retainer and nut.
4. SET REAR AXLE LOAD
5. SET VALVE BODY
(a) When pulling down the load sensing spring, check that the valve piston moves down smoothly.
(b) Position the valve body so that the valve piston lightly contacts with the load sensing spring. (c)
Tighten the 2 valve body mounting nuts.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)
Capacity Specifications
Engine Oil: Capacity Specifications
Engine Oil
With filter ..............................................................................................................................................
.......................................................... 6.4 Qts.(6.1L) Without filter .......................................................
............................................................................................................................................ 6.0
Qts.(5.7L)
Service and Repair
Output Shaft: Service and Repair
For further information regarding this component and the system that it is a part of, please refer to
Transfer Case; Service and Repair.
Page 6887
Light Auto Turn Off
Page 3224
Instrument Panel
Connector Location
IA1 Engine Room Main and Cowl Wire (Left Kick Panel)
IA2 Engine Room Main and Cowl Wire (Left Kick Panel)
IA3 Engine Room Main and Cowl Wire (Left Kick Panel)
IA4 Engine Room Main and Cowl Wire (Left Kick Panel)
IB1 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IB2 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IB3 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IC1 Cowl Wire and Roof Wire (Left Side of Instrument Panel)
Instrument Panel
Connector Location
ID1 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH)
ID2 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH)
IE1 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IE2 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IE3 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IF1 Front Door RH Wire and Cowl Wire (Right Kick Panel)
IF2 Front Door RH Wire and Cowl Wire (Right Kick Panel)
IF3 Front Door RH Wire and Cowl Wire (Right Kick Panel)
Page 5222
Compressor Clutch: Service and Repair Disassembly and Reassembly
COMPRESSOR AND MAGNETIC CLUTCH
DISASSEMBLY
1. REMOVE PRESSURE PLATE
a. Using SST and a socket wrench, remove the shaft bolt.
SST 07112-76060
Torque: 13.2 N.m (135 kgf.cm, 9 ft.lbf)
b. Install SST on the pressure palate.
SST 07112-66040
c. Using SST and socket wrench, remove the pressure plate.
SST 07112-66040, 07112-76060,
Page 6307
Cigarette Lighter: Harness Locations
Engine Compartment
Connector Location
EA1 Cowl Wire Harness and Wire Harness (Connector Location)
EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B)
EC1 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC2 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC3 Engine No. 2 Wire and Engine Wire (Near the Starter)
ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission)
Page 5239
1. INSPECT ILLUMINATION OPERATION
Connect the positive (+) lead from the battery to terminal B7 and negative (-) lead to terminal AB
then check that the illuminations lights up. If operation is not as specified, check the faulty bulb.
2. INSPECT BULB
Apply the tester as shown in the illustration to the test for continuity.
If continuity exists, replace the heater control. If no continuity exists, replace the bulb.
Page 6254
Instrument Panel
Connector Location
IA1 Engine Room Main and Cowl Wire (Left Kick Panel)
IA2 Engine Room Main and Cowl Wire (Left Kick Panel)
IA3 Engine Room Main and Cowl Wire (Left Kick Panel)
IA4 Engine Room Main and Cowl Wire (Left Kick Panel)
IB1 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IB2 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IB3 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IC1 Cowl Wire and Roof Wire (Left Side of Instrument Panel)
Instrument Panel
Connector Location
ID1 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH)
ID2 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH)
IE1 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IE2 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IE3 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IF1 Front Door RH Wire and Cowl Wire (Right Kick Panel)
IF2 Front Door RH Wire and Cowl Wire (Right Kick Panel)
IF3 Front Door RH Wire and Cowl Wire (Right Kick Panel)
Engine - Accessory Drive Belt Squealing Noise
Drive Belt Tensioner: Customer Interest Engine - Accessory Drive Belt Squealing Noise
ENGINE EG026-06 REVISED
Title: 2UZ-FE ACCESSORY DRIVE BELT NOISE
Models: '00 - '06 Tundra
April 21, 2006
TSB REVISION NOTICE:
^ July 9, 2007: The Introduction has been updated. Production Change Effective VINs have been
updated in the Production Change Information table. In the Repair Procedure steps 12 and 13 and
the illustration below step 13 have been updated, and steps 14 - 17 have been renumbered.
Previous versions of this TSB should be discarded.
Introduction
Some customers may experience an abnormal squeal noise from the engine accessory drive belt
area, usually during cold start-up. An improved accessory drive belt tensioner, A/C compressor
bracket, and revised installation procedure have been developed to address this condition.
Applicable Vehicles
^ 2000 - 2006 model year Tundra vehicles produced BEFORE the Production Change Effective
VINs shown below.
Production Change Information
Parts Information
Warranty Information
Applicable Warranty* This repair is covered under the Toyota Comprehensive Warranty. This
warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's
in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Repair Procedure
Page 4155
6. INSTALL NEW PADS
NOTICE: When replacing worn pads, the anti-squeal shims must be replaced together with the
pads.
(a) Draw out a small amount of brake fluid from the reservoir. (b) Press in the pistons with a
monkey wrench handle or equivalent.
HINT: Tape the monkey wrench handle before use.
- Always change the pad on one wheel at a time as there is a possibility of the opposite piston
flying out.
- If the piston is difficult to push in, loosen the bleeder plug and push in the piston while letting
some brake fluid escape.
(c) Install the anti-squeal shims to new pads.
HINT: Apply disc brake grease to both sides of inner anti-squeal shims.
(d) Install new pads.
NOTICE: Do not allow oil or grease to get on the rubbing face.
7. INSTALL ANTI-RATTLE SPRING AND 2 PINS 8. INSTALL CLIP 9. INSTALL FRONT WHEEL
Torque: 113 Nm (1,150 kgf-cm, 83 ft. lbs.)
10. DEPRESS BRAKE PEDAL SEVERAL TIMES 11. CHECK THAT FLUID LEVEL IS AT MAX
LINE
Page 4627
Wiring Harness Connector
E: Indicates the wiring harness and wiring harness connector. The wiring harness with male
terminal is shown with arrows.
Outside numerals are pin numbers.
The first letter of the code for each wiring harness and wiring harness connector(s) indicates the
component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and
Surrounding area, and "B" for the Body and Surrounding area.
When more than one code has the first and second letters in common, followed by numbers (e.g,
IH1, IH2), this indicates the same type of wiring harness and wiring harness connector.
F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in
parts position.
G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside
it). Junction Blocks are shaded to clearly separate
them from other parts.
H: When 2 parts both use one connector in common, the parts connector name used in wire
routing is shown in square brackets [ ].
Wiring Color
I: Indicates the wiring color.
Wire colors are indicated by an alphabetical code.
B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR =
Brown SB = Sky Blue LG = Light Green GR = Gray
The first letter indicates the basic wire color and the second letter indicates the color of the stripe.
Diagram Information and Instructions
Transmission Mode Indicator - A/T: Diagram Information and Instructions
Key to Diagrams
A: System Title
B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to
distinguish it from the J/B
Example: 1 Indicates Relay Block No.1
C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type,
or specification is different.
D: Indicates related system.
Page 4402
Brake Fluid: Testing and Inspection
Check for fluid leakage from actuator or hydraulic lines.
Specifications
Three-Way Catalytic Converter (TWC) System
Page 4303
Torque: 50 N.m (510 kgf.cm, 37 ft.lbf)
25. Install shock absorber with coil spring.
A. Install the upper side of shock absorber to the chassis frame with the 3 nuts.
Torque: 64 N.m (650 kgf.cm, 47 ft.lbf)
B. Connect the lower side of shock absorber to the lower suspension arm with bolt, washer, and
nut.
Torque: 135 N.m (1,400 kgf.cm, 100 ft.lbf)
26. Inspect and install the brake rotor and install the brake caliper with new mounting bolts.
A. Inspect the brake rotors and machine using an on-the-car brake lathe. Replace the rotor if it is
below minimum thickness values
Minimum Thickness: 26.0 mm (1.024 in.)
NOTE:
It is necessary to turn the rotors using the on-the-car brake lathe to ensure even and uniform rotor
run out. DO NOT turn the rotor using an off-the-car brake lathe.
B. Install the disc, brake caliper, and 2 NEW bolts.
Torque: 123 N.m (1,259 kgf.cm, 90 ft.lbf)
C. Install the brake line clamp to the steering knuckle with the bolt.
Torque: 28 N.m (285 kgf.cm, 21 ft.lbf)
27. Install new brake line.
Using the SST, connect NEW brake line.
SST P/N: 09023-00100
Torque: 15 N.m (155 kgf.cm, 11 ft.lbf)
28. With ABS:
Connect the ABS speed sensor and wire harness clamp to the steering knuckle with the 2 bolts.
Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
29. 4WD:
Install drive shaft lock nut.
A. While applying the brakes, tighten the nut.
Torque: 235 N.m (2,400 kgf.cm, 173 ft.lbf)
B. Install the lock cap and a NEW cotter pin. If the holes for the cotter pin are not aligned, tighten
the nut further up to 600.
30. 2WD:
Install grease cap.
31. Install front wheel.
NOTE:
Do NOT use an air wrench.
Torque: 110 N.m (1,150 kgf.cm, 83 ft.lbf)
Page 6563
Terminal Retainer
Push the terminal retainer down to the temporary lock position.
c. Release the locking lug from terminal and pull the terminal out from rear.
4. INSTALL TERMINAL TO CONNECTOR
a. Insert the terminal.
HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug
locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position.
Page 4929
Non-Waterproof Type Connector
"Case 1" Raise the terminal retainer up to the temporary lock position.
Non-Waterproof Type Connector
"Case 2" Open the secondary locking device.
Page 6872
Wiring Harness Connector
E: Indicates the wiring harness and wiring harness connector. The wiring harness with male
terminal is shown with arrows.
Outside numerals are pin numbers.
The first letter of the code for each wiring harness and wiring harness connector(s) indicates the
component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and
Surrounding area, and "B" for the Body and Surrounding area.
When more than one code has the first and second letters in common, followed by numbers (e.g,
IH1, IH2), this indicates the same type of wiring harness and wiring harness connector.
F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in
parts position.
G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside
it). Junction Blocks are shaded to clearly separate
them from other parts.
H: When 2 parts both use one connector in common, the parts connector name used in wire
routing is shown in square brackets [ ].
Wiring Color
I: Indicates the wiring color.
Wire colors are indicated by an alphabetical code.
B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR =
Brown SB = Sky Blue LG = Light Green GR = Gray
The first letter indicates the basic wire color and the second letter indicates the color of the stripe.
Page 5660
Impact Sensor: Service and Repair Removal and Installation
Front Airbag Sensor
REMOVAL
NOTE:
- If the wiring connector of the SRS is disconnected with the ignition switch at ON or ACC position,
DTCs will be recorded.
- Never use SRS parts from another vehicle. When replacing parts, replace them with new parts.
- Never reuse the sensor involved in a collision when the SRS has deployed.
- Never repair a sensor in order to reuse it.
Page 6876
The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit
breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery
power is supplied to each system are explained. Since all System Circuit diagrams start from the
power source, the power source system must be fully understood.
Page 3339
L. The calibration file will now be downloaded to the Diagnostic Tester Program Card. This process
takes approximately 2-6 minutes (see Figure 15).
M. The CUW will prompt when the calibration file is completely downloaded. Click OK to close the
CUW (Figure 16).
NOTE:
With the calibration file loaded on the Diagnostic Tester Program Card, it is not necessary to repeat
the above steps to reprogram a different vehicle needing the same calibration file. The steps above
are only required when a new calibration file must be loaded onto the Diagnostic Tester Program
Card.
The Diagnostic Tester now has the calibration file stored and you may proceed to the next step to
reprogram the vehicle ECU.
REPROGRAM ECU WITH TESTER
3. Reprogram the vehicle ECU with the Diagnostic Tester.
NOTICE:
Errors during the flash reprogramming process can permanently damage the vehicle ECU.
Minimize the risks by following the steps below.
^ Battery voltage MUST NOT FALL BELOW 11.4 volts during reprogramming.
^ Confirm battery voltage is higher than 11.4 volts, but be sure voltage DOES NOT RISE ABOVE
16.0 volts during reprogramming.
^ Turn off all electrical accessories (e.g. Audio system, A/C, interior lights, DRL, etc.).
^ Do not add to or significantly change the vehicle's electrical load while reprogramming.
^ Confirm the hood is open and ensure under hood temperatures do not exceed 158°F.
Page 5606
Glossary Of Terms And Symbols (Part 2)
Page 3322
During ECU flash reprogramming, the Error screen shown may be displayed on the Diagnostic
Tester for one of the following reasons:
1. Immobilizer key not properly registered or auto-registration mode left open.
2. Ignition ON/OFF cycling not followed correctly during the flash reprogramming procedure.
3. The Diagnostic Tester cable is damaged, causing an open communication circuit.
NOTE:
The Diagnostic Tester may operate properly in other modes such as OBD, OBDII, or CARB, with a
damaged cable.
To eliminate the possibility of the first 2 reasons causing the error message, do the following:
1. Confirm the Immobilizer Transponder Master Key is properly registered and auto registration
mode is closed. Follow the appropriate Repair Manual procedure and consult TSB SS001-99,
"Scan tool Immobilizer key Code Utility
2. Conduct the ECU flash reprogramming process explicitly following key operation instructions.
Refer to TSB SS002-01, "ECU Flash Reprogramming Process, "for more details.
To determine if the Diagnostic Tester cable is damaged, follow the test procedures below to check
the electrical integrity of the cable. Conduct all continuity tests with an Ohm meter. For all five test
procedures, the resistance values must be below 6.0 ohms to pass.
Test CABLE TEST 1.
Page 2033
The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit
breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery
power is supplied to each system are explained. Since all System Circuit diagrams start from the
power source, the power source system must be fully understood.
Page 493
Crankshaft Position Sensor
Component Tests and General Diagnostics
Engine Control Module: Component Tests and General Diagnostics
Terminals Of ECM - Connector View
Terminals Of ECU - Connector Pinouts (Part 1)
Page 1572
w/o Tachometer
HINT: Connect the test leads so that the current from the ohmmeter can flow according to the
above order. This circuit includes the diode.
If resistance value is not as specified, replace the receiver gauge.
Page 6342
Body
Connector Location (Standard Cab)
BA1 Front Door LH Wire and Speaker Tweeter Wire LH (Inside of Front Door LH)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Seat
Connector Location
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
BJ1 Seat No. 1 Wire and Seat No. 2 Wire (Under the Driver's Seat)
Page 5031
2. CONNECT LOWER BALL JOINT TO LOWER SUSPENSION ARM
Connect the lower ball joint and install the nut and a new cotter pin. Torque: 140 Nm (1,450 kgf-cm,
103 ft. lbs.) If the holes for the cotter pin are not aligned, tighten thee nut further up to 60°.
3. CONNECT SHOCK ABSORBER TO LOWER SUSPENSION ARM
Torque: 135 Nm (1,400 kgf-cm, 100 ft. lbs.)
4. CONNECT STABILIZER BAR LINK TO LOWER SUSPENSION ARM
Torque: 69 Nm (700 kgf-cm, 51 ft. lbs.)
HINT: If the ball joint turns together with the nut, use a hexagon (6 mm) wrench to hold the stud.
5. INSTALL POWER STEERING GEAR
Torque:
A bolt: 165 Nm (1,700 kgf-cm, 122 ft. lbs.) B bolt: 130 Nm (1,350 kgf-cm, 96 ft. lbs.) Bolt and nut:
265 Nm (1,700 kgf-cm, 122 ft. lbs.)
6. CONNECT RH AND LH TIE ROD ENDS
Connect the RH and LH tie rod ends to the lower ball joints with the nuts and new cotter pins.
Torque: 91 Nm (930 kgf-cm, 67 ft. lbs.) If the holes for the cotter pin are not aligned, tighten the nut
further up to 60°.
7. INSTALL RH AND LH FRONT WHEELS
Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.)
8. CHECK FRONT WHEEL ALIGNMENT
Page 4553
b. Place the voltage regulator and brush holder on the rectifier end frame.
NOTE: Be careful of the brush holder installation direction.
c. Install the 5 screws.
Torque: 1.96 N.m (20 kgf.cm, 17 in.lbf)
d. Place the brush holder cover on the brush holder.
7. INSTALL REAR END COVER
a. Install the end cover and plate terminal with the bolt and 3 nuts.
Torque: Bolt: 3.85 N.m (39 kgf.cm, 34 in.lbf) Nut: 4.4 N.m (46 kgf.cm, 39 in.lbf)
Page 1723
J. The top half of the CUW screen displays the calibrations currently stored on the Diagnostic
Tester Program Card. The bottom half of the screen displays the new calibration to be loaded onto
the Diagnostic Tester Program Card (see Figure 13). Click NEXT to continue the process.
K. Confirm the calibration file to be sent to the Diagnostic Tester Program Card (Figure 14). Click
SEND.
Page 891
Compression Check: Testing and Inspection
INSPECTION
HINT: If there is lack of power, excessive oil consumption or poor fuel economy, measure the
compression pressure.
1. WARM UP AND STOP ENGINE
Allow the engine to warm up to normal operating temperature.
2. REMOVE SPARK PLUGS
3. CHECK CYLINDER COMPRESSION PRESSURE
a. Insert a compression gauge into the spark plug hole. b. Fully open the throttle. c. While cranking
the engine, measure the compression pressure.
HINT: Always use a fully charged battery to obtain engine speed of 250 rpm or more.
d. Repeat steps (a) through (c) for each cylinder.
NOTICE: This measurement must be done in as short a time as possible.
Compression pressure: 1,324 kPa (13.5 kgf/cm2, 192 psi) or more Minimum pressure: 981 kPa
(10.0 kgf/cm2, 142 psi) Difference between each cylinder: 98 kPa (1.0 kgf/cm2, 14 psi) or less
e. If the cylinder compression in one or more cylinders is low, pour small amount of engine oil into
the cylinder through the spark plug hole and
repeat steps (a) through (c) for cylinders with low compression. If adding oil helps the compression, chances are that the piston rings and/or cylinder bore are worn
or damaged.
- If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage
past the gasket.
4. REINSTALL SPARK PLUGS
Page 2953
Fuel Pressure: Specifications Volume Specification
Information not supplied by the manufacturer.
Page 2707
Knock Sensor: Service and Repair
1. REMOVE THROTTLE BODY COVER
2. REMOVE INTAKE AIR CONNECTOR
3. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS
4. REMOVE UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY
5. INSPECT KNOCK SENSOR 1,2
Disconnect the knock sensor connectors.
1. REPLACE THE SENSOR WITH SST.
SST 09816-30010
Torque: 45 N.m (450 kgf.cm, 33 ft.lbf)
Reconnect the knock sensor connectors.
2. REINSTALL UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY
3. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS
4. REINSTALL INTAKE AIR CONNECTOR
5. REINSTALL THROTTLE BODY COVER
Component Locations
Wire Harness And Connector
Page 2407
Required Tools & Material
NOTE:
Additional Diagnostic Tester Kits, Program Cards or SSTs may be ordered by calling SPX-OTC at
1-800-933-8335.
Repair Procedure
Using the chart, refer to the Diagnostic Section (DI-###) in the appropriate Repair Manual and
follow the diagnostic procedure for the specific DTC.
Page 5697
Application Chart
Page 988
Coolant: Testing and Inspection
INSPECTION
HINT: Check the coolant level when the engine is cold.
1. CHECK ENGINE COOLANT LEVEL AT RADIATOR RESERVOIR
The engine coolant level should be between the "LOW" and "FULL" lines at normal temperature
(20°C (68°F)). If low, check for leaks and add "TOYOTA Long Life Coolant" or equivalent up to the
"FULL" line.
2. CHECK ENGINE COOLANT QUALITY
a. Remove the radiator cap.
CAUTION: To avoid the danger of being burned, do not remove the radiator cap while the engine
and radiator are still hot, as fluid and steam can be blown out under pressure.
b. There should not be any excessive deposits of rust or scale around the radiator cap or radiator
hole, and the coolant should be free from oil.
If excessively dirty, clean the coolant passages and replace the coolant.
c. Reinstall the radiator cap.
Page 2716
Required Tools & Material
NOTE:
Additional Diagnostic Tester Kits, Program Cards or SSTs may be ordered by calling SPX-OTC at
1-800-933-8335.
Repair Procedure
Using the chart, refer to the Diagnostic Section (DI-###) in the appropriate Repair Manual and
follow the diagnostic procedure for the specific DTC.
Page 6528
Non-Waterproof Type Connector
"Case 1" Raise the terminal retainer up to the temporary lock position.
Non-Waterproof Type Connector
"Case 2" Open the secondary locking device.
Page 4364
^ 09023-00100
6. REMOVE BRAKE CALIPER AND DISC
A. Remove the bolt and brake line clamp from the steering knuckle.
B. Remove the 2 bolts, brake caliper and disc.
7. REMOVE SHOCK ABSORBER
A. Disconnect Shock Absorber from lower suspension arm.
B. Remove the shock absorber lower side set nut and washer.
NOTE:
Do not remove the bolt.
C. Wrap the bolt's head with vinyl tape to prevent the drive shaft boot from being damaged.
D. Pry down the lower suspension arm to remove the bolt and disconnect the shock absorber.
E. Remove the 3 nuts and shock absorber with the coil spring.
NOTE:
Do not damage the brake tube.
Page 3911
Non-Waterproof Type Connector
"Case 1" Raise the terminal retainer up to the temporary lock position.
Non-Waterproof Type Connector
"Case 2" Open the secondary locking device.
Page 794
Transmission Position Switch/Sensor: Service and Repair
ON-VEHICLE REPAIR
1. DISCONNECT OIL COOLER PIPE 2. REMOVE PARK/NEUTRAL POSITION SWITCH
a. Disconnect the connector. b. Pry off the lock washer and remove the nut. c. Remove the bolt and
park/neutral position switch.
3. INSTALL PARK/NEUTRAL POSITION SWITCH
a. Install the park/neutral position switch and bolt.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)
b. Install a new lock plate and the nut.
Torque: 3.9 Nm (40 kgf-cm, 35 inch lbs.)
c. Bend claws on the lock plate to fix the nut. d. Connect the connector. e. Check that the engine
can be started with the shift lever only in the N or P position, but not in other positions. If not as
stated, carry out the
adjustment procedure. See: Transmission and Drivetrain/Automatic
Transmission/Transaxle/Testing and Inspection/Initial Inspection and Diagnostic Overview
4. CONNECT OIL COOLER PIPE 5. FILL ATF AND CHECK FLUID LEVEL 6. TEST DRIVE
VEHICLE
Page 4545
1. REMOVE GENERATOR DRIVE BELT
Loosen the belt tension by turning the belt tensioner counter-clockwise, and remove the drive belt.
HINT: The pulley bolt for the belt tensioner has a left-hand thread.
2. REMOVE PS VANE PUMP FROM ENGINE
3. REMOVE ENGINE UNDER COVER
4. REMOVE NO.2 FAN SHROUD
Remove the 2 clips and No.2 fan shroud.
5. REMOVE GENERATOR
a. Disconnect the generator connector. b. Remove the cap and nut, and disconnect the generator
wire. c. Disconnect the generator wire clamp from the cord clip on the generator. d. Remove the
bolt, nut and generator.
INSTALLATION
1. INSTALL GENERATOR
a. Install the generator with the bolt and nut.
Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)
b. Connect the generator connector. c. Connect the generator wire with the nut and rubber. d.
Install the cap. e. Install the generator wire clamp to the cord clip on the generator.
Page 3336
F. Confirm the Diagnostic Tester software version and connections to the TIS workstation are
correct.
* NOTE:
This screen displays the required version of Diagnostic Tester software that is compatible with the
selected calibration file, and the other required steps to properly connect the Diagnostic Tester to
your PC.
^ Type I calibration files are only compatible with software version 10.1a and older versions.
^ Type II calibration files are only compatible with software version 10.2a and newer versions.
G. Place the Diagnostic Tester in the "GET CAL FROM PC" mode to receive the calibration file
(Figure 10).
Click NEXT on the TIS workstation. Once communications begin between the PC and the
Diagnostic Tester, the Diagnostic Tester display will flash CONNECTED.
H. The CUW determines if there is enough memory to store the calibration file on the Diagnostic
Tester Program Card. If there is insufficient
Page 72
Lamp Control Module: Electrical Diagrams
Service Hints
LIGHT AUTO TURN OFF
HEAD RELAY
2 - 1 : Closed with the light control SW at HEAD position or the dimmer SW at FLASH position.
Closed with the engine running and the parking brake lever released (w/ daytime running light)
C15 LIGHT CONTROL SW [COMB. SW]
13 - 16 : Closed with light control SW at HEAD position
14 - 16 : Closed with light control SW at TAIL or HEAD position
D16 DOOR COURTESY SW FRONT LH
1 - GROUND : Continuity with the front LH door open
INTEGRATION RELAY
9 - GROUND : Approx. 12 volts with the ignition SW at ON position
14 - GROUND : Continuity with the front LH door open
3, 6 - GROUND : Always approx. 12 volts
8 - GROUND : Always continuity
ILLUMINATION
C15 LIGHT CONTROL SW [COMB. SW]
14 - 16 : Closed with light control SW at TAIL or HEAD position
Electrical Specifications
Page 6306
Splice Location
B11
Page 5069
Page 5012
Ball Joint: Specifications
Upper Ball Joint Turning Torque 0.7-4.4 Nm (6.0-39.0 in.lb)
Page 3386
^ Confirm cable connections between the vehicle and Diagnostic Tester are secure. (Reference
TSB No. SS004-01, "ECU Flash Reprogramming Error Message.")
^ Do not disconnect or turn off the Diagnostic Tester or the vehicle ignition during reprogramming.
^ Set the parking brake.
^ Complete ALL flash calibration updates provided for each ECU.
If the battery's state of charge or capacity are in question, test with SST No. 00002-MP815-T,
"Midtronics Battery Tester," and follow TSB No. PG017-02, "Battery Maintenance for In-Stock
Vehicles & Pre-Delivery."
To ensure stable battery voltage, a battery charger may be connected during reprogramming if:
^ Voltage does not fall below 11.4 volts.
^ Voltage does not rise above 16.0 volts.
^ Setting is on SLOW charge and not BOOST.
A. Connect the Diagnostic Tester to the vehicle and select CURRENT ECU CAL from the ECU
REPROGRAM MAIN MENU. Determine the vehicle's current ECU calibration. (See Figure 17.)
NOTE:
The vehicle may contain up to 3 separate calibration ID numbers. In the example shown, the
vehicle ECU contains only 2 calibration IDs.
Locations
Relay Box: Locations
Driver Side J/B And Integration Relay
Page 1907
A. The Diagnostic Tester displays 17" as a value of the Time $81" (see illustration).
B. Find the Conversion Factor value of Time $81" in the O2S Failure Threshold chart. 0.3906 is
specified for Time $81 in this chart.
C. Multiply "17" in step "A" by 0.3906 (Conversion Factor) in step "B."
17 x 0.3906 = 6.6%
D. If the answer is within the Standard Value of TEST LIMIT, the Time $81" can be confirmed to be
normal.
NOTE:
^ "LOW SW V" indicates the O2S voltage when the O2S status changes from rich to lean.
^ "HIGH SW V" indicates the O2S voltage when the O2S status changes from lean to rich.
^ If the O2S voltage is lower than "LOW SW V," the O2S status is lean.
^ If the O2S voltage is higher than "HIGH SW V," the O2S status is rich.
NOTE:
Before the O2S Monitor completes or after the ignition switch is turned OFF, the Diagnostic Tester
displays the viewable upper limit or a lower limit of the test value (example: 0 V, 1.275 V, Os
[seconds], 10.2s, 0 and 255).
Page 2171
Camshaft Position Sensor
Page 3189
Knock Sensor: Locations
Knock Sensor (Part 1)
Page 5713
BJ Inside of Rear Door LH
BK Inside of Rear Door RH
BL Surrounding of the Front of the Fuel Tank
Connector Location
BA1 Front Door LH Wire and Wire Harness (Connector Location)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel)
BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel)
BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel)
BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Page 3195
Knock Sensor: Service and Repair
1. REMOVE THROTTLE BODY COVER
2. REMOVE INTAKE AIR CONNECTOR
3. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS
4. REMOVE UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY
5. INSPECT KNOCK SENSOR 1,2
Disconnect the knock sensor connectors.
1. REPLACE THE SENSOR WITH SST.
SST 09816-30010
Torque: 45 N.m (450 kgf.cm, 33 ft.lbf)
Reconnect the knock sensor connectors.
2. REINSTALL UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY
3. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS
4. REINSTALL INTAKE AIR CONNECTOR
5. REINSTALL THROTTLE BODY COVER
Page 5261
3. INSPECT THERMISTOR RESISTANCE
a. Disconnect the connector. b. Measure resistance between terminals.
Standard resistance: 1,500 ohms at 25 °C (77 °F).
If resistance is not as specified, replace the thermistor.
Page 4544
Generator (Part 2)
REMOVAL
Testing and Inspection
Parking Brake Warning Switch: Testing and Inspection
INSPECT PARKING BRAKE SWITCH CONTINUITY a. Check that there is continuity terminals
with the switch ON (switch pin released). b. Check that there is no continuity between terminals
with the switch OFF (switch pin pushed in).
If operation is not as specified, replace the switch.
Page 1953
Applicable Vehicles
Locations
Airbag Sensor Assembly: Locations
Instrument Panel
Page 3905
The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit
breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery
power is supplied to each system are explained. Since all System Circuit diagrams start from the
power source, the power source system must be fully understood.
Page 812
5. INSPECT ACTUATOR OPERATION
a. 2WD 4HI shift: Connect lines via a relay, then check that the actuator fork shaft moves to 2WD
-> 4HI position.
b. 4HI -> 2WD shift: Connect lines via a relay, then check that the actuator fork shaft moves to 4HI
-> 2WD position.
Page 2981
Fuel: Specifications
Fuel Type Unleaded Gasoline
Octane Rating 87 or Higher
Page 5518
Seat Belt
Page 3081
If operation is not as specified, replace the MAF meter.
6. Turn the ignition switch OFF. 7. Disconnect the negative (-) terminal cable from the battery. 8.
Disconnect the MAF meter connector.
4. REINSTALL MAF METER
Install the MAF meter with the 2 screws.
5. RECONNECT MAF METER CONNECTOR
Page 2437
CHART 23
Page 3688
3. 2WD: REMOVE LOCK NUT AND ABS SPEED SENSOR ROTOR/SPACER
a. Using a chisel and hammer, loosen the staked part of the lock nut.
NOTICE: Be careful not to damage the bushing.
b. Using Special Service Tool (SST), remove the lock nut.
SST 09318-12010
c. Remove the ABS speed sensor rotor/spacer.
NOTICE: Take care not to scratch the serration of the speed sensor rotor.
4. REMOVE AXLE HUB FROM STEERING KNUCKLE
a. Remove the 4 bolts and shift the dust cover towards the hub side (outside). b. Using SST,
remove the axle hub from the steering knuckle.
SST 09710-30021 (09710-03051), 09950-40011 (09951-04020, 09952-04010, 09953-04020,
09954-04010, 09955-04031, 09957-04010, 09958-04011)
c. Remove the dust cover from the steering knuckle. d. 4WD: Remove the bearing spacer and ABS
speed sensor rotor (w/ABS)/spacer (w/o ABS).
NOTICE: Take care not to scratch the serration of the speed sensor rotor.
5. REMOVE OIL SEAL (OUTSIDE)
Using a screwdriver, remove the oil seal (outside) from the steering knuckle.
6. REMOVE BEARING FROM STEERING KNUCKLE
a. Using snap ring pliers, remove the snap ring. b. Using SST and a press, remove the bearing
from the steering knuckle.
SST 09950-60020 (09951-00810), 09950-70010 (09951-07150)
REASSEMBLY
Page 6515
Body
Connector Location (Standard Cab)
BA1 Front Door LH Wire and Speaker Tweeter Wire LH (Inside of Front Door LH)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Seat
Connector Location
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
BJ1 Seat No. 1 Wire and Seat No. 2 Wire (Under the Driver's Seat)
Page 4687
The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit
breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery
power is supplied to each system are explained. Since all System Circuit diagrams start from the
power source, the power source system must be fully understood.
Page 5416
Supplemental Restraint System
Page 1142
DISASSEMBLY
1. 2WD: REMOVE GREASE CAP
a. Mount the axle hub in a soft jaw vise.
HINT: Close the vise until it holds hub bolts. Do not tighten further.
b. Using a screwdriver, remove the grease cap.
2. 4WD: REMOVE OIL SEAL (INSIDE)
a. Mount the axle hub in a soft jaw vise.
HINT: Close the vise until it holds hub bolts. Do not tighten further.
b. Using a screwdriver, remove the oil seal (inside).
Page 2292
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 3088
4. INSPECT THROTTLE POSITION SENSOR
a. Disconnect the throttle position sensor connector. b. Using an ohmmeter, measure the
resistance between terminals VC and E2.
Resistance: 1.25 - 2.35 kohms at 20 °C (68 °F)
If the resistance is not as specified, replace the throttle position sensor.
c. Reconnect the throttle position sensor connector.
5. INSPECT ACCELERATOR PEDAL POSITION SENSOR
a. Disconnect the pedal position sensor connector. b. Using an ohmmeter, measure the resistance
between terminals VC and E2.
Resistance: 1.64 - 3.28 kohms at 20 °C (68 °F)
If the resistance is not as specified, replace the accelerator pedal position sensor.
c. Reconnect the pedal position sensor connector.
6. REINSTALL THROTTLE BODY COVER
Page 1674
A. Connect Diagnostic Tester cables DLC (P/N 02001637) and CAN Interface Module / J1962
OBDII together (P/N 01002744).
B. Test for continuity.
^ If there is continuity, the cable is OK. Check steps 1 and 2 above to complete the flash
reprogramming process.
^ If there is no continuity, proceed to CABLE TEST 2.
CABLE TEST 2.
A. Disconnect Diagnostic Tester cables DLC (P/N 02001637) and CAN Interface Module /J1962
OBDII (P/N 01002744).
B. Test DLC cable (P/N 02001637) for continuity.
^ If there is continuity, the cable is OK. Proceed to CABLE TEST 3.
^ If there is no continuity, the cable needs to be replaced.
CABLE TEST 3.
Testing and Inspection
Seat Sensor/Switch: Testing and Inspection
Passenger's seat only: INSPECT SEAT BELT WARNING OCCUPANT DETECTION SENSOR
CONTINUITY
Check that continuity exists between the terminals 1 and 2 when pressing the sensing part. If
operation is not as specified, replace the sensor.
Page 150
B. You have the option to delete calibrations off the tester before downloading a new calibration.
The CUW also provides this option if there is not enough memory for the new calibration. To delete
one or all of the calibrations, follow the screen flow shown (Figure 5).
C. If this is the first time you have downloaded a calibration file from TIS to the Diagnostic Tester
Program Card, you MUST first install the latest version of the Calibration Update Wizard (CUW)
onto your TIS workstation PC, as shown in Figure 6.
This step is also required if you are using a version of CUW earlier than version 6.0. CUW 6.0 is
the only version compatible with Diagnostic Tester software version 10.2a and later. If necessary,
select the link to the TIS Diagnostic Applications Installer and follow the on-screen prompts to
install or reinstall CUW.
Page 4085
Torque: 64 N.m (650 kgf.cm, 47 ft.lbf)
B. Connect the lower side of shock absorber to the lower suspension arm with bolt, washer and
nut.
Torque: 135 N.m (1,400 kgf.cm, 100 ft.lbf)
26. INSPECT AND INSTALL THE BRAKE ROTOR AND INSTALL THE BRAKE CALIPER WITH
NEW MOUNTING BOLTS
A. Inspect the brake rotors, and machine using an on-the-car brake lathe. Replace the rotor if it is
below minimum thickness values Minimum Thickness: 26.0 mm (1.024 in.)
B. Install the disc, brake caliper and 2 NEW bolts.
Torque: 123 N.m (1,259 kgf.cm, 90 ft.lbf)
C. Install the brake line clamp to the steering knuckle with the bolt.
Torque: 28 N.m (285 kgf.cm, 21 ft.lbf)
27. INSTALL NEW BRAKE LINE
Using the SST, connect NEW brake line.
^ 09023-00100
Torque: 15 N.m (155 kgf.cm, 11 ft.lbf)
28. W/ABS: CONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP
Connect the ABS speed sensor and wire harness clamp to the steering knuckle with the 2 bolts.
Torque: 8.0 N.m (82 kgf.cm, 71 in..lbf)
29. 4WD: INSTALL DRIVE SHAFT LOCK NUT
A. While applying the brakes, tighten the nut.
Torque: 235 N.m (2,400 kgf.cm, 173 ft.lbf)
B. Install the lock cap and a NEW cotter pin.
If the holes for the cotter pin are not aligned, tighten the nut further up to 60°.
30. 2WD: INSTALL GREASE CAP
31. INSTALL FRONT WHEEL
NOTE:
Do NOT use air wrench.
Torque: 110 N.m (1,150 kgf.cm, 83 ft.lbf)
32. DEPRESS BRAKE PEDAL SEVERAL TIMES
33. FILL THE BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM
34. CHECK ABS SPEED SENSOR SIGNAL (SEE REPAIR MANUAL)
Page 2589
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 5549
and the seat belt are both facing outward as shown.
You will hear a click when the tab locks into the buckle.
When releasing the seat belt, press on the buckle-release button on the extender not on the seat
belt. This helps prevent damage to the vehicle interior and extender itself.
When not in use, remove the extender and store in the vehicle for future use.
Page 1702
3. Start the engine and warm it up to normal operating temperatures before test-driving.
4. Perform a thorough test drive with several accelerations from a stop with "light throttle"
application until proper transmission shifting is verified.
Reset Procedure 2
1. Disconnect the negative battery cable for 5 minutes.
2. Reconnect battery cable.
3. Start the engine and warm it up to normal operating temperatures before test-driving.
4. Perform a thorough test drive with several accelerations from a stop with "light throttle"
application until proper transmission shifting is verified.
Page 562
Page 6969
d. Hold the back window glass in place securely with a protective tape or equivalent until the
adhesive hardens.
NOTE: Take care not to drive the vehicle during the time described in the table.
9. INSPECT FOR LEAK AND REPAIR
NOTE: Conduct a leak test after the hardening time has elapsed.
Part No. 08833-00030 or equivalent
10. INSTALL REAR PART OF ROOF HEADLINING
a. Standard cab:
Install the rear part of roof headlining with the 2 clips.
b. Access cab:
Install the rear part of roof headlining with the 3 clips.
11. INSTALL QUARTER TRIMS 12. Standard cab:
INSTALL BACK PANEL UPPER GARNISH
13. Standard cab:
INSTALL COAT HOOK
14. INSTALL ROOM LIGHT 15. Access cab:
INSTALL ROOF SIDE RAIL GARNISHES
16. Standard cab:
INSTALL FRONT PILLAR GARNISHES
17. INSTALL ASSIST GRIPS 18. Access cab:
INSTALL ACCESS DOOR SCUFF PLATES
19. Standard cab:
INSTALL FRONT DOOR SCUFF PLATES
20. Access cab:
INSTALL REAR SEAT
Page 2601
Refer to Reset Procedure 1 for the vehicles with Electronically Controlled Automatic
Transmissions:
Page 2510
Heated Oxygen Sensor
Engine Controls - Techstream(R) ECU Re-Flash
Procedure
Engine Control Module: All Technical Service Bulletins Engine Controls - Techstream(R) ECU
Re-Flash Procedure
T-SB-0064-10
February 4, 2010
Techstream ECU Flash Reprogramming Procedure
Service Category Engine/Hybrid System
Section Engine Control
Market USA
Applicability
TSB SUPERSESSION NOTICE
The information contained in this TSB supersedes TSB No. SS002-07.
^ Applicability has been updated to include 2009 - 2011 model year Toyota vehicles.
^ A new section, Techstream Preparation, has been added.
^ Techstream Lite has been added as an option in Required Tools & Materials.
^ Process Overview and Operation Procedure sections have been updated.
TSB No. SS002-07 is Obsolete and any printed versions should be discarded. Be sure to review
the entire content of this service bulletin before proceeding.
Introduction
Flash reprogramming allows the ECU software to be updated without replacing the ECU. Flash
calibration updates for specific vehicle models/ECUs are released as field-fix procedures described
in individual service bulletins. This bulletin details the Techstream ECU flash reprogramming
process and outlines use of the Technical Information System (TIS) and the Calibration Update
Wizard (CUW). Flash calibration updates can only be applied to the vehicle/ECU combination for
which they are intended. ECUs have internal security that will not allow them to be programmed
with another ECU's information.
ECU
Electronic Control Unit (ECU) is a Toyota term used to describe integrated computerized devices
responsible for managing the operation of a system or subsystem. For the purposes of this bulletin,
the term "ECU" is used as a generic label for the following SAE J1930 standard references:
^ Powertrain Control Module (PCM)
Page 2756
CHART 10
Page 1856
Crankshaft Position Sensor: Mechanical Specifications
Torque: ................................................................................................................................................
.................................. 6.5 N.m (65 kgf.cm, 58 in.lbf)
Page 3953
Transmission Speed Sensor: Service and Repair
Vehicle Speed Sensor NO.1
1. DISCONNECT NO. 1 VEHICLE SPEED SENSOR CONNECTOR
2. REMOVE NO. 1 VEHICLE SPEED SENSOR
Remove the bolt and No.1 vehicle speed sensor.
3. DISASSEMBLE NO. 1 VEHICLE SPEED SENSOR
a. Remove the O-ring from the speedometer driven gear assembly. b. Remove the clip and
speedometer driven gear from the speedometer driven gear sleeve.
4. ASSEMBLE NO. 1 VEHICLE SPEED SENSOR
a. Install the speedometer driven gear and clip to the speedometer driven gear sleeve. b. Coat a
new O-ring with ATF. c. Install the O-ring to the speedometer driven gear assembly.
5. INSTALL NO. 1 VEHICLE SPEED SENSOR
Testing and Inspection
Control Module: Testing and Inspection
For further information regarding this component and the system that it is a part of, please refer to
Four Wheel Drive Selector Relay; Testing and Inspection; Procedures.
Page 5911
A. AFFECTED VIN RANGE
III. Preparation
A. PARTS
^ No parts are required for the inspection.
B. EQUIPMENT & MATERIALS
^ Protective eyewear
^ Standard heater core hose
Page 5759
Splice Location
I1 Cowl Wire
I2 Cowl Wire
I3 Cowl Wire
I4 Cowl Wire
I5 Cowl Wire
I6 Cowl Wire
I7 Engine Wire
I8 Engine Wire
I9 Engine Wire
I10 Engine Wire
I11 Engine Wire
I12 Engine Wire
I13 Engine Wire
I14 Engine Wire
I15 Engine Wire
I16 Cowl Wire
Body
Splice Location (Access Cab)
B1 Speaker Tweeter Wire LH
B2 Front Door LH Wire
B3 Front Door LH Wire
B4 Roof Wire
B5 Speaker Tweeter Wire RH
B6 B7
Front Door RH Wire
B8 Front Door RH Wire
B9 Rear Door No. 1 Wire RH
B10 Frame Wire
Page 3338
J. The top half of the CUW screen displays the calibrations currently stored on the Diagnostic
Tester Program Card. The bottom half of the screen displays the new calibration to be loaded onto
the Diagnostic Tester Program Card (see Figure 13). Click NEXT to continue the process.
K. Confirm the calibration file to be sent to the Diagnostic Tester Program Card (Figure 14). Click
SEND.
Electrical Specifications
Page 6186
BJ Inside of Rear Door LH
BK Inside of Rear Door RH
BL Surrounding of the Front of the Fuel Tank
Connector Location
BA1 Front Door LH Wire and Wire Harness (Connector Location)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel)
BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel)
BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel)
BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Page 6597
Splice Point
J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel,
and "B" for the Body).
The Location of splice Point I5 is shaded.
K: Indicates a shielded cable.
L: Indicates the pin number of the connector.
The numbering system is different for female and male connectors.
M: Indicates a ground point.
The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for
the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body
and Surrounding area.
How to Read Connector List
HOW TO READ CONNECTOR LIST
A: Indicates connector to be connected to a part. (The numeral indicates the pin No.)
Page 1088
Waterproof Type Connector
B: For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White
: Gray
Black or White : Dark Gray
Gray or White : Black
Waterproof Type Connector
"Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up
to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Waterproof Type Connector
"Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 5317
Refrigerant Oil: Fluid Type Specifications
Type ND-OIL 8
Speed Sensor, Front
Wheel Speed Sensor: Service and Repair Speed Sensor, Front
REMOVAL
1. REMOVE FRONT WHEEL
Torque: 113 Nm (1,150 kgf-cm, 83 ft. lbs.)
2. DISCONNECT SPEED SENSOR CONNECTOR
3. REMOVE SPEED SENSOR
(a) Remove the clips and 3 clamp bolts holding the sensor harness from the frame, upper arm and
steering knuckle.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
(b) Remove the bolt and speed sensor from the steering knuckle.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
INSTALLATION
Installation is in the reverse order of removal.
HINT: After installation, check speed sensor signal.
Page 4029
Testing and Inspection
Power Door Lock Switch: Testing and Inspection
Master switch
INSPECT DRIVER'S DOOR LOCK CONTROL SWITCH CONTINUITY
If continuity is not as specified, replace the switch.
INSPECT PASSENGER'S DOOR LOCK CONTROL SWITCH CONTINUITY
If continuity is not as specified, replace the switch.
Page 5020
2. REMOVE UPPER BALL JOINT
a. Remove the wire and boot. b. Using a snap ring expander, remove the snap ring. c. Using
Special Service Tool (SST) and a deep socket wrench, remove the upper ball joint.
SST 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04031,
09957-04010, 09958-04011)
INSPECTION
1. INSPECT UPPER BALL JOINT BOOT FOR DAMAGE
2. INSPECT UPPER BALL JOINT FOR ROTATION CONDITION
a. As shown in the illustration, flip the ball joint stud back and forth 5 times, before installing the nut.
b. Using a torque wrench, turn the nut continuously 1 turn per 2 - 4 seconds and take the torque
reading on the 5th turn.
Turning torque: 0.7 - 4.4 Nm (7 - 45 kgf-cm, 6 - 39 inch lbs.)
INSTALLATION
1. INSTALL UPPER BALL JOINT
a. Using Special Service Tool (SST) and a socket wrench, install a new ball joint.
SST 09309-37010
b. Using a snap ring expander, install a new snap ring. c. Install a new boot and fix it with a new
wire.
HINT: Use the grease supplied in the kit.
2. INSTALL STEERING KNUCKLE WITH AXLE HUB
Page 2445
Page 3818
c. 4HI -> 4LO shift: Connect lines via a relay, then check that the actuator fork shaft moves to 4HI
-> 4LO position.
d. 4LO 4HI shift: Connect lines via a relay, then check that the actuator fork shaft moves to 4LO ->
4HI position.
HINT: When inspecting the operation described, use a heater main relay.
NOTICE: Connect the terminals being careful not to touch the neighboring terminals or metallic
parts of relay housing.
Page 6437
d. Disconnect the negative (-) lead from the body ground to terminal 1 or 10. e. Check that the
buzzer stops sounding.
If operation is not as specified, replace the combination meter.
4. INSPECT COMBINATION METER CIRCUIT
Page 6101
b. Continue to apply voltage, check that the current changes to less than 1 ampere within 4 to 90
seconds.
c. Disconnect the leads from the terminals. d. Approximately 60 seconds later, connect the positive
(+) lead from the battery to terminal 1 and the negative (-) lead to terminal 2, check that the
seat back begins to fall backward. If operation is not as specified, replace the seat adjuster.
INSPECT LUMBAR SUPPORT MOTOR OPERATION
a. Connect the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal
2, check that the lumbar support moves to release
side.
b. Reverse the polarity, check that the lumbar support moves forward.
If operation is not as specified, replace the lumber support adjuster.
INSPECT LUMBAR SUPPORT MOTOR CIRCUIT BREAKER OPERATION
a. Connect the positive (+) lead from the battery to terminal 2 and the negative (-) lead to terminal 1
on the lumbar support motor connector and
Page 2337
The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit
breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery
power is supplied to each system are explained. Since all System Circuit diagrams start from the
power source, the power source system must be fully understood.
Page 2535
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.
Service and Repair
Fuel Pressure Release: Service and Repair
SFI SYSTEM
PRECAUTION
1. BEFORE WORKING ON FUEL SYSTEM, DISCONNECT NEGATIVE (-) TERMINAL CABLE
FROM BATTERY
HINT: Any diagnostic trouble code retained by the computer will be erased when the negative (-)
terminal cable is removed from the battery.
Therefore, if necessary, read the diagnosis before removing the negative (-) terminal cable from the
battery.
2. DO NOT SMOKE OR WORK NEAR AN OPEN FLAME WHEN WORKING ON THE FUEL
SYSTEM
3. KEEP GASOLINE AWAY FROM RUBBER OR LEATHER PARTS
4. FUEL SYSTEM
a. When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so
observe these procedures:
1. Disconnect the fuel pump connector. 2. Start the engine. After the engine has stopped on its
own, turn the ignition switch OFF.
3. Put a container under the connection. 4. Slowly loosen the connection. 5. Disconnect the
connection. 6. Plug the connection with a rubber plug. 7. Reconnect the fuel pump connector.
b. When connecting the union bolt (fuel pressure pulsation damper) on the high pressure pipe
union, observe these procedures:
1. Always use 2 new gaskets.
Page 3012
39 N.m (400 kgf.cm, 29 ft.lbf) for union bolts 7.5 N.m (80 kgf.cm, 66 in.lbf) for bolt
i. Install the bolt holding the clamp on the fuel return pipe to the LH delivery pipe.
Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf)
j. Check that the injectors rotate smoothly.
HINT: If injectors do not rotate smoothly, the probable cause is incorrect installation of O-rings.
Replace the O-rings.
k. Position injector connector outward. l.
Tighten the 4 nuts holding the delivery pipes to the lower intake manifold.
Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)
m. Connect the 8 injectors connectors.
2. INSTALL ENGINE WIRES
a. Install the 2 wire clamps on the engine wire to the brackets on the RH delivery pipe. b. Connect
the engine wire clamps to the No.1 engine hanger and engine wire bracket. c. Install the engine
wire protector with the 2 bolts.
3. CONNECT PCV HOSE TO PCV VALVE
Page 4602
Continuity And Resistance Check
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Continuity And Resistance Check
C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the
electrical circuit.
Finding A Short Circuit
Finding A Short Circuit
Finding A Short Circuit
A. Remove the blown fuse and disconnect all loads of the fuse.
Page 2464
Engine Bank Identification
Page 3560
Instrument Panel
Connector Location
IA1 Engine Room Main and Cowl Wire (Left Kick Panel)
IA2 Engine Room Main and Cowl Wire (Left Kick Panel)
IA3 Engine Room Main and Cowl Wire (Left Kick Panel)
IA4 Engine Room Main and Cowl Wire (Left Kick Panel)
IB1 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IB2 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IB3 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IC1 Cowl Wire and Roof Wire (Left Side of Instrument Panel)
Instrument Panel
Connector Location
ID1 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH)
ID2 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH)
IE1 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IE2 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IE3 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IF1 Front Door RH Wire and Cowl Wire (Right Kick Panel)
IF2 Front Door RH Wire and Cowl Wire (Right Kick Panel)
IF3 Front Door RH Wire and Cowl Wire (Right Kick Panel)
Page 27
Body
Connector Location (Access Cab)
BA1 Front Door LH Wire and Wire Harness (Connector Location)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel)
BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel)
BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel)
BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Page 5997
a. Using a screwdriver, remove the left side lens.
b. Remove the 2 screws. c. Using a screwdriver, rotate the clip by 90 degrees and remove it. d.
Remove the front personal light, then disconnect the connector.
HINT: At the time of installation, please refer to the following item. When installing the front
personal light, attach the clip to the housing and push it to the bracket.
12. REMOVE ROOM LIGHT
a. Using a screwdriver, remove the room light cover. b. Remove the 2 screws and room light, then
disconnect the connector.
13. Standard cab:
REMOVE COAT HOOK
a. Using a screwdriver, open the cap. b. Remove the screw and coat hook.
14. Standard cab:
REMOVE BACK PANEL UPPER GARNISH
Page 2484
CHART 11
Locations
Engine Room R/B
Page 4649
Engine Compartment
Instrument Panel
Locations
Service Precautions
Air Bag(s) Arming and Disarming: Service Precautions
SRS AIRBAG PRECAUTION
CAUTION: TOYOTA trucks are equipped with SRS, which comprises a driver airbag, front
passenger airbag and failure to carry out service operations in the correct sequence could cause
the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Further, if
a mistake is made in servicing the SRS, it is possible that the SRS may fail to operate when
required. Before performing servicing (including removal or installation of parts, inspection or
replacement), be sure to read the following items carefully, then follow the correct procedures
described.
Work must be started 90 seconds after the ignition switch is turned to the "LOCK" position and the
negative (-) terminal cable is disconnected from the battery.
The SRS is equipped with a back-up power source so that if work is started within 90 seconds from
disconnecting the negative (-) terminal cable of the battery, the SRS may be deployed.)
Do not expose the steering wheel pad, front passenger airbag assembly, airbag sensor assembly
or front airbag sensor directly to hot air or flames.
NOTE: Malfunction symptoms of the SRS are difficult to confirm, so the DTCs become the most
important source of information when troubleshooting. When troubleshooting the SRS, always
inspect the DTCs before disconnecting the battery.
Even in cases of a minor collision where the SRS does not deploy, the steering wheel pad, front
passenger airbag assembly, airbag sensor assembly and front airbag sensor should be inspected.
Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during
repairs.
Never use SRS parts from another vehicle. When replacing parts, replace them with new parts.
Never disassemble and repair the steering wheel pad, front passenger airbag assembly, airbag
sensor assembly or front airbag sensor, in order to reuse it.
If the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag
sensor, has been dropped, or if there are cracks, dents or other defects in the case, bracket or
connector, replace it with new one.
Use a volt/ohmmeter with high impedance (10 Kohms/V minimum) for troubleshooting the system's
electrical circuits.
Information labels are attached to the periphery of the SRS components. Follow the instructions on
the notices.
After work on the SRS is completed, check the SRS warning light check.
When the negative (-) terminal cable is disconnected from the battery, the memory of the clock and
audio system will be canceled. So before starting work, make a record of the contents memorized
in the audio memory system. When work is finished, reset the audio systems as they were before
and adjust the clock. To avoid erasing the memory in each memory system, never use a back-up
power supply from outside the vehicle.
If the vehicle is equipped with a mobile communication system, refer to the precaution.
Diagram Information and Instructions
Engine Control Module: Diagram Information and Instructions
Key to Diagrams
A: System Title
B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to
distinguish it from the J/B
Example: 1 Indicates Relay Block No.1
C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type,
or specification is different.
D: Indicates related system.
Page 6514
Body
Connector Location (Access Cab)
BA1 Front Door LH Wire and Wire Harness (Connector Location)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel)
BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel)
BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel)
BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Page 3324
A. Test J1962 OBDIII CAN Interface Module (P/N 01002744) for continuity.
^ If there is continuity, the cable and CAN Interface Module are OK. Re-check Cable Tests 1, 2,
and 3 while wiggling and flexing the cables.
^ If there is no continuity, proceed to CABLE TEST 4.
CABLE TEST 4.
A. Disconnect the CAN Interface Module (P/N 01002744) from the J1962 OBDII cable using a
Phillips screwdriver.
B. Test J1962 OBDII cable (P/N 02003180) for continuity.
^ If there is no continuity, the cable needs to be replaced.
^ If there is continuity, proceed to CAN Interface Module Test 5.
CAN INTERFACE MODULE TEST 5.
Page 2630
B: Junction Connector
Indicates a connector which is connected to a short terminal.
Junction connector in this include a short terminal which is connected to a number of wire
harnesses. Always perform inspection with the short terminal installed. (When installing the wire
harnesses, the harnesses can be connected to any position within the short terminal grouping.
Accordingly, in other vehicles, the same position in the short terminal may be connected to wire
harness from a different part.) Wire harness sharing the same short terminal grouping ha the same
color.
C: Parts Code
The first letter of the code is taken from the first letter of part, and the numbers indicates its order in
parts which start with the same letter.
D: Connector Color
Connectors not indicated are milky white in color.
How to Read Ground Points
HOW TO READ GROUND POINTS
Page 5101
Information
PRELIMINARY INSPECTION INSTRUCTIONS
Page 2394
A/F and 02 Sensor Identification
Page 1776
Engine Control Module (ECM)
Page 1936
Page 285
Starter Relay: Testing and Inspection
INSPECTION
1. REMOVE STARTER RELAY
Remove the relay box cover and starter relay.
2. INSPECT STARTER RELAY CONTINUITY
a. Using an ohmmeter, check that there is continuity between terminals 1 and 2.
If there is no continuity, replace the relay.
b. Check that there is no continuity between terminals 3 and 5.
If there is continuity, replace the relay.
3. INSPECT STARTER RELAY OPERATION
a. Apply battery positive voltage across terminals 1 and 2. b. Using an ohmmeter, check that there
is continuity between terminals 3 and 5.
If there is no continuity, replace the relay.
4. REINSTALL STARTER RELAY
Page 2481
CHART 7
Paint - Refinishing Bumper Cover
Paint: Technical Service Bulletins Paint - Refinishing Bumper Cover
PAINT PA003-02 REVISED
June 4, 2002
Title REFINISHING REPLACEMENT BUMPER COVERS
Models All '83 - '05 Models
TSB REVISION NOTICE: ^ February 14, 2005: Applicable Vehicles now includes 2004 - 2005
model years. Previous versions of this TSB should be discarded.
Introduction In cases where a bumper cover is being replaced a special preparation process is
necessary to assure the refinish is customer acceptable. This bulletin provides the recommended
refinishing procedure for new bumper covers.
Applicable Vehicles ^ All 1983 - 2005 model year Toyota vehicles.
Required Tools & Material
Note:Please visit www.3m.comlautomotive to find the nearest store that sells 3M automotive
products.
Warranty Information
Refinishing Procedure
1. Mix a solution of mild soap (car wash soap with no wax additives) and clean water.
Note: Carefully follow mixing instructions on the soap container. Too much soap or too much water
may cause surface contamination or rinsing difficulty.
Page 1830
If operation is not as specified, replace the MAF meter.
6. Turn the ignition switch OFF. 7. Disconnect the negative (-) terminal cable from the battery. 8.
Disconnect the MAF meter connector.
4. REINSTALL MAF METER
Install the MAF meter with the 2 screws.
5. RECONNECT MAF METER CONNECTOR
Page 694
Mass Air Flow (MAF) Meter
Page 3491
Step 3
Page 1021
Engine Oil: Fluid Type Specifications
Engine Oil Type
GRADE ..................................................................................................................................... API
SJ Energy-Conserving or ILSAC multigrade engine oil All temperatures ............................................
............................................................................................................................................ 5W-30
(preferred) Above 0° F .........................................................................................................................
....................................................................................... 10W-30
Pressure Specification
Fuel Pressure: Specifications
Fuel Pressure No Vacuum 38 to 44 psi
Page 5807
Trailer Connector: Diagnostic Aids
Voltage Check
Voltage Check
Voltage Check
A. Establish conditions in which voltage is present at the check point.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(SW 2 OFF)
B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or
component terminal. This check can be done with a test light instead of a voltmeter.
Continuity and Resistance Check
Continuity and Resistance Check
Continuity And Resistance Check
A. Disconnect the battery terminal or wire so there is no voltage between the check points. B.
Contact the two leads of an ohmmeter to each of the check points.
Locations
Anti-Lock Brake System
Brakes - Vibration From Rear
Brake Shoe: Customer Interest Brakes - Vibration From Rear
BRAKES BR001-01
January 12, 2001
Title: REAR BRAKE VIBRATION
Models: '00 - '01 Tundra
TSB Update Notice:
The information contained in this TSB updates BR006-00, dated November 17, 2000.
Revised text is underlined.
New parking brake struts (star wheel adjusters) have been developed to reduce the possibility of
rear brake vibration on 2000 and 2001 model year Tundra vehicles. The number of teeth on the
star wheel adjuster has been reduced from 30 to 26 teeth.
Applicable Vehicles ^
2000 - 2001 model year Tundra vehicles.
Production Change Information
Parts Information
Repair Procedure
1. Grind rear brake drums with brake lathe to within serviceable limits.
2. If the drums are unserviceable or above maximum inside diameter, replace the drums.
3. If there is uneven wear on the lining, replace the left and right brake shoes.
4. Replace the parking brake shoe strut sets.
5. Adjust the parking brake to specifications.
6. Reinstall the rear wheels, and torque wheel nuts to:
Torque: 113 Nm (1,150 kgf cm, 83 ft.lbf)
7. Road test.
Warranty Information
Brakes - Front Brakes Vibrate Upon Application
Technical Service Bulletin # BR004R-02 Date: 050404
Brakes - Front Brakes Vibrate Upon Application
BRAKES BR004-02 REVISED
Title: FRONT BRAKE VIBRATION
Models: '00 - '05 Tundra
September 12, 2002
TSB REVISION NOTICE:
^ April 4, 2005: Applicable Vehicles has been updated to include 2003 - 2005 model years. The
following sections have been updated, expanded, or added: Introduction, Warranty Information,
Production Change Information, Parts Information, Required SSTs, Diagnosis Procedure, Repair
Procedure No.1, and Repair Procedure No.2. PLEASE READ ENTIRE TSB.
^ September 24, 2004: A note has been added, step 26.
^ March 5, 2004: A torque specification in step 24, was changed.
^ September 8, 2003: A torque specification in step 28, was changed.
Previous versions of this TSB should be discarded.
Introduction
Under certain usage conditions, some Tundra trucks may exhibit front brake vibration.
Improvements have been made to various brake components to help improve this condition.
Applicable Vehicles
^ 2000 - 2005 model year Tundra vehicles produced BEFORE the Production Change Effective
VINs shown.
Production Change Information
Page 3089
Throttle Position Sensor: Service and Repair
Refer to Fuel Delivery and Air Induction / Throttle Body / Service and Repair, for removal and
installation of this component.
Page 912
Alternately loosen the 2 bolts, and remove them, the belt tensioner and dust boot.
18. DISCONNECT TIMING BELT FROM CAMSHAFT TIMING PULLEYS
a. Using SST, loosen the tension spring between the LH and RH camshaft timing pulleys by slightly
turning the LH camshaft timing pulley
clockwise. SST 09960-10010 (09962-01000, 09963-01000)
b. Disconnect the timing belt from the camshaft timing pulleys.
19. REMOVE CAMSHAFT TIMING PULLEYS
Using SST, remove the bolt and timing pulley. Remove the 2 timing pulleys. SST 09960-10010
(09962-01000, 09963-01000)
20. REMOVE GENERATOR 21. REMOVE DRIVE BELT TENSIONER
Remove the bolt, 2 nuts and belt tensioner.
22. REMOVE CRANKSHAFT PULLEY
Using SST, remove the crankshaft pulley. SST 09950-50012 (09951-05010, 09952-05010,
09953-05010, 09953-05020, 09954-05020)
NOTICE: Do not turn the crankshaft pulley.
23. REMOVE NO.1 TIMING BELT COVER
Remove the 4 bolts and timing belt cover.
Page 202
DOWNLOAD FILE TO TESTER
2. Download the calibration file to the Diagnostic Tester.
The Calibration Update Wizard (CUW) is a new application on TIS which downloads calibration
files from TIS onto the Diagnostic Tester Program Card.
NOTE:
Before you begin, ensure that the Diagnostic Tester is equipped with software version 8.0a, or
later. Only a 12 MB program card (P/N 01002593-005) may be used for this process.
A. Before downloading a new calibration file from TIS, check the current calibration files stored on
the Diagnostic Tester Program Card by following the screen flow shown (Figure 4).
NOTE:
^ Screen D may be blank if no calibrations are stored on the Diagnostic Tester Program Card.
^ If the desired calibration file is already on the Diagnostic Tester, proceed to Step 3 (Reprogram
ECU with Tester shown).
^ A maximum of two calibration files may be loaded on the tester at one time with Diagnostic Tester
software version 10.2a and later. Prior versions may store up to four calibration files.
Page 2501
Page 3572
Transmission Mode Indicator - A/T: Diagnostic Aids
Voltage Check
Voltage Check
Voltage Check
A. Establish conditions in which voltage is present at the check point.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(SW 2 OFF)
B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or
component terminal. This check can be done with a test light instead of a voltmeter.
Continuity and Resistance Check
Continuity and Resistance Check
Continuity And Resistance Check
A. Disconnect the battery terminal or wire so there is no voltage between the check points. B.
Contact the two leads of an ohmmeter to each of the check points.
Page 3087
If you have no TOYOTA hand-held tester, measure voltage between terminals VPA and E2 of the
ECM connector.
d. Inspect the air assist system.
1. Start the engine and check that the MIL does not light up. 2. Allow the engine to warm up to
normal operating temperature. 3. Turn the A/C compressor ON to OFF, and check the idle speed.
Idle speed (Transmission in neutral): 700 ± 50 rpm
NOTE: Perform inspection under condition without electrical load.
e. After checking the above (b) to (d), perform the driving test and check that there is no sense of
incongruity.
3. INSPECT THROTTLE CONTROL MOTOR
a. Disconnect the throttle control motor connector. b. Using an ohmmeter, measure the motor
resistance between terminal 1 (M+) and 2 (M-).
Motor resistance: 0.3 - 100 ohms at 20 °C (68 °F)
If the resistance is not as specified, replace the throttle control motor.
c. Using an ohmmeter, measure the clutch resistance between terminal 3 (CL-) and 4 (CL+).
Clutch resistance: 4.2 - 5.2 ohms at 20 °C (68 °F)
If the resistance is not as specified, replace the throttle control motor.
d. Reconnect the throttle control motor connector.
Page 4345
Parts Information
Page 4117
8. DISCONNECT LOWER BALL JOINT
Remove the 4 bolts and disconnect the lower ball joint.
9. REMOVE STEERING KNUCKLE
A. Remove the cotter pin and loosen the nut.
B. Using the following SSTs, disconnect the steering knuckle.
09950-40011(09951-04010, 09952-04010, 09553-04020, 09554-04010, 09955-04031,
09958-04011)
C. Remove the nut and steering knuckle.
NOTE:
4WD:
Be careful not to damage the oil seal and drive shaft boot.
HINT: 4WD:
When it is difficult to disconnect the drive shaft, tap the tip of the drive shaft with a plastic hammer.
10. 2WD:
REMOVE GREASE CAP
A. Mount the axle hub in a soft jaw vise.
HINT:
Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further.
B. Using a screwdriver, remove the grease cap.
HINT:
Be careful not to damage the grease cap.
Page 4814
Relay Box: Connector Views
Engine Room R/B
Lower
Ball Joint: Specifications
Lower Ball Joint Turning Torque 0.1-2.5 Nm (1.0-22.0 in.lb)
Maximum Play 0.5 mm (0.020 in)
Page 1656
Exhaust Manifold: Service and Repair
For further information regarding this component and the system that it is a part of, please refer to
Cylinder Head Assembly; Service and Repair.
Page 4791
Driver Side J/B And Integration Relay
Page 6229
Problem Symptoms Table
Cruise Main Indicator Light Circuit
CRUISE MAIN Indicator Light Switch
CIRCUIT DESCRIPTION
When the cruise control main switch is turned ON, CRUISE main indicator light lights up.
Page 5629
6. Disconnect the pretensioner connector as shown in the illustration.
c. Access cab:
Disconnect the pretensioner connector. 1. Remove the front door scuff plate. 2. Remove the rear
door scuff plate. 3. Remove the front seat outer belt floor anchor. 4. Remove the front seat outer
belt shoulder belt. 5. Remove the roof side rail garnish. 6. Remove the front door rear scuff plate
and cover.
7. Disconnect the pretensioner connector as shown in the illustration,
d. Install the SST.
1. Buckle the front seat belt and check that there is no looseness and slack in the front seat inner
belt and front seat outer belt.
2. Connect the 2 SST, then connect them to the seat belt pretensioner.
SST 09082-00700,09082-00740
NOTE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of
the twin lock.
Testing and Inspection
Power Seat Switch: Testing and Inspection
Slide Switch
Front Tilt Switch
Rear Lifter Switch
Reclining Switch
INSPECT POWER SEAT SWITCH CONTINUITY
If continuity is not as specified, replace the switch.
Page 3543
3. MEASURE TORQUE CONVERTER CLUTCH SLEEVE RUNOUT
Temporarily mount the torque converter clutch to the drive plate. Set up a dial indicator, measure
the torque converter clutch sleeve runout. Maximum runout: 0.30 mm (0.0118 inch) If runout is not
within the specification, try to correct by reorienting the installation of the converter clutch.
HINT: Mark the position of the torque converter clutch to ensure the correct installation.
Page 45
Fog/Driving Lamp Relay: Testing and Inspection
INSPECT FOG LIGHT RELAY CONTINUITY If continuity is not as specified, replace the relay.
Page 475
Camshaft Position Sensor: Testing and Inspection
ON-VEHICLE INSPECTION
NOTE: "Cold" and "Hot" in these sentences express the temperature of the coils themselves.
"Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F).
INSPECT CAMSHAFT POSITION SENSOR
a. Disconnect the camshaft position sensor connector.
Resistance
b. Using an ohmmeter, measure the resistance between terminals.
If the resistance is not as specified, replace the camshaft position sensor.
c. Reconnect the camshaft position sensor connector.
Page 4535
Generator (Part 2)
Page 905
Part 4 of 4
Page 3517
Vehicle Speed Sensor NO.2
Page 1605
Coolant Temperature Sensor/Switch (For Computer): Description and Operation
Engine Coolant Temperature Sensor
A thermistor that is built into the engine coolant temperature sensor changes the resistance value
according to the engine coolant temperature.
The lower the engine coolant temperature sensor, the greater the thermistor resistance value, and
the higher the engine coolant temperature sensor temperature, the lower the thermistor resistance
value.
The engine coolant temperature sensor is connected to the ECM. The 5 V power source voltage in
the ECM is applied to the engine coolant temperature sensor from the terminal THA via a resistor
R. That is, the resistor R and the engine coolant temperature sensor are connected in series.
When the resistance value of the engine coolant temperature sensor changes in accordance with
changes in the engine coolant temperature, the potential at terminal THA also changes. Based on
this signal, the ECM increases the fuel injection volume to improve driveability during cold engine
operation.
Page 3893
Body
Splice Location (Standard Cab)
B1 Speaker Tweeter Wire LH
B2 Front Door LH Wire
B3 Front Door LH Wire
B4 Roof Wire
B5 Speaker Tweeter Wire RH
B6 B7
Front Door RH Wire
B10 Frame Wire
Seat
Page 241
Windows 2000 SP2 or later Windows XP Pro SP1 or later
For more information about the J2534 devices listed above, contact the vendors. To report
compatibility problems with listed hardware/software, please contact the device manufacturer.
For more information about Toyota vehicle reprogramming CDs or to report problems running
Toyota's Calibration Update Wizard software, please contact Toyota.
OBTAINING A CALIBRATION CD
The Calibration CD is compatible with the above mentioned scantools and J2534 interfaces. A
Calibration CD contains all of the most current vehicle calibration files, applicable TSBs, the
Calibration Update Wizard application software for a Windows PC, and instructions for use.
Calibration CDs can be ordered through the Toyota Material Distribution Center; order P/N
00456-REPRG-001.
IMPORTANT NOTICE
It is possible to permanently damage a vehicle controller during the flash reprogramming process.
It is especially important to understand that once started, the reprogramming process must not be
interrupted, reprogramming devices must not be disconnected and PCs must not be allowed to go
into standby, hibernation or similar power management modes. The information provided herein is
intended expressly for use by qualified professional automobile technicians. To prevent damage to
your customer's vehicle and ensure safe service practice, read these materials completely and
thoroughly before servicing the vehicle and be sure to follow all instructions.
Page 2862
Splice Point
J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel,
and "B" for the Body).
The Location of splice Point I5 is shaded.
K: Indicates a shielded cable.
L: Indicates the pin number of the connector.
The numbering system is different for female and male connectors.
M: Indicates a ground point.
The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for
the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body
and Surrounding area.
How to Read Connector List
HOW TO READ CONNECTOR LIST
A: Indicates connector to be connected to a part. (The numeral indicates the pin No.)
Page 5918
Page 5739
Radio/Stereo: Testing and Inspection
RADIO AND PLAYER
R2 (B) RADIO AND PLAYER
(B) 3 - GROUND: Approx. 12 volts with ignition SW at ON or ACC position (B) 4 - GROUND:
Always approx. 12 volts
(B) 7 - GROUND: Always continuity
S7 (D) STEREO COMPONENT AMPLIFIER
(D) 3 - GROUND: Approx. 12 volts with ignition SW at ON or ACC position (D) 4 - GROUND:
Always approx. 12 volts
(D) 7 - GROUND: Always continuity
Page 5254
2. INSTALL INTEGRATION CIRCUIT
a. Connect the 2 connectors. b. Install the circuit.
3. INSTALL HEATER CONTROL HOUSING
a. Connect the connector. b. Install the heater control housing. c. Install the 5 screws.
4. INSTALL BULBS
Install the 5 bulbs.
5. INSTALL AIRBAG INDICATOR CIRCUIT
a. Connect the connector. b. Install the circuit.
Page 6283
BJ Inside of Rear Door LH
BK Inside of Rear Door RH
BL Surrounding of the Front of the Fuel Tank
Connector Location
BA1 Front Door LH Wire and Wire Harness (Connector Location)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel)
BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel)
BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel)
BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Testing and Inspection
Parking Brake Warning Switch: Testing and Inspection
INSPECT PARKING BRAKE SWITCH CONTINUITY a. Check that there is continuity terminals
with the switch ON (switch pin released). b. Check that there is no continuity between terminals
with the switch OFF (switch pin pushed in).
If operation is not as specified, replace the switch.
Airbag(s) Arming and Disarming
Air Bag(s) Arming and Disarming: Service and Repair Airbag(s) Arming and Disarming
CAUTION: *
Work must be started 90 seconds after the ignition switch is turned to the "LOCK" position and the
negative (-) terminal cable is disconnected from the battery. (The SRS is equipped with a back-up
power source so that if work is started within 90 seconds of disconnecting the negative (-) terminal
cable of the battery, the SRS may be deployed.)
* When the negative (-) terminal cable is disconnected from the battery, the memory of the clock
and audio system will be canceled. So before starting work, make a record of the contents
memorized in the audio memory system. When work is finished, reset the audio systems as before
and adjust the clock. To avoid erasing the memory of each memory system, never use a backup
power supply from outside the vehicle.
* Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during
repairs.
* Do not expose the steering wheel pad, front passenger airbag assembly, airbag sensor assembly
or front airbag sensor directly to hot air or flames.
AIR BAG SYSTEM DISARMING
The Air Bag/Supplemental Restraint System (SRS) incorporates a backup energy source that
maintains sufficient deployment voltage for up to 90 seconds after the ignition is turned Off and the
battery has been disconnected. Before disconnecting battery, note radio station settings, since all
vehicle memory will be lost. Never use a backup power source from outside the vehicle.
1. Turn ignition to Lock, then disconnect battery ground cable. 2. Wait at least 90 seconds after
disconnection before beginning service or diagnostic procedures.
AIR BAG SYSTEM ARMING
1. Ensure ignition is in Lock position. 2. Connect battery ground cable. 3. Wait at least 10 seconds
before turning ignition from Lock position. 4. Turn ignition to ACC or On position and ensure SRS
lamp lights, then goes off after approximately six seconds. If lamp remains lit, an SRS
condition is indicated. Refer to Restraint Systems, Air Bag Systems, Testing And Inspection. See:
Restraint Systems/Air Bag Systems/Testing and Inspection
Page 156
L. The calibration file will now be downloaded to the Diagnostic Tester Program Card. This process
takes approximately 2-6 minutes (see Figure 15).
M. The CUW will prompt when the calibration file is completely downloaded. Click OK to close the
CUW (Figure 16).
NOTE:
With the calibration file loaded on the Diagnostic Tester Program Card, it is not necessary to repeat
the above steps to reprogram a different vehicle needing the same calibration file. The steps above
are only required when a new calibration file must be loaded onto the Diagnostic Tester Program
Card.
The Diagnostic Tester now has the calibration file stored and you may proceed to the next step to
reprogram the vehicle ECU.
REPROGRAM ECU WITH TESTER
3. Reprogram the vehicle ECU with the Diagnostic Tester.
NOTICE:
Errors during the flash reprogramming process can permanently damage the vehicle ECU.
Minimize the risks by following the steps below.
^ Battery voltage MUST NOT FALL BELOW 11.4 volts during reprogramming.
^ Confirm battery voltage is higher than 11.4 volts, but be sure voltage DOES NOT RISE ABOVE
16.0 volts during reprogramming.
^ Turn off all electrical accessories (e.g. Audio system, A/C, interior lights, DRL, etc.).
^ Do not add to or significantly change the vehicle's electrical load while reprogramming.
^ Confirm the hood is open and ensure under hood temperatures do not exceed 158°F.
Page 2624
Engine Control Module: Locations
Instrument Panel
Page 2639
Waterproof Type Connector
B: For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White
: Gray
Black or White : Dark Gray
Gray or White : Black
Waterproof Type Connector
"Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up
to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Waterproof Type Connector
"Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 3366
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 5914
Engine Controls - O2 Sensor Monitor Threshold Values
Oxygen Sensor: All Technical Service Bulletins Engine Controls - O2 Sensor Monitor Threshold
Values
SPECIAL SERVICE TOOLS SS002-03
December 17, 2003
Title O2S TEST RESULTS (MODE 05)
Models All '96 - '03, '04 Corolla, ECHO, Matrix, Sienna & Scion xA & xB
Introduction
This Service Bulletin contains Oxygen Sensor (O2S) Monitor threshold values for all models from
1996 to 2003 and some 2004 models. Starting in 2004, the O2S Monitor threshold values can be
found in the repair manual. These values are used when analyzing the O2S test results to
determine the O2S condition.
Applicable Vehicles ^
All 1996 - 2003 model year Toyota vehicles.
^ 2004 model year Corolla, ECHO, Matrix and Sienna vehicles.
^ 2004 model year Scion xA and xB vehicles.
Function Description
Checking O2S Test Results
To view O2S test results, the O2S Monitor must be completed and the test results must be
checked within the same key cycle. If the ignition key is cycled OFF, the O2S test results will be set
to the minimum or maximum limits, and all test results will be erased. The O2S test results are
stored in the ECU (SAE term: Powertrain Control Module/PCM) when the monitor is completed.
The test results are static and will not change once the monitor is complete.
The process for checking 02S test results is described in the following three basic steps:
1. Completing the O2S Readiness Monitor.
2. Accessing O2S Test Results.
3. Comparing O2S Test Results to Failure Thresholds.
Required SSTs
NOTE:
Additional Diagnostic Tester Kits, Program Cards or other SSTs may be ordered by calling
SPX-OTC at 1-800-933-8335.
Warranty Information
Completing O2S Readiness Monitor
1. Clear any stored Diagnostic Trouble Codes (DTCs) using the Toyota Diagnostic Tester.
Page 2813
CHART 8
CHART 9
Page 3731
Step 3
Page 4761
Driver Side J/B And Integration Relay Inner Circuit
Brakes - Front Brakes Vibrate Upon Application
Technical Service Bulletin # BR004R-02 Date: 050404
Brakes - Front Brakes Vibrate Upon Application
BRAKES BR004-02 REVISED
Title: FRONT BRAKE VIBRATION
Models: '00 - '05 Tundra
September 12, 2002
TSB REVISION NOTICE:
^ April 4, 2005: Applicable Vehicles has been updated to include 2003 - 2005 model years. The
following sections have been updated, expanded, or added: Introduction, Warranty Information,
Production Change Information, Parts Information, Required SSTs, Diagnosis Procedure, Repair
Procedure No.1, and Repair Procedure No.2. PLEASE READ ENTIRE TSB.
^ September 24, 2004: A note has been added, step 26.
^ March 5, 2004: A torque specification in step 24, was changed.
^ September 8, 2003: A torque specification in step 28, was changed.
Previous versions of this TSB should be discarded.
Introduction
Under certain usage conditions, some Tundra trucks may exhibit front brake vibration.
Improvements have been made to various brake components to help improve this condition.
Applicable Vehicles
^ 2000 - 2005 model year Tundra vehicles produced BEFORE the Production Change Effective
VINs shown.
Production Change Information
Description and Operation
Throttle Position Sensor: Description and Operation
Throttle Position Sensor
Throttle position sensor is mounted on the throttle body and it has 2 sensors to detect the throttle
opening angle and a malfunction of the throttle position sensor's own.
Voltage applied to the terminals VTA and VTA2 of the ECM changes between 0 V and 5 V in
proportion to the opening angle of the throttle valve.
The ECM judges the current opening angle of the throttle valve from these signals output from
terminals VTA and VTA2, and the ECM controls the throttle motor to make the throttle valve
opening angle properly in accordance with the driving condition.
If this DTC is stored, the ECM cuts down the power for the throttle motor and the electromagnetic
clutch, and the throttle valve is fully closed by the return spring. However, the opening angle of the
throttle valve can be controlled by the accelerator pedal through the throttle cable.
Page 5034
2. INSTALL NEW BUSHING
Using SST, a press and steel plate, install a new bushing. SST 09631-12090, 09710-30021
(09710-03051)
INSTALLATION
1. INSTALL UPPER SUSPENSION ARM
Install the upper suspension arm with 2 washers, bolt and nut. Torque: 98 Nm (1,000 kgf-cm, 72 ft.
lbs.)
HINT: After stabilizing the suspension, torque the nut.
2. INSTALL BRAKE AND FUEL LINE CLAMP
Torque: 5.5 Nm (56 kgf-cm, 49 inch lbs.)
3. INSTALL REAR FENDER APRON SEAL 4. CONNECT UPPER BALL JOINT
a. Connect the upper ball joint to the upper suspension arm. b. Install the nut and a new cotter pin.
If the holes for the cotter pin are not aligned, tighten the nut further up to 60°. Torque: 105 Nm
(1,100 kgf-cm, 77 ft. lbs.)
5. w/ ABS: CONNECT ABS SPEED SENSOR WIRE HARNESS CLAMPS.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
6. INSTALL SHOCK ABSORBER WITH COIL SPRING 7. CHECK FRONT WHEEL ALIGNMENT
Trailer Harness - Updated Design/Diagnostics
Trailer Adapter Kit: Technical Service Bulletins Trailer Harness - Updated Design/Diagnostics
ACCESSORIES AX006-02
October 18, 2002
Title: TRAILER WIRE HARNESS
Models: 4Runner, Highlander, land Cruiser, RAV4, Sienna, Tacoma & Tundra
Introduction
Beginning in 2000, the accessory trailer wire harness supplier was changed and a new design was
adopted which incorporated in-line fuses in the tow wire harness in addition to the vehicle fuse.
This bulletin identifies the fuse location to supplement dealer diagnostics troubleshooting. In the
future please reference the accessory trailer wire harness Owner's Guide for the vehicle specific
diagnostic procedures. As a general note please place the towing wire harness Owner's Guide in
glove box after every DIO installation.
Applicable Vehicles ^
4Runner, Highlander, Land Cruiser, RAV4, Sienna, Tacoma, and Tundra vehicles using the
Accessory Towing Receiver Hitch and factory Towing Receiver Hitch option. (See table below for
applicable model years.)
Accessory Wire Harness Kit Information
Warranty Information
Page 2701
Knock Sensor: Locations
Knock Sensor (Part 1)
Page 3370
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 2211
Continuity And Resistance Check
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Continuity And Resistance Check
C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the
electrical circuit.
Finding A Short Circuit
Finding A Short Circuit
Finding A Short Circuit
A. Remove the blown fuse and disconnect all loads of the fuse.
Page 5475
Air Bag(s) Arming and Disarming: Service and Repair Release Method of Airbag Activation
Prevention Mechanism
RELEASE METHOD OF AIRBAG ACTIVATION PREVENTION MECHANISM
Check Steering Wheel Free Play and Effort
Steering Wheel: Testing and Inspection Check Steering Wheel Free Play and Effort
INSPECTION
1. CHECK STEERING WHEEL FREE PLAY
a. Stop the vehicle and face the tires straight ahead. b. Rock the steering wheel gently up and
down with a finger lightly, check the steering wheel free play.
Maximum free play: 30 mm (1.18 inch)
2. CHECK STEERING EFFORT
a. Center the steering wheel. b. Remove the steering wheel pad. c. Start the engine and run it at
idle. d. Measure the steering effort in both directions.
Steering effort (Reference): 4.9 Nm (50 kgf-cm, 43 inch lbs.)
HINT: Take the tire type, pressure and contact surface into consideration before making your
diagnosis.
e. Torque the steering wheel set nut.
Torque: 50 Nm (500 kgf-cm, 35 ft. lbs.)
f. Install the steering wheel pad.
Page 2894
Vehicle Speed Sensor NO.2
Page 5715
Splice Location
I1 Cowl Wire
I2 Cowl Wire
I3 Cowl Wire
I4 Cowl Wire
I5 Cowl Wire
I6 Cowl Wire
I7 Engine Wire
I8 Engine Wire
I9 Engine Wire
I10 Engine Wire
I11 Engine Wire
I12 Engine Wire
I13 Engine Wire
I14 Engine Wire
I15 Engine Wire
I16 Cowl Wire
Body
Splice Location (Access Cab)
B1 Speaker Tweeter Wire LH
B2 Front Door LH Wire
B3 Front Door LH Wire
B4 Roof Wire
B5 Speaker Tweeter Wire RH
B6 B7
Front Door RH Wire
B8 Front Door RH Wire
B9 Rear Door No. 1 Wire RH
B10 Frame Wire
Page 6177
Tailgate: Service and Repair
REMOVAL
1. REMOVE TAILGATE PROTECTOR 2. REMOVE SERVICE HOLE COVER
Using a torx socket wrench (T30), remove the 8 screws and service hole cover.
3. REMOVE TAILGATE LOCK
a. Disconnect the 2 tailgate lock links from the tailgate lock control. b. Using a torx socket wrench
(T40), remove the 4 screws and 2 tailgate locks.
4. REMOVE TAILGATE HANDLE ASSEMBLY
Remove the 2 bolts and tailgate handle assembly.
5. REMOVE TAILGATE LOCK STRIKERS
Using a torx socket wrench (T40), remove the 4 screws and tailgate lock strikers.
6. REMOVE TAILGATE CABLE
a. Remove the deck side shaft and tailgate cable from deck. b. Remove the gate side shaft and
tailgate cable. c. Employ the same manner described above to the other side.
7. REMOVE TAILGATE
a. Remove the 2 bolts and tailgate.
NOTE: Be careful not to drop the tailgate.
Page 6107
b. Inspect the connector on the wire harness side.
If circuit is not as specified, inspect the circuits connected to other parts.
On-Vehicle Cleaning
Radiator: Service and Repair On-Vehicle Cleaning
ON-VEHICLE CLEANING
CLEAN RADIATOR Using water or a steam cleaner, remove any mud or dirt from the radiator core.
NOTICE: If using a high pressure type cleaner, be careful not to deform the fins of the radiator
core. (i.e. Maintain a distance between the cleaner nozzle and radiator core.)
Page 2030
Splice Point
J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel,
and "B" for the Body).
The Location of splice Point I5 is shaded.
K: Indicates a shielded cable.
L: Indicates the pin number of the connector.
The numbering system is different for female and male connectors.
M: Indicates a ground point.
The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for
the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body
and Surrounding area.
How to Read Connector List
HOW TO READ CONNECTOR LIST
A: Indicates connector to be connected to a part. (The numeral indicates the pin No.)
Page 1415
Oil Pressure Sender: Testing and Inspection
INSPECT OIL PRESSURE SWITCH CONTINUITY a. Disconnect the connector from the switch. b.
Check that continuity exists between terminal and ground with the engine stopped. c. Check that
no continuity exists between terminal and ground with the engine running.
HINT: Oil pressure should be over 24.5 kPa (0.25 kgf/sq.cm, 3.55 psi).
If operation is not as specified, replace the switch.
5VZ-FE (Access cab) and 2UZ-FE: INSPECT OIL PRESSURE SENDER GAUGE CONTINUITY a.
Disconnect the connector from the sender gauge. b. Check that no continuity exists between the
terminal and ground with the engine stopped. c. Check that continuity exists between the terminal
and ground with the engine running.
HINT: The oil pressure should be over 29.0 kPa (0.3 kgf/cm2, 4.2 psi).
If the continuity is not as specified, replace the sender gauge.
Page 1229
g. Reinstall the camshafts. h. Reinstall the timing belt. i.
Recheck the valve clearance.
11. REINSTALL CYLINDER HEAD COVERS 12. REINSTALL IGNITION COILS 13. REINSTALL
NO.3 TIMING BELT COVERS 14. REINSTALL AIR CLEANER AND INTAKE AIR CONNECTOR
ASSEMBLY 15. REINSTALL THROTTLE BODY COVER 16. REINSTALL BATTERY CLAMP
COVER
Page 3574
B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(Connect the Relay) and SW 2 OFF (or Disconnect SW 2)
D. Disconnect and reconnect the connectors while watching the test light.
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
E. Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION:
a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals
are touched, the IC may be destroyed by
static electricity.)
b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact
with the terminals of leads from the IC, etc. of the replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
Special Tool
1. PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown.
2. DISCONNECT CONNECTOR
3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
a. Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the
secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
A: For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
Page 530
Engine Bank Identification
Page 1975
Page 1331
TOY 730 - 73mm Toyota Oil Filter Wrench
M 0219 - 74mm Oil Filter Wrench
Testing and Inspection
Brake Warning Indicator: Testing and Inspection
INSPECT BRAKE WARNING LIGHT
a. Disconnect the connector from the brake fluid warning switch b. Release the parking brake
pedal. c. Connect the terminals on the harness side of the level Warning switch connector. d. Start
the engine, check that the warning light lights up.
If warning light does not light up, test the bulb or wire harness.
Page 2145
Valve Clearance: Testing and Inspection
INSPECTION
HINT: Inspect and adjust the valve clearance when the engine is cold.
1. REMOVE BATTERY CLAMP COVER 2. REMOVE THROTTLE BODY COVER 3. REMOVE AIR
CLEANER AND INTAKE AIR CONNECTOR ASSEMBLY 4. REMOVE NO.3 TIMING BELT
COVERS 5. REMOVE IGNITION COILS 6. REMOVE RH CYLINDER HEAD COVER
Remove the 9 bolts, seal washers and cylinder head cover.
7. REMOVE LH CYLINDER HEAD COVER
a. Remove the oil dipstick for the transmission. b. Disconnect the PCV hose. c. Disconnect the
engine wire clamp from the wire bracket on the cylinder head cover. d. Remove the 9 bolts, 9 seal
washers and cylinder head cover.
8. SET NO.1 CYLINDER TO TDC/COMPRESSION
a. Turn the crankshaft pulley, and align its groove with timing mark "0" of the No.1 timing belt cover.
b. Check that the timing marks of the camshaft timing pulleys and timing belt rear plates are
aligned.
If not, turn the crankshaft 1 revolution (360°) and align the mark.
9. INSPECT VALVE CLEARANCE
Page 1137
Page 681
Vehicle Speed Sensor: Testing and Inspection
INSPECT VEHICLE SPEED SENSOR OPERATION
a. Connect the positive (+) lead from the battery to terminal 1 and negative (-) lead to terminal 2. b.
Connect the positive (+) lead from the tester to terminal 3 and the negative (-) lead to terminal 2. c.
Rotate the shaft. d. Check that there is voltage change from approx. 0 V to 11 V or more between
terminals 2 and 3.
HINT: The voltage change should be performed 4 times for every revolution of the speed sensor
shaft.
If operation is not as specified, replace the sensor.
Page 1513
b. Check that the fluid coupling is not damaged and that no silicon oil leaks.
If necessary, replace the fluid coupling.
c. Reinstall the fan to the fluid coupling with the 4 nuts.
Torque: 5.4 Nm (55 kgf-cm, 47 inch lbs.)
3. INSPECT FAN PULLEY BRACKET
Check the turning smoothness of the fan pulley. If necessary, replace the pulley bracket.
4. INSPECT TIMING BELT COMPONENTS
INSTALLATION
1. INSTALL WATER PUMP
a. Install a new O-ring to the water bypass pipe end. b. Apply soapy water to the O-ring. c. Connect
the water pump to the water bypass pipe end. d. Install the water pump and a new gasket with the
5 bolts, 2 stud bolts and nut. Uniformly tighten the bolts, stud bolts and nut in several passes.
Torque:
Bolt: 21 Nm (215 kgf-cm, 15 ft. lbs.) Stud bolt and nut: 18 Nm (185 kgf-cm, 13 ft. lbs.)
2. INSTALL WATER INLET AND INLET HOUSING ASSEMBLY
a. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact
surfaces of the water inlet housing and water pump.
^ Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the
gasket surfaces and sealing groove.
^ Thoroughly clean all components to remove all the loose material.
^ Using a non-residue solvent, clean both sealing surfaces.
Page 1582
a. Lightly tap the radiator port (inlet or outlet) with a soft-faced hammer, and remove the tank. b.
Remove the O-ring.
REASSEMBLY
1. INSPECT LOCK PLATE
Inspect the lock plate for damage.
HINT: ^
If the sides of the lock plate groove are deformed, reassembly of the tank will be impossible.
^ Therefore, first correct any deformation with pliers or similar object. Water leakage will result if the
bottom of the lock plate groove is damaged or dented. Therefore, repair or replace if necessary.
NOTICE: The radiator can only be recaulked 2 times. After the 2nd time, the radiator core must be
replaced.
2. INSTALL NEW O-RINGS AND TANKS
a. After checking that there are no foreign objects in the lock plate groove, install the new O-ring
without twisting it.
HINT: When cleaning the lock plate groove, lightly rub it with sand paper without scratching it.
b. Install the tank without damaging the O-ring.
c. Tap the lock plate with a soft-faced hammer so that there is no gap between it and the tank.
Page 6273
Key Reminder And Seat Belt Warning
Testing and Inspection
Four Wheel Drive Selector Switch: Testing and Inspection
INSPECTION
1. INSPECT 2WD -> 4HI SHIFT
a. Ignition switch ON. b. Check that the 4HI indicator lights come on when the touch select 2-4
switch is in ON position. c. Check that the 4HI indicator lights go off when the touch select 2-4
switch is in OFF position.
HINT: If the light does not light up, even though the switch has been turned ON, the vehicle should be
moved back and forth.
- If switching is not completed after 3 seconds of shift operation, the 4HI indicator light will flash.
2. INSPECT 4HI -> 4LO SHIFT
Page 4119
^ 09710-28012-01 (09710-07031) 09950-40011 (09951-04020, 09952-04010, 09953-04020,
09954-04010, 09955-04031, 09957-04010, 09958-04011)
HINT:
If necessary, use a press to remove the axle hub from the steering knuckle.
C. Remove the dust cover from the steering knuckle.
D. 4WD:
Remove the bearing spacer and ABS speed sensor rotor (W/ABS) or spacer (W/O ABS).
NOTE:
Take care not to scratch the serration of the speed sensor rotor.
14. REMOVE OIL SEAL (OUTSIDE)
Using a screwdriver, remove the oil seal (outside) from the steering knuckle.
15. REMOVE BEARING FROM STEERING KNUCKLE
A. Using snap ring pliers, remove the snap ring.
B. Using the following SSTs and a press, remove the bearing from the steering knuckle.
^ 09950-60020 (09951-00810)
^ 09950-70010 (09951-07150)
16. INSTALL NEW BEARING
A. Using the following SSTs and a press, install a NEW bearing to the steering knuckle.
^ 09527-17011
^ 09950-60020 (09951-00910)
Page 3558
Splice Location
B11
Page 4873
2. REMOVE DRIVE BELT
Loosen the drive belt tension by turning the drive belt tensioner counterclockwise, and remove the
drive belt.
3. DISCONNECT 2 VACUUM HOSES
Remove the 2 clips and disconnect the 2 vacuum hoses.
4. DISCONNECT RETURN HOSE
Remove the clip and disconnect the return hose.
5. DISCONNECT PRESSURE FEED TUBE
Remove the union bolt and gasket, disconnect the pressure feed tube.
6. REMOVE PS VANE PUMP ASSEMBLY
Remove the 2 bolts, nut, stud bolt and PS vane pump assembly.
INSTALLATION
1. INSTALL PS VANE PUMP ASSEMBLY
a. Install the PS vane pump assembly with the stud bolt.
Torque: 22 Nm (220 kgf-cm, 16 ft. lbs.)
b. Install the 2 bolt and nut.
Torque: 44 Nm (450 kgf-cm, 33 ft. lbs.)
2. INSTALL PRESSURE FEED TUBE
a. Connect the pressure feed tube. b. Install a new gasket and the union bolt to the pressure feed
tube.
HINT: Make sure the stopper of the pressure feed tube touches the PS vane pump body as shown
in the illustration, then torque the union bolt.
Torque: 46.5 Nm (475 kgf-cm, 34 ft. lbs.)
3. CONNECT RETURN HOSE
Connect the return hose with the clip.
4. CONNECT 2 VACUUM HOSES
Connect the 2 vacuum hoses and install the 2 clips.
5. INSTALL DRIVE BELT
Loosen the drive belt tension by turning the drive belt tensioner counterclockwise, and install the
belt.
6. INSTALL AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE
Description and Operation
Transmission Position Switch/Sensor: Description and Operation
PARK / NEUTRAL POSITION SWITCH
Engine Control System
The park/neutral position switch comes on when the shift lever is in the N or P position. When it
comes on, terminal NSW of the ECM is grounded to the body ground via the starter relay, thus the
terminal NSW voltage becomes 0 V. When the shift lever is in the D, 2, L or R position, the
park/neutral position switch goes off, so the voltage of the terminal NSW becomes battery voltage
and the voltage of the ECM internal power source. If the shift lever is moved from the N position to
the D position, this signal is used for air-fuel ratio correction and for idle speed control (estimated
control), etc.
Transmission Control System
The park/neutral position switch detects the shift lever position and sends signals to the ECM.
The ECM receives signals (NSW, R, D, 2 and L) from the park/neutral position switch.
Page 3218
BJ Inside of Rear Door LH
BK Inside of Rear Door RH
BL Surrounding of the Front of the Fuel Tank
Connector Location
BA1 Front Door LH Wire and Wire Harness (Connector Location)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel)
BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel)
BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel)
BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Brakes - Front Brakes Vibrating
Technical Service Bulletin # BR004R-02 Date: 040305
Brakes - Front Brakes Vibrating
BRAKES BR004-02 REVISED
September 16, 2002
Title: FRONT BRAKE VIBRATION
Models: '00 - '03 Tundra
TSB REVISION NOTICE: ^
March 5, 2004: A torque specification in, step 24, was changed.
^ September 8, 2003: A torque specification in, step 28, was changed.
The previous TSB should be discarded.
Introduction
Under certain usage conditions, some Tundra trucks may exhibit front brake vibration. Improved
brake caliper assemblies have been introduced to correct this condition.
Applicable Vehicles ^
2000 - 2003 model year Tundra trucks built before the VIN shown below.
Production Change Information
Warranty Information
Applicable Warranty:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36
months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Page 931
12. Install the NEW A/C compressor mounting bracket and hand tighten bolts 1 and 2 while holding
the bracket forward (refer to illustration).
13. While holding the bracket forward, tighten the A/C compressor mounting bolts in the following
sequence: bolt 2, bolt 1, bolt 3.
Torque: 47 N.m (475 kgf.cm, 34 ft.lbf)
14. Remove the accessory drive belt tensioner.
15. Install the NEW accessory drive belt tensioner.
16. Reassemble in the reverse order of disassembly.
17. Refill cooling system.
Page 6546
Instrument Panel
Connector Location
IA1 Engine Room Main and Cowl Wire (Left Kick Panel)
IA2 Engine Room Main and Cowl Wire (Left Kick Panel)
IA3 Engine Room Main and Cowl Wire (Left Kick Panel)
IA4 Engine Room Main and Cowl Wire (Left Kick Panel)
IB1 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IB2 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IB3 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IC1 Cowl Wire and Roof Wire (Left Side of Instrument Panel)
Instrument Panel
Connector Location
ID1 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH)
ID2 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH)
IE1 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IE2 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IE3 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IF1 Front Door RH Wire and Cowl Wire (Right Kick Panel)
IF2 Front Door RH Wire and Cowl Wire (Right Kick Panel)
IF3 Front Door RH Wire and Cowl Wire (Right Kick Panel)
Specifications
Valve Clearance: Specifications
Valve Clearance (Cold)
Intake ...................................................................................................................................................
.......................................................... 0.15 - 0.25 mm Exhaust ...........................................................
............................................................................................................................................... 0.25 0.35 mm
Page 5014
Page 4744
Wiring Harness Connector
E: Indicates the wiring harness and wiring harness connector. The wiring harness with male
terminal is shown with arrows.
Outside numerals are pin numbers.
The first letter of the code for each wiring harness and wiring harness connector(s) indicates the
component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and
Surrounding area, and "B" for the Body and Surrounding area.
When more than one code has the first and second letters in common, followed by numbers (e.g,
IH1, IH2), this indicates the same type of wiring harness and wiring harness connector.
F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in
parts position.
G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside
it). Junction Blocks are shaded to clearly separate
them from other parts.
H: When 2 parts both use one connector in common, the parts connector name used in wire
routing is shown in square brackets [ ].
Wiring Color
I: Indicates the wiring color.
Wire colors are indicated by an alphabetical code.
B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR =
Brown SB = Sky Blue LG = Light Green GR = Gray
The first letter indicates the basic wire color and the second letter indicates the color of the stripe.
Page 2640
Terminal Retainer
Push the terminal retainer down to the temporary lock position.
c. Release the locking lug from terminal and pull the terminal out from rear.
4. INSTALL TERMINAL TO CONNECTOR
a. Insert the terminal.
HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug
locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position.
Page 2263
A. Test J1962 OBDIII CAN Interface Module (P/N 01002744) for continuity.
^ If there is continuity, the cable and CAN Interface Module are OK. Re-check Cable Tests 1, 2,
and 3 while wiggling and flexing the cables.
^ If there is no continuity, proceed to CABLE TEST 4.
CABLE TEST 4.
A. Disconnect the CAN Interface Module (P/N 01002744) from the J1962 OBDII cable using a
Phillips screwdriver.
B. Test J1962 OBDII cable (P/N 02003180) for continuity.
^ If there is no continuity, the cable needs to be replaced.
^ If there is continuity, proceed to CAN Interface Module Test 5.
CAN INTERFACE MODULE TEST 5.
Page 406
B: Junction Connector
Indicates a connector which is connected to a short terminal.
Junction connector in this include a short terminal which is connected to a number of wire
harnesses. Always perform inspection with the short terminal installed. (When installing the wire
harnesses, the harnesses can be connected to any position within the short terminal grouping.
Accordingly, in other vehicles, the same position in the short terminal may be connected to wire
harness from a different part.) Wire harness sharing the same short terminal grouping ha the same
color.
C: Parts Code
The first letter of the code is taken from the first letter of part, and the numbers indicates its order in
parts which start with the same letter.
D: Connector Color
Connectors not indicated are milky white in color.
How to Read Ground Points
HOW TO READ GROUND POINTS
Capacity Specifications
Fluid - Differential: Capacity Specifications
Differential Fluid
Front ....................................................................................................................................................
......................................................................... 1.2 Qt Rear ................................................................
..............................................................................................................................................................
3.7 Qt
Page 2662
If operation is not as specified, replace the MAF meter.
6. Turn the ignition switch OFF. 7. Disconnect the negative (-) terminal cable from the battery. 8.
Disconnect the MAF meter connector.
4. REINSTALL MAF METER
Install the MAF meter with the 2 screws.
5. RECONNECT MAF METER CONNECTOR
Page 6275
Audible Warning Device: Testing and Inspection
KEY REMINDER AND SEAT BELT WARNING
B7 (A), (B) BUCKLE SW LH
(A) 1 - (A) 2, (B) 2 - (B) 1 : Closed with driver's seat belt in use
D16 DOOR COURTESY SW FRONT LH
1 - GROUND : Closed with front LH door open
U1 UNLOCK WARNING SW
1 - 2 : Closed with ignition key in cylinder
C11 (A), C12 (B), C13 (C) COMBINATION METER
(A) 12, (B) 15 - GROUND : Always continuity (B) 10 - GROUND
: Continuity with the front LH door open (Standard cab) : Continuity with the each LH door open
(Access cab)
(C) 1 - GROUND : Continuity with the ignition key in cylinder
(B) 9 - GROUND : Continuity with the driver's seat belt in use
(B) 5 - GROUND : Always approx. 12 volts
(A) 7 - GROUND : Approx. 12 volts with the ignition SW at ON or ST position
Page 168
A. Test J1962 OBDIII CAN Interface Module (P/N 01002744) for continuity.
^ If there is continuity, the cable and CAN Interface Module are OK. Re-check Cable Tests 1, 2,
and 3 while wiggling and flexing the cables.
^ If there is no continuity, proceed to CABLE TEST 4.
CABLE TEST 4.
A. Disconnect the CAN Interface Module (P/N 01002744) from the J1962 OBDII cable using a
Phillips screwdriver.
B. Test J1962 OBDII cable (P/N 02003180) for continuity.
^ If there is no continuity, the cable needs to be replaced.
^ If there is continuity, proceed to CAN Interface Module Test 5.
CAN INTERFACE MODULE TEST 5.
Brakes - Front Brakes Vibrate Upon Application
Technical Service Bulletin # BR004R-02 Date: 050404
Brakes - Front Brakes Vibrate Upon Application
BRAKES BR004-02 REVISED
Title: FRONT BRAKE VIBRATION
Models: '00 - '05 Tundra
September 12, 2002
TSB REVISION NOTICE:
^ April 4, 2005: Applicable Vehicles has been updated to include 2003 - 2005 model years. The
following sections have been updated, expanded, or added: Introduction, Warranty Information,
Production Change Information, Parts Information, Required SSTs, Diagnosis Procedure, Repair
Procedure No.1, and Repair Procedure No.2. PLEASE READ ENTIRE TSB.
^ September 24, 2004: A note has been added, step 26.
^ March 5, 2004: A torque specification in step 24, was changed.
^ September 8, 2003: A torque specification in step 28, was changed.
Previous versions of this TSB should be discarded.
Introduction
Under certain usage conditions, some Tundra trucks may exhibit front brake vibration.
Improvements have been made to various brake components to help improve this condition.
Applicable Vehicles
^ 2000 - 2005 model year Tundra vehicles produced BEFORE the Production Change Effective
VINs shown.
Production Change Information
Page 4804
The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit
breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery
power is supplied to each system are explained. Since all System Circuit diagrams start from the
power source, the power source system must be fully understood.
Page 4670
Terminal Retainer
Push the terminal retainer down to the temporary lock position.
c. Release the locking lug from terminal and pull the terminal out from rear.
4. INSTALL TERMINAL TO CONNECTOR
a. Insert the terminal.
HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug
locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position.
Page 4348
4. With ABS:
Disconnect ABS speed sensor and wire harness clamp from steering knuckle.
Remove the 2 bolts and disconnect the ABS speed sensor and wire harness clamp from the
steering knuckle.
5. Disconnect brake line.
Using the following SST, disconnect the brake line. Use a container to catch the brake fluid.
SST P/N: 09023-00100
6. Remove brake caliper and disc.
A. Remove the bolt and brake line clamp from the steering knuckle.
B. Remove the 2 bolts, brake caliper, and disc.
7. Remove shock absorber.
Page 4431
(b) Install the 2 collars and 4 bushings.
HINT: Apply lithium soap-base glycol grease to all rubbing areas.
- Do not mistake the valve side for the shackle side of the load sensing spring.
2. INSTALL SHACKLE NO. 1 AND NO. 2
Install the lock nut, plate washer and shackle No. 1 to the shackle No. 2 then install the upper nut.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)
3. INSTALL LOAD SENSING SPRING TO SHACKLE NO. 1
(a) Install the load sensing spring and 2 plate washers to shackle No. 1. (b) Install the bolt, washer
and nut.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)
4. INSTALL LOAD SENSING SPRING TO VALVE BODY
Install the load sensing spring to the load sensing valve with the clip.
5. INSTALL VALVE BRACKET
(a) Install the set plate to the load sensing valve through the valve bracket and temporarily tighten
the 2 washers and 2 nuts. (b) Install the load sensing spring assembly, 2 plate washers, bolt,
washer and nut.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)
Page 666
Splice Point
J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel,
and "B" for the Body).
The Location of splice Point I5 is shaded.
K: Indicates a shielded cable.
L: Indicates the pin number of the connector.
The numbering system is different for female and male connectors.
M: Indicates a ground point.
The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for
the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body
and Surrounding area.
How to Read Connector List
HOW TO READ CONNECTOR LIST
A: Indicates connector to be connected to a part. (The numeral indicates the pin No.)
Page 2485
CHART 12
CHART 13
Page 1805
EFI Main Relay: Testing and Inspection
EFI MAIN RELAY
INSPECTION
1. REMOVE RELAY BOX COVER
2. REMOVE EFI MAIN RELAY (Marking: EFI)
3. INSPECT EFI MAIN RELAY CONTINUITY
a. Using an ohmmeter, check that there is continuity between terminals 1 and 2.
If there is no continuity, replace the relay.
b. Check that there is no continuity between terminals 3 and 5.
If there is continuity, replace the relay.
4. INSPECT EFI MAIN RELAY OPERATION
a. Apply battery voltage across terminals 1 and 2. b. Using an ohmmeter, check that there is
continuity between terminals 3 and 5.
If there is no continuity, replace the relay.
5. REINSTALL EFI MAIN RELAY
6. REINSTALL RELAY BOX COVER
Electrical Specifications
Resistance
Page 2363
Knock Sensor: Description and Operation
P0325 - Knock Sensor 1 Circuit Malfunction (Bank 1) CIRCUIT DESCRIPTION
DTC Detection Condition
One of the knock sensors is fitted to the right bank and another to the left bank of the cylinder block
to detect the engine knocking. This sensor contains a piezoelectric element which generates
voltage when it becomes deformed. This occurs when the cylinder block vibrates due to knocking.
If the engine knocking occurs, ignition timing is retarded to suppress it.
Wiring Diagram
Testing and Inspection
Interior Light Switch: Testing and Inspection
INSPECT FRONT PERSONAL LIGHT SWITCH CONTINUITY
a. Disconnect the connector from the personal light. b. Push the personal light switch ON, check
that continuity exists between terminal 3 and body terminal 1.
c. Turn the light switch to DOOR, check that continuity exists between terminal 2 and 3.
If operation is as specified, replace the switch.
INSPECT ROOM LIGHT SWITCH
a. Disconnect the connector from the interior light assembly. b. Turn the interior light switch ON,
check that continuity exists terminal 2 and body ground.
c. Turn the interior light switch to DOOR, check that continuity exists between terminals 1 and 2.
If operation is not as specified, replace the switch.
Air Conditioning Control Assembly
Control Assembly: Testing and Inspection Air Conditioning Control Assembly
On-Vehicle Inspection
AIR CONDITIONING CONTROL ASSEMBLY (Center Cluster Integration)
ON-VEHICLE INSPECTION
1. REMOVE CENTER CLUSTER INTEGRATION PANEL
2. INSPECT A/C CONTROL ASSEMBLY CIRCUIT
Wire Harness Side
a. Disconnect the connector from the A/C control assembly and inspect the connector on the wire
harness side, as shown in the chart.
Test condition: Turn ignition switch to ON
If circuit is as specified, try replacing the amplifier with a new one. If the circuit is not as specified,
inspect the circuits connected to other parts.
Page 5779
Waterproof Type Connector
B: For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White
: Gray
Black or White : Dark Gray
Gray or White : Black
Waterproof Type Connector
"Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up
to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Waterproof Type Connector
"Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 2249
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 6509
Splice Location
I1 Cowl Wire
I2 Cowl Wire
I3 Cowl Wire
I4 Cowl Wire
I5 Cowl Wire
I6 Cowl Wire
I7 Engine Wire
I8 Engine Wire
I9 Engine Wire
I10 Engine Wire
I11 Engine Wire
I12 Engine Wire
I13 Engine Wire
I14 Engine Wire
I15 Engine Wire
I16 Cowl Wire
Body
Splice Location (Access Cab)
B1 Speaker Tweeter Wire LH
B2 Front Door LH Wire
B3 Front Door LH Wire
B4 Roof Wire
B5 Speaker Tweeter Wire RH
B6 B7
Front Door RH Wire
B8 Front Door RH Wire
B9 Rear Door No. 1 Wire RH
B10 Frame Wire
Page 2228
A. Connect Diagnostic Tester cables DLC (P/N 02001637) and CAN Interface Module / J1962
OBDII together (P/N 01002744).
B. Test for continuity.
^ If there is continuity, the cable is OK. Check steps 1 and 2 above to complete the flash
reprogramming process.
^ If there is no continuity, proceed to CABLE TEST 2.
CABLE TEST 2.
A. Disconnect Diagnostic Tester cables DLC (P/N 02001637) and CAN Interface Module /J1962
OBDII (P/N 01002744).
B. Test DLC cable (P/N 02001637) for continuity.
^ If there is continuity, the cable is OK. Proceed to CABLE TEST 3.
^ If there is no continuity, the cable needs to be replaced.
CABLE TEST 3.
Page 4613
Engine Room R/B
Details
Page 2015
Throttle Position Sensor: Testing and Inspection
ON-VEHICLE INSPECTION
1. REMOVE THROTTLE BODY COVER
2. INSPECT SYSTEM OPERATION
a. Check that the throttle linkage moves smoothly.
b. Inspect the throttle control motor for operating sound.
1. Turn the ignition switch ON. 2. When turning the accelerator pedal position sensor lever, check
the running sound of the motor. Also, check that there is no friction sound.
If operation is not as specified, check the throttle control motor (See step 3), wiring and ECM.
c. Inspect the accelerator pedal position sensor.
1. Connect the TOYOTA hand-held tester to the DLC3. 2. Check that the MIL does not light up. 3.
When turning the accelerator pedal position sensor lever to the full-open position, check that the
throttle valve opening percentage
(THROTTLE POS) of the CURRENT DATA shows the standard value.
Standard throttle valve opening percentage: 60 % or more
If operation is not as specified, check that the accelerator pedal position sensor (See step 5), wiring
and ECM.
Page 1759
Materials System.
Required SSTs
NOTE:
Additional Diagnostic Tester Kits, CAN Interface Modules, Program Cards or SSTs may be ordered
by calling SPX/OTC at 1-800-933-8335.
Process Overview
ECU Flash Reprogramming is a 4-step process:
1. Locate the desired calibration file on TIS (Technical Information System).
Calibration files may be found in two areas:
a. Search by model and year for a Technical Service Bulletin addressing a specific product issue.
b. Search by model under the ECU Flash Reprogramming section.
2. Download the calibration file from TIS to the Diagnostic Tester.
The Calibration Update Wizard (CUW) is an application on TIS which downloads calibration files
from TIS to the Diagnostic Tester Program Card. This step is only required when the calibration file
is not currently stored on the Diagnostic Tester Program Card.
3. Reprogram the vehicle ECU with the Diagnostic Tester.
Diagnostic Tester Software now incorporates a function to update a vehicle's ECU calibration
through flash reprogramming.
4. Confirm successful flash update and affix calibration update sticker.
Modifications to ECU calibration files must be recorded and properly displayed on the vehicle using
the calibration update sticker.
NOTE:
Page 2618
^ Confirm cable connections between the vehicle and Diagnostic Tester are secure. (Reference
TSB No. SS004-01, "ECU Flash Reprogramming Error Message.")
^ Do not disconnect or turn off the Diagnostic Tester or the vehicle ignition during reprogramming.
^ Set the parking brake.
^ Complete ALL flash calibration updates provided for each ECU.
If the battery's state of charge or capacity are in question, test with SST No. 00002-MP815-T,
"Midtronics Battery Tester," and follow TSB No. PG017-02, "Battery Maintenance for In-Stock
Vehicles & Pre-Delivery."
To ensure stable battery voltage, a battery charger may be connected during reprogramming if:
^ Voltage does not fall below 11.4 volts.
^ Voltage does not rise above 16.0 volts.
^ Setting is on SLOW charge and not BOOST.
A. Connect the Diagnostic Tester to the vehicle and select CURRENT ECU CAL from the ECU
REPROGRAM MAIN MENU. Determine the vehicle's current ECU calibration. (See Figure 17.)
NOTE:
The vehicle may contain up to 3 separate calibration ID numbers. In the example shown, the
vehicle ECU contains only 2 calibration IDs.
Page 4065
8. DISCONNECT LOWER BALL JOINT
Remove the 4 bolts and disconnect the lower ball joint.
9. REMOVE STEERING KNUCKLE
A. Remove the cotter pin and loosen the nut.
B. Using the following SSTs, disconnect the steering knuckle.
09950-40011(09951-04010, 09952-04010, 09553-04020, 09554-04010, 09955-04031,
09958-04011)
C. Remove the nut and steering knuckle.
NOTE:
4WD:
Be careful not to damage the oil seal and drive shaft boot.
HINT: 4WD:
When it is difficult to disconnect the drive shaft, tap the tip of the drive shaft with a plastic hammer.
10. 2WD:
REMOVE GREASE CAP
A. Mount the axle hub in a soft jaw vise.
HINT:
Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further.
B. Using a screwdriver, remove the grease cap.
HINT:
Be careful not to damage the grease cap.
Page 4796
Engine Room R/B
Details
Page 2723
Page 4464
Vacuum Brake Booster: Service and Repair
REMOVAL
1. REMOVE MASTER CYLINDER 2. DISCONNECT VACUUM HOSE FROM BRAKE BOOSTER
3. REMOVE SCUFF PLATE LH, COWL SIDE TRIM LH, LOWER FINISH PANEL AND NO. 2
HEATER TO REGISTER DUCT 4. REMOVE PEDAL RETURN SPRING 5. REMOVE CLIP AND
CLEVIS PIN
6. REMOVE BRAKE BOOSTER
(a) Remove the 4 nuts and clevis. (b) Pull out the brake booster and gasket. (c) Remove the 2
stopper rings, brake booster bracket and gasket from the brake booster.
INSTALLATION
1. INSTALL BRAKE BOOSTER
(a) Install a new gasket to the brake booster. (b) Install the brake booster bracket and 2 stopper
rings to the brake booster. (c) Install the booster and a new gasket. (d) Install the clevis to the
operating rod. (e) Install and torque the booster installation nuts.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)
(f) Install the clevis pin into the clevis and brake pedal, and install the clip to the clevis pin. (g)
Connect the vacuum hose to the brake booster.
2. INSTALL NO.2 HEATER TO REGISTER DUCT, LOWER FINISH PANEL, COWL SIDE TRIM
LH AND SCUFF PLATE 3. ADJUST LENGTH OF BOOSTER PUSH ROD
Page 2245
^ 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 5457
Airbag Sensor Assembly: Description and Operation
AIRBAG SENSOR ASSEMBLY
The airbag sensor assembly is mounted on the floor inside the lower center cover. The airbag
sensor assembly consists of an airbag sensor, safing sensor, diagnosis circuit, ignition control and
drive circuit, etc. It receives signals from the airbag sensor and judges whether the SRS must be
activated or not.
Page 2704
Step 1
Description and Operation
Transmission Position Switch/Sensor: Description and Operation
PARK / NEUTRAL POSITION SWITCH
Engine Control System
The park/neutral position switch comes on when the shift lever is in the N or P position. When it
comes on, terminal NSW of the ECM is grounded to the body ground via the starter relay, thus the
terminal NSW voltage becomes 0 V. When the shift lever is in the D, 2, L or R position, the
park/neutral position switch goes off, so the voltage of the terminal NSW becomes battery voltage
and the voltage of the ECM internal power source. If the shift lever is moved from the N position to
the D position, this signal is used for air-fuel ratio correction and for idle speed control (estimated
control), etc.
Transmission Control System
The park/neutral position switch detects the shift lever position and sends signals to the ECM.
The ECM receives signals (NSW, R, D, 2 and L) from the park/neutral position switch.
Specifications
Camshaft Bearing: Specifications
INSTALL CAMSHAFTS
NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while
it is being installed. If the camshaft is not kept level, the portion of the cylinder head receiving the
shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the
following steps should be carried out.
a. Install the RH camshafts.
1. Apply MP grease to the thrust portion of the intake and exhaust camshafts. 2. Place the intake
and exhaust camshafts.
3. Set the timing mark (1 dot mark) of the camshaft main gear at approximately 10° angle. 4.
Remove any old packing (FIPG) material from front bearing cap.
5. Apply seal packing to the front bearing cap as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent Install a nozzle that has been cut to a 1.5 mm (0.06 inch) opening.
- Parts must be assembled within 5 minutes of application. Otherwise the material must be
removed and reapplied.
- Immediately remove nozzle from the tube and reinstall cap.
NOTICE: Do not apply seal packing to the front bearing cap grooves.
6. Install the front bearing cap.
HINT: Installing the front bearing cap will determine the thrust portion of the camshaft.
7. Install the other bearing cap in the sequence shown with the arrow mark facing forward.
HINT: Align the arrow marks at the front and rear of the cylinder head with the mark on the bearing
cap.
Diagram Information and Instructions
Transmission Mode Indicator - A/T: Diagram Information and Instructions
Key to Diagrams
A: System Title
B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to
distinguish it from the J/B
Example: 1 Indicates Relay Block No.1
C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type,
or specification is different.
D: Indicates related system.
Page 6292
Audible Warning Device Control Module: Testing and Inspection
LIGHT AUTO TURN OFF
HEAD RELAY
2 - 1 : Closed with the light control SW at HEAD position or the dimmer SW at FLASH position.
Closed with the engine running and the parking brake lever released (w/ daytime running light)
C15 LIGHT CONTROL SW [COMB. SW]
13 - 16 : Closed with light control SW at HEAD position
14 - 16 : Closed with light control SW at TAIL or HEAD position
D16 DOOR COURTESY SW FRONT LH
1 - GROUND : Continuity with the front LH door open
INTEGRATION RELAY
9 - GROUND : Approx. 12 volts with the ignition SW at ON position
14 - GROUND : Continuity with the front LH door open
3, 6 - GROUND : Always approx. 12 volts
8 - GROUND : Always continuity
POWER WINDOW
D16, D17 DOOR COURTESY SW LH, RH
1 - GROUND : Continuity with door open
INTEGRATION RELAY
9 - GROUND : Approx. 12 volts with ignition SW at ON position
3 - GROUND : Always approx. 12 volts
14 - GROUND : Continuity with front LH door open (Standard cab)
14 - GROUND : Continuity with each LH door open (Access cab)
15 - GROUND : Continuity with front RH door open (Standard cab)
15 - GROUND : Continuity with each RH door open (Access cab)
P9 POWER WINDOW CONTROL SW RH
4 - GROUND : Approx. 12 volts with ignition SW on and stays at 12 volts for 41.5 - 44.5 seconds
after the ignition SW is turned off, but if a door is
open in the 45 seconds period, voltage will drop to 0 volts
P10 POWER WINDOW MASTER SW 1 - GROUND : Always continuity 9 - GROUND : Approx. 12
volts with ignition SW on and stays at 12 volts for 41.5 - 44.5 seconds after the ignition SW is
turned off, but if a door is
opened in this 41.5 - 44.5 seconds period, voltage will drop to 0 volts
3 - GROUND : Approx. 12 volts with ignition SW at ON position and master SW at UP position 4 GROUND : Approx. 12 volts with ignition SW at ON position and master SW at DOWN or AUTO
DOWN position
WINDOW LOCK SW
Open with window lock SW at LOCK position
DOOR LOCK CONTROL
INTEGRATION RELAY
8 - GROUND : Always continuity
3 - GROUND : Always approx. 12 volts
Page 2353
Engine Control Module: Service and Repair
VEHICLE REPROGRAMMING
Beginning with some 2001 models and expanding to all models by 2007, Toyota/Scion and Lexus
vehicles are equipped with flash reprogrammable Powertrain Control Modules (PCM).
Reprogramming should only be performed if a Technical Service Bulletin or Service Campaign
provides direction to do so.
Flash reprogramming may be accomplished using one of the following methods: Toyota/Lexus factory scantool
- Vetronix Mastertech
- J2534 Compatible Vehicle Interface (Toyota validated and approved)
REPROGRAMMING WITH SCANTOOL
Toyota/Scion/Lexus ECMs can be reprogrammed using either the Toyota/Lexus factory scantool,
or the Vetronix Mastertech scantool. The ECM reprogramming function is only available with the
authentic Toyota factory scantool software which runs on either of the above mentioned scantools.
Scantool software version requirements are specified in applicable Technical Service Bulletin
(TSB)/Service Communication (SC) documents.
The Toyota/Lexus factory scantool and/or authentic factory software program cards can be
purchased through the official Toyota and Lexus Special Service Tool provider, SPX Corp. To
order, call (800) 933-8335 and request either: P/N 01001271 for the Toyota/Lexus factory scantool including factory software program card
- P/N 01002593-005 for the "stand alone" program card
Program cards are provided with the latest production version software available at time of
purchase.
Vehicle recalibration using a scantool requires use of the following: Personal Computer running a Microsoft Windows 2000 or Windows XP operating system
- Toyota Diagnostic Tester or Vetronix Mastertech Scantool with Toyota factory software
- Toyota/Lexus factory scantool program card
- PC Interface Cable (P/N 01001090) to transfer data from PC to scantool
- Calibration CD (00456-REPRG-001)
REPROGRAMMING WITH J2534 INTERFACE
Toyota/Scion/Lexus ECMs that can be reprogrammed with a scantool can also be reprogrammed
using a Toyota validated J2534-1 interface. Vehicle recalibration requires the use of the following: Toyota validated J2534 interface
- Toyota Calibration Update Wizard software (available on calibration CD)
- Personal Computer running Microsoft Windows 2000/XP or later operating system
- Calibration CD (00456-REPRG-001)
Toyota strongly recommends USING ONLY VALIDATED INTERFACE DEVICES that appear on
this list.
Validated J2534 Devices Toyota works closely with J2534 interface manufacturers to ensure that
their hardware works safely and efficiently with their products. Every device listed on this page has
been thoroughly tested and validated on Toyota, Scion and Lexus vehicles.
It is important to understand that only the specific devices, firmware, DLLs and APIs listed here
have been tested by Toyota. Toyota does not recommend use of any other J2534 device, firmware,
DLL or API that is not listed here. Changes to J2534 hardware/software is outside of Toyota's
control; in some cases, changes made to device hardware/software can negatively impact
reprogramming performance. Toyota makes every effort to continue to work with J2534 interface
manufacturers to ensure continued product compatibility as the respective products evolve.
Requirement for device:
Supplier Device Name Version (Firmware* / DLL* / API*)
Drew Technologies CarDAQ Plus (01.08.06 / 01.08.06 / 04.04)
Actia PassThru+ XS (02.01 / 02.01 / 04.04)
Vetronix Corporation ES6510 Flasher (06.12 / 04.23 / 04.04)
EASE Diagnostics Universal Reprogrammer (JPI1_11b / 1.3.0.13 / 04.04)
Snap-On Pass Thru Pro (02.01 / 02.01 / 04.04)
Blue Streak Electronics Inc. BSE-2534 Global Programmer (01.21 / 02.27 / 04.04)
* Original validated firmware/DLL versions may be superceded by the device manufacturer.
Contact the device manufacturer if you are unable to find the versions listed above.
Support OS:
OS Name and Version:
Front Shock Absorber With Coil Spring
Suspension Strut / Shock Absorber: Service and Repair Front Shock Absorber With Coil Spring
REMOVAL
1. REMOVE FRONT WHEEL
Page 6610
Key Reminder And Seat Belt Warning
Page 6650
w/o Tachometer
HINT: Connect the test leads so that the current from the ohmmeter can flow according to the
above order. This circuit includes the diode.
If resistance value is not as specified, replace the receiver gauge.
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 2194
Crankshaft Position Sensor: Service and Repair
Crankshaft Position Sensor
REMOVAL
1. REMOVE ENGINE UNDER COVER
Page 5209
11. INSTALL LOWER COVER
12. INSTALL LOWER LH FINISH PANEL
13. INSTALL LOWER CENTER COVER
14. INSTALL LOWER NO.2 FINISH PANEL
15. INSTALL GLOVE COMPARTMENT PARTS
Page 4254
Brake Drum: Service and Repair
For information regarding the service and repair of this component and the system that it is a part
of, please refer to Drum Brake System; Service and Repair.
Page 92
Glossary Of Terms And Symbols (Part 2)
Page 4555
a. Using SST, remove the bearing cover (outside) and bearing.
SST 09820-00021
NOTE: Be careful not to damage the fan.
b. Remove the bearing cover (inside).
c. Place the bearing cover (inside) on the rotor.
d. Using SST and a press, press in a new bearing.
SST 09820-00030
e. Using SST, push in the bearing cover (outside).
SST 09285-76010
Page 521
Page 2415
Page 2785
Applicable Vehicles
Locations
DLC3
Engine Controls - ECU Reprogramming Procedure
Technical Service Bulletin # SS002R-01 Date: 030922
Engine Controls - ECU Reprogramming Procedure
SPECIAL SERVICE TOOLS SS002-01 REVISED
March 9, 2001
Title: ECU FLASH REPROGRAMMING PROCESS
Models: Applicable Models
TSB REVISION NOTICE:
^ September 22, 2003: Models added - 2002 (and later) Solara, 2003 (and later) Corolla and
Matrix, and 2004 models; Operation Procedures updated for CAN Interface Module with the latest
Diagnostic Tester software (v. 10.1a and 10.2a), Calibration Update Wizard (v.6.0), and calibration
files.
^ June 20, 2003: Camry and Tacoma models added; Special Service Tools table updated. The
previous TSB should be discarded.
Introduction
Electronic Control Unit (ECU) is a Toyota term used to describe integrated computerized devices
responsible for managing the operation of a system or sub-system. For the purposes of this
bulletin, the term "ECU" is used as a generic label for the following SAE J1930 standard
references:
^ Powertrain Control Module (PCM)
^ Engine Control Module (ECM)
^ Transmission Control Module (TCM)
^ or any other Toyota specific control unit
Flash reprogramming allows the ECU software to be updated for changes in vehicle calibrations
without removing the ECU from the vehicle. Flash calibration updates for specific vehicle
models/ECUs will be released as field fix procedures described in individual service bulletins. This
bulletin details the ECU flash reprogramming process and the applications within the Technical
Information System (TIS) and the Toyota Diagnostic Tester used for reprogramming.
Flash calibration updates can only be applied to the vehicle/ECU combination for which they are
intended. ECUs have internal security that will not allow them to be programmed with another
ECU's information.
Applicable Vehicles ^
2001 (and later) model year 4Runner, Highlander, Land Cruiser, RAV4, Sequoia and Tundra
vehicles.
^ 2002 (and later) model year Camry, Solara and Tacoma vehicles.
^ 2003 (and later) model year Corolla and Matrix vehicles.
^ All 2004 (and later) model year Toyota vehicles except Celica, MR2 Spyder, Avalon, and Tacoma
(3RZ-FE engine)
Warranty Information
Parts Information
NOTE:
Authorized Modifications Labels may be ordered in packages of 25 from the Materials Distribution
Center (MDC) through the TDN Dealer Support
Page 3668
6. REMOVE OIL SEAL (OUTER SIDE)
Using SST, remove the oil seal. SST 09308-00010
7. INSPECT REAR AXLE BEARING
Check for wear or damage.
8. REPLACE REAR AXLE BEARING
a. Using SST and a press, remove the bearing.
SST 09223-56010, 09950-60010 (09951-00560)
b. Using SST and a press, install a new bearing.
SST 09515-30010, 09950-60020 (09951-00890)
9. INSTALL NEW OIL SEAL (OUTER SIDE)
Using SST and a hammer, install a new oil seal. SST 09950-60010 (09951-00610), 09950-70010
(09951-07150)
10. INSPECT BEARING CASE
Check for wear or damage.
Page 605
2. Start the engine.
3. Perform the drive pattern to run and complete the Oxygen Sensor (O2S) Monitor.
HINT:
The 02S Monitor is completed when the following conditions are met:
^ Two (2) minutes or more passed after the engine start.
^ The Engine Coolant Temperature (ECT) is 167°F (75°C) or more.
^ Cumulative running time at 30 mph (48 km/h) or more exceeds 6 minutes.
^ Vehicle is in closed loop.
^ The fuel-cut is operated for 8 seconds or more (for Rear O2S Monitor).
A. Allow the engine to idle for two minutes.
B. Warm up the engine until the Engine Coolant Temperature (ECT) reaches 167°F (75°C).
C. Drive the vehicle over 30 mph (48 km/h) for more than 40 seconds.
D. Stop the vehicle and allow the engine to idle for more than 20 seconds.
E. Repeat steps C and D at least 8 times in one driving cycle. (Do not cycle the ignition key.)
In addition, perform the following steps for the Rear O2S Readiness Monitor:
A. Select second gear.
B. Allow the vehicle to run at 30 mph (48 km/h) or more.
C. Keep the accelerator pedal "off-idle" for more than 10 seconds.
D. Immediately after step C, release the accelerator pedal for at least 10 seconds without
depressing the brake pedal (to execute the fuel-cut).
E. Decelerate the vehicle until the vehicle speed reaches less than 6mph (10km/h).
F. Repeat steps B - E at least twice in one driving cycle.
Accessing O2S Test Results
1. On the Diagnostic Tester* screen, select the following menus:
^ DIAGNOSTICS
^ CARB OBD II
Page 5568
Splice Point
J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel,
and "B" for the Body).
The Location of splice Point I5 is shaded.
K: Indicates a shielded cable.
L: Indicates the pin number of the connector.
The numbering system is different for female and male connectors.
M: Indicates a ground point.
The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for
the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body
and Surrounding area.
How to Read Connector List
HOW TO READ CONNECTOR LIST
A: Indicates connector to be connected to a part. (The numeral indicates the pin No.)
Page 4526
Battery: Service Precautions
PRECAUTION
* Check that the battery cables are connected to the correct terminals.
* Disconnect the battery cables when the battery is given a quick charge.
* Do not perform tests with a high voltage insulation resistance tester. Never disconnect the battery
while the engine is running.
Specifications
Firing Order: Specifications
Firing Order 1 - 8 - 4 - 3 - 6 - 5 - 7 - 2
Page 1981
CHART 8
CHART 9
Page 4594
Wiring Harness Connector
E: Indicates the wiring harness and wiring harness connector. The wiring harness with male
terminal is shown with arrows.
Outside numerals are pin numbers.
The first letter of the code for each wiring harness and wiring harness connector(s) indicates the
component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and
Surrounding area, and "B" for the Body and Surrounding area.
When more than one code has the first and second letters in common, followed by numbers (e.g,
IH1, IH2), this indicates the same type of wiring harness and wiring harness connector.
F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in
parts position.
G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside
it). Junction Blocks are shaded to clearly separate
them from other parts.
H: When 2 parts both use one connector in common, the parts connector name used in wire
routing is shown in square brackets [ ].
Wiring Color
I: Indicates the wiring color.
Wire colors are indicated by an alphabetical code.
B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR =
Brown SB = Sky Blue LG = Light Green GR = Gray
The first letter indicates the basic wire color and the second letter indicates the color of the stripe.
Page 3130
Camshaft Position Sensor: Service and Repair
Camshaft Position Sensor
REMOVAL
1. DRAIN ENGINE COOLANT
2. REMOVE DRIVE BELT
3. REMOVE LH NO.3 TIMING BELT COVER
Page 3244
Electronically Controlled Transmission And A/T Indicator (Part 2)
Page 6560
B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(Connect the Relay) and SW 2 OFF (or Disconnect SW 2)
D. Disconnect and reconnect the connectors while watching the test light.
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
E. Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION:
a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals
are touched, the IC may be destroyed by
static electricity.)
b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact
with the terminals of leads from the IC, etc. of the replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
Special Tool
1. PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown.
2. DISCONNECT CONNECTOR
3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
a. Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the
secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
A: For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
Page 4462
Page 5158
ERROR: stackunderflow
OFFENDING COMMAND: ~
STACK:
Page 6305
Body
Splice Location (Standard Cab)
B1 Speaker Tweeter Wire LH
B2 Front Door LH Wire
B3 Front Door LH Wire
B4 Roof Wire
B5 Speaker Tweeter Wire RH
B6 B7
Front Door RH Wire
B10 Frame Wire
Seat
Front Seat Cover - Damaged
Seat Bottom Frame: Customer Interest Front Seat Cover - Damaged
BODY
BO006-02
Title: FRONT SEAT COVER DAMAGE
Models: '00 - '02 Tundra & '01 - '02 Sequoia Equipped with Power Seats
March 1, 2002
Introduction
Due to the unique curvature of the front seat frames' outboard edge, the driver or passenger could
potentially wear a hole into the seat cover material during entry and exit of the vehicle. This
condition has been addressed and corrected in production. The instructions below will illustrate
how to properly repair vehicles with this condition.
Applicable Vehicles
2000 - 2002 model year Tundra vehicles equipped with power seats produced before the VIN
shown below.
2001 - 2002 model year Sequoia vehicles equipped with power seats produced before the VIN
shown below.
Production Change 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.
Page 4296
4. With ABS:
Disconnect ABS speed sensor and wire harness clamp from steering knuckle.
Remove the 2 bolts and disconnect the ABS speed sensor and wire harness clamp from the
steering knuckle.
5. Disconnect brake line.
Using the following SST, disconnect the brake line. Use a container to catch the brake fluid.
SST P/N: 09023-00100
6. Remove brake caliper and disc.
A. Remove the bolt and brake line clamp from the steering knuckle.
B. Remove the 2 bolts, brake caliper, and disc.
7. Remove shock absorber.
Page 3048
Fuel Supply Line: Service Precautions
FUEL TANK AND LINE
PRECAUTION
- Always use new gaskets when replacing the fuel tank or component parts.
- Apply the proper torque to all parts tightened.
Page 4963
4. INSTALL BUSHING
a. Coat a new O-ring with power steering fluid and install it to the bushing. b. To prevent oil seal lip
damage, wind vinyl tape on the steering rack end, and apply power steering fluid. c. Install the
bushing.
NOTICE: ^
Make sure to install the bushing facing in the correct direction.
^ Be careful not to damage the oil seal lip.
5. INSTALL CYLINDER END STOPPER
a. Align the installation hole for the wire of the stopper with the slot of the rack housing. b. Install a
new wire into the stopper. c. Using SST, turn the stopper clockwise 450 ± 50°.
SST 09631-16010
6. AIR TIGHTNESS TEST
a. Install SST to the rack housing.
SST 09631-12071
b. Apply 53 kPa (400 mm Hg, 15.75 inch Hg) of vacuum for about 30 seconds. c. Check that there
is no change in the vacuum.
If there is change in the vacuum, check the installation of the oil seals.
7. INSTALL CONTROL VALVE ASSEMBLY
Page 4655
Engine Compartment
Instrument Panel
Locations
Page 6398
Air Bag(s) Arming and Disarming: Service and Repair Release Method of Airbag Activation
Prevention Mechanism
RELEASE METHOD OF AIRBAG ACTIVATION PREVENTION MECHANISM
Page 2702
Knock Sensor (Part 2)
Page 4114
Parts Information
Diagnosis Procedure
1. Confirm the customer complaint.
2. Determine if vibration is from front or rear (while brakes are still warm from confirmation driving).
The following procedure will isolate the drum brakes from the rest of the hydraulic system by using
the parking brake (PKB).
NOTE:
Remember, with a foot PKB (on automatic transmission) the pedal must be pressed a second time
to disengage the parking brake.
HINT:
When diagnosing a Tundra with a foot PKB, slowly apply the PKB until the first "click, " then press
the PKB pedal a second time so it will disengage if it is released.
At this time the PKB can be pressed to the desired level for continued diagnosis.
A. Drive the Tundra along a smooth, level section of road at approximately 40 mph - 50 mph.
B. Slowly apply the PKB while driving until the brake begins to engage and slow the vehicle. Do not
apply the PKB past this point of initial engagement.
C. Hold the PKB at this point of initial engagement for a few seconds to slowly reduce the vehicle
speed and allow adequate time to monitor the ride condition.
D. Disengage the PKB.
E. If brake vibration is felt during step (C), then it indicates that the rear brake drums are one
source of brake vibration on this vehicle.
Refer to TSB BR003-02 for parts and repair information relating to Tundra rear brake vibration.
F. If no vibration is felt during step (C), then the front brake assemblies are the cause of brake
vibration on this vehicle.
Proceed to the following repair procedure.
Page 6800
Splice Location
I1 Cowl Wire
I2 Cowl Wire
I3 Cowl Wire
I4 Cowl Wire
I5 Cowl Wire
I6 Cowl Wire
I7 Engine Wire
I8 Engine Wire
I9 Engine Wire
I10 Engine Wire
I11 Engine Wire
I12 Engine Wire
I13 Engine Wire
I14 Engine Wire
I15 Engine Wire
I16 Cowl Wire
Body
Splice Location (Access Cab)
B1 Speaker Tweeter Wire LH
B2 Front Door LH Wire
B3 Front Door LH Wire
B4 Roof Wire
B5 Speaker Tweeter Wire RH
B6 B7
Front Door RH Wire
B8 Front Door RH Wire
B9 Rear Door No. 1 Wire RH
B10 Frame Wire
Page 5143
Compress and extend the shock absorber rod and check that there is no abnormal resistance or
unusual operation sounds. If there is any abnormality, replace the shock absorber with a new one.
NOTICE: When disposing of the shock absorber, see DISPOSAL.
DISPOSAL
1. FULLY EXTEND SHOCK ABSORBER ROD
2. DRILL HOLE TO REMOVE GAS FROM CYLINDER
Using a drill, make a hole in the cylinder, as shown in the illustration to discharge the gas inside.
CAUTION: The discharged gas is harmless, but be careful of chips which may fly up when drilling.
REPLACEMENT
REPLACE BUSHING
a. Using Special Service Tool (SST), 19 mm deep socket wrench and a press, remove the bushing.
SST 09632-36010
b. Using SST and a press, install a new bushing.
SST 09630-24014 (09620-24041), 09632-36010
INSTALLATION
1. INSTALL REAR SHOCK ABSORBER
a. Install the 2 retainers and cushion to the shock absorber.
Locations
EFI Main Relay: Locations
Engine Room R/B
Page 3194
Knock Sensor: Testing and Inspection
INSPECTION
1. REMOVE THROTTLE BODY COVER
2. REMOVE INTAKE AIR CONNECTOR
3. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS
4. REMOVE UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY
5. INSPECT KNOCK SENSOR 1,2
a. Disconnect the knock sensor connectors. b. Using an ohmmeter, check that there is no
continuity between the terminal and body.
If there is continuity, replace the sensor with SST. SST 09816-30010
Torque: 45 N.m (450 kgf.cm, 33 ft.lbf)
c. Reconnect the knock sensor connectors.
6. REINSTALL UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY
7. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS
8. REINSTALL INTAKE AIR CONNECTOR
9. REINSTALL THROTTLE BODY COVER
Page 1932
CHART 24
Page 634
Page 5264
Specified amount: 600 ± 50 g (21.16 ± 1.76 oz.)
2. DISCONNECT LIQUID TUBE
5VZ-FE Shown
a. Using SST, remove the piping clamp.
SST 09870-00025 (Liquid tube)
1. Insert SST to piping clamp.
HINT: Confirm the direction of the piping clamp claw and SST using the illustration showing on the
caution label.
2. Push down SST and release the clamp lock.
NOTE: Be careful not to deform the tubes, when pushing SST.
3. Pull SST slightly and push the release lever, then remove the piping clamp with SST. 4. Remove
the piping clamp from SST.
b. Disconnect the both tubes.
Page 3664
Grease capacity (Color = Black): 190 - 210 g (6.70 - 7.41 oz.)
b. Temporarily install the boot to the inboard joint shaft.
7. CHECK DRIVE SHAFT LENGTH
a. Make sure that the 2 boots are on the shaft groove. b. Make sure that the 2 boots are not
stretched or contracted when the drive shaft is at standard length.
Drive shaft standard length: 523.5 ± 2.0 mm (20.610 ± 0.079 inch)
8. INSTALL LARGE INBOARD JOINT BOOT CLAMP TO INBOARD JOINT SHAFT BOOT
a. Place the large inboard joint boot clamp. b. Using pliers, compress the clamp and attach the
claws.
9. INSTALL OTHER BOOT CLAMPS TO BOTH BOOTS
a. Secure the clamp onto the boot.
b. Place Special Service Tool (SST) onto the clamp.
SST 09521-24010
c. Tighten the SST so that the clamp is pinched.
NOTICE: Do not overtighten the SST.
d. Using SST, adjust the clearance of the clamp.
SST 09240-00020 Clearance: 1.0 - 1.5 mm (0.039 - 0.059 inch)
10. CHECK DRIVE SHAFT
Page 2293
^ 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 2465
A/F and 02 Sensor Identification
Specifications
Page 2423
CHART 7
Page 2344
Waterproof Type Connector
B: For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White
: Gray
Black or White : Dark Gray
Gray or White : Black
Waterproof Type Connector
"Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up
to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Waterproof Type Connector
"Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
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 6511
Splice Location
B11
Page 5098
Page 1683
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 6037
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 3582
Transmission Mode Indicator - A/T: Description and Operation
ELECTRONICALLY CONTROLLED TRANSMISSION AND A/T INDICATOR
SYSTEM OUTLINE
The electronically controlled transmission electrically controls the, throttle pressure, lock-up
pressure, and accumulator pressure etc. through the solenoid valve.
The electronically controlled transmission is a system which precisely controls the gear shift timing
and lock-up timing in response to the vehicle's driving conditions and the engine condition detected
by various sensors. It makes smooth driving possible by shift selection of the gear which is the
most appropriate to the driving conditions at that time, and by preventing downing, squat and gear
shift shock when starting off.
1. GEAR SHIFT OPERATION
When driving, the engine warm up condition is input as a control signal from the engine coolant
temperature sensor to TERMINAL THW of the engine control module, and the vehicle speed is
input to TERMINAL SP2+ of the engine control module from the vehicle speed sensor. At the same
time, the throttle valve opening signal from the throttle position sensor is input to TERMINALS VTA,
VTA2 of the engine control module as a throttle angle signal. Based on these signals, the engine
control module selects the best shift position for the driving conditions and sends current to the
electronically controlled transmission solenoid.
2. LOCK-UP OPERATION
When the engine control module decides based on each signal that the lock-up condition has been
met, the current flows from the engine control module TERMINAL SL to TERMINAL 7 of the
electronically controlled transmission solenoid to GROUND.
3. STOP LIGHT SW CIRCUIT
If the brake pedal is depressed (Stop light SW on) when driving in lock-up position, a signal is input
to TERMINAL STP of the engine control module. As a result, the engine control module cuts the
current to the solenoid to release the lock-up.
4. OVERDRIVE CIRCUIT
- O/D main SW on When the O/D main SW is switched to ON position, a signal is input to
TERMINAL ODMS of the engine control module, and enables shift change to the overdrive range,
through the control of the engine control module.
- O/D main SW off When the O/D main SW is switched to OFF position, a signal is input to
TERMINAL ODMS of the engine control module, and prohibits shift change to the overdrive range
through the control of the engine control module. When in the overdrive range already, shift down
is made.
Page 712
Camshaft Position Sensor
Page 5919
Valve Cover Oil Baffle - Damage Prevention
Valve Cover: Technical Service Bulletins Valve Cover Oil Baffle - Damage Prevention
ENGINE EG007-02
Title: GENERAL MAINTENANCE TIP
Models: All '93 - '03 Models
March 22, 2002
Introduction
To help prevent unnecessary complications during the oil fill process, no undue load should be
placed on the oil baffle attached to the inside of the valve cover (see illustration). This baffle is
designed to deflect oil and should not be used to support the weight of heavy oil fill devices. These
devices can place stress on the baffle, and bend or break it during the oil fill process.
Applicable Vehicles ^
All 1993 - 2003 model year Toyota vehicles.
Oil Filling Procedure
Please take measures to ensure that the baffle is not damaged during the oil fill process. If it does
become damaged, repair it before any collateral damage occurs.
Warranty Information
Diagram Information and Instructions
Brake Lamp: Diagram Information and Instructions
Key to Diagrams
A: System Title
B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to
distinguish it from the J/B
Example: 1 Indicates Relay Block No.1
C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type,
or specification is different.
D: Indicates related system.
Tools and Equipment
Clutch: Tools and Equipment
Clutch - SST (Special Service Tools)
Clutch - Recommended Tools
Clutch - Equipment
Page 4920
Splice Point
J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel,
and "B" for the Body).
The Location of splice Point I5 is shaded.
K: Indicates a shielded cable.
L: Indicates the pin number of the connector.
The numbering system is different for female and male connectors.
M: Indicates a ground point.
The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for
the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body
and Surrounding area.
How to Read Connector List
HOW TO READ CONNECTOR LIST
A: Indicates connector to be connected to a part. (The numeral indicates the pin No.)
Page 1929
Page 1684
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 6983
Windshield
Page 1205
Crankshaft: Service and Repair
For further information regarding this component and the system that it is a part of, please refer to
Cylinder Block Assembly; Service and Repair.
Page 1073
Engine Room R/B
Details
Page 4684
Splice Point
J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel,
and "B" for the Body).
The Location of splice Point I5 is shaded.
K: Indicates a shielded cable.
L: Indicates the pin number of the connector.
The numbering system is different for female and male connectors.
M: Indicates a ground point.
The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for
the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body
and Surrounding area.
How to Read Connector List
HOW TO READ CONNECTOR LIST
A: Indicates connector to be connected to a part. (The numeral indicates the pin No.)
Page 6981
^ Allow recommended cure time for urethane bond before delivering vehicle.
^ Always use OEM or manufacturers approved replacement glass and equivalent bonding
materials.
Page 5756
Instrument Panel
Ground Location
IE Left Kick Panel
IF Left Kick Panel
IG Instrument Panel Brace RH
IH Right Kick Panel
II Right Kick Panel
Body
Ground Location (Access Cab)
Page 5999
f. Access cab: Using a screwdriver, open the cap.
g. Access cab:
Unfasten the bolt and remove rear seat outer belt shoulder anchor.
Torque: 42 N.m (430 kgf.cm, 31 ft.lbf)
h. Insert a screwdriver between the quarter trim and body panel to remove the quarter trim. i.
Employ the same manner described above to the other side.
16. REMOVE ROOF HEADLINING
a. Remove the 2 screws and 2 sun visor holders. b. Standard cab:
Remove the 2 clips and roof headlining.
c. Access cab:
Remove the 3 clips and roof headlining.
INSTALLATION Installation is in the reverse order of removal.
Page 6823
Horn: Electrical Diagrams
Service Hints
C16 HORN SW [COMB.SW]
6 - GROUND : Continuity with horn SW on
Horn
Specifications
Tail Gate
Page 6561
Non-Waterproof Type Connector
"Case 1" Raise the terminal retainer up to the temporary lock position.
Non-Waterproof Type Connector
"Case 2" Open the secondary locking device.
Page 841
Locations
Engine Room R/B
Page 5217
INSPECT MAGNETIC CLUTCH OPERATION a. Disconnect the connector. b. Connect the positive
(+) lead from the battery to terminal 3 and the negative (-) lead to the body ground. c. Check that
the magnetic clutch is energized.
If operation is not as specified, replace the magnetic clutch.
13. 2UZ-FE engine
INSPECT COMPRESSOR LOCK SENSOR RESISTANCE a. Disconnect the connector. b.
Measure resistance between terminals 1 and 2.
Standard resistance: 65 - 125 ohms at 20 °C (68 °F)
If resistance is not as specified, replace the compressor.
Testing and Inspection
Brake Fluid Level Sensor/Switch: Testing and Inspection
INSPECT BRAKE FLUID LEVEL WARNING SWITCH CONTINUITY a. remove the reservoir tank
cap and strainer. b. Disconnect the connector. c. Check that no continuity exists between the
terminals with the switch OFF (float up). d. Use siphon, etc. to take fluid out of the reservoir tank. e.
Check that continuity exists between the terminals with the switch ON (float down) f.
Pour the fluid back in the reservoir tank. If operation is not as specified, replace switch.
Page 2538
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 4235
NOTE:
If replacing the rear axle shaft and if the vehicle is equipped with ABS, ensure proper installation of
the ABS speed sensor rotor and the bearing retainer (differential side). Use SST P/N:
09521-25011-01 to press and install a new sensor rotor and new bearing retainer to the axle shaft
(Refer to Figure 2).
4. Replace the rear brake shoes and brake drums. For additional information on rear brake shoes
and brake drum replacement, refer to the Technical Information System (TIS): 2000 - 2005 model
year Tundra Repair Manual: Brakes: Rear Drum Brake: Removal/Installation.
5. Adjust the PKB to specifications.
6. Remount the tire and wheel assembly to the vehicle. Torque all wheel nuts to the vehicle
according to the vehicle specifications found in TIS: 2000 - 2005 model year Tundra Repair
Manual: Brakes: Rear Drum Brake: Removal/Installation.
7. Road test the vehicle to determine if all brake vibration has been eliminated.
8. If brake vibration remains, determine if the vibration is from the front or the rear (while brakes are
still warm from confirmation driving). If it is front vibration, refer to TSB No. BR004-02, Front Brake
Vibration," for parts and repair information relating to Tundra front brake vibration.
Page 6590
Key Reminder Switch: Harness Locations
Engine Compartment
Connector Location
EA1 Cowl Wire Harness and Wire Harness (Connector Location)
EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B)
EC1 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC2 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC3 Engine No. 2 Wire and Engine Wire (Near the Starter)
ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission)
Page 4430
3. REMOVE SHACKLES NO. 1 AND NO. 2
(a) Remove the nut washer and bolt, and remove the load sensing spring and 2 plate washers. (b)
Loosen the 2 nuts and plate washer plate, and remove the shackle No. 1 from the shackle No. 2.
4. DISASSEMBLE LOAD SENSING SPRING
(a) Remove the 4 bushings and 2 collars. (b) Remove the load sensing valve boot and load
sensing spring boot.
INSPECTION
INSPECT VALVE PISTON PIN AND LOAD SENSING CONTACT SURFACE FOR WEAR
Wear limit: 0.7 mm (0.028 inch)
REASSEMBLY
1. ASSEMBLE LOAD SENSING SPRING
(a) Install the load sensing valve boot and load sensing spring boot.
Page 6250
Splice Location
I1 Cowl Wire
I2 Cowl Wire
I3 Cowl Wire
I4 Cowl Wire
I5 Cowl Wire
I6 Cowl Wire
I7 Engine Wire
I8 Engine Wire
I9 Engine Wire
I10 Engine Wire
I11 Engine Wire
I12 Engine Wire
I13 Engine Wire
I14 Engine Wire
I15 Engine Wire
I16 Cowl Wire
Body
Splice Location (Access Cab)
B1 Speaker Tweeter Wire LH
B2 Front Door LH Wire
B3 Front Door LH Wire
B4 Roof Wire
B5 Speaker Tweeter Wire RH
B6 B7
Front Door RH Wire
B8 Front Door RH Wire
B9 Rear Door No. 1 Wire RH
B10 Frame Wire
Page 6179
Torque: 13 N.m (133 kgf.cm, 10 ft.lbf)
4. INSTALL TAILGATE HANDLE ASSEMBLY
Install the tailgate handle assembly with the 2 bolts.
Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf)
5. INSTALL TAILGATE LOCK
a. Using a torx socket wrench, install the 2 tailgate locks with the 4 torx screws.
Torque: 13 N.m (133 kgf.cm, 10 ft.lbf)
b. Connect the 2 tailgate lock links to the tailgate lock control
6. INSTALL SERVICE HOLE COVER
Using a torx socket wrench, install the service hole cover with the 8 torx screws.
7. INSTALL TAILGATE PROTECTOR
Testing and Inspection
Four Wheel Drive Selector Switch: Testing and Inspection
INSPECTION
1. INSPECT 2WD -> 4HI SHIFT
a. Ignition switch ON. b. Check that the 4HI indicator lights come on when the touch select 2-4
switch is in ON position. c. Check that the 4HI indicator lights go off when the touch select 2-4
switch is in OFF position.
HINT: If the light does not light up, even though the switch has been turned ON, the vehicle should be
moved back and forth.
- If switching is not completed after 3 seconds of shift operation, the 4HI indicator light will flash.
2. INSPECT 4HI -> 4LO SHIFT
Instruments - Oil Pressure Gauge Reads Abnormally Low
Oil Pressure Sender: Customer Interest Instruments - Oil Pressure Gauge Reads Abnormally Low
ELECTRICAL EL017-03
December 23, 2503
Title OIL PRESSURE GAUGE READS LOW
Models '01 - '04 Sequoia & '00 - '02 Tundra
TSB UPDATE NOTICE:
This TSB updates EL006-03. TSB EL006-03 is now obsolete and should be discarded.
Introduction
Some customers with Sequoia or Tundra vehicles may encounter an oil pressure gauge that reads
abnormally low at idle. An updated oil pressure sender has been created to address this condition.
Applicable Vehicles ^
2001 - 2004 model year Sequoia vehicles produced BEFORE the Production Change Effective
VINs shown below.
^ 2000 - 2002 model year Tundra vehicles produced BEFORE the Production Change Effective
VIN shown below.
Production Change Information
Parts Information
Repair Procedure
1. Replace the Oil Pressure Sender.
2. Verify proper operation of the Oil Pressure Gauge.
Warranty Information
Applicable Warranty*:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36
months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Brakes - Front Brakes Vibrating
Technical Service Bulletin # BR004R-02 Date: 040305
Brakes - Front Brakes Vibrating
BRAKES BR004-02 REVISED
September 16, 2002
Title: FRONT BRAKE VIBRATION
Models: '00 - '03 Tundra
TSB REVISION NOTICE: ^
March 5, 2004: A torque specification in, step 24, was changed.
^ September 8, 2003: A torque specification in, step 28, was changed.
The previous TSB should be discarded.
Introduction
Under certain usage conditions, some Tundra trucks may exhibit front brake vibration. Improved
brake caliper assemblies have been introduced to correct this condition.
Applicable Vehicles ^
2000 - 2003 model year Tundra trucks built before the VIN shown below.
Production Change Information
Warranty Information
Applicable Warranty:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36
months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Page 3889
Instrument Panel
Ground Location
IE Left Kick Panel
IF Left Kick Panel
IG Instrument Panel Brace RH
IH Right Kick Panel
II Right Kick Panel
Body
Ground Location (Access Cab)
Page 1444
Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.)
21. INSTALL RH NO.3 TIMING BELT COVER
a. Fit the RH No.3 timing belt cover, matching it with the fan bracket. b. Install the RH No.3 timing
belt cover with the 3 bolts and nut.
Torque: 7.5 Nm (80 kgf-cm, 66 inch lbs.)
22. INSTALL LH NO.3 TIMING BELT COVER
a. Install the oil cooler pipe with the bolt and nut. b. Run the camshaft position sensor wire through
the LH No.3 timing belt cover hole. c. Fit the LH No.3 timing belt cover, matching it with the fan
bracket. d. Install the LH No.3 timing belt cover with the 4 bolts and nut.
Torque: 7.5 Nm (80 kgf-cm, 66 inch lbs.)
e. Install the wire grommet to the LH No.3 timing belt cover. f.
Install the camshaft position sensor connector to the connector bracket.
g. Connect the camshaft position sensor connector. h. Install the sensor wire to the wire clamp on
the LH No.3 timing belt cover. i.
Install the engine wire to the 2 wire clamps on the LH No.3 timing belt cover.
23. INSTALL DRIVE BELT IDLER PULLEY
Install the idler pulley and cover plate with the bolt. Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.)
24. INSTALL PS PUMP
Install the PS pump with the 3 bolts. Torque: 17 Nm (175 kgf-cm, 13 ft. lbs.)
25. INSTALL FAN PULLEY, FAN, FLUID COUPLING AND DRIVE BELT
a. Temporarily install the fan pulley, the fan, fluid coupling assembly with the 4 nuts. b. Install the
drive belt. c. Tighten the 4 nuts holding the fluid coupling to the fan bracket.
Torque: 21 Nm (215 kgf-cm, 16 ft. lbs.)
26. INTAKE AIR CONNECTOR ASSEMBLY 27. INSTALL THROTTLE BODY COVER 28.
INSTALL RADIATOR ASSEMBLY 29. FILL WITH ENGINE COOLANT 30. START ENGINE AND
CHECK FOR LEAKS
Page 4353
SST P/N: 09527-17011
B. Coat MP grease to the oil seal lip.
18. Install new dust cover and axle hub to steering knuckle.
A. Install the NEW dust cover to the steering knuckle with the 4 bolts.
Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)
B. Using the following SST and a press, install the axle hub to the steering knuckle.
SST P/N: 09649-17010
19. Install ABS speed sensor rotor (with ABS) or spacer (without ABS).
NOTE:
Take care not to scratch the serration of the speed sensor rotor and ensure the speed sensor is
installed completely.
20. 2WD:
Install new lock nut.
A. Using the following SST, install and torque a NEW lock nut to the axle hub.
SST P/N: 00002-00909 (09318-12010)
Torque: 274 N.m (2,800 kgf.cm, 203 ft.lbf)
NOTE:
Do NOT use air wrench.
B. Using a chisel and hammer, stake the lock nut.
Locations
Instrument Panel
Diagram Information and Instructions
Engine Control Module: Diagram Information and Instructions
Key to Diagrams
A: System Title
B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to
distinguish it from the J/B
Example: 1 Indicates Relay Block No.1
C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type,
or specification is different.
D: Indicates related system.
Page 2157
If operation is not as specified, replace the MAF meter.
6. Turn the ignition switch OFF. 7. Disconnect the negative (-) terminal cable from the battery. 8.
Disconnect the MAF meter connector.
4. REINSTALL MAF METER
Install the MAF meter with the 2 screws.
5. RECONNECT MAF METER CONNECTOR
Page 606
^ O2S TEST RESULTS
A list of the available oxygen sensors will be displayed.
2. Select the desired oxygen sensor and press Enter.
NOTE:
The monitor result of the A/F sensor will not be displayed. If you select "Bank 1-Sensor 1" or Bank
2-Sensor 1" for a vehicle equipped with an A/F sensor, the Diagnostic Tester will display "No
parameter to display."
3. Compare the test results with the values listed in the Failure Threshold Chart.
* Although this procedure references the Toyota Diagnostic Tester, the O2S test results can be
checked using a generic OBD II scantool. Refer to your OBD II scantool operator's manual for
specific procedures.
Comparing O2S Test Results to Failure Thresholds
1. Determine the correct O2S Failure Threshold Chart for your vehicle by looking in the "O2S
Application Table," in this bulletin.
2. Select appropriate year, model, and engine for specified O2S Failure Threshold Chart.
3. Compare O2S test results with the specified O2S Failure Threshold Chart. It may be necessary
to convert O2S test results to a specific measurement unit using the conversion factor that is
supplied in the specified table. See example.
Example:
Page 5958
Information
PRELIMINARY INSPECTION INSTRUCTIONS
Page 623
CHART 16
CHART 17
Page 3903
B: Junction Connector
Indicates a connector which is connected to a short terminal.
Junction connector in this include a short terminal which is connected to a number of wire
harnesses. Always perform inspection with the short terminal installed. (When installing the wire
harnesses, the harnesses can be connected to any position within the short terminal grouping.
Accordingly, in other vehicles, the same position in the short terminal may be connected to wire
harness from a different part.) Wire harness sharing the same short terminal grouping ha the same
color.
C: Parts Code
The first letter of the code is taken from the first letter of part, and the numbers indicates its order in
parts which start with the same letter.
D: Connector Color
Connectors not indicated are milky white in color.
How to Read Ground Points
HOW TO READ GROUND POINTS
Page 1655
Exhaust Manifold: Testing and Inspection
For further information regarding this component and the system that it is a part of, please refer to
Cylinder Head Assembly; Service and Repair.
Page 5075
Page 520
Applicable Vehicles
Page 1817
EFI Main Relay: Testing and Inspection
EFI MAIN RELAY
INSPECTION
1. REMOVE RELAY BOX COVER
2. REMOVE EFI MAIN RELAY (Marking: EFI)
3. INSPECT EFI MAIN RELAY CONTINUITY
a. Using an ohmmeter, check that there is continuity between terminals 1 and 2.
If there is no continuity, replace the relay.
b. Check that there is no continuity between terminals 3 and 5.
If there is continuity, replace the relay.
4. INSPECT EFI MAIN RELAY OPERATION
a. Apply battery voltage across terminals 1 and 2. b. Using an ohmmeter, check that there is
continuity between terminals 3 and 5.
If there is no continuity, replace the relay.
5. REINSTALL EFI MAIN RELAY
6. REINSTALL RELAY BOX COVER
Page 4175
Torque: 50 N.m (510 kgf.cm, 37 ft.lbf)
25. Install shock absorber with coil spring.
A. Install the upper side of shock absorber to the chassis frame with the 3 nuts.
Torque: 64 N.m (650 kgf.cm, 47 ft.lbf)
B. Connect the lower side of shock absorber to the lower suspension arm with bolt, washer, and
nut.
Torque: 135 N.m (1,400 kgf.cm, 100 ft.lbf)
26. Inspect and install the brake rotor and install the brake caliper with new mounting bolts.
A. Inspect the brake rotors and machine using an on-the-car brake lathe. Replace the rotor if it is
below minimum thickness values
Minimum Thickness: 26.0 mm (1.024 in.)
NOTE:
It is necessary to turn the rotors using the on-the-car brake lathe to ensure even and uniform rotor
run out. DO NOT turn the rotor using an off-the-car brake lathe.
B. Install the disc, brake caliper, and 2 NEW bolts.
Torque: 123 N.m (1,259 kgf.cm, 90 ft.lbf)
C. Install the brake line clamp to the steering knuckle with the bolt.
Torque: 28 N.m (285 kgf.cm, 21 ft.lbf)
27. Install new brake line.
Using the SST, connect NEW brake line.
SST P/N: 09023-00100
Torque: 15 N.m (155 kgf.cm, 11 ft.lbf)
28. With ABS:
Connect the ABS speed sensor and wire harness clamp to the steering knuckle with the 2 bolts.
Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
29. 4WD:
Install drive shaft lock nut.
A. While applying the brakes, tighten the nut.
Torque: 235 N.m (2,400 kgf.cm, 173 ft.lbf)
B. Install the lock cap and a NEW cotter pin. If the holes for the cotter pin are not aligned, tighten
the nut further up to 600.
30. 2WD:
Install grease cap.
31. Install front wheel.
NOTE:
Do NOT use an air wrench.
Torque: 110 N.m (1,150 kgf.cm, 83 ft.lbf)
Page 1023
Engine Oil: Service and Repair
REPLACEMENT
CAUTION: Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the
skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially
harmful contaminants which may cause skin cancer.
- Care should be taken, therefore, when changing engine oil to minimize the frequency and length
of time your skin is exposed to used engine oil. Protective clothing and gloves that cannot be
penetrated by oil should be worn. The skin should be thoroughly washed with soap and water, or
use water-less hand cleaner, to remove any used engine oil. Do not use gasoline, thinners, or
solvents.
- In order to preserve the environment, used oil and used oil filters must be disposed of only at
designated disposal sites.
1. w/ Oil filter change: REMOVE ENGINE UNDER COVER
2. DRAIN ENGINE OIL
a. Remove the oil filler cap. b. Remove the oil drain plug and gasket, and drain the oil into a
container.
3. REPLACE OIL FILTER
a. Using SST, remove the oil filter.
SST 09228-07501
b. Clean the oil filter contact surface on the oil filter mounting. c. Lubricate the filter rubber gasket
with clean engine oil.
d. Tighten the oil filter by hand until the rubber gasket contacts the seat of the filter mounting.
e. Using SST, give it an additional 3/4 turn to seat the filter.
SST 09228-07501
Page 4630
The ground points circuit diagram shows the connections from all major parts to the respective
ground points. When troubleshooting a faulty ground point, checking the system circuits which use
a common ground may help you identify the problem ground quickly. The relationship between
ground points (EA, IB and IC) can also be checked this way.
How to Read Power Source
HOW TO READ POWER SOURCE
Page 5402
c. Using a service-purpose wire harness, tie down the steering wheel pad to the disc wheel.
Wire harness : Stripped wire harness section 1.25 sq.mm or more (0.0019 sq.in. or more).
CAUTION: If a wire harness which is too thin or some other thing is used to tie down the steering
wheel pad, it may be snapped by the shock when the airbag is deployed. This is highly dangerous.
Always use a wire harness for vehicle use which is at least 1.25 sq.mm (0.0019 sq.in).
HINT: To calculate the square of the stripped wire harness section: Square = 3.14 * sq.(Diameter)
divided by 4
1. Install the 2 bolts with washers in the 2 bolt holes in the steering wheel pad.
Bolt: L : 35.0 mm (1.387 in.) M : 6.0 mm (0.236 in.) Pitch : 1.0 mm (0.039 in.)
NOTE: Tighten the bolts by hand until the bolts become difficult to turn.
- Do not tighten the bolts too much.
Specifications
Crankshaft Gear/Sprocket: Specifications
Crankshaft Pulley Bolt Torque .............................................................................................................
.................................................... 245 Nm (181 ft.lb)
Page 1069
Interior Panel Fuse Details
Page 407
The ground points circuit diagram shows the connections from all major parts to the respective
ground points. When troubleshooting a faulty ground point, checking the system circuits which use
a common ground may help you identify the problem ground quickly. The relationship between
ground points (EA, IB and IC) can also be checked this way.
How to Read Power Source
HOW TO READ POWER SOURCE
Page 2900
The ground points circuit diagram shows the connections from all major parts to the respective
ground points. When troubleshooting a faulty ground point, checking the system circuits which use
a common ground may help you identify the problem ground quickly. The relationship between
ground points (EA, IB and IC) can also be checked this way.
How to Read Power Source
HOW TO READ POWER SOURCE
Page 2747
Locations
Anti-Lock Brake System
Page 6822
b. Push the secondary locking device or terminal retainer in to the full lock position.
5. CONNECT CONNECTOR
Disconnection of Male and Female Connectors
Disconnection of Male and Female Connectors
Disconnection Of Male And Female Connectors
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Locations
Intake Air Temperature Sensor: Locations
Mass Air Flow (MAF) Meter
The Intake Air Temperature (IAT) Sensor is installed in the Mass Air Flow (MAF) Meter.
Locations
Vapor Pressure Sensor
Page 4070
INSTALL NEW OIL SEAL (INSIDE)
A. Using the following SST and a plastic hammer, install a NEW oil seal (inside).
09527-17011
NOTE:
Lightly strike the SST on its circumference evenly.
B. Coat MP grease to the oil seal lip.
23. INSTALL STEERING KNUCKLE
A. 4WD:
Insert the drive shaft into the axle hub and temporarily tighten the nut.
NOTE:
Be careful not to damage the oil seal and drive shaft boot.
B. Connect the steering knuckle to the upper suspension arm.
C. Install the nut and a NEW cotter pin. If the holes for the cotter pin are not aligned, tighten the nut
further up to 600.
Torque: 105 N.m (1,100 kgf.cm, 77 ft.lbf)
24. CONNECT LOWER BALL JOINT
Connect the lower ball joint to the steering knuckle with 4 bolts.
Torque: 50 N.m (510 kgf.cm, 37 ft.lbf)
25. INSTALL SHOCK ABSORBER WITH COIL SPRING
A. Install the upper side of shock absorber to the chassis frame with the 3 nuts.
Torque: 64 N.m (650 kgf.cm, 47 ft.lbf)
B. Connect the lower side of shock absorber to the lower suspension arm with bolt, washer and
nut.
Torque: 135 N.m (1,400 kgf.cm, 100 ft.lbf)
26. INSPECT AND INSTALL THE BRAKE ROTOR AND INSTALL THE BRAKE CALIPER WITH
NEW MOUNTING BOLTS
A. Inspect the brake rotors, and machine using an on-the-car brake lathe. Replace the rotor if it is
below minimum thickness values
Minimum Thickness: 26.0 mm (1.024 in.)
NOTE:
It is necessary to turn the rotors using the on-the-car brake lathe to ensure even and uniform rotor
run out. DO NOT turn the rotor using an off-the-car brake lathe.
B. Install the disc, brake caliper and 2 NEW bolts.
Torque: 123 N.m (1,259 kgf.cm, 90 ft.lbf)
C. Install the brake line clamp to the steering knuckle with the bolt.
Torque: 28 N.m (285 kgf.cm, 21 ft.lbf)
27. INSTALL NEW BRAKE LINE
Using the SST, connect NEW brake line.
09023-00100
Page 3136
Crankshaft Position Sensor: Mechanical Specifications
Torque: ................................................................................................................................................
.................................. 6.5 N.m (65 kgf.cm, 58 in.lbf)
Page 2588
^ 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 3352
A. Test the CAN Interface Module (P/N 01002744) for continuity.
^ If there is no continuity, the CAN Interface Module needs to be replaced.
^ If there is continuity, the CAN Interface Module is OK. Re-check Cable Tests 1, 2, 3, and 4 while
wiggling and flexing the cables.
Page 3139
Crankshaft Position Sensor: Testing and Inspection
INSPECTION
NOTE: "Cold" and "Hot" in these sentences express the temperature of the coils themselves.
"Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F).
INSPECT CRANKSHAFT POSITION SENSOR
Resistance
Using an ohmmeter, measure the resistance between the terminals.
If the resistance is not as specified, replace the crankshaft position sensor.
Page 1752
Refer to Reset Procedure 1 for the vehicles with Electronically Controlled Automatic
Transmissions:
Page 2448
CHART 30
Engine/Transmission Controls - Resetting ECM Memory
Engine Control Module: All Technical Service Bulletins Engine/Transmission Controls - Resetting
ECM Memory
TRANSMISSION & CLUTCH TC002-03 REVISED
Title: ECM RESET MEMORY FUNCTION
Models: '00 - '05 All Models
June 10, 2003
TSB REVISION NOTICE:
^ December 20, 2004: Applicable Vehicles section has been updated - 2004 and 2005 model years
added, models and model years updated for various models; and Reset Procedure 2 has been
revised.
^ January 16, 2004: Tundra vehicles were added to the Applicable Vehicles chart.
^ December 17, 2003: T-100 vehicles were removed from the Applicable Vehicles chart.
Previous versions of this TSB should be discarded.
Introduction
Whenever an automatic transmission is replaced, overhauled or individual components are
replaced, use this procedure to clear Engine Control Module ( ECM, SAE term: Powertrain Control
Module, PCM) "Learned Values" to minimize subsequent performance concerns.
CAUTION:
Failure to follow the procedure below may lengthen the time to readjust the ECM "Learned Values,"
potentially resulting in performance concerns.
Required SSTs
Warranty Information
Applicable Vehicles
Page 4992
d. Install the SST.
CAUTION: Place the disc wheel on the level ground.
1. Connect the connectors of the 2 SST to the steering wheel pad connector.
SST 09082-0700, 09082-0760
NOTE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of
the twin lock. Also, secure some slack for the SST wire harness inside the disc wheel.
2. Move the SST to at least 10 m (33 ft) away from the steering wheel pad tied down on the disc
wheel.
e. Cover the steering wheel pad with a cardboard box or tires.
- Covering method using a cardboard box: Cover the steering wheel pad with the cardboard box
and weight the cardboard box down in 4 places with at least 190 N (20 kg, 44 lb). Size of cardboard
box: Must exceed the following dimensions: X = 460 mm (18.11 in.) Y = 650 mm (25.59 in.)
NOTE: When dimension Y of the cardboard box exceeds the diameter of the disc wheel with tire to which
the steering wheel pad is tied, X should be the following size. X = 460 mm (18.11 in.) + width of tire
- If a cardboard box smaller than the specified size is used, the cardboard box will be broken by the
shock from the airbag deployment.
- Covering method using tires: Place at least 3 tires without disc wheel on top of the disc wheel with
tire to which the steering wheel pad is tied. Tire size: Must exceed the following dimensions- Width:
185 mm (7.87 in.)
Page 4050
9. Remove steering knuckle.
A. Remove the cotter pin and loosen the nut.
B. Using the following SSTs, disconnect the steering knuckle.
SST P/N: 09950-40011 (09951-04010, 09952-04010, 09553-04020, 09554-04010 09955-04031,
09958-04011)
C. Remove the nut and steering knuckle.
NOTE:
4WD: Be careful not to damage the oil seal and drive shaft boot.
HINT: 4WD: When it is difficult to disconnect the drive shaft, tap the tip of the drive shaft with a
plastic hammer.
10. 2WD: Remove grease cap.
A. Mount the axle hub in a soft jaw vise.
NOTE:
Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further (refer to
the illustration).
HINT: Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further
(refer to the illustration).
B. Using a screwdriver, remove the grease cap.
NOTE:
Be careful not to damage the grease cap.
Testing and Inspection
Igniter: Testing and Inspection
ON-VEHICLE INSPECTION
NOTE: "Cold" and "Hot" in these sentences express the temperature of the coils themselves.
"Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F).
INSPECT IGNITION COIL (WITH IGNITER) AND SPARK TEST
Check that the spark occurs.
1. Remove the ignition coils (with igniter). 2. Remove the spark plugs. 3. Install the spark plugs to
each ignition coil (with igniter), and connect the ignition coil (with igniter) connector. 4. Disconnect
the 8 injector connectors. 5. Ground the spark plug. 6. Check that spark occurs while engine is
being cranked.
NOTE: To prevent gasoline from being injected out of injectors during this test, crank the engine for
no more than 5 - 10 seconds at a time.
If the spark does not occur, do the test as per the given flow chart.
7. Using a 16 mm plug wrench, install the spark plugs.
Torque: 17.5 N.m (180 kgf.cm, 13 ft.lbf)
8. Reinstall the ignition coils (with igniter).
Component Tests and General Diagnostics
Brake Light Switch: Component Tests and General Diagnostics
w/o Cruise Control:
INSPECT STOP LIGHT SWITCH CONTINUITY
If continuity is not as specified, replace the switch.
w/ Cruise Control:
INSPECT STOP LIGHT SWITCH CONTINUITY
If continuity is not as specified, replace the switch.
Locations
Relay Box: Locations
Driver Side J/B And Integration Relay
Diagram Information and Instructions
Audible Warning Device: Diagram Information and Instructions
Key to Diagrams
A: System Title
B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to
distinguish it from the J/B
Example: 1 Indicates Relay Block No.1
C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type,
or specification is different.
D: Indicates related system.
Page 1226
a. Check only the valves indicated.
- Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
- Record the out-of-specification valve clearance measurements. They will be used later to
determine the required replacement adjusting shim.
Valve clearance (Cold):
b. Turn the crankshaft 1 revolution (360°) and align the mark. (See procedure in step 8) c. Check
only the valves indicated as shown. Measure the valve clearance. (See procedure in step (a))
10. ADJUST VALVE CLEARANCE
a. Remove the timing belt. b. Remove the camshafts. c. Remove the valve lifter and adjusting shim.
d. Determine the replacement adjusting shim size according to these Formula or Charts:
1. Using a micrometer, measure the thickness of the removed shim. 2. Calculate the thickness of a
new shim so that the valve clearance comes within the specified value.
T ..........................................................................................................................................................
................. Thickness of removed shim A ...........................................................................................
.................................................................................. Measured valve clearance N ............................
......................................................................................................................................................
Thickness of new shim
Page 3667
b. Grind the retainer and sensor rotor surfaces, then chisel them out. c. Attach washers and nuts to
the serration bolts, then torque the nuts to install the serration bolts to the backing plate. d. Remove
the 4 nuts and washers from the serration bolts.
2. REMOVE SNAP RING FROM AXLE SHAFT
Using a snap ring expander, remove the snap ring.
3. REMOVE REAR AXLE SHAFT FROM BACKING PLATE
a. Position Special Service Tool (SST) on the backing plate with the 4 nuts.
SST 09521-25011
b. Using a press, remove the rear axle shaft and bearing retainer from the backing plate. c.
Remove the SST
SST 09521-25011
4. INSPECT AXLE SHAFT
Using a dial indicator, measure the runout of the shaft and flange. Maximum shaft runout: 2.0 mm
(0.079 inch) Maximum flange runout: 0.1 mm (0.004 inch) If the rear axle shaft or flange are
damaged or worn, or if runout is greater than the maximum, replace the rear axle shaft.
5. INSPECT OIL SEAL (OUTER SIDE)
a. Check for damage. b. Check the oil seal lip for wear or damage.
Diagram Information and Instructions
Engine Control Module: Diagram Information and Instructions
Key to Diagrams
A: System Title
B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to
distinguish it from the J/B
Example: 1 Indicates Relay Block No.1
C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type,
or specification is different.
D: Indicates related system.
Page 3709
a. Align the matchmarks on the propeller shaft and differential flanges, and connect the flanges
with the 4 bolts, washers and nuts. b. Torque the 4 bolts.
Torque: 74 Nm (750 kgf-cm, 54 ft. lbs.)
c. Temporarily install the center support bearing with 2 mount bolts.
HINT: Make sure the bearing is installed with the drain hole facing downwards.
d. Align the matchmarks on the propeller shaft and transfer flanges, and connect the flanges with
the 4 nuts and washers. e. Torque the 4 nuts.
Torque: 74 Nm (750 kgf-cm, 54 ft. lbs.)
3. ADJUST CENTER SUPPORT BEARING
HINT:
- With the vehicle unladen, adjust the center support bearing to keep the intervals.
- In the same condition, check the center line in the axial direction. Adjust the bearing if necessary.
- Center bearing center line and center bearing housing center line must be adjusted to within 0 ±
1.0 mm of each other in the vehicle's longitudinal direction when the vehicle is unloaded. Torque
the 2 bolts. Torque: 40 Nm (410 kgf-cm, 30 ft. lbs.)
Page 6350
Glossary Of Terms And Symbols (Part 1)
Page 5085
Diagrams
Steering Gear: Diagrams
POWER STEERING GEAR REPLACEMENT AND OVERHAUL W/ RELATED COMPONENTS
Part 1 of 3
Page 1267
12. Install the NEW A/C compressor mounting bracket and hand tighten bolts 1 and 2 while holding
the bracket forward (refer to illustration).
13. While holding the bracket forward, tighten the A/C compressor mounting bolts in the following
sequence: bolt 2, bolt 1, bolt 3.
Torque: 47 N.m (475 kgf.cm, 34 ft.lbf)
14. Remove the accessory drive belt tensioner.
15. Install the NEW accessory drive belt tensioner.
16. Reassemble in the reverse order of disassembly.
17. Refill cooling system.
Page 4957
12. REMOVE CONTROL VALVE ASSEMBLY
a. To prevent oil seal lip damage, wind vinyl tape on the serrated part of the valve shaft. b. Press
out the valve assembly with the oil seal.
NOTICE: ^
Place a shop rag between the valve housing and the blocks.
^ Be careful not to drop the valve assembly.
^ Be careful not to damage the oil seal lip.
13. REMOVE OIL SEAL
Remove the oil seal from the control valve assembly.
14. REMOVE CYLINDER END STOPPER
a. Using SST, turn the stopper clockwise until the wire end is visible through the service hole.
SST 09631-16010
b. Using SST, turn the stopper counterclockwise, and remove the wire.
SST 09631-16010
15. REMOVE STEERING RACK AND BUSHING
a. Using SST, press out the steering rack with the bushing
NOTICE: Take care not to drop the rack.
SST 09950-70010 (09951-07200)
b. Remove the bushing from the rack. c. Remove the O-ring from the bushing.
Page 195
3. Start the engine and warm it up to normal operating temperatures before test-driving.
4. Perform a thorough test drive with several accelerations from a stop with "light throttle"
application until proper transmission shifting is verified.
Reset Procedure 2
1. Disconnect the negative battery cable for 5 minutes.
2. Reconnect battery cable.
3. Start the engine and warm it up to normal operating temperatures before test-driving.
4. Perform a thorough test drive with several accelerations from a stop with "light throttle"
application until proper transmission shifting is verified.
ABS/TCS - Zero Point Calibration Information
Yaw Rate Sensor: Technical Service Bulletins ABS/TCS - Zero Point Calibration Information
T-SB-0020-08
March 25, 2008
Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment
Service Category Brake
Section Brake Control/Dynamic Control System
Market USA
Applicability
Introduction
The purpose of this TSB is to provide information on when and how to perform the zero point
calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting
the battery is a necessary step for performing the zero point calibration.
Warranty Information
Required Tools & Equipment
^ Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE).
^ The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the
service procedures listed in this bulletin.
Preliminary Information
Perform this procedure if any of these repairs have been performed on the vehicle:
^ Wheel alignment has been adjusted.
^ Any chassis components have been removed/installed or replaced.
Page 6498
Body
Connector Location (Access Cab)
BA1 Front Door LH Wire and Wire Harness (Connector Location)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel)
BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel)
BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel)
BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Page 5589
BJ Inside of Rear Door LH
BK Inside of Rear Door RH
BL Surrounding of the Front of the Fuel Tank
Connector Location
BA1 Front Door LH Wire and Wire Harness (Connector Location)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel)
BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel)
BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel)
BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Page 726
2. REMOVE CRANKSHAFT POSITION SENSOR
a. Disconnect the crankshaft position sensor connector. b. Remove the bolt and crankshaft position
sensor.
INSTALLATION
1. INSTALL CRANKSHAFT POSITION SENSOR
a. Install the crankshaft position sensor with the bolt.
Torque: 6.5 N.m (65 kgf.cm, 58 in.lbf)
b. Connect the crankshaft position sensor connector.
2. INSTALL ENGINE UNDER COVER
Page 5076
Information
PRELIMINARY INSPECTION INSTRUCTIONS
Page 4960
f. Using SST, press in the bearing. SST 09950-60010 (09951-00320), 09950-70010 (09951-07150)
3. IF NECESSARY, REPLACE OIL SEAL
a. Using SST, remove the oil seal from the bushing.
SST 09527-20011, 09612-24014 (09613-22011)
NOTICE: Be careful not to damage the bushing.
b. Coat a new oil seal lip with power steering fluid. c. Using SST, press in the oil seal.
SST 09950-60010 (09951-00300, 09951-00460, 09952-06010)
NOTICE: Make sure to install the oil seal facing in the correct direction.
4. IF NECESSARY, REPLACE TEFLON RING AND O-RING
a. Using a screwdriver, remove the teflon ring and O-ring from the steering rack.
NOTICE: Be careful not to damage the groove for the Teflon ring.
b. Coat a new O-ring with power steering fluid and install it to steering rack.
Page 5464
2. REMOVE AIRBAG SENSOR ASSEMBLY
a. Disconnect the airbag sensor assembly connectors.
NOTE: Disconnect the connectors with the sensor assembly installed.
b. Using a torx wrench, remove the 4 screws.
Torx wrench: T40 (Part No. 09042-00020 or locally manufactured tool)
c. Remove the airbag sensor assembly.
INSTALLATION
NOTE:
- Never use SRS parts from another vehicle. When replacing parts, replace them with new parts.
- Never reuse the airbag sensor assembly involved in a collision when the airbag has deployed.
- Never repair a sensor in order to reuse it.
1. INSTALL AIRBAG SENSOR ASSEMBLY
a. Using a torx wrench, install the airbag sensor assembly with 4 screws.
Torx wrench: T40 (Part No. 09042-00020 or locally manufactured tool) Torque: 20 N.m (205
kgf.cm, 15 ft.lbf)
b. Connect the airbag sensor connectors.
NOTE: Connection of the connector is done after the sensor assembly has been installed.
- Make sure the sensor assembly is installed with the specified torque.
- If the sensor assembly has been dropped, or there are cracks, dents or other defects in the case,
bracket or connector, replace the sensor assembly with a new one.
- When installing the sensor assembly, take care that the SRS wiring does not interfere with other
parts and is not pinched between other parts.
- After installing , shake the sensor assembly to check that there is no looseness.
2. INSTALL LOWER CENTER COVER
Page 4912
Splice Location
B11
Page 2325
B. Continue to update the ECU calibration file following the screen flow (Figure 18). Details for
selected screens are shown in Figure 19.
NOTE:
^ Each flash calibration update will take approximately 15 to 45 minutes.
^ Screens E through J (Figure 18) will need to be repeated for each flash calibration update
(calibration ID number).
^ All updates must display "YES" to complete the entire calibration file update for the vehicle ECU.
^ Failure to complete all updates may result in PERMANENT ECU DAMAGE!
CONFIRM UPDATE
4. Confirm successful flash calibration update and affix calibration update sticker.
Follow these steps to confirm the calibration was reprogrammed to the ECU.
Page 4438
3. DISCONNECT BRAKE LINES
Using SST, disconnect the 5 or 6 brake lines from the master cylinder and 3-way or 4-way. SST
09023-00100 Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.)
4. REMOVE MASTER CYLINDER
(a) w/ ABS:
Remove the 2 nuts, wire harness bracket 3-way and check valve bracket. Torque: 13 Nm (130
kgf-cm, 9 ft. lbs.)
(b) w/o ABS:
Remove the 2 nuts, wire harness bracket 4-way and check valve bracket. Torque: 13 Nm (130
kgf-cm, 9 ft. lbs.)
(c) Pull out the master cylinder from brake booster.
INSTALLATION
Installation is in the reverse order of removal.
HINT: Before installation, adjust length of brake booster push rod.
- After installation, fill brake reservoir with brake fluid and bleed brake system.
- Check for leaks, check and adjust brake pedal.
Page 2874
b. Push the secondary locking device or terminal retainer in to the full lock position.
5. CONNECT CONNECTOR
Disconnection of Male and Female Connectors
Disconnection of Male and Female Connectors
Disconnection Of Male And Female Connectors
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Page 5963
Engine/Transmission Controls - Resetting ECM Memory
Engine Control Module: All Technical Service Bulletins Engine/Transmission Controls - Resetting
ECM Memory
TRANSMISSION & CLUTCH TC002-03 REVISED
Title: ECM RESET MEMORY FUNCTION
Models: '00 - '05 All Models
June 10, 2003
TSB REVISION NOTICE:
^ December 20, 2004: Applicable Vehicles section has been updated - 2004 and 2005 model years
added, models and model years updated for various models; and Reset Procedure 2 has been
revised.
^ January 16, 2004: Tundra vehicles were added to the Applicable Vehicles chart.
^ December 17, 2003: T-100 vehicles were removed from the Applicable Vehicles chart.
Previous versions of this TSB should be discarded.
Introduction
Whenever an automatic transmission is replaced, overhauled or individual components are
replaced, use this procedure to clear Engine Control Module ( ECM, SAE term: Powertrain Control
Module, PCM) "Learned Values" to minimize subsequent performance concerns.
CAUTION:
Failure to follow the procedure below may lengthen the time to readjust the ECM "Learned Values,"
potentially resulting in performance concerns.
Required SSTs
Warranty Information
Applicable Vehicles
Page 6584
Instrument Panel
Ground Location
IE Left Kick Panel
IF Left Kick Panel
IG Instrument Panel Brace RH
IH Right Kick Panel
II Right Kick Panel
Body
Ground Location (Access Cab)
Page 6227
b. Check the DTC.
HINT: If a malfunction occurs in the speed sensor or actuator, etc. during cruise control driving, the
ECU actuates AUTO CANCEL of the cruise control and turns ON and OFF the CRUISE MAIN
indicator light to inform the driver of a malfunction. At the same time, the malfunction is stored in
memory as a diagnostic trouble code.
c. Output DTC using diagnosis check wire.
1. Turn the ignition switch ON. 2. Using SST connect terminals Tc and CG of DLC3.
SST 09843-18020
3. Read the DTC on the CRUISE MAIN indicator light.
HINT: If the DTC is not output, inspect the diagnosis circuit.
As an example, the blinking patterns for codes; normal 52 are shown in the illustration.
Page 39
Engine Room R/B
Page 6804
Instrument Panel
Connector Location
IA1 Engine Room Main and Cowl Wire (Left Kick Panel)
IA2 Engine Room Main and Cowl Wire (Left Kick Panel)
IA3 Engine Room Main and Cowl Wire (Left Kick Panel)
IA4 Engine Room Main and Cowl Wire (Left Kick Panel)
IB1 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IB2 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IB3 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IC1 Cowl Wire and Roof Wire (Left Side of Instrument Panel)
Instrument Panel
Connector Location
ID1 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH)
ID2 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH)
IE1 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IE2 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IE3 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IF1 Front Door RH Wire and Cowl Wire (Right Kick Panel)
IF2 Front Door RH Wire and Cowl Wire (Right Kick Panel)
IF3 Front Door RH Wire and Cowl Wire (Right Kick Panel)
Page 6874
B: Junction Connector
Indicates a connector which is connected to a short terminal.
Junction connector in this include a short terminal which is connected to a number of wire
harnesses. Always perform inspection with the short terminal installed. (When installing the wire
harnesses, the harnesses can be connected to any position within the short terminal grouping.
Accordingly, in other vehicles, the same position in the short terminal may be connected to wire
harness from a different part.) Wire harness sharing the same short terminal grouping ha the same
color.
C: Parts Code
The first letter of the code is taken from the first letter of part, and the numbers indicates its order in
parts which start with the same letter.
D: Connector Color
Connectors not indicated are milky white in color.
How to Read Ground Points
HOW TO READ GROUND POINTS
Page 950
Drive Belt: Testing and Inspection
INSPECTION
INSPECT DRIVE BELT
a. Visually check the belt for excessive wear, frayed cords, etc.
If any defect has been found, replace the drive belt.
HINT: Cracks on the rib side of a belt are considered acceptable. If the missing chunks from the
ribs are found on the belt, it should be replaced.
b. 5VZ-FE engine:
Belt tension gauge: DENSO BTG-20 (95506-00020) Borroughs No. BT-33-73F Drive belt tension:
New belt: 135 - 180 lbs. Used belt: 85 - 120 lbs. If the belt tension is not as specified, adjust it.
HINT: "New belt" refers to a belt which has been used less than 5 minutes on a running engine.
- "Used belt" refers to a belt which has been used on a running engine for 5 minutes or more.
- After installing a belt, check that it fits properly in the ribbed grooves.
- Check with your hand to confirm that the belt has not slipped out of the groove on the bottom of
the pulley.
- After installing a new belt, run the engine for about 5 minutes and recheck the belt tension.
Locations
Daytime Running Lamp Relay: Locations
Instrument Panel
Page 3147
1. DISCONNECT IGNITION COIL (WITH IGNITER) CONNECTORS
2. REMOVE IGNITION COILS (WITH IGNITER) FROM SPARK PLUGS
Remove the bolt, and pull out the ignition coil (with igniter). Remove the 8 ignition coils (with
igniter).
INSTALLATION
1. INSTALL IGNITION COILS (WITH IGNITER) TO SPARK PLUGS
Install the ignition coil (with igniter) with the bolt. Install the 8 ignition coils (with igniter). Torque: 7.5
N.m (80 kgf.cm, 66 in.lbf)
2. CONNECT IGNITION COIL (WITH IGNITER) CONNECTORS
Page 3845
6. INSPECT LIMIT SWITCH CONTINUITY
a. Start the engine and raise the vehicle. b. With the actuator connector connected, shift the
transfer shift lever and after checking the operating sound, disconnect the connector and
inspect the continuity between each terminal.
HINT: When shifting the actuator fork shaft, connect the connectors.
7. INSPECT VEHICLE SPEED SENSOR 8. INSPECT 4HI AND 4LO INDICATOR LIGHT Check
the combination meter.
9. INSPECT 4WD CONTROL ECU
Connect the wire harness side connector to the 4WD control ECU and inspect wire harness side
connector from the back side.
Page 670
Glossary Of Terms And Symbols (Part 1)
Seat Belts - Shoulder Belt Particle (Dirt) Buildup
Seat Belt: All Technical Service Bulletins Seat Belts - Shoulder Belt Particle (Dirt) Buildup
BODY BO019-01
August 10, 2001
Title: SHOULDER BELT ANCHOR TAPE SET
Models: All Applicable Models
Introduction To assist customers in preventing particle buildup and preserve the appearance of the
shoulder belt anchor, the following procedure has been developed.
Applicable Vehicles ^
1996-2001 model year 4Runner*1 vehicles.
^ 1996-2001 model year Land Cruiser vehicles.
^ 1996-2001 model year RAV4*2 vehicles.
^ 2001 model year Sequoia vehicles.
^ 1996-1998 model year T100 trucks.
^ 1996-2001 model year Tacoma*1 trucks.
^ 2000-2001 model year Tundra trucks.
*1 Except rear seat belt. *2 Except rear seat belt of soft top models.
Parts Information
Warranty Information
Applicable Warranty*:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36
months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Installation Procedure
1. CLEAN SHOULDER BELT ANCHOR
NOTE:
^ Do not install the tape when the vehicle temperature is below the freezing point.
^ Do not re-use removed fluorocarbon resin tape.
Engine Controls - O2 Sensor Monitor Threshold Values
Oxygen Sensor: All Technical Service Bulletins Engine Controls - O2 Sensor Monitor Threshold
Values
SPECIAL SERVICE TOOLS SS002-03
December 17, 2003
Title O2S TEST RESULTS (MODE 05)
Models All '96 - '03, '04 Corolla, ECHO, Matrix, Sienna & Scion xA & xB
Introduction
This Service Bulletin contains Oxygen Sensor (O2S) Monitor threshold values for all models from
1996 to 2003 and some 2004 models. Starting in 2004, the O2S Monitor threshold values can be
found in the repair manual. These values are used when analyzing the O2S test results to
determine the O2S condition.
Applicable Vehicles ^
All 1996 - 2003 model year Toyota vehicles.
^ 2004 model year Corolla, ECHO, Matrix and Sienna vehicles.
^ 2004 model year Scion xA and xB vehicles.
Function Description
Checking O2S Test Results
To view O2S test results, the O2S Monitor must be completed and the test results must be
checked within the same key cycle. If the ignition key is cycled OFF, the O2S test results will be set
to the minimum or maximum limits, and all test results will be erased. The O2S test results are
stored in the ECU (SAE term: Powertrain Control Module/PCM) when the monitor is completed.
The test results are static and will not change once the monitor is complete.
The process for checking 02S test results is described in the following three basic steps:
1. Completing the O2S Readiness Monitor.
2. Accessing O2S Test Results.
3. Comparing O2S Test Results to Failure Thresholds.
Required SSTs
NOTE:
Additional Diagnostic Tester Kits, Program Cards or other SSTs may be ordered by calling
SPX-OTC at 1-800-933-8335.
Warranty Information
Completing O2S Readiness Monitor
1. Clear any stored Diagnostic Trouble Codes (DTCs) using the Toyota Diagnostic Tester.
Page 4618
Driver Side J/B And Integration Relay Fuse Applications (Part 2)
Driver Side J/B And Integration Relay Fuse Applications (Part 3)
Page 1512
4. REMOVE WATER INLET AND INLET HOUSING ASSEMBLY
a. Disconnect the water bypass hose from the water inlet housing. b. Remove the 2 bolts holding
the water inlet housing to the water pump. c. Disconnect the water inlet housing from the front
water bypass joint, and remove the water inlet and inlet housing assembly. d. Remove the O-ring
from the water inlet housing.
5. REMOVE WATER PUMP
a. Remove the 5 bolts, 2 stud bolts, nut, water pump and gasket. b. Remove the O-ring from the
water bypass pipe.
INSPECTION
1. INSPECT WATER PUMP
a. Visually check the air hole and water hole for coolant leakage. If leakage is found, replace the
water pump and timing belt. b. Turn the pulley, and check that the water pump bearing moves
smoothly and quietly.
If necessary, replace the water pump.
2. INSPECT FLUID COUPLING
a. Remove the 4 nuts and fan from the fluid coupling.
Testing and Inspection
Dimmer Switch: Testing and Inspection
INSPECT LIGHT CONTROL RHEOSTAT
a. Connect terminals 1 and 3 through a 3.4 W test bulb. b. Connect the positive (+) lead from the
battery to terminal 1 and the negative (-) lead to terminal 2. c. Turn the rheostat knob to fully
counterclockwise, check that the test bulb goes out. d. Gradually turn the rheostat knob to
clockwise, check that the test bulb brightness changes from dark to bright.
If operation is not as specified, replace the rheostat.
Page 3461
Glossary Of Terms And Symbols (Part 1)
Page 5345
Repairs and Inspections Required After a Collision: Service and Repair Seat Belt System
REPAIRS AND INSPECTIONS REQUIRED AFTER A COLLISION
SEAT BELT SYSTEMS
CAUTION: Replace the seat belt assembly (outer belt, inner belt, bolts, nuts or sill-bar) if it has
been used in a severe impact. The entire assembly should be replaced even if damage is not
obvious.
1. PRETENSIONER IS NOT ACTIVATED
a. Perform a diagnostic system check. *
b. Perform a visual check which includes the following items with the front seat outer belt removed
from the vehicle.
- Standard cab: Check for cuts and cracks in, or marked discoloration on the quarter trim.
- Access cab: Check for cuts and cracks in, or marked discoloration on the front door rear scuff
plate.
- Check for cuts and cracks in wire harness, and for chipping in connectors.
Page 4733
Engine Room R/B Fuse Applications (Part 2)
Engine Room Fuse Details
Page 2078
Camshaft Position Sensor: Testing and Inspection
ON-VEHICLE INSPECTION
NOTE: "Cold" and "Hot" in these sentences express the temperature of the coils themselves.
"Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F).
INSPECT CAMSHAFT POSITION SENSOR
a. Disconnect the camshaft position sensor connector.
Resistance
b. Using an ohmmeter, measure the resistance between terminals.
If the resistance is not as specified, replace the camshaft position sensor.
c. Reconnect the camshaft position sensor connector.
Specifications
Crankshaft: Specifications
Crankshaft Crank Pin Diameter Mark 1 ...............................................................................................
..................................................................................................... 51.994 - 52.000 mm Mark 2 ..........
..............................................................................................................................................................
............................ 51.988 - 51.994 mm Mark 3 ...................................................................................
................................................................................................................. 51.982 - 51.986 mm
Crankshaft Thrust Clearance Standard ...............................................................................................
...................................................................................................... 0.020 - 0.220 mm Maximum .........
..............................................................................................................................................................
.......................................... 0.30 mm Thrust Washer Thickness ..........................................................
................................................................................................................. 2.440 - 2.490 mm
Crankshaft Maximum Circle Runout ....................................................................................................
.................................................................... 0.08 mm
Main Journal Diameter ........................................................................................................................
.................................................. 66.988 - 67.000 mm Crank Pin Diameter .........................................
....................................................................................................................................... 51.982 52.000 mm Maximum Taper and Out-Of-Round .................................................................................
....................................................................................... 0.02 mm
Page 5216
Compressor Clutch: Testing and Inspection
COMPRESSOR AND MAGNETIC CLUTCH
ON-VEHICLE INSPECTION
1. SET ON MANIFOLD GAUGE SET
2. START ENGINE
3. INSPECT COMPRESSOR FOR METALLIC SOUND
Check if there is a metallic sound from the compressor when the A/C switch is on. If metallic sound
is not heard, replace the compressor assembly.
4. INSPECT REFRIGERANT PRESSURE
5. STOP ENGINE
6. INSPECT VISUALLY FOR LEAKAGE OF REFRIGERANT FROM SAFETY SEAL
Using a gas leak detector, check for leakage of refrigerant. If there is any leakage, replace the
compressor assembly.
7. SET OFF MANIFOLD GAUGE SET
8. CHECK FOR LEAKAGE OF GREASE FROM CLUTCH BEARING
9. CHECK FOR SIGNS OF OIL ON PRESSURE PLATE
If necessary, repair or replace.
10. INSPECT MAGNETIC CLUTCH BEARING FOR NOISE
a. Start engine. b. Check for abnormal noise from near the compressor when the A/C switch is
OFF.
If abnormal noise is being emitted, replace the magnetic clutch.
11. 5VZ-FE engine
INSPECT MAGNETIC CLUTCH OPERATION a. Disconnect the connector. b. Connect the positive
(+) lead from the battery to terminal on the magnetic clutch connector and the negative (-) lead to
the body ground. c. Check that the magnetic clutch is energized.
If operation is not as specified, replace the magnetic clutch.
12. 2UZ-FE engine
Page 4958
16. REMOVE OIL SEAL
Using SST, press out the oil seal. SST 09950-60010 (09951-00360), 09950-70010 (09951-07360)
INSPECTION
INSPECT STEERING RACK
a. Using a dial indicator, check the rack for runout, teeth wear and damage.
Maximum runout: 0.03 mm (0.0118 inch)
b. Check the back surface for wear and damage.
REPLACEMENT
NOTICE: When using a vise, do not overtighten it.
1. IF NECESSARY, REPLACE OIL SEAL AND BEARING
a. Using SST, press out the oil seal and bearing from the control valve housing.
SST 09950-60010 (09951-00250), 09950-70010 (09951-07150)
b. Coat a new oil seal lip with power steering fluid.
c. Using SST, press in the oil seal.
SST 09950-60010 (09951-00180, 09951-00320, 09952-06010), 09950-70010 (09951-07150)
Page 2035
Glossary Of Terms And Symbols (Part 2)
Page 2264
A. Test the CAN Interface Module (P/N 01002744) for continuity.
^ If there is no continuity, the CAN Interface Module needs to be replaced.
^ If there is continuity, the CAN Interface Module is OK. Re-check Cable Tests 1, 2, 3, and 4 while
wiggling and flexing the cables.
Page 1638
Part 2 of 3
Page 5909
FOR
SPECIAL SERVICE CAMPAIGN
REAR FRAME CROSS MEMBER &
LOAD SENSING PROPORTIONING & BY-PASS VALVE INSPECTION
2000-2003 MODEL YEAR TUNDRA
Page 4505
Starter Relay: Testing and Inspection
INSPECTION
1. REMOVE STARTER RELAY
Remove the relay box cover and starter relay.
2. INSPECT STARTER RELAY CONTINUITY
a. Using an ohmmeter, check that there is continuity between terminals 1 and 2.
If there is no continuity, replace the relay.
b. Check that there is no continuity between terminals 3 and 5.
If there is continuity, replace the relay.
3. INSPECT STARTER RELAY OPERATION
a. Apply battery positive voltage across terminals 1 and 2. b. Using an ohmmeter, check that there
is continuity between terminals 3 and 5.
If there is no continuity, replace the relay.
4. REINSTALL STARTER RELAY
Page 3337
memory, the CUW will ask you to select the calibration file(s) to delete from the Diagnostic Tester
Program Card to make room for the new calibration file.
If necessary, check the calibration file(s) to delete, as shown in Figure 11. Click DELETE.
NOTE:
If there is adequate memory to store the calibration file, skip to Step J.
I. The CUW will now delete the calibration file(s) selected (see Figure 12).
Page 1499
a. Check only the valves indicated.
- Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
- Record the out-of-specification valve clearance measurements. They will be used later to
determine the required replacement adjusting shim.
Valve clearance (Cold):
b. Turn the crankshaft 1 revolution (360°) and align the mark. (See procedure in step 8) c. Check
only the valves indicated as shown. Measure the valve clearance. (See procedure in step (a))
10. ADJUST VALVE CLEARANCE
a. Remove the timing belt. b. Remove the camshafts. c. Remove the valve lifter and adjusting shim.
d. Determine the replacement adjusting shim size according to these Formula or Charts:
1. Using a micrometer, measure the thickness of the removed shim. 2. Calculate the thickness of a
new shim so that the valve clearance comes within the specified value.
T ..........................................................................................................................................................
................. Thickness of removed shim A ...........................................................................................
.................................................................................. Measured valve clearance N ............................
......................................................................................................................................................
Thickness of new shim
Page 2986
2. Tighten the union bolt by hand.
3. Using SST, tighten the union bolt to the specified torque.
SST 09612-24014 (09617-24011)
Torque: 33 N.m (340 kgf.cm, 24 ft.lbf) for use with SST 39 N.m (400 kgf.cm, 29 ft.lbf)
HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
c. When connecting the flare nut on the high pressure pipe union, observe these procedures:
1. Apply a light coat of engine oil to the flare nut, and tighten the flare nut by hand. 2. Using SST,
tighten the flare nut to the specified torque.
SST 09023-38400
NOTE: Do not rotate the fuel filter outlet, when tightening the flare nut.
Torque: 28 N.m (285 kgf.cm, 21 ft.lbf) for use with SST 34.3 N.m (350 kgf.cm, 25 ft.lbf)
HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
d. Observe these precautions when removing and installing the injectors.
1. Never reuse the O-ring. 2. When placing a new O-ring on the injector, take care not to damage it
in any way. 3. Coat a new O-ring with spindle oil or gasoline before installing-never use engine,
gear or brake oil.
Page 4809
B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(Connect the Relay) and SW 2 OFF (or Disconnect SW 2)
D. Disconnect and reconnect the connectors while watching the test light.
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
E. Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION:
a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals
are touched, the IC may be destroyed by
static electricity.)
b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact
with the terminals of leads from the IC, etc. of the replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
Special Tool
1. PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown.
2. DISCONNECT CONNECTOR
3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
a. Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the
secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
A: For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
Page 6552
Splice Point
J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel,
and "B" for the Body).
The Location of splice Point I5 is shaded.
K: Indicates a shielded cable.
L: Indicates the pin number of the connector.
The numbering system is different for female and male connectors.
M: Indicates a ground point.
The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for
the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body
and Surrounding area.
How to Read Connector List
HOW TO READ CONNECTOR LIST
A: Indicates connector to be connected to a part. (The numeral indicates the pin No.)
Front
Wheel Bearing: Service and Repair Front
Removal and Installation
REMOVAL
1. REMOVE FRONT WHEEL 2. REMOVE GREASE CAP
Using a screwdriver and hammer, remove the grease cap.
Air Bag System
Repairs and Inspections Required After a Collision: Service and Repair Air Bag System
REPAIRS AND INSPECTIONS REQUIRED AFTER A COLLISION
FRONT PASSENGER AIRBAG ASSEMBLY
VEHICLE NOT INVOLVED IN COLLISION
a. Do a diagnostic system check.
See: Air Bag Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble
Codes/Displaying & Reading Trouble Codes
b. Do a visual check which includes the following item with the front passenger airbag assembly
installed in the vehicle.
Check cuts, minute cracks or marked discoloration on the front passenger airbag assembly and
instrument panel.
VEHICLE INVOLVED IN COLLISION AND AIRBAG IS NOT DEPLOYED
a. Do a diagnostic system check.
See: Air Bag Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble
Codes/Displaying & Reading Trouble Codes
b. Do a visual check which includes the following items with the front passenger airbag assembly
removed from the vehicle.
- Check cuts, minute cracks or marked discoloration on the front passenger airbag assembly.
- Check cuts and cracks in wire harnesses, and for chipping in connectors.
- Check the deformation or cracks on the instrument panel and instrument panel reinforcement.
HINT: If the instrument panel or instrument panel reinforcement is deformed or cracked, never repair it.
Always replace it with a new one.
Page 4715
The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit
breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery
power is supplied to each system are explained. Since all System Circuit diagrams start from the
power source, the power source system must be fully understood.
Page 62
The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit
breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery
power is supplied to each system are explained. Since all System Circuit diagrams start from the
power source, the power source system must be fully understood.
Page 5286
Heater Control Valve: Service and Repair
WATER VALVE
REMOVAL
1. DRAIN ENGINE COOLANT FROM RADIATOR
HINT: It is not necessary to drain out all the coolant.
2. DISCONNECT WATER VALVE CONTROL CABLE FROM WATER VALVE
HINT: At the time of installation, please refer to the following item. After connection, adjust the
control cable.
3. DISCONNECT WATER HOSES
a. Using pliers, grip the claws of the hose clip and slide the hose clip along the hose. b. Disconnect
the water hoses.
HINT: At the time of installation, please refer to the following item. Heater radiator pipe: Push the water hose onto the heater radiator pipe as far as second ridge on
the pipe.
- Water valve: Push the water hose onto the water valve pipe as far as water valve.
- Install the hose clip in a position, as shown in the illustration.
Page 4797
Engine Compartment
Instrument Panel
Locations
Page 3578
b. Push the secondary locking device or terminal retainer in to the full lock position.
5. CONNECT CONNECTOR
Disconnection of Male and Female Connectors
Disconnection of Male and Female Connectors
Disconnection Of Male And Female Connectors
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Page 4872
REMOVAL
1. REMOVE AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE
a. Disconnect the MAF meter connector. b. Disconnect the hoses. c. Remove the clamp. d.
Remove the 3 bolts and air cleaner assembly with air cleaner hose.
Page 6558
Seat Belt Reminder Lamp: Diagnostic Aids
Voltage Check
Voltage Check
Voltage Check
A. Establish conditions in which voltage is present at the check point.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(SW 2 OFF)
B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or
component terminal. This check can be done with a test light instead of a voltmeter.
Continuity and Resistance Check
Continuity and Resistance Check
Continuity And Resistance Check
A. Disconnect the battery terminal or wire so there is no voltage between the check points. B.
Contact the two leads of an ohmmeter to each of the check points.
Page 6351
Glossary Of Terms And Symbols (Part 2)
Page 5901
Page 2427
CHART 12
CHART 13
Page 953
Assenmacher Specialty Tools 1-800-525-2943
Locations
Supplemental Restraint System
Page 4338
Torque: 64 N.m (650 kgf.cm, 47 ft.lbf)
B. Connect the lower side of shock absorber to the lower suspension arm with bolt, washer and
nut.
Torque: 135 N.m (1,400 kgf.cm, 100 ft.lbf)
26. INSPECT AND INSTALL THE BRAKE ROTOR AND INSTALL THE BRAKE CALIPER WITH
NEW MOUNTING BOLTS
A. Inspect the brake rotors, and machine using an on-the-car brake lathe. Replace the rotor if it is
below minimum thickness values Minimum Thickness: 26.0 mm (1.024 in.)
B. Install the disc, brake caliper and 2 NEW bolts.
Torque: 123 N.m (1,259 kgf.cm, 90 ft.lbf)
C. Install the brake line clamp to the steering knuckle with the bolt.
Torque: 28 N.m (285 kgf.cm, 21 ft.lbf)
27. INSTALL NEW BRAKE LINE
Using the SST, connect NEW brake line.
^ 09023-00100
Torque: 15 N.m (155 kgf.cm, 11 ft.lbf)
28. W/ABS: CONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP
Connect the ABS speed sensor and wire harness clamp to the steering knuckle with the 2 bolts.
Torque: 8.0 N.m (82 kgf.cm, 71 in..lbf)
29. 4WD: INSTALL DRIVE SHAFT LOCK NUT
A. While applying the brakes, tighten the nut.
Torque: 235 N.m (2,400 kgf.cm, 173 ft.lbf)
B. Install the lock cap and a NEW cotter pin.
If the holes for the cotter pin are not aligned, tighten the nut further up to 60°.
30. 2WD: INSTALL GREASE CAP
31. INSTALL FRONT WHEEL
NOTE:
Do NOT use air wrench.
Torque: 110 N.m (1,150 kgf.cm, 83 ft.lbf)
32. DEPRESS BRAKE PEDAL SEVERAL TIMES
33. FILL THE BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM
34. CHECK ABS SPEED SENSOR SIGNAL (SEE REPAIR MANUAL)
Description and Operation
Throttle Position Sensor: Description and Operation
Throttle Position Sensor
Throttle position sensor is mounted on the throttle body and it has 2 sensors to detect the throttle
opening angle and a malfunction of the throttle position sensor's own.
Voltage applied to the terminals VTA and VTA2 of the ECM changes between 0 V and 5 V in
proportion to the opening angle of the throttle valve.
The ECM judges the current opening angle of the throttle valve from these signals output from
terminals VTA and VTA2, and the ECM controls the throttle motor to make the throttle valve
opening angle properly in accordance with the driving condition.
If this DTC is stored, the ECM cuts down the power for the throttle motor and the electromagnetic
clutch, and the throttle valve is fully closed by the return spring. However, the opening angle of the
throttle valve can be controlled by the accelerator pedal through the throttle cable.
Page 1794
Terminals Of ECU - Connector Pinouts (Part 2)
Page 2773
CHART 26
Testing and Inspection
Oil Filter: Testing and Inspection
For further information regarding this component and the system that it is a part of, please refer to
Engine Lubrication; Testing and Inspection; Procedures.
Page 790
Step 4
O/D OFF indicator light does not light up
Steps 1 - 2
O/D OFF indicator light remains ON
Page 6409
Splice Location
I1 Cowl Wire
I2 Cowl Wire
I3 Cowl Wire
I4 Cowl Wire
I5 Cowl Wire
I6 Cowl Wire
I7 Engine Wire
I8 Engine Wire
I9 Engine Wire
I10 Engine Wire
I11 Engine Wire
I12 Engine Wire
I13 Engine Wire
I14 Engine Wire
I15 Engine Wire
I16 Cowl Wire
Body
Splice Location (Access Cab)
B1 Speaker Tweeter Wire LH
B2 Front Door LH Wire
B3 Front Door LH Wire
B4 Roof Wire
B5 Speaker Tweeter Wire RH
B6 B7
Front Door RH Wire
B8 Front Door RH Wire
B9 Rear Door No. 1 Wire RH
B10 Frame Wire
Page 6967
a. Cut off the tip of the cartridge nozzle.
Part No. 08850-00801 or equivalent
HINT: After cutting off the tip, use all adhesive within the time described in the table.
b. Load the cartridge into the sealer gun. c. Coat the glass with adhesive as shown in the
illustration.
A: 8.0 mm (0.314 in.) B: 12.0 mm (0.472 in.)
7. Slide type:
APPLY ADHESIVE
Page 272
Airbag Sensor Assembly: Testing and Inspection Replacement Requirements
REPLACEMENT REQUIREMENTS
In the following cases, replace the airbag sensor assembly.
- If the SRS has been deployed in a collision.
- If the airbag sensor assembly has been found to be faulty in troubleshooting.
- If the airbag sensor assembly has been dropped.
CAUTION: For removal and installation of the airbag sensor assembly. Be sure to follow the correct
procedure.
Page 3703
Drive/Propeller Shaft: Testing and Inspection
PROBLEM SYMPTOMS TABLE
Use the table to help you find the cause of the problem. The numbers indicate the priority of the
likely cause of the problem. Check each part in order. If necessary, replace these parts.
Page 4740
Engine Room R/B
Details
Locations
Vehicle Speed Sensor: Locations
Vehicle Speed Sensor NO.1
Vehicle Speed Sensor NO.2
Vehicle Speed Sensor NO.1
Page 4512
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.
Specifications
Valve Body: Specifications
Valve Body Spring Upper Valve Body Lock-Up Relay Valve Red Free Length 23.42 mm
Coil Outer Diameter 4.66 mm
Total No. Of Coils 12.25
Secondary Regulator Valve Purple Free Length 32.88 mm
Coil Outer Diameter 8.2 mm
Total No. Of Coils 9.13
3-4 Shift Valve Purple Free Length 30.77 mm
Coil Outer Diameter 9.7 mm
Total No. Of Coils 8.5
2-3 Shift Valve Purple Free Length 30.77 mm
Coil Outer Diameter 9.7 mm
Total No. Of Coils 8.5
2nd Coast Modulator Valve Blue Free Length 24.55 mm
Coil Outer Diameter 8.32 mm
Total No. Of Coils 9
Low Coast Modulator Yellow Free Length 26.43 mm
Coil Outer Diameter 8.26 mm
Total No. Of Coils 10.51
Lower Valve Body Primary Regulator Valve White Free Length 38.58 mm
Coil Outer Diameter 16.88 mm
Total No. Of Coils 9.5
Cut Back Valve None Free Length 33.95 mm
Coil Outer Diameter 8.2 mm
Total No. Of Coils 12.5
Solenoid Modulator Valve Light Blue Free Length 26.60 mm
Coil Outer Diameter 5.89 mm
Total No. Of Coils 12.0
Accumulator Control Valve None Free Length 33.81 mm
Coil Outer Diameter 9.7 mm
Engine Controls - Bank 1/Bank 2 O2 Sensor identification
Oxygen Sensor: All Technical Service Bulletins Engine Controls - Bank 1/Bank 2 O2 Sensor
identification
ENGINE EG034-07
Title: ENGINE BANK 1 AND BANK 2 A/F AND O2 IDENTIFICATION
Models: '93 - '08 Applicable Models
June 28, 2007
The information contained in this TSB supercedes TSB No. EG037-04. TSB No. EG037-04 is now
obsolete and should be discarded.
Introduction
This service bulletin provides information on the proper identification of engine bank 1 and engine
bank 2 for correct A/F sensor and oxygen sensor replacement.
This bulletin contains information that identifies engine bank 1 and engine bank 2 on the following
engines: 1AZ-FE, 2AZ-FE, 2AZ-FE (PZEV), 1GR-FE, 2GR-FE, 2GR-FSE, 2JZ-GE, 1MZ-FE,
3MZ-FE, 1UR-FSE, 3UR-FE, 2UZ-FE, 3UZ-FE, 5VZ-FE, and 1ZZ-FE.
^ Bank 1 (B1) refers to the bank that includes cylinder No. 1.
^ Bank 2 (B2) refers to the bank opposite bank 1.
^ Sensor 1 (S1) refers to the sensor that is located before the catalytic converters.
^ Sensor 2 (S2) refers to the sensor that is located after the catalytic converters.
Warranty Information
Page 6226
e. Inspect the RES (resume) switch.
1. Push the main switch ON. 2. Drive at a desired speed (40 km/h (25 mph) or higher). 3. When
operating one of the followings, check that the cruise control system is cancelled and that the
normal driving mode is reset.
- Depress the brake pedal.
- Shift into except D position.
- Pull the cruise control switch for CANCEL.
4. After the control switch is turned to RES/ACC at the driving speed of more than 40 km/h (25
mph), check that the vehicle restores the speed
before the cancellation.
Clearing Diagnostic Trouble Codes
NOTE: This is the only information provided by the manufacturer for Clearing Diagnostic Trouble
Codes for this system.
DTC CLEARANCE
a. The following actions will erase DTCs and freeze frame data.
1. Operating the OBD II scan tool (complying with SAE J1978) or TOYOTA hand-held tester to
erase codes. (See the OBD II scan tool's
instruction book for operating instructions.)
2. Disconnecting the battery terminals or EFI fuse.
b. After completing repairs, the DTC retained in the memory can be cleared by removing the
ECU-B fuse for 10 seconds or more with the ignition
switch OFF.
c. Check that the normal code is displayed after connecting the fuse.
Displaying & Reading Trouble Codes
NOTE: This is the only information provided by the manufacturer for reading diagnostic trouble
codes for this system.
1. DIAGNOSIS SYSTEM
a. Check the indicator.
1. Turn the ignition switch to ON. 2. Check that the CRUISE MAIN indicator light comes on when
the cruise control main switch is turned ON, and that the indicator light goes
off when the main switch is turned OFF.
HINT: If the indicator check result is not normal, proceed to troubleshooting for the combination
meter section.
Page 5355
An airbag activation prevention mechanism is built into the connector for the squib circuit of the
SRS.
When release of the airbag activation prevention mechanism is directed in the troubleshooting
procedure, as shown in the illustration of the connectors, insert paper which has the same
thickness as the male terminal, between the terminal and the short spring.
CAUTION: Never release the airbag activation prevention mechanism on the steering wheel pad
connector.
NOTE:
Page 5214
Compressor Clutch: Diagrams
Compressor And Magnetic Clutch (Part 1)
Engine Controls - O2 Sensor Monitor Threshold Values
Oxygen Sensor: All Technical Service Bulletins Engine Controls - O2 Sensor Monitor Threshold
Values
SPECIAL SERVICE TOOLS SS002-03
December 17, 2003
Title O2S TEST RESULTS (MODE 05)
Models All '96 - '03, '04 Corolla, ECHO, Matrix, Sienna & Scion xA & xB
Introduction
This Service Bulletin contains Oxygen Sensor (O2S) Monitor threshold values for all models from
1996 to 2003 and some 2004 models. Starting in 2004, the O2S Monitor threshold values can be
found in the repair manual. These values are used when analyzing the O2S test results to
determine the O2S condition.
Applicable Vehicles ^
All 1996 - 2003 model year Toyota vehicles.
^ 2004 model year Corolla, ECHO, Matrix and Sienna vehicles.
^ 2004 model year Scion xA and xB vehicles.
Function Description
Checking O2S Test Results
To view O2S test results, the O2S Monitor must be completed and the test results must be
checked within the same key cycle. If the ignition key is cycled OFF, the O2S test results will be set
to the minimum or maximum limits, and all test results will be erased. The O2S test results are
stored in the ECU (SAE term: Powertrain Control Module/PCM) when the monitor is completed.
The test results are static and will not change once the monitor is complete.
The process for checking 02S test results is described in the following three basic steps:
1. Completing the O2S Readiness Monitor.
2. Accessing O2S Test Results.
3. Comparing O2S Test Results to Failure Thresholds.
Required SSTs
NOTE:
Additional Diagnostic Tester Kits, Program Cards or other SSTs may be ordered by calling
SPX-OTC at 1-800-933-8335.
Warranty Information
Completing O2S Readiness Monitor
1. Clear any stored Diagnostic Trouble Codes (DTCs) using the Toyota Diagnostic Tester.
Page 4628
Splice Point
J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel,
and "B" for the Body).
The Location of splice Point I5 is shaded.
K: Indicates a shielded cable.
L: Indicates the pin number of the connector.
The numbering system is different for female and male connectors.
M: Indicates a ground point.
The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for
the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body
and Surrounding area.
How to Read Connector List
HOW TO READ CONNECTOR LIST
A: Indicates connector to be connected to a part. (The numeral indicates the pin No.)
Page 637
CHART 27
Page 5634
HINT: Tape the screwdriver tip before use.
d. Remove the bolt and front seat outer belt floor anchor.
e. Remove the quarter trim.
1. Using a screwdriver, remove the quarter trim belt hole cover.
HINT: Tape the screwdriver tip before use.
2. Using a screwdriver, remove the cap.
HINT: Tape the screwdriver tip before use.
3. Remove the bolt and front seat outer belt shoulder anchor.
4. Using a screwdriver, remove the quarter trim.
HINT: Tape the screwdriver tip before use.
f. Remove the retractor of front seat outer belt.
CAUTION: Never disassemble the front seat outer belt.
NOTE: When removing the retractor of front seat outer belt, take care not to pull the seat belt
pretensioner wire harness.
Page 4441
NOTICE: Apply lithium soap base glycol grease to the rubber parts indicated by the arrows.
Page 3732
Step 4
O/D OFF indicator light does not light up
Steps 1 - 2
O/D OFF indicator light remains ON
Page 1213
Piston: Service and Repair
For further information regarding this component and the system that it is a part of, please refer to
Cylinder Block Assembly; Service and Repair.
Page 5694
Page 4224
Brake Rotor/Disc: Testing and Inspection
For information regarding the inspection of this component, please refer to Brake Caliper; Service
and Repair; Disassembly and Reassembly.
Locations
Vapor Pressure Sensor
Page 6438
Key Reminder Switch: Pinout Values and Diagnostic Parameters
KEY REMINDER AND SEAT BELT WARNING
B7 (A), (B) BUCKLE SW LH
(A) 1 - (A) 2, (B) 2 - (B) 1 : Closed with driver's seat belt in use
D16 DOOR COURTESY SW FRONT LH
1 - GROUND : Closed with front LH door open
U1 UNLOCK WARNING SW
1 - 2 : Closed with ignition key in cylinder
C11 (A), C12 (B), C13 (C) COMBINATION METER
(A) 12, (B) 15 - GROUND : Always continuity (B) 10 - GROUND
: Continuity with the front LH door open (Standard cab) : Continuity with the each LH door open
(Access cab)
(C) 1 - GROUND : Continuity with the ignition key in cylinder
(B) 9 - GROUND : Continuity with the driver's seat belt in use
(B) 5 - GROUND : Always approx. 12 volts
(A) 7 - GROUND : Approx. 12 volts with the ignition SW at ON or ST position
Page 4363
Repair Procedure
1. REMOVE FRONT WHEEL
2. 4WD:
REMOVE GREASE CAP
Using a screwdriver and hammer, remove the grease cap.
3. 4WD:
DISCONNECT DRIVE SHAFT
A. Remove the cotter pin and lock cap.
B. While applying the brakes, remove the lock nut.
4. W/ABS DISCONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP FROM
STEERING KNUCKLE
Remove the 2 bolts and disconnect the ABS speed sensor and wire harness clamp from the
steering knuckle.
5. DISCONNECT BRAKE LINE
Using the SST, disconnect the brake line. Use a container to catch the brake fluid.
Page 1029
Steering - Lubricant
Page 2299
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 6510
Body
Splice Location (Standard Cab)
B1 Speaker Tweeter Wire LH
B2 Front Door LH Wire
B3 Front Door LH Wire
B4 Roof Wire
B5 Speaker Tweeter Wire RH
B6 B7
Front Door RH Wire
B10 Frame Wire
Seat
Page 2315
DOWNLOAD FILE TO TESTER
2. Download the calibration file to the Diagnostic Tester.
The Calibration Update Wizard (CUW) is a new application on TIS which downloads calibration
files from TIS onto the Diagnostic Tester Program Card.
NOTE:
Before you begin, ensure that the Diagnostic Tester is equipped with software version 8.0a, or
later. Only a 12 MB program card (P/N 01002593-005) may be used for this process.
A. Before downloading a new calibration file from TIS, check the current calibration files stored on
the Diagnostic Tester Program Card by following the screen flow shown (Figure 4).
NOTE:
^ Screen D may be blank if no calibrations are stored on the Diagnostic Tester Program Card.
^ If the desired calibration file is already on the Diagnostic Tester, proceed to Step 3 (Reprogram
ECU with Tester shown).
^ A maximum of two calibration files may be loaded on the tester at one time with Diagnostic Tester
software version 10.2a and later. Prior versions may store up to four calibration files.
Page 3100
Throttle Body (Part 2)
REMOVAL
1. REMOVE THROTTLE BODY COVER
2. DRAIN ENGINE COOLANT
Page 3663
6. REMOVE DUST COVER
Using SST and a press, remove the dust cover. SST 09950-00020
REASSEMBLY
1. INSTALL DUST COVER
Using a screwdriver and hammer, install a new dust cover.
2. INSTALL DUST SEAL
Using a screwdriver and hammer, install a new dust seal.
3. TEMPORARILY INSTALL OUTBOARD AND INBOARD JOINT BOOTS AND NEW BOOT
CLAMPS
HINT: ^
Before installing the boots, wrap the spline of the outboard joint shaft with vinyl tape to prevent the
boots from bearing damaged.
^ Before installing the boots, place 3 new clamps to the small boot ends and large boot end
(outboard joint side).
4. INSTALL INBOARD JOINT SHAFT TO OUTBOARD JOINT SHAFT
Align the matchmarks; placed before disassembly, and using a snap ring expander, put in the
inboard joint shaft while expanding the snap ring.
5. INSTALL BOOT TO OUTBOARD JOINT
Before assembling the boot, pack the outboard joint and boot with grease in the boot kit. Grease
capacity (Color = Black): 205 - 225 g (7.23 - 7.94 oz.)
6. INSTALL BOOT TO INBOARD JOINT SHAFT
a. Pack the inboard joint and boot with grease in the boot kit.
Page 269
Airbag Sensor Assembly: Description and Operation
AIRBAG SENSOR ASSEMBLY
The airbag sensor assembly is mounted on the floor inside the lower center cover. The airbag
sensor assembly consists of an airbag sensor, safing sensor, diagnosis circuit, ignition control and
drive circuit, etc. It receives signals from the airbag sensor and judges whether the SRS must be
activated or not.
Page 2371
Page 677
Terminal Retainer
Push the terminal retainer down to the temporary lock position.
c. Release the locking lug from terminal and pull the terminal out from rear.
4. INSTALL TERMINAL TO CONNECTOR
a. Insert the terminal.
HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug
locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position.
Page 2914
Vehicle Speed Sensor: Service and Repair
Vehicle Speed Sensor NO.1
1. DISCONNECT NO. 1 VEHICLE SPEED SENSOR CONNECTOR
2. REMOVE NO. 1 VEHICLE SPEED SENSOR
Remove the bolt and No.1 vehicle speed sensor.
3. DISASSEMBLE NO. 1 VEHICLE SPEED SENSOR
a. Remove the O-ring from the speedometer driven gear assembly. b. Remove the clip and
speedometer driven gear from the speedometer driven gear sleeve.
4. ASSEMBLE NO. 1 VEHICLE SPEED SENSOR
a. Install the speedometer driven gear and clip to the speedometer driven gear sleeve. b. Coat a
new O-ring with ATF. c. Install the O-ring to the speedometer driven gear assembly.
5. INSTALL NO. 1 VEHICLE SPEED SENSOR
Page 5301
Hose/Line HVAC: Service and Repair
REPLACEMENT
1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM
2. REPLACE FAULTY TUBE OR HOSE
NOTE: Cap the open fittings immediately to keep moisture or dirt out of the system
3. TIGHTEN JOINT OF BOLT OR NUT AT SPECIFIED TORQUE
NOTE: Connections should not be torqued tighter than the specified torque.
4. EVACUATE AIR IN REFRIGERATION SYSTEM AND CHARGE SYSTEM WITH
REFRIGERANT
Specified amount: 600 ± 50 g (21.16 ± 1.76 oz.)
5. INSPECT FOR LEAKAGE OF REFRIGERANT
Using a gas leak detector, check for leakage of refrigerant.
6. INSPECT AIR CONDITIONING OPERATION
Page 5445
Steps 1 - 2
INSPECTION PROCEDURE
SRS (Does Not Light Up, When Ignition Switch Is on ACC Or On)
SRS Warning Light Circuit Malfunction (Does not light up, when ignition switch is turned to ACC or
ON)
CIRCUIT DESCRIPTION
The SRS warning light is located on the combination meter.
When the SRS is normal, the SRS warning light lights up for approx. 6 seconds after the ignition
switch is turned from the LOCK position to ACC or ON position, and then turns off automatically.
If there is a malfunction in the SRS, the SRS warning light lights up to inform the driver of the
abnormality.
When terminals Tc and E1 of the DLC1 are connected, the DTC is displayed by blinking the SRS
warning light.
Page 5729
Glossary Of Terms And Symbols (Part 1)
Page 6838
Non-Waterproof Type Connector
"Case 1" Raise the terminal retainer up to the temporary lock position.
Non-Waterproof Type Connector
"Case 2" Open the secondary locking device.
Page 2743
2. Start the engine.
3. Perform the drive pattern to run and complete the Oxygen Sensor (O2S) Monitor.
HINT:
The 02S Monitor is completed when the following conditions are met:
^ Two (2) minutes or more passed after the engine start.
^ The Engine Coolant Temperature (ECT) is 167°F (75°C) or more.
^ Cumulative running time at 30 mph (48 km/h) or more exceeds 6 minutes.
^ Vehicle is in closed loop.
^ The fuel-cut is operated for 8 seconds or more (for Rear O2S Monitor).
A. Allow the engine to idle for two minutes.
B. Warm up the engine until the Engine Coolant Temperature (ECT) reaches 167°F (75°C).
C. Drive the vehicle over 30 mph (48 km/h) for more than 40 seconds.
D. Stop the vehicle and allow the engine to idle for more than 20 seconds.
E. Repeat steps C and D at least 8 times in one driving cycle. (Do not cycle the ignition key.)
In addition, perform the following steps for the Rear O2S Readiness Monitor:
A. Select second gear.
B. Allow the vehicle to run at 30 mph (48 km/h) or more.
C. Keep the accelerator pedal "off-idle" for more than 10 seconds.
D. Immediately after step C, release the accelerator pedal for at least 10 seconds without
depressing the brake pedal (to execute the fuel-cut).
E. Decelerate the vehicle until the vehicle speed reaches less than 6mph (10km/h).
F. Repeat steps B - E at least twice in one driving cycle.
Accessing O2S Test Results
1. On the Diagnostic Tester* screen, select the following menus:
^ DIAGNOSTICS
^ CARB OBD II
Page 4669
Waterproof Type Connector
B: For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White
: Gray
Black or White : Dark Gray
Gray or White : Black
Waterproof Type Connector
"Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up
to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Waterproof Type Connector
"Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 6204
Cruise Control: Diagnostic Aids
Voltage Check
Voltage Check
Voltage Check
A. Establish conditions in which voltage is present at the check point.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(SW 2 OFF)
B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or
component terminal. This check can be done with a test light instead of a voltmeter.
Continuity and Resistance Check
Continuity and Resistance Check
Continuity And Resistance Check
A. Disconnect the battery terminal or wire so there is no voltage between the check points. B.
Contact the two leads of an ohmmeter to each of the check points.
Page 6106
INSPECT POWER SEAT SWITCH CIRCUIT
a. Disconnect the switch connector and connect the seat wire harness to the floor wire harness. b.
Inspect the connector on the wire harness side.
If circuit is not as specified, inspect the circuits connected to other parts.
INSPECT LUMBAR SUPPORT SWITCH CONTINUITY
If continuity is not as specified, replace the switch.
INSPECT LUMBAR SUPPORT SWITCH CIRCUIT
a. Disconnect the switch connector and connect the seat wire harness to the floor wire harness.
Page 5062
Page 3843
5. INSPECT ACTUATOR OPERATION
a. 2WD 4HI shift: Connect lines via a relay, then check that the actuator fork shaft moves to 2WD
-> 4HI position.
b. 4HI -> 2WD shift: Connect lines via a relay, then check that the actuator fork shaft moves to 4HI
-> 2WD position.
Page 5978
Perform the procedure shown if there is any lamp malfunction.
Page 6078
CLADDING CODE FORMULA
TUNDRA TWO-TONE COMBINATION
CAMRY GALLERY SERLES (Special Edition)
Page 5542
Part Number Information
Owner Instructions
Failure to follow the recommendations indicated below could result in reduced effectiveness of the
seat belt restraint system in case of vehicle collision, causing personal injury.
The Seat Belt Extender must not be used:
a. By anyone other than for whom it was provided (name recorded on seat belt extender).
b. In any vehicle and/or seat position other than the one for which it was provided.
c. When the Seat Belt Extender is provided for rear seat positions (with automatic locking
retractor), make sure the retractor is locked when in use.
If your seat belt cannot be fastened securely because it is not long enough, a personalized Seat
Belt Extender is available from your Toyota dealer free of charge.
Please contact your local Toyota dealer so that the dealer can order the proper required length for
the extender. Bring the heaviest coat you expect to wear for proper measurement and selection of
length. Additional ordering information is available at your Toyota dealer.
CAUTION:
When using the Seat Belt Extender, observe the following. Failure to follow these instructions could
result in reduced effectiveness of the seat belt restraint system in case of vehicle accident,
increasing the chance of personal injury.
^ Never use the Seat Belt Extender if you can COMFORTABLY fasten the seat belt without it.
^ The Seat Belt Extender must never be used with any child safety seats.
^ Remember that the extender provided for you may not be safe when used on a different vehicle,
or for another person or at a different seating position than the one originally intended for.
Diagrams
Page 4454
Parking Brake Pedal: Service and Repair
REMOVAL
1. REMOVE SCUFF PLATE LH, COWL SIDE TRIM LH, LOWER FINISH PANEL AND NO. 2
HEATER TO REGISTER DUCT 2. REMOVE PARKING BRAKE PEDAL ASSEMBLY
(a) Disconnect the parking brake switch connector. (b) Remove the lock nut and adjusting nut from
the parking brake wire. (c) Remove the clip and parking brake wire. (d) Remove the 4 bolts and
parking brake pedal assembly.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)
INSTALLATION
Installation is in the reverse order of removal.
HINT: After the installation, check and adjust parking brake pedal travel.
Page 5848
Front Door (Part 2)
Page 2087
Crankshaft Position Sensor: Description and Operation
Crankshaft Position Sensor
Crankshaft position sensor (NE signal) consists of a signal plate and pick up coil.
The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor
generates 34 signals of every engine revolution.
The ECM detects the standard crankshaft angle based on the G signals, and the actual crankshaft
angle the engine speed by the NE signals.
Page 1737
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 4604
Non-Waterproof Type Connector
"Case 1" Raise the terminal retainer up to the temporary lock position.
Non-Waterproof Type Connector
"Case 2" Open the secondary locking device.
Specifications
Compression Check: Specifications
Compression Pressure ........................................................................................................................
...................................................... 1,324 kPa or More Minimum Pressure .........................................
...........................................................................................................................................................
981 kPa Difference Between Each Cylinder ........................................................................................
......................................................................... 98 kPa or Less
Engine/Transmission Controls - Resetting ECM Memory
Engine Control Module: All Technical Service Bulletins Engine/Transmission Controls - Resetting
ECM Memory
TRANSMISSION & CLUTCH TC002-03 REVISED
Title: ECM RESET MEMORY FUNCTION
Models: '00 - '05 All Models
June 10, 2003
TSB REVISION NOTICE:
^ December 20, 2004: Applicable Vehicles section has been updated - 2004 and 2005 model years
added, models and model years updated for various models; and Reset Procedure 2 has been
revised.
^ January 16, 2004: Tundra vehicles were added to the Applicable Vehicles chart.
^ December 17, 2003: T-100 vehicles were removed from the Applicable Vehicles chart.
Previous versions of this TSB should be discarded.
Introduction
Whenever an automatic transmission is replaced, overhauled or individual components are
replaced, use this procedure to clear Engine Control Module ( ECM, SAE term: Powertrain Control
Module, PCM) "Learned Values" to minimize subsequent performance concerns.
CAUTION:
Failure to follow the procedure below may lengthen the time to readjust the ECM "Learned Values,"
potentially resulting in performance concerns.
Required SSTs
Warranty Information
Applicable Vehicles
Page 5200
After connection, adjust the control cable.
c. Remove the nut, bolt and blower unit.
INSTALLATION
Installation is in the reverse order of removal.
Page 2192
Crankshaft Position Sensor: Description and Operation
Crankshaft Position Sensor
Crankshaft position sensor (NE signal) consists of a signal plate and pick up coil.
The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor
generates 34 signals of every engine revolution.
The ECM detects the standard crankshaft angle based on the G signals, and the actual crankshaft
angle the engine speed by the NE signals.
Page 3745
Body
Connector Location (Access Cab)
BA1 Front Door LH Wire and Wire Harness (Connector Location)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel)
BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel)
BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel)
BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Page 3952
An AC voltage is generated in the No.2 vehicle speed sensor coil as the rotor mounted on the
output shaft rotates, and this voltage is sent to the ECM.
The gear shift point and lock-up timing are controlled by the ECM based on the signals from this
vehicle speed sensor and the throttle position sensor signal.
If the No.2 vehicle speed sensor malfunctions, the ECM uses input signals from the No.1 vehicle
speed sensor as a back-up signal.
Service and Repair
Cylinder Head Gasket: Service and Repair
For further information regarding this component and the system that it is a part of, please refer to
Cylinder Head Assembly; Service and Repair.
Page 5560
Splice Location
B11
Page 1838
Camshaft Position Sensor: Description and Operation
The Camshaft Position Sensor
Camshaft position sensor (G signal) consists of a magnet iron core and pickup coil.
The G signal plate has 1 tooth on its outer circumference and is installed on the LH camshaft timing
pulley. When the camshafts rotate, protrusion on the signal plate and air gap on the pickup coil
change, causing fluctuations in the magnetic field and generating an electromotive force in the
pickup coil.
The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor
generates 34 signals at every engine revolution. The ECM detects the standard angle of the
crankshaft based on the G signal and the actual angle of the crankshaft and the engine speed by
the NE signal.
Page 3138
Crankshaft Position Sensor: Description and Operation
Crankshaft Position Sensor
Crankshaft position sensor (NE signal) consists of a signal plate and pick up coil.
The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor
generates 34 signals of every engine revolution.
The ECM detects the standard crankshaft angle based on the G signals, and the actual crankshaft
angle the engine speed by the NE signals.
Page 921
31. RECHECK ENGINE COOLANT LEVEL 32. INSTALL ENGINE UNDER COVER
Specifications
Case: Specifications
Transmission Case Transmission Case Bushing Maximum 38.19 mm
Parking Lock Pawl Bracket x Transmission Case 7.4 Nm
Transmission Case Plug x Transmission Case 5.4 Nm
Page 5540
Front Seat Belt Extender Applications
Page 2913
Vehicle Speed Sensor: Testing and Inspection
INSPECT VEHICLE SPEED SENSOR OPERATION
a. Connect the positive (+) lead from the battery to terminal 1 and negative (-) lead to terminal 2. b.
Connect the positive (+) lead from the tester to terminal 3 and the negative (-) lead to terminal 2. c.
Rotate the shaft. d. Check that there is voltage change from approx. 0 V to 11 V or more between
terminals 2 and 3.
HINT: The voltage change should be performed 4 times for every revolution of the speed sensor
shaft.
If operation is not as specified, replace the sensor.
Page 1641
Page 329
Repair Procedure
1. Disconnect the cable from the negative (-) battery terminal for MORE THAN two (2) seconds.
2. Reconnect the cable to the negative (-) battery terminal.
3. Perform the applicable zero point calibration of the yaw rate sensor and/or the steering angle
sensor.
HINT Refer to the applicable TSB or Repair Manual for the zero point calibration procedure.
4. Re-initialize all applicable systems available on the vehicle (power window sunroof power lift
door etc.).
Ground Locations
Trailer Connector: Ground Locations
Engine Compartment
Ground Location
EA Front Left Fender
EB Rear Bank of Right Cylinder
EC Rear Bank of Left Cylinder
Connector Location
EA1 Cowl Wire Harness and Wire Harness (Connector Location)
EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B)
EC1 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC2 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC3 Engine No. 2 Wire and Engine Wire (Near the Starter)
ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission)
Page 3452
Body
Connector Location (Access Cab)
BA1 Front Door LH Wire and Wire Harness (Connector Location)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel)
BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel)
BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel)
BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Page 2937
2. Apply battery positive voltage across the terminals. 3. Check that air flows from ports E to F.
If operation is not as specified, replace the VSV.
3. REINSTALL VSV
Page 4546
2. INSTALL PS VANE PUMP
3. INSTALL DRIVE BELT
Install the belt by turning the belt tensioner counterclockwise.
HINT: The pulley bolt for the belt tensioner has a left-hand thread.
4. PERFORM ON-VEHICLE INSPECTION
5. INSTALL NO.2 FAN SHROUD
Install the No.2 fan shroud with the 2 clips.
6. INSTALL ENGINE UNDER COVER
Locations
Vehicle Lift And Support Locations
Page 5084
Page 1442
13. CONNECT TIMING BELT TO RH CAMSHAFT TIMING PULLEY
a. Remove any oil or water on the RH camshaft timing pulley and water pump pulley, and keep
them clean.
NOTICE: Only wipe the pulleys; do not use any cleansing agent.
b. Turn the RH camshaft timing pulley. Align the installation mark on the timing belt with the timing
mark of the camshaft timing pulley, and
hang the timing belt on the RH camshaft timing pulley.
14. SET TIMING BELT TENSIONER
a. Using a press, slowly press in the push rod using 981 - 9,807 N (100 - 1,000 kgf, 220 - 2,205
lbs.) of pressure. b. Align the holes of the push rod and housing, pass a 1.27 mm hexagon wrench
through the holes to keep the setting position of the push rod. c. Release the press. d. Install the
dust boot to the belt tensioner.
15. INSTALL TIMING BELT TENSIONER
a. Temporarily install the belt tensioner with the 2 bolts. b. Alternately tighten the 2 bolts.
Torque: 26 Nm (270 kgf-cm, 19 ft. lbs.)
c. Using pliers, remove the 1.27 mm hexagon wrench from the belt tensioner.
16. CHECK VALVE TIMING
a. Temporarily install the crankshaft pulley bolt.
b. Slowly turn the crankshaft pulley 2 revolutions from TDC to TDC.
NOTICE: Always turn the crankshaft pulley clockwise.
Page 1596
5. When using the radiator cap tester, tilt it more than 30 degrees.
6. Pump the radiator cap tester several times, and check the maximum pressure.
Pumping speed: 1 pump/second
HINT:
Stop pumping when the valve opens and read the gauge. The gauge must be within the standard
values listed below when the pressure valve opens. The cap is considered OK when the pressure
holds steady or falls very slowly, but holds within the standard values listed below for one minute.
Specification:
If the maximum pressure is less than the minimum standard value, replace the radiator cap
sub-assembly.
Page 3950
Vehicle Speed Sensor NO.2
Page 2490
CHART 20
Page 5425
1. LH:
REMOVE FRONT AIRBAG SENSOR
a. 2UZ-FE:
Remove the battery carrier, battery and battery tray.
b. Disconnect the front airbag sensor connector.
NOTE: Disconnect the connector with sensor assembly installed.
c. Remove the 2 bolts and front airbag sensor.
2. RH:
REMOVE FRONT AIRBAG SENSOR
a. Remove the air cleaner assembly. b. Disconnect the front airbag sensor connector.
NOTE: Disconnect the connector with sensor assembly installed.
c. Remove the 2 bolts and front airbag sensor.
INSTALLATION
INSTALL FRONT AIRBAG SENSORS
Page 746
Supplemental Restraint System
Page 3331
The calibration file contains the Calibration ID number(s) for a specific vehicle ECU (see Figure 1).
NOTE:
The total number of Calibration ID numbers corresponds to the number of reprogrammable
processors in the ECU (see Figure 2).
Operation Procedure
LOCATE CALIBRATION FILE
The following steps in this bulletin describe how to properly flash reprogram an ECU.
1. Locate calibration file on TIS.
Calibration files may be found in two areas (see Figure 3):
A. Search by model and year for a Technical Service Bulletin addressing a specific Product issue.
^ Within the TSB, click on the link for the calibration file.
B. Search by model under the ECU Flash Reprogramming Section.
^ Under the ECU Flash Reprogramming section on TIS, a drop-down list of the latest calibration
files will be displayed.
C. Proceed to step 2 for instructions on how to download the calibration file from TIS to the
Diagnostic Tester Program Card.
Symptom Related Diagnostic Procedures
Problem Symptoms Table - Ignition Switch And Key Unlock Warning Switch
Page 5717
Splice Location
B11
Page 5865
Wheel Arch Moulding
Page 1506
Water Pump: Diagrams
WATER PUMP REPLACEMENT W/ RELATED COMPONENTS
Part 1 of 3
Page 6159
INSPECT POWER SEAT SWITCH CIRCUIT
a. Disconnect the switch connector and connect the seat wire harness to the floor wire harness. b.
Inspect the connector on the wire harness side.
If circuit is not as specified, inspect the circuits connected to other parts.
INSPECT LUMBAR SUPPORT SWITCH CONTINUITY
If continuity is not as specified, replace the switch.
INSPECT LUMBAR SUPPORT SWITCH CIRCUIT
a. Disconnect the switch connector and connect the seat wire harness to the floor wire harness.
Page 2296
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.
Electrical Specifications
Oxygen Sensor: Electrical Specifications
Air/Fuel Ratio Sensor
Resistance:
at 20°C (68°F): 0.8 - 1.4 ohms
at 800°C (1,472°F): 1.8 - 3.2 ohms
Heated Oxygen Sensor
Resistance Between Terminals +B and HT:
at 20°C (68°F) 11 - 16 Ohms
at 800°C (1,472°F) 23 - 32 Ohms
Page 1734
^ 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 4813
b. Push the secondary locking device or terminal retainer in to the full lock position.
5. CONNECT CONNECTOR
Disconnection of Male and Female Connectors
Disconnection of Male and Female Connectors
Disconnection Of Male And Female Connectors
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Page 4380
Remove the 4 bolts and disconnect the lower ball joint.
9. REMOVE STEERING KNUCKLE
A. Remove the cotter pin and loosen the nut.
B. Using the following SSTs, disconnect the steering knuckle.
^ 09950-40011 (09951-04010, 09952-04010, 09553-04020, 09554-04010, 09955-04031,
09958-04011)
C. Remove the nut and steering knuckle.
NOTE:
4WD: Be careful not to damage the oil seal and drive shaft boot.
HINT:
4WD: When it is difficult to disconnect the drive shaft, tap the tip of the drive shaft with a plastic
hammer.
10. 2WD: REMOVE GREASE CAP
A. Mount the axle hub in a soft jaw vise.
HINT:
Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further.
B. Using a screwdriver, remove the grease cap.
HINT:
Be careful not to damage the grease cap.
11. 4WD: REMOVE OIL SEAL (INSIDE)
A. Mount the axle hub in a soft jaw vise.
HINT:
Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further.
B. Using a screwdriver, remove the oil seal (inside).
Brakes - Vibration From Front Brakes
Technical Service Bulletin # BR004R-02 Date: 040924
Brakes - Vibration From Front Brakes
BRAKES BR004-02 REVISED
Title: FRONT BRAKE VIBRATION
Models: '00 - '03 Tundra
September 16, 2002
TSB REVISION NOTICE:
^ September 24, 2004: A note has been added, step 26.
^ March 5, 2004: A torque speification, step 24, was changed.
^ September 8, 2003: A torque specification, step 28, was changed.
Previous versions of this TSB should be discarded.
Introduction
Under certain usage conditions, some Tundra trucks may exhibit front brake vibration. Improved
brake caliper assemblies have been introduced to correct this condition.
Applicable Vehicles
2000 - 2003 model year Tundra trucks built before the VIN shown below.
Production Change Information
Warranty Information
Applicable Warranty*:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36
months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Page 6512
Seat Belt Reminder Buzzer: Harness Locations
Engine Compartment
Connector Location
EA1 Cowl Wire Harness and Wire Harness (Connector Location)
EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B)
EC1 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC2 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC3 Engine No. 2 Wire and Engine Wire (Near the Starter)
ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission)
Service and Repair
Transmission Temperature Sensor/Switch: Service and Repair
ON-VEHICLE REPAIR
1. 5VZ-FE:
DISCONNECT OIL COOLER PIPE
a. Remove the 3 bolts and clamps.
b. Disconnect the oil cooler pipe. c. Remove the elbow from the transmission.
2. DISCONNECT ATF TEMPERATURE SENSOR CONNECTOR 3. REMOVE ATF
TEMPERATURE SENSOR
a. Remove the ATF temperature sensor. b. Remove the O-ring from the ATF temperature sensor.
4. INSTALL ATF TEMPERATURE SENSOR
a. Coat a new O-ring with ATF and install it to the ATF temperature sensor. b. Install the ATF
temperature sensor.
Torque: 15 Nm (150 kgf-cm, 11 ft. lbs.)
5. CONNECT ATF TEMPERATURE SENSOR CONNECTOR
NOTICE: Be careful not to twist the wire harness.
6. CONNECT OIL COOLER PIPE
a. Install the elbow to the transmission.
Page 5776
Continuity And Resistance Check
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Continuity And Resistance Check
C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the
electrical circuit.
Finding A Short Circuit
Finding A Short Circuit
Finding A Short Circuit
A. Remove the blown fuse and disconnect all loads of the fuse.
Page 6268
B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(Connect the Relay) and SW 2 OFF (or Disconnect SW 2)
D. Disconnect and reconnect the connectors while watching the test light.
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
E. Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION:
a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals
are touched, the IC may be destroyed by
static electricity.)
b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact
with the terminals of leads from the IC, etc. of the replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
Special Tool
1. PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown.
2. DISCONNECT CONNECTOR
3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
a. Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the
secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
A: For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
Collision / Non-Collision Inspections
Impact Sensor: Testing and Inspection Collision / Non-Collision Inspections
INSPECTION
1. VEHICLES NOT INVOLVED IN COLLISION
Do a diagnostic system check. *
2. VEHICLES INVOLVED IN COLLISION
a. Do a diagnostic system check. *
b. If the front fender of the car or its periphery is damaged, do a visual check for damage to the
front airbag sensor, which includes the following
items even if the airbag was not deployed: Check the bracket deformation.
- Check the paint peeling off the bracket.
- Check the cracks, dents or chips in the case.
- Check the cracks, dents, chipping and scratches in the connector.
- Check the peeling off of the label or damage to the serial number.
* Refer to SRS Warning Light Check, and How to Display and Read Diagnostic Trouble Codes.
See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Displaying & Reading
Trouble Codes
Body - Plastic Bumper Refinishing
Rear Bumper Cover / Fascia: Technical Service Bulletins Body - Plastic Bumper Refinishing
TITLE: PLASTIC BUMPER REFINISHING
SECTION: REFINISH
BULLETIN # 170
MODELS: ALL TOYOTA LEXUS and SCION
DATE: OCTOBER 2008
When it is necessary to replace a damaged plastic bumper, proper consideration should be given
to preparation and refinishing to ensure high quality, long-term durability, and customer
satisfaction. While it is important to follow paint manufacturer recommendations for application of
refinish materials, this bulletin provides Toyota recommended procedures for cleaning and
preparation of original equipment (OE) raw plastic bumpers.
Background:
Toyota bumper covers are manufactured using several types of plastic however, cleaning and
preparation procedures outlined here are applicable to all Toyota, Lexus, and Scion raw plastic OE
bumpers.
Soap-base mold release agent replaced the wax-base type beginning in 1995 to reduce volatile
organic compound (VOC) emissions produced by the use of cleaning solvents. This topic is
covered in Collision Repair Information Bulletin (CRIB) #69. Thorough cleaning with recommended
soap and water removes soap-base mold release agent.
Cleaning and Preparation:
^ Wash new part thoroughly inside and out with a hot water and ph neutral wax-free carwash soap
solution. Rinse well and dry with clean towels.
Cleaning and Preparation, Continued^ Clean exterior surface and all edges thoroughly with paint manufacturer recommended plastic
parts cleaner or water-base wax and grease remover, or a 1-1 mixture of isopropyl alcohol and
deionized water.
^ Scuff exterior surface and all edges with a medium to fine scuff pad (as recommended by paint
manufacturer), with sanding paste and clean water. Repeat wash sequence, rinse well and dry with
clean towels.
^ Examine the bumper closely, especially hard to reach areas. Re-scuff any areas that do not
appear to have been scuffed sufficiently. Repeat wash- rinse-dry sequence.
^ Make final surface inspection and clean with paint manufacturer recommended cleaner or a 1-1
mixture of isopropyl alcohol and deionized water.
^ Apply anti-static measures.
^ Apply adhesion promoter per paint manufacturer7s recommendations.
^ Apply primer and topcoats per paint manufacturer7s recommendations.
Note:
Toyota recommends the use of adhesion promoter and elastifier for all OE raw plastic bumpers to
ensure adhesion, flexibility, and long-term durability of topcoats; and the use of refinish materials
that meet or exceed the Toyota new vehicle limited paint finish warranty.
Toyota, Lexus and Scion bumpers are primarily made from TSOP (Toyota Super Olefin Polymer).
This type of plastic requires the use of adhesion
Page 667
B: Junction Connector
Indicates a connector which is connected to a short terminal.
Junction connector in this include a short terminal which is connected to a number of wire
harnesses. Always perform inspection with the short terminal installed. (When installing the wire
harnesses, the harnesses can be connected to any position within the short terminal grouping.
Accordingly, in other vehicles, the same position in the short terminal may be connected to wire
harness from a different part.) Wire harness sharing the same short terminal grouping ha the same
color.
C: Parts Code
The first letter of the code is taken from the first letter of part, and the numbers indicates its order in
parts which start with the same letter.
D: Connector Color
Connectors not indicated are milky white in color.
How to Read Ground Points
HOW TO READ GROUND POINTS
Page 2282
A. The new calibration file should be displayed as the current ECU calibration file.
B. Using a permanent marker or ball point pen, enter the required information on the Authorized
Modifications Label (Figures 21 and 22).
C. Affix this label under the hood in the location determined by the specific vehicle TSB or
Campaign.
NOTE:
Wait 60-90 seconds for ink to set before handling.
Page 1428
Part 2 of 4
Part 3 of 4
Page 3233
The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit
breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery
power is supplied to each system are explained. Since all System Circuit diagrams start from the
power source, the power source system must be fully understood.
Page 2793
Applicable Vehicles
Page 1938
Page 2120
e. Install the injector to the delivery pipe and lower intake manifold as shown in the illustration.
Before installing the injector, must apply spindle oil or gasoline on the place where a delivery pipe
or an intake manifold touches an O-ring of the injector.
f. Observe these precautions when disconnecting the fuel tube connector (quick type): 1. Check
that there is any dirt or the like on the pipe and around the connector before disconnecting them
and clean the dirt away. 2. Be sure to disconnect by hands. 3. When the connector and the pipe
are stuck, turn and pull the connector to free to disconnect and pull it out. Do not use any tools at
this
time.
4. Inspect if there is any dirt or the like on the seal surface of the disconnected pipe and clean it
away.
5. Prevent the disconnected pipe and connector from being damaged or mixed with foreign objects
by covering them with a vinyl bag.
g. Observe these precautions when connecting the fuel tube connector (quick type):
1. Do not reuse the retainer removed from the pipe. 2. Must use hands to remove the retainer from
the pipe. 3. Check that there is any damage or foreign objects on the connected part of the pipe.
Page 1266
1. Remove the engine under cover.
2. Drain the engine coolant.
3. Remove the intake air connector assembly.
4. Remove the radiator fan shroud.
5. Remove the drive belt, fan, fluid coupling, and fan pulley.
6. Without disconnecting the power steering fluid lines, remove the power steering pump.
HINT: Suspend the power steering pump securely.
7. Remove the drive belt idler pulley.
8. Remove the right hand (RH) No. 3 timing belt cover.
9. Remove the No.2 timing belt cover.
10. Without disconnecting the A/C refrigerant lines, remove the A/C compressor from the mounting
bracket.
HINT: Suspend the A/C compressor securely.
11. Disconnect the A/C compressor mounting bracket.
Page 3670
15. REPLACE OIL SEAL (INNER SIDE)
a. Using SST, remove the oil seal.
SST 09308-00010
b. Using SST and a hammer, install a new oil seal.
SST 09950-60020 (09951-00710), 09950-70010 (09951-07150)
c. Coat a new oil seal lip with MP grease.
INSTALLATION
1. INSTALL NEW O-RING TO REAR AXLE HOUSING 2. INSTALL REAR AXLE SHAFT
ASSEMBLY
Torque: 69 Nm (700 kgf-cm, 51 ft. lbs.)
3. CONNECT BRAKE LINE AND PARKING BRAKE CABLE
a. Connect the parking brake cable with the pin and clip. b. Using Special Service Tool (SST),
connect the brake line to the wheel cylinder.
SST 09023-00100 Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.)
4. INSTALL REAR BRAKE ASSEMBLY 5. w/ ABS: INSTALL ABS SPEED SENSOR
Torque: 8.0 Nm (82 kgf-cm, 71 ft. lbs.)
6. CHECK BEARING BACKLASH AND AXLE SHAFT DEVIATION 7. INSTALL NEW GASKET
AND BRAKE DRUM 8. INSTALL REAR WHEEL
Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.)
9. BLEED BRAKE SYSTEM
10. w/ ABS: CHECK ABS SPEED SENSOR SIGNAL
Page 2920
Three-Way Catalytic Converter (TWC) System
Page 750
Impact Sensor: Testing and Inspection Replacement Requirements
REPLACEMENT REQUIREMENTS
In the following cases, replace the front airbag sensor.
- If the SRS has been deployed in a collision. (Replace both the left and right airbag sensors.)
- If the front airbag sensor has been found to be faulty in troubleshooting.
- If the front airbag sensor has been found to be faulty during checking items.
- If the front airbag sensor has been dropped.
CAUTION: Be sure to follow the correct procedure for removal and installation of the front airbag
sensor.
Engine Controls - Error When Reprogramming ECU
PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - Error
When Reprogramming ECU
SPECIAL SERVICE TOOLS SS004-01 REVISED
May 25, 2001
Title: ECU FLASH REPROGRAMMING ERROR MESSAGE
Models: Applicable Models
TSB REVISION NOTICE:
September 23, 2003: Models added - 2002 (and later) Solara, 2003 (and later) Corolla and Matrix,
and 2004 models; Test Procedures updated for new CAN Interface Module. The previous TSB
should be discarded.
Introduction
During ECU flash reprogramming, an error message may be displayed on the Diagnostic Tester
that will not allow ECU flash reprogramming to complete. This bulletin provides test procedures to
determine the cause for the error message.
Applicable Vehicles ^
2001 (and later) model year 4Runner, Highlander, Land Cruiser, RAV4, Sequoia and Tundra
vehicles.
^ 2002 (and later) model year Camry, Solara and Tacoma vehicles.
^ 2003 (and later) model year Corolla and Matrix vehicles.
^ All 2004 (and later) model year Toyota vehicles except Celica, MR2 Spyder, Avalon, and Tacoma
(3RZ-FE engine)
Required SSTs
NOTE:
Additional Diagnostic Tester Kits, CAN Interface Modules, Program Cards or other SSTs may be
ordered by calling SPX/OTC at 1-800-933-8335.
Warranty Information
Test Procedure
Page 2867
Glossary Of Terms And Symbols (Part 2)
Page 4719
Continuity And Resistance Check
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Continuity And Resistance Check
C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the
electrical circuit.
Finding A Short Circuit
Finding A Short Circuit
Finding A Short Circuit
A. Remove the blown fuse and disconnect all loads of the fuse.
Page 4864
j. Measure the fluid pressure at engine speeds of 1,000 rpm and 3,000 rpm. Difference fluid
pressure: 490 kPa (5 kgf/cm2, 71 psi) or less
NOTICE: Do not turn the steering wheel.
k. With the engine idling and valve fully opened, turn the steering wheel to full lock.
Minimum fluid pressure: 8,336 kPa (85 kgf/cm2, 1,209 psi)
NOTICE: ^
Do not maintain lock position for more than 10 seconds.
^ Do not let the fluid temperature become too high.
l. Disconnect the SST. SST 09640-10010 (09641-01010, 09641-01030, 09641-01060)
m. Connect the pressure feed tube. n. 5VZ-FE engine: Install the air cleaner assembly. o. 2UZ-FE
engine: Install the air cleaner assembly with air cleaner hose. p. Bleed the power steering system.
Page 3629
Differential Lock: Testing and Inspection
INSPECTION
1. INSPECT A.D.D. ACTUATOR
a. Disconnect the actuator connector. b. Measure the resistance between the terminals 2 and 6.
Standard resistance: 0.3 - 100 ohms
c. Measure the resistance between the terminals 2 or 6 and body ground.
Page 2141
Compression Check: Testing and Inspection
INSPECTION
HINT: If there is lack of power, excessive oil consumption or poor fuel economy, measure the
compression pressure.
1. WARM UP AND STOP ENGINE
Allow the engine to warm up to normal operating temperature.
2. REMOVE SPARK PLUGS
3. CHECK CYLINDER COMPRESSION PRESSURE
a. Insert a compression gauge into the spark plug hole. b. Fully open the throttle. c. While cranking
the engine, measure the compression pressure.
HINT: Always use a fully charged battery to obtain engine speed of 250 rpm or more.
d. Repeat steps (a) through (c) for each cylinder.
NOTICE: This measurement must be done in as short a time as possible.
Compression pressure: 1,324 kPa (13.5 kgf/cm2, 192 psi) or more Minimum pressure: 981 kPa
(10.0 kgf/cm2, 142 psi) Difference between each cylinder: 98 kPa (1.0 kgf/cm2, 14 psi) or less
e. If the cylinder compression in one or more cylinders is low, pour small amount of engine oil into
the cylinder through the spark plug hole and
repeat steps (a) through (c) for cylinders with low compression. If adding oil helps the compression, chances are that the piston rings and/or cylinder bore are worn
or damaged.
- If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage
past the gasket.
4. REINSTALL SPARK PLUGS
Testing and Inspection
Power Window Relay: Testing and Inspection
INSPECT POWER MAIN RELAY CONTINUITY If continuity is not as specified, replace the switch.
Page 3104
NOTE: After turning the ignition switch ON, do not depress the accelerator pedal.
4. While reading the value of the throttle valve opening percentage (THROTTLE POS) of the
CURRENT DATA, turn the throttle position
sensor slowly to left and right and set the sensor at the center value of the standard value, and
then tighten the screws.
Standard throttle valve opening percentage: 14.4 - 16 %
Torque: 2.0 N.m (20 kgf.cm, 18 in.lbf)
5. Recheck throttle valve opening percentage.
If the throttle valve opening percentage is not as specified, repeat step (4).
6. Perform fully closed throttle valve by hand and check that the valve of the throttle valve opening
percentage (THROTTLE POS) of the
CURRENT DATA stays with the standard value.
Standard throttle valve opening percentage: 10 - 14 %
If the throttle valve opening percentage is not as specified, repeat steps (4) to (6).
7. Paint the 2 set screws. 8. Turn the ignition switch OFF. 9. Disconnect the TOYOTA hand-held
tester or OBD II scan tool from the DLC3.
10. Disconnect the throttle position sensor connector.
2. REPLACE THROTTLE CONTROL MOTOR
a. Remove the throttle position sensor. (See step 1) b. Remove the throttle control motor.
1. Disconnect the throttle control motor connector from the connector bracket. 2. Remove the 6
screws, the throttle control motor cover, motor assembly and washer.
3. Remove the 3 screws, throttle control motor and wave washer from the throttle control motor
cover.
c. Reinstall a new throttle control motor.
Page 506
Knock Sensor (Part 2)
Page 2705
Steps 2 - 3
INSPECTION PROCEDURE
HINT:
- DTC P0325 is for the left bank knock sensor circuit.
- DTC P0330 is for the right bank knock sensor circuit.
- Read freeze frame data using TOYOTA hand-held tester or OBD II scan tool, as freeze frame
data records the engine conditions when a malfunction is detected. When troubleshooting it is
useful for determining whether the vehicle was running or stopped, the engine was warmed up or
not, the air-fuel ratio was lean or rich, etc. at the time of the malfunction.
Page 4120
B. Using Snap ring pliers, install a NEW snap ring.
17. INSTALL NEW OIL SEAL (OUTSIDE)
A. Using the following SSTs and a plastic hammer, install a NEW oil seal (outside).
^ 09223-15030
^ 09527-17011
B. Coat MP grease to the oil seal lip.
18. INSTALL NEW DUST COVER AND AXLE HUB TO STEERING KNUCKLE
A. Install the NEW dust cover to the steering knuckle with the 4 bolts.
Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)
B. Using the following SST and a press, install the axle hub to the steering knuckle.
09649-17010
19. INSTALL ABS SPEED SENSOR
ROTOR (W/ABS) OR SPACER (W/O ABS)
NOTE:
Take care not to scratch the serration of the speed sensor rotor.
Page 4607
b. Push the secondary locking device or terminal retainer in to the full lock position.
5. CONNECT CONNECTOR
Disconnection of Male and Female Connectors
Disconnection of Male and Female Connectors
Disconnection Of Male And Female Connectors
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Page 4045
Parts Information
Page 989
Coolant: Service and Repair
REPLACEMENT
1. REMOVE ENGINE UNDER COVER
2. DRAIN ENGINE COOLANT
a. Remove the radiator cap.
CAUTION: To avoid the danger of being burned, do not remove the radiator cap while the engine
and radiator are still hot, as fluid and steam can be blown out under pressure.
b. Remove the 3 drain plugs on the engine and radiator, and drain the coolant. c. Close the 3 drain
plugs.
Torque: 12.7 Nm (130 kgf-cm, 9 ft. lbs.) for engine
3. REFILL WITH ENGINE COOLANT
a. Slowly fill the system with coolant.
^ Use of improper coolants may damage engine cooling system.
^ Use "TOYOTA Long Life Coolant" or equivalent and mix it with plain water according to the
manufacturer's directions.
^ Use of the coolant which includes more than 50% [freezing protection down to -35°C (-31°F)] or
60% [freezing protection down to -50°C (-58°F)] of ethylene-glycol is recommended, but not more
than 70%.
NOTICE: ^
Do not use an alcohol type coolant or plain water alone.
^ The coolant should be mixed with plain water (preferably demineralized water or distilled water).
Capacity: 11.6 liters (12.3 US qts, 10.2 Imp. qts)
b. Install the radiator cap. c. Bleed the cooling system.
1. Start the engine, and open the heater water valve. 2. Maintain the engine speed at 2,000 - 2,500
rpm, and warm up the engine.
d. Stop the engine, and wait until the engine coolant cools down. e. Refill coolant into the reservoir
until it is "FULL".
4. CHECK FOR ENGINE COOLANT LEAKS 5. CHECK ENGINE COOLANT SPECIFIC GRAVITY
CORRECTLY 6. REINSTALL ENGINE UNDER COVER
Page 6806
Body
Connector Location (Standard Cab)
BA1 Front Door LH Wire and Speaker Tweeter Wire LH (Inside of Front Door LH)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Seat
Connector Location
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
BJ1 Seat No. 1 Wire and Seat No. 2 Wire (Under the Driver's Seat)
Page 5523
B. Pinch the tongue plate stopper into the webbing using an adjustable wrench, and turn and push
the adjustment screw by hand.
HINT: Press the adjustment screw in order to position the male and female parts of the tongue
plate stopper parallel to each other as shown in illustration.
CAUTION: DO NOT use pliers. They may damage the webbing.
C. When the adjustment screw for the adjustable wrench cannot be turned by hand, tighten the
adjustment screw using a pair of adjustable joint
pliers until the space between jaws of the adjustable wrench is 4.5 - 5.0 mm. (0.18 in. - 0.20 in.
[See illustrations.])
Page 4548
a. Remove the nut and cord clip.
b. Remove the 4 screws and rectifier holder. c. Remove the 4 rubber insulators.
5. REMOVE PULLEY
a. Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque.
SST 09820-63011
Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)
b. Check that SST (A) is secured to the rotor shaft.
c. Mount SST (C) in a vise. d. Insert SST (B) into SST (C), and attach the pulley nut to SST (C).
Locations
Anti-Lock Brake System
Page 3223
Transmission Mode Indicator - A/T: Harness Locations
Engine Compartment
Connector Location
EA1 Cowl Wire Harness and Wire Harness (Connector Location)
EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B)
EC1 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC2 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC3 Engine No. 2 Wire and Engine Wire (Near the Starter)
ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission)
Page 2486
CHART 14
Instruments - Oil Pressure Gauge Reads Abnormally Low
Oil Pressure Gauge: All Technical Service Bulletins Instruments - Oil Pressure Gauge Reads
Abnormally Low
ELECTRICAL EL017-03
December 23, 2503
Title OIL PRESSURE GAUGE READS LOW
Models '01 - '04 Sequoia & '00 - '02 Tundra
TSB UPDATE NOTICE:
This TSB updates EL006-03. TSB EL006-03 is now obsolete and should be discarded.
Introduction
Some customers with Sequoia or Tundra vehicles may encounter an oil pressure gauge that reads
abnormally low at idle. An updated oil pressure sender has been created to address this condition.
Applicable Vehicles ^
2001 - 2004 model year Sequoia vehicles produced BEFORE the Production Change Effective
VINs shown below.
^ 2000 - 2002 model year Tundra vehicles produced BEFORE the Production Change Effective
VIN shown below.
Production Change Information
Parts Information
Repair Procedure
1. Replace the Oil Pressure Sender.
2. Verify proper operation of the Oil Pressure Gauge.
Warranty Information
Applicable Warranty*:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36
months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Page 6287
Splice Location
B11
Page 1940
CHART 29
Page 3610
8. INSTALL 29 BOLTS TO UPPER VALVE BODY
Torque: 6.4 Nm (65 kgf-cm, 4.7 ft. lbs.)
HINT: Each bolt length is indicated.
Bolt length:
Bolt A: 20 mm (0.79 inch) Bolt B: 28 mm (1.10 inch) Bolt C: 40 mm (1.57 inch)
9. INSTALL SOLENOID VALVE
a. Install 3 new O-rings to the 3 solenoid valves. b. Install the solenoid valve and lock plate with
bolt.
Torque: 10 Nm (100 kgf-cm, 7 ft. lbs.)
c. Install the 3 solenoid valves with the 3 bolts.
Torque: 10 Nm (100 kgf-cm, 7 ft. lbs.)
10. INSTALL MANUAL VALVE
11. INSTALL PRESSURE RELEASE VALVE
Install the spring, ball, spring seat and bolt. Torque: 6.9 Nm (70 kgf-cm, 61 inch lbs.)
Page 5141
2. INSTALL SUSPENSION SUPPORT
a. Install the cushion, 2 retainers and suspension support to the piston rod. b. Temporarily tighten a
new suspension support center nut. c. Position the suspension support as shown in the illustration.
d. Remove the SST.
SST 09727-30021 (09727-00010, 09727-00021, 09727-00031)
NOTICE: Do not make your position at the top side of the shock absorber.
HINT: After removing the SST, recheck the direction of the suspension support.
e. Torque the suspension center nut.
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)
INSTALLATION
1. INSTALL SHOCK ABSORBER WITH COIL SPRING
a. Install the upper side of shock absorber to the chassis frame with the 3 nuts.
Torque: 64 Nm (650 kgf-cm, 47 ft. lbs.)
b. Connect the lower side of shock absorber to the lower suspension arm with bolt, washer and nut.
Torque: 135 Nm (1,400 kgf-cm, 100 ft. lbs.)
2. INSTALL FRONT WHEEL
Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.)
Page 3080
Mass Air Flow Meter: Testing and Inspection
MASS AIR FLOW (MAF) METER
INSPECTION
1. DISCONNECT MAF METER CONNECTOR
2. REMOVE MAF METER
Remove the 2 screws and MAF meter.
3. INSPECT MAF METER
a. Using an ohmmeter, measure the resistance between terminals THA and E2.
If the resistance is not as specified, replace the MAF meter.
b. Inspect for operation.
1. Connect the MAF meter connector. 2. Connect the negative (-) terminal cable to the battery. 3.
Turn the ignition switch ON. 4. Using a voltmeter, connect the positive (+) tester probe to terminal
VG, and negative (-) tester probe to terminal E2G. 5. Blow air into the MAF meter, and check that
the voltage fluctuates.
Page 6834
Glossary Of Terms And Symbols (Part 2)
Page 4097
9. Remove steering knuckle.
A. Remove the cotter pin and loosen the nut.
B. Using the following SSTs, disconnect the steering knuckle.
SST P/N: 09950-40011 (09951-04010, 09952-04010, 09553-04020, 09554-04010 09955-04031,
09958-04011)
C. Remove the nut and steering knuckle.
NOTE:
4WD: Be careful not to damage the oil seal and drive shaft boot.
HINT: 4WD: When it is difficult to disconnect the drive shaft, tap the tip of the drive shaft with a
plastic hammer.
10. 2WD: Remove grease cap.
A. Mount the axle hub in a soft jaw vise.
NOTE:
Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further (refer to
the illustration).
HINT: Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further
(refer to the illustration).
B. Using a screwdriver, remove the grease cap.
NOTE:
Be careful not to damage the grease cap.
Diagram Information and Instructions
Relay Box: Diagram Information and Instructions
Key to Diagrams
A: System Title
B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to
distinguish it from the J/B
Example: 1 Indicates Relay Block No.1
C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type,
or specification is different.
D: Indicates related system.
Page 1873
Steps 2 - 3
INSPECTION PROCEDURE
HINT:
- DTC P0325 is for the left bank knock sensor circuit.
- DTC P0330 is for the right bank knock sensor circuit.
- Read freeze frame data using TOYOTA hand-held tester or OBD II scan tool, as freeze frame
data records the engine conditions when a malfunction is detected. When troubleshooting it is
useful for determining whether the vehicle was running or stopped, the engine was warmed up or
not, the air-fuel ratio was lean or rich, etc. at the time of the malfunction.
Page 4513
Battery: Technical Service Bulletins Battery - Absorbed Glass Mat Battery (AGM) Information
SPECIAL SERVICE TOOLS SS006-07
Title: ABSORBED GLASS MAT (AGM) BATTERY INFORMATION
Models '01 - '08 Toyota
August 11, 2007
Introduction This TSB provides background on the differences and similarities between AGM
(Absorbed-electrolyte Glass Mat) batteries and flooded lead acid batteries. It also explains charging
procedures performed by the GR8 Battery Diagnostic Station (SST P/N 00002-MCGR8) and its
ability to charge AGM batteries at higher current levels then a standard battery charger.
Applicable Vehicles
^ 2001 - 2008 model year Toyota vehicles equipped with an AGM battery.
Required Tools & Equipment
Warranty Information
Battery Comparison
Differences between AGM and flooded lead acid batteries:
^ AGM batteries have thin, sponge-like, glass mat separators that absorb all liquid electrolytes.
^ Flooded lead acid batteries have free, liquid electrolyte all around the plates and separators.
^ Flooded lead acid batteries can easily release gas that is formed during a charge, while AGM
battery life is diminished if gas is formed during charging.
Similarities between AGM and flooded lead acid batteries:
^ Both share the exact same lead acid chemistry.
Page 6585
BJ Inside of Rear Door LH
BK Inside of Rear Door RH
BL Surrounding of the Front of the Fuel Tank
Connector Location
BA1 Front Door LH Wire and Wire Harness (Connector Location)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel)
BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel)
BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel)
BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Page 589
Applicable Vehicles
Page 3342
B. Continue to update the ECU calibration file following the screen flow (Figure 18). Details for
selected screens are shown in Figure 19.
NOTE:
^ Each flash calibration update will take approximately 15 to 45 minutes.
^ Screens E through J (Figure 18) will need to be repeated for each flash calibration update
(calibration ID number).
^ All updates must display "YES" to complete the entire calibration file update for the vehicle ECU.
^ Failure to complete all updates may result in PERMANENT ECU DAMAGE!
CONFIRM UPDATE
4. Confirm successful flash calibration update and affix calibration update sticker.
Follow these steps to confirm the calibration was reprogrammed to the ECU.
Page 1742
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 6316
The ground points circuit diagram shows the connections from all major parts to the respective
ground points. When troubleshooting a faulty ground point, checking the system circuits which use
a common ground may help you identify the problem ground quickly. The relationship between
ground points (EA, IB and IC) can also be checked this way.
How to Read Power Source
HOW TO READ POWER SOURCE
Page 1974
Page 5460
Airbag Sensor Assembly: Testing and Inspection Replacement Requirements
REPLACEMENT REQUIREMENTS
In the following cases, replace the airbag sensor assembly.
- If the SRS has been deployed in a collision.
- If the airbag sensor assembly has been found to be faulty in troubleshooting.
- If the airbag sensor assembly has been dropped.
CAUTION: For removal and installation of the airbag sensor assembly. Be sure to follow the correct
procedure.
A/T, M/T - Alignment Pin Service Precaution
Manual Transmission/Transaxle: Technical Service Bulletins A/T, M/T - Alignment Pin Service
Precaution
T-SB-0053-08
May 8, 2008
Alignment Pin Installation during Transmission/Transaxle Assembly Installation
Service Category Drivetrain
Section Automatic Transmission/Transaxle
Market USA
Applicability
Introduction
The purpose of this TSB is to provide information regarding the installation of alignment pins during
transmission/transaxle assembly installation. Missing alignment pins may result in incorrect
alignment and failure of the transmission/transaxle assembly. Use the information below when
installing a transmission/transaxle assembly.
Parts Information
Warranty Information
Repair Procedure
1. Inspect the rear side of the engine block assembly for 2 alignment pins.
^ If there are less than 2 alignment pins present one may have been removed with the
transmission/transaxle assembly. Check the removed assembly for the missing alignment pins. Go
to step 2.
Page 6682
Terminal Retainer
Push the terminal retainer down to the temporary lock position.
c. Release the locking lug from terminal and pull the terminal out from rear.
4. INSTALL TERMINAL TO CONNECTOR
a. Insert the terminal.
HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug
locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position.
Page 815
STANDARD VALUE OF ECU TERMINAL
Testing and Inspection
Windshield Washer Switch: Testing and Inspection
INSPECT FRONT WIPER AND WASHER SWITCH CONTINUITY
w/ MIST
w/ INTERMITTENT
If continuity is not as specified, replace the switch.
Page 5912
- Length: 6 in.
^ Ratcheting tie down strap (quantity 1)
- Minimum Width & Length: 1 in. x 6 ft.
^ Bicycle Cable Lock (quantity 1)
- Minimum Width & Length: 3/8 in. x 5 ft.
- Built-in lock with key
- Bell: P/N 1002107, Master Lock: P/N 8126D, Kryptonite: P/N 999782 or equivalent
IV. Background
On certain 2000 through 2003 model year Tundra vehicles operated in cold climate areas with high
road salt use (Severe Cold Climate States) excessive corrosion may be exhibited on the rear frame
cross-member. In the worst case the spare tire stowed under the truck bed may become separated
from the rear cross-member. Eventually excessive corrosion of the rear cross-member may also
affect the functionality of the brake system Load Sensing Proportioning & By-Pass Valve and/or
associated brake lines.
Page 1103
Engine Room R/B
Details
Page 4685
B: Junction Connector
Indicates a connector which is connected to a short terminal.
Junction connector in this include a short terminal which is connected to a number of wire
harnesses. Always perform inspection with the short terminal installed. (When installing the wire
harnesses, the harnesses can be connected to any position within the short terminal grouping.
Accordingly, in other vehicles, the same position in the short terminal may be connected to wire
harness from a different part.) Wire harness sharing the same short terminal grouping ha the same
color.
C: Parts Code
The first letter of the code is taken from the first letter of part, and the numbers indicates its order in
parts which start with the same letter.
D: Connector Color
Connectors not indicated are milky white in color.
How to Read Ground Points
HOW TO READ GROUND POINTS
Page 2280
Page 6259
Wiring Harness Connector
E: Indicates the wiring harness and wiring harness connector. The wiring harness with male
terminal is shown with arrows.
Outside numerals are pin numbers.
The first letter of the code for each wiring harness and wiring harness connector(s) indicates the
component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and
Surrounding area, and "B" for the Body and Surrounding area.
When more than one code has the first and second letters in common, followed by numbers (e.g,
IH1, IH2), this indicates the same type of wiring harness and wiring harness connector.
F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in
parts position.
G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside
it). Junction Blocks are shaded to clearly separate
them from other parts.
H: When 2 parts both use one connector in common, the parts connector name used in wire
routing is shown in square brackets [ ].
Wiring Color
I: Indicates the wiring color.
Wire colors are indicated by an alphabetical code.
B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR =
Brown SB = Sky Blue LG = Light Green GR = Gray
The first letter indicates the basic wire color and the second letter indicates the color of the stripe.
Page 3403
Clutch: Specifications
O/D Direct Clutch Clutch Drum Bushing Inside Diameter Maximum 27.11 mm
O/D Direct Clutch Piston Stroke 1.77 - 2.07 mm
O/D Planetary Gear Bushing Maximum 11.27 mm
Planetary Pinion Gear Thrust Clearance Standard 0.20 - 0.60 mm
Maximum 1.00 mm
Flange Thickness No.16 3.6 mm
No.17 3.5 mm
No.18 3.4 mm
No.19 3.3 mm
No.20 3.2 mm
No.21 3.1 mm
Clutch Drum Standard Distance 15.5 - 16.5 mm
Piston Return Spring Standard Free Length 15.8 mm
Direct Clutch Piston Stroke 1.03 - 1.33 mm
Piston Return Spring Standard Free Length 23.25 mm
Drum Bushing Inside Diameter 53.99 mm
Flange Thickness No.33 3.0 mm
No.32 3.1 mm
No.31 3.2 mm
No.30 3.3 mm
No.29 3.4 mm
No.28 3.5 mm
No.27 3.6 mm
No.34 3.7 mm
O/D Direct Clutch Speed Sensor x Transmission Case 5.4 Nm
Page 735
Knock Sensor: Testing and Inspection
INSPECTION
1. REMOVE THROTTLE BODY COVER
2. REMOVE INTAKE AIR CONNECTOR
3. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS
4. REMOVE UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY
5. INSPECT KNOCK SENSOR 1,2
a. Disconnect the knock sensor connectors. b. Using an ohmmeter, check that there is no
continuity between the terminal and body.
If there is continuity, replace the sensor with SST. SST 09816-30010
Torque: 45 N.m (450 kgf.cm, 33 ft.lbf)
c. Reconnect the knock sensor connectors.
6. REINSTALL UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY
7. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS
8. REINSTALL INTAKE AIR CONNECTOR
9. REINSTALL THROTTLE BODY COVER
Page 1848
Coolant Temperature Sensor/Switch (For Computer): Description and Operation
Engine Coolant Temperature Sensor
A thermistor that is built into the engine coolant temperature sensor changes the resistance value
according to the engine coolant temperature.
The lower the engine coolant temperature sensor, the greater the thermistor resistance value, and
the higher the engine coolant temperature sensor temperature, the lower the thermistor resistance
value.
The engine coolant temperature sensor is connected to the ECM. The 5 V power source voltage in
the ECM is applied to the engine coolant temperature sensor from the terminal THA via a resistor
R. That is, the resistor R and the engine coolant temperature sensor are connected in series.
When the resistance value of the engine coolant temperature sensor changes in accordance with
changes in the engine coolant temperature, the potential at terminal THA also changes. Based on
this signal, the ECM increases the fuel injection volume to improve driveability during cold engine
operation.
Page 4991
2. Using 3 wire harness, wind the wire harness at least 2 times each around the bolts installed on
the left and right sides of the steering wheel pad.
CAUTION: Tightly wind the wire harness around the bolts so that there is no slack.
- If there is slack in the wire harness, the steering wheel pad may come loose due to the shock
when the airbag Is deployed. This is highly dangerous.
3. Face the upper surface of the steering wheel pad upward. Separately tie the left and right sides
of the steering wheel pad to the disc wheel
through the hub nut holes. Position the steering wheel pad connector so that it hangs downward
through a hub hole in the disc wheel.
CAUTION: Make sure that the wire harness is tight. It is very dangerous when looseness in the wire harness
results in the steering wheel pad coming free through the shock from the airbag deploying.
- Always tie down the steering wheel pad with the pad side facing upward. It is very dangerous if
the steering wheel pad is tied down with the metal surface facing upward as the wire harness will
be cut by the shock from the airbag deploying and the steering wheel pad will be thrown into the
air.
NOTE: The disc wheel will be marked by airbag deployment, so when disposing of the airbag use a
redundant disc wheel.
c. Check functioning of the SST. SST 09082-0700
Page 3367
^ 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 5242
Control Assembly: Testing and Inspection Heater Control Assembly
On-Vehicle Inspection
HEATER CONTROL ASSEMBLY
ON-VEHICLE INSPECTION
INSPECT HEATER CONTROL DIAL AND LEVER OPERATION Move the control dial and lever
left to right and check for stiffness and binding through the full range of the levers.
If click sound can not be heard or recoil is felt, adjust the control cable or check control cable and
heater control assembly.
Component Inspection
HEATER CONTROL ASSEMBLY
INSPECTION
1. INSPECT BLOWER SPEED CONTROL SWITCH CONTINUITY
If continuity is not as specified, replace the switch and check bulb.
2. INSPECT DEF. MODE SWITCH
Page 404
Wiring Harness Connector
E: Indicates the wiring harness and wiring harness connector. The wiring harness with male
terminal is shown with arrows.
Outside numerals are pin numbers.
The first letter of the code for each wiring harness and wiring harness connector(s) indicates the
component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and
Surrounding area, and "B" for the Body and Surrounding area.
When more than one code has the first and second letters in common, followed by numbers (e.g,
IH1, IH2), this indicates the same type of wiring harness and wiring harness connector.
F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in
parts position.
G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside
it). Junction Blocks are shaded to clearly separate
them from other parts.
H: When 2 parts both use one connector in common, the parts connector name used in wire
routing is shown in square brackets [ ].
Wiring Color
I: Indicates the wiring color.
Wire colors are indicated by an alphabetical code.
B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR =
Brown SB = Sky Blue LG = Light Green GR = Gray
The first letter indicates the basic wire color and the second letter indicates the color of the stripe.
Electrical Specifications
Page 2146
a. Check only the valves indicated.
- Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
- Record the out-of-specification valve clearance measurements. They will be used later to
determine the required replacement adjusting shim.
Valve clearance (Cold):
b. Turn the crankshaft 1 revolution (360°) and align the mark. (See procedure in step 8) c. Check
only the valves indicated as shown. Measure the valve clearance. (See procedure in step (a))
10. ADJUST VALVE CLEARANCE
a. Remove the timing belt. b. Remove the camshafts. c. Remove the valve lifter and adjusting shim.
d. Determine the replacement adjusting shim size according to these Formula or Charts:
1. Using a micrometer, measure the thickness of the removed shim. 2. Calculate the thickness of a
new shim so that the valve clearance comes within the specified value.
T ..........................................................................................................................................................
................. Thickness of removed shim A ...........................................................................................
.................................................................................. Measured valve clearance N ............................
......................................................................................................................................................
Thickness of new shim
Page 5547
Rear Seat Belt Extender Applications
Page 974
Hose/Line HVAC: Testing and Inspection
REFRIGERANT LINE
ON-VEHICLE INSPECTION
1. INSPECT HOSE AND TUBE CONNECTIONS FOR LOOSENESS
2. INSPECT HOSES AND TUBES FOR LEAKAGE
Using a gas leak detector, check for leakage of refrigerant.
Page 3977
Steps 1 - 3
Page 4877
1. MEASURE PS VANE PUMP ROTATING TORQUE
a. Check that the pump rotates smoothly without abnormal noise. b. Temporarily install the bolt. c.
Using a torque wrench, check the pump rotating torque.
Rotating torque: 0.28 Nm (2.8 kgf-cm, 2.4 inch lbs.) or less
2. REMOVE SUCTION PORT UNION
a. Remove the bolt and suction port union. b. Remove the O-ring from the union.
3. REMOVE PRESSURE PORT UNION, FLOW CONTROL VALVE AND SPRING
a. Remove the pressure port union, flow control valve and spring. b. Remove the O-ring from the
pressure port union.
4. REMOVE REAR HOUSING
a. Remove the 4 bolts and rear housing.
HINT: If the wave washer and side plate are stuck to the rear housing, lightly tap the rear housing
with a plastic hammer, and remove the wave washer and side plate.
b. Remove the 2 O-rings from the rear housing.
5. REMOVE WAVE WASHER 6. REMOVE SIDE PLATE 7. REMOVE GASKET 8. REMOVE CAM
RING, 10 VANE PLATES AND VANE PUMP ROTOR
a. Using a screwdriver, remove the snap ring from the vane pump shaft. b. Remove the cam ring,
10 vane plates and vane pump rotor.
NOTICE: Be careful not to drop the plate.
9. REMOVE VANE PUMP SHAFT WITH VANE PUMP PULLEY
10. REMOVE STRAIGHT PINS
Remove the 2 pins from the front housing.
INSPECTION
1. CHECK OIL CLEARANCE BETWEEN VANE PUMP SHAFT AND BUSHING
Using a micrometer and caliper gauge, measure the oil clearance. Standard clearance: 0.03 - 0.05
mm (0.0012 - 0.0020 inch) Maximum clearance: 0.07 mm (0.0028 inch) If it is more than the
maximum, replace the shaft and front housing.
2. INSPECT VANE PUMP ROTOR AND VANE PLATES
Page 3846
STANDARD VALUE OF ECU TERMINAL
Page 6837
B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(Connect the Relay) and SW 2 OFF (or Disconnect SW 2)
D. Disconnect and reconnect the connectors while watching the test light.
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
E. Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION:
a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals
are touched, the IC may be destroyed by
static electricity.)
b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact
with the terminals of leads from the IC, etc. of the replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
Special Tool
1. PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown.
2. DISCONNECT CONNECTOR
3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
a. Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the
secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
A: For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
Page 5512
CAUTION
For this procedure, do not use pliers. They may damage the webbing.
C. Tighten the c-clamp until the space between its jaws are 4.5 - 5.0 mm (0.18 in. -0.20 in.) Figures
5&6
Page 3976
ABS Light: Testing and Inspection
CIRCUIT DESCRIPTION
If the ECU detects a trouble, the ABS warning light comes on while the ABS control is prohibited
and at the same time, the ECU records a DTC in memory.
After removing the short pin of the DLC3, connect terminals Tc and CG of the DLC3 to make the
ABS warning light blink and to output the DTC.
Wiring Diagram
Component Locations
Audible Warning Device Control Module: Component Locations
Instrument Panel
Page 1717
DOWNLOAD FILE TO TESTER
2. Download the calibration file to the Diagnostic Tester.
The Calibration Update Wizard (CUW) is a new application on TIS which downloads calibration
files from TIS onto the Diagnostic Tester Program Card.
NOTE:
Before you begin, ensure that the Diagnostic Tester is equipped with software version 8.0a, or
later. Only a 12 MB program card (P/N 01002593-005) may be used for this process.
A. Before downloading a new calibration file from TIS, check the current calibration files stored on
the Diagnostic Tester Program Card by following the screen flow shown (Figure 4).
NOTE:
^ Screen D may be blank if no calibrations are stored on the Diagnostic Tester Program Card.
^ If the desired calibration file is already on the Diagnostic Tester, proceed to Step 3 (Reprogram
ECU with Tester shown).
^ A maximum of two calibration files may be loaded on the tester at one time with Diagnostic Tester
software version 10.2a and later. Prior versions may store up to four calibration files.
Page 5406
g. Deploy the airbag.
1. Connect the SST red clip to the battery positive (+) terminal and the black clip to the battery
negative (-) terminal. 2. Check that no one is within 10 m (33 ft) area around the disc wheel which
the steering wheel pad is tied to. 3. Press the SST activation switch and deploy the airbag.
HINT: The airbag deploys simultaneously as the LED of the SST activation switch lights up.
h. Dispose of the steering wheel pad (with airbag).
CAUTION: The steering wheel pad is very hot when the airbag Is deployed, so leave it alone for at least 30
minutes after deployment.
- Use gloves and safety glasses when handling a steering wheel pad with deployed airbag.
- Always wash your hands with water after completing the operation.
- Do not apply water, etc. to a steering wheel pad with deployed airbag.
1. Remove the steering wheel pad from the disc wheel. 2. Place the steering wheel pad in a vinyl
bag, tie the end tightly and dispose of it in the same way as other general parts disposal.
Disposing of Steering Wheel Pad With Airbag Deployed
DISPOSAL
HINT: When scrapping vehicle equipped with an SRS or disposing of a steering wheel pad (with
airbag), always first deploy the air-bag in accordance with the procedure described below. If any
abnormality occurs with the airbag deployment, contact the SERVICE DEPT of TOYOTA MOTOR
SALES, U.S.A., INC.
CAUTION:
- Never dispose of a steering wheel pad which has an undeployed airbag.
- The airbag produces a sizeable exploding sound when it deploys, so perform the operation
out-of-doors and where it will not create a nuisance to nearby residents.
Page 6039
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 4052
A. Using snap ring pliers, remove the snap ring.
B. Using the following SSTs and a press, remove the bearing from the steering knuckle.
SST P/N: 09950-60020
(09951-00810)
SST P/N: 09950-70010
(09951-07150)
16. Install new bearing.
A. Using the following SSTs and a press, install a NEW bearing to the steering knuckle.
SST P/N: 09527-17011
SST P/N: 09950-60020 (09951-00910)
B. Using snap ring pliers, install a NEW snap ring.
17. Install new oil seal (outside).
A. Using the following SSTs and a plastic hammer, install a NEW oil seal (outside).
SST P/N: 09223-15030
Page 2865
The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit
breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery
power is supplied to each system are explained. Since all System Circuit diagrams start from the
power source, the power source system must be fully understood.
Page 5907
Page 3330
Materials System.
Required SSTs
NOTE:
Additional Diagnostic Tester Kits, CAN Interface Modules, Program Cards or SSTs may be ordered
by calling SPX/OTC at 1-800-933-8335.
Process Overview
ECU Flash Reprogramming is a 4-step process:
1. Locate the desired calibration file on TIS (Technical Information System).
Calibration files may be found in two areas:
a. Search by model and year for a Technical Service Bulletin addressing a specific product issue.
b. Search by model under the ECU Flash Reprogramming section.
2. Download the calibration file from TIS to the Diagnostic Tester.
The Calibration Update Wizard (CUW) is an application on TIS which downloads calibration files
from TIS to the Diagnostic Tester Program Card. This step is only required when the calibration file
is not currently stored on the Diagnostic Tester Program Card.
3. Reprogram the vehicle ECU with the Diagnostic Tester.
Diagnostic Tester Software now incorporates a function to update a vehicle's ECU calibration
through flash reprogramming.
4. Confirm successful flash update and affix calibration update sticker.
Modifications to ECU calibration files must be recorded and properly displayed on the vehicle using
the calibration update sticker.
NOTE:
A/T - Fluid Requirements
Fluid - CVT: Technical Service Bulletins A/T - Fluid Requirements
TRANSMISSION & CLUTCH TC001-02
May 24, 2002
Title: AUTOMATIC TRANSMISSION FLUID REQUIREMENTS
Models: All '00 - '02 Models & '03 Corolla & Matrix
Introduction
Please refer to the table for correct application of Dexron(R) III (Dexron(R) II) and Toyota Type T-IV
Automatic Transmission Fluids or equivalent.
Parts Information
Warranty Information
Page 6757
Engine Room R/B
Page 2412
2. Start the engine.
3. Perform the drive pattern to run and complete the Oxygen Sensor (O2S) Monitor.
HINT:
The 02S Monitor is completed when the following conditions are met:
^ Two (2) minutes or more passed after the engine start.
^ The Engine Coolant Temperature (ECT) is 167°F (75°C) or more.
^ Cumulative running time at 30 mph (48 km/h) or more exceeds 6 minutes.
^ Vehicle is in closed loop.
^ The fuel-cut is operated for 8 seconds or more (for Rear O2S Monitor).
A. Allow the engine to idle for two minutes.
B. Warm up the engine until the Engine Coolant Temperature (ECT) reaches 167°F (75°C).
C. Drive the vehicle over 30 mph (48 km/h) for more than 40 seconds.
D. Stop the vehicle and allow the engine to idle for more than 20 seconds.
E. Repeat steps C and D at least 8 times in one driving cycle. (Do not cycle the ignition key.)
In addition, perform the following steps for the Rear O2S Readiness Monitor:
A. Select second gear.
B. Allow the vehicle to run at 30 mph (48 km/h) or more.
C. Keep the accelerator pedal "off-idle" for more than 10 seconds.
D. Immediately after step C, release the accelerator pedal for at least 10 seconds without
depressing the brake pedal (to execute the fuel-cut).
E. Decelerate the vehicle until the vehicle speed reaches less than 6mph (10km/h).
F. Repeat steps B - E at least twice in one driving cycle.
Accessing O2S Test Results
1. On the Diagnostic Tester* screen, select the following menus:
^ DIAGNOSTICS
^ CARB OBD II
Instruments - Oil Pressure Gauge Reads Abnormally Low
Oil Pressure Sender: Customer Interest Instruments - Oil Pressure Gauge Reads Abnormally Low
ELECTRICAL EL017-03
December 23, 2503
Title OIL PRESSURE GAUGE READS LOW
Models '01 - '04 Sequoia & '00 - '02 Tundra
TSB UPDATE NOTICE:
This TSB updates EL006-03. TSB EL006-03 is now obsolete and should be discarded.
Introduction
Some customers with Sequoia or Tundra vehicles may encounter an oil pressure gauge that reads
abnormally low at idle. An updated oil pressure sender has been created to address this condition.
Applicable Vehicles ^
2001 - 2004 model year Sequoia vehicles produced BEFORE the Production Change Effective
VINs shown below.
^ 2000 - 2002 model year Tundra vehicles produced BEFORE the Production Change Effective
VIN shown below.
Production Change Information
Parts Information
Repair Procedure
1. Replace the Oil Pressure Sender.
2. Verify proper operation of the Oil Pressure Gauge.
Warranty Information
Applicable Warranty*:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36
months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Page 628
CHART 22
Page 999
Fluid - A/T: Service and Repair
1. Drain transaxle fluid, then install drain plug and new gasket.
2. With engine Off, add fluid through dipstick tube.
Do not overfill.
3. Start engine, then move shift selector through all positions, ensuring smooth operation.
4. Allow to idle, then check at COOL level.
5. Allow to reach normal operating temperature, then recheck.
Page 4077
Parts Information
Diagnosis Procedure
1. Confirm the customer complaint.
2. Determine if vibration is from front or rear (while brakes are still warm from confirmation driving).
The following procedure will isolate the drum brakes from the rest of the hydraulic system by using
the parking brake (PKB).
NOTE:
Remember, with a foot PKB (on automatic transmission) the pedal must be pressed a second time
to disengage the parking brake.
HINT:
When diagnosing a Tundra with a foot PKB, slowly apply the PKB until the first "click, " then press
the PKB pedal a second time so it will disengage if it is released. At this time the PKB can be
pressed to the desired level for continued diagnosis.
A. Drive the Tundra along a smooth, level section of road at approximately 40 mph - 50 mph.
B. Slowly apply the PKB while driving until the brake begins to engage and slow the vehicle. Do not
apply the PKB past this point of initial engagement.
C. Hold the PKB at this point of initial engagement for a few seconds to slowly reduce the vehicle
speed and allow adequate time to monitor the ride condition.
D. Disengage the PKB.
E. If brake vibration is felt during step (C), then it indicates that the rear brake drums are one
source of brake vibration on this vehicle.
Refer to TSB BR003-02 for parts and repair information relating to Tundra rear brake vibration.
F. If no vibration is felt during step (C), then the front brake assemblies are the cause of brake
vibration on this vehicle.
Proceed to the following repair procedure.
Repair Procedure
Page 424
Key Reminder Switch: Pinout Values and Diagnostic Parameters
KEY REMINDER AND SEAT BELT WARNING
B7 (A), (B) BUCKLE SW LH
(A) 1 - (A) 2, (B) 2 - (B) 1 : Closed with driver's seat belt in use
D16 DOOR COURTESY SW FRONT LH
1 - GROUND : Closed with front LH door open
U1 UNLOCK WARNING SW
1 - 2 : Closed with ignition key in cylinder
C11 (A), C12 (B), C13 (C) COMBINATION METER
(A) 12, (B) 15 - GROUND : Always continuity (B) 10 - GROUND
: Continuity with the front LH door open (Standard cab) : Continuity with the each LH door open
(Access cab)
(C) 1 - GROUND : Continuity with the ignition key in cylinder
(B) 9 - GROUND : Continuity with the driver's seat belt in use
(B) 5 - GROUND : Always approx. 12 volts
(A) 7 - GROUND : Approx. 12 volts with the ignition SW at ON or ST position
Page 6946
INSPECT PASSENGER'S DOOR POWER WINDOW SWITCH CONTINUITY
If continuity is not as specified, replace the switch.
INSPECT POWER WINDOW MASTER SWITCH CIRCUIT
Disconnect the connector from the master switch and inspect the connector on the wire harness
side.
* Exceptions: During 60 seconds after the ignition switch is turned ON to OFF (ACC) or until driver
or a passenger's door is opened after the ignition switch is turned ON to OFF (ACC).
If the circuit is not as specified, inspect the circuits connected to other parts.
Page 5933
Information
PRELIMINARY INSPECTION INSTRUCTIONS
Page 487
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
1. DRAIN ENGINE COOLANT
2. REMOVE THROTTLE BODY COVER
3. REMOVE INTAKE AIR CONNECTOR
4. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS
a. Disconnect the accelerator cable from the throttle body. b. Remove the 2 bolts and 2 nuts, and
disconnect the throttle body from the intake manifold. c. Remove the gasket
5. REMOVE ECT SENSOR
a. Disconnect the ECT sensor connector. b. Remove the ECT sensor and gasket.
6. REINSTALL ECT SENSOR
a. Install a new gasket and the ECT sensor.
Torque: 20.4 N.m (208 kgf.cm, 15 ft.lbf)
b. Connect the ECT sensor connector.
7. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS
a. Install a new gasket and the throttle body with the 2 bolts and 2 nuts.
Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)
b. Connect the accelerator cable to the throttle body.
8. REINSTALL INTAKE AIR CONNECTOR
9. REFILL WITH ENGINE COOLANT
10. REINSTALL THROTTLE BODY COVER
Page 5995
Headliner: Service and Repair
REMOVAL
HINT: Tape the screwdriver tip before using it to remove the parts.
1. Access cab:
REMOVE REAR SEAT
2. REMOVE FRONT DOOR SCUFF PLATES
a. Standard cab:
Remove the 10 screws and front door scuff plates.
b. Access cab:
Remove the 8 screws and front door scuff plates.
3. Access cab:
REMOVE ACCESS DOOR SCUFF PLATES Remove the 6 screws and access door scuff plates.
4. Access cab:
REMOVE FRONT DOOR REAR SCUFF PLATES a. Remove the 2 clips and 2 covers. b. Remove
the 2 clips and 2 front door rear scuff plates.
5. REMOVE ASSIST GRIPS
a. Using a screwdriver, remove the caps. b. Driver's side:
Using a torx driver, remove the 2 torx screws and assist grip
c. Passenger's side:
Using a torx driver, remove the 4 torx screws and 2 assist grips.
6. REMOVE FRONT PILLAR GARNISH
a. Using a screwdriver, remove the front pillar garnish. b. Employ the same manner described
above to the other side.
7. Access cab:
REMOVE FRONT SEAT OUTER BELT ANCHORS
Locations
Instrument Panel
Page 1991
CHART 21
Page 734
Steps 2 - 3
INSPECTION PROCEDURE
HINT:
- DTC P0325 is for the left bank knock sensor circuit.
- DTC P0330 is for the right bank knock sensor circuit.
- Read freeze frame data using TOYOTA hand-held tester or OBD II scan tool, as freeze frame
data records the engine conditions when a malfunction is detected. When troubleshooting it is
useful for determining whether the vehicle was running or stopped, the engine was warmed up or
not, the air-fuel ratio was lean or rich, etc. at the time of the malfunction.
Testing and Inspection
Air Bag Deactivation Indicator: Testing and Inspection
INSPECT PASSENGER AIRBAG MANUAL ON-OFF INDICATOR OPERATION
a. Using a service wire, connect B1 and B3. b. Connect the positive (+) lead from the battery to
terminal A13 and negative (-) lead to terminal A1. c. Check that the indicator light lights up.
If the operation is not as specified, replace the indicator.
Page 2482
CHART 8
CHART 9
Page 6616
Key Reminder Switch: Pinout Values and Diagnostic Parameters
KEY REMINDER AND SEAT BELT WARNING
B7 (A), (B) BUCKLE SW LH
(A) 1 - (A) 2, (B) 2 - (B) 1 : Closed with driver's seat belt in use
D16 DOOR COURTESY SW FRONT LH
1 - GROUND : Closed with front LH door open
U1 UNLOCK WARNING SW
1 - 2 : Closed with ignition key in cylinder
C11 (A), C12 (B), C13 (C) COMBINATION METER
(A) 12, (B) 15 - GROUND : Always continuity (B) 10 - GROUND
: Continuity with the front LH door open (Standard cab) : Continuity with the each LH door open
(Access cab)
(C) 1 - GROUND : Continuity with the ignition key in cylinder
(B) 9 - GROUND : Continuity with the driver's seat belt in use
(B) 5 - GROUND : Always approx. 12 volts
(A) 7 - GROUND : Approx. 12 volts with the ignition SW at ON or ST position
Description and Operation
Brake Signal: Description and Operation
Stop Light Switch Signal
Engine
This signal is used to detect when the brakes have been applied. The STP signal voltage is the
same as the voltage supplied to the stop lights.
The STP signal is used mainly to control the fuel cut-off engine speed (The fuel cut-off engine
speed is reduced slightly when the vehicle is braking.).
Automatic Transaxle
The purpose of this circuit is to prevent the engine from stalling, while driving in lock-up condition,
when brakes are suddenly applied.
When the brake pedal is operated, this switch sends a signal to ECM. Then the ECM cancels
operation of the lock-up clutch while braking is in progress.
Page 4711
Wiring Harness Connector
E: Indicates the wiring harness and wiring harness connector. The wiring harness with male
terminal is shown with arrows.
Outside numerals are pin numbers.
The first letter of the code for each wiring harness and wiring harness connector(s) indicates the
component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and
Surrounding area, and "B" for the Body and Surrounding area.
When more than one code has the first and second letters in common, followed by numbers (e.g,
IH1, IH2), this indicates the same type of wiring harness and wiring harness connector.
F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in
parts position.
G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside
it). Junction Blocks are shaded to clearly separate
them from other parts.
H: When 2 parts both use one connector in common, the parts connector name used in wire
routing is shown in square brackets [ ].
Wiring Color
I: Indicates the wiring color.
Wire colors are indicated by an alphabetical code.
B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR =
Brown SB = Sky Blue LG = Light Green GR = Gray
The first letter indicates the basic wire color and the second letter indicates the color of the stripe.
Diagrams
Locations
Intake Air Temperature Sensor: Locations
Mass Air Flow (MAF) Meter
The Intake Air Temperature (IAT) Sensor is installed in the Mass Air Flow (MAF) Meter.
Page 1583
3. ASSEMBLE SST
SST 09230-01010, 09231-14010 a. Install the punch assembly to the overhaul handle, inserting it
in the hole in part "A" as shown in the illustration. b. While gripping the handle, adjust the stopper
bolt so that dimension "B" shown in the diagram.
Dimension "B": 8.4 mm (0.34 inch)
4. CAULK LOCK PLATE
a. Lightly press SST against the lock plate in the order shown in the illustration. After repeating this
a few times, fully caulk the lock plate by
squeezing the handle until stopped by the stopper bolt. SST 09230-01010
HINT:
^ Do not stake the areas protruding around the ports and flanges.
Page 4317
^ 09023-00100
6. REMOVE BRAKE CALIPER AND DISC
A. Remove the bolt and brake line clamp from the steering knuckle.
B. Remove the 2 bolts, brake caliper and disc.
7. REMOVE SHOCK ABSORBER
A. Disconnect Shock Absorber from lower suspension arm.
B. Remove the shock absorber lower side set nut and washer.
NOTE:
Do not remove the bolt.
C. Wrap the bolt's head with vinyl tape to prevent the drive shaft boot from being damaged.
D. Pry down the lower suspension arm to remove the bolt and disconnect the shock absorber.
E. Remove the 3 nuts and shock absorber with the coil spring.
NOTE:
Do not damage the brake tube.
Page 1715
Materials System.
Required SSTs
NOTE:
Additional Diagnostic Tester Kits, CAN Interface Modules, Program Cards or SSTs may be ordered
by calling SPX/OTC at 1-800-933-8335.
Process Overview
ECU Flash Reprogramming is a 4-step process:
1. Locate the desired calibration file on TIS (Technical Information System).
Calibration files may be found in two areas:
a. Search by model and year for a Technical Service Bulletin addressing a specific product issue.
b. Search by model under the ECU Flash Reprogramming section.
2. Download the calibration file from TIS to the Diagnostic Tester.
The Calibration Update Wizard (CUW) is an application on TIS which downloads calibration files
from TIS to the Diagnostic Tester Program Card. This step is only required when the calibration file
is not currently stored on the Diagnostic Tester Program Card.
3. Reprogram the vehicle ECU with the Diagnostic Tester.
Diagnostic Tester Software now incorporates a function to update a vehicle's ECU calibration
through flash reprogramming.
4. Confirm successful flash update and affix calibration update sticker.
Modifications to ECU calibration files must be recorded and properly displayed on the vehicle using
the calibration update sticker.
NOTE:
Page 6165
Sound Proofing / Insulation: Description and Operation
Low Vibration, Low Noise Body
Description
An effective application of vibration damping and noise supressant materials reduces engine and
road noise.
Sound Absorbing and Vibration Damping Materials
^ In conjunction with the use of a asphalt sheet which decreases the noise level, asphalt sheet is
applied to most of the floor area to reduce engine and
road noise during vehicle operation.
^ Foamed material is provided inside the piller; rockers and doors. As a result, the wind noise and
road noise that are transmitted to the rockers and the
pillers have been reduced.
Page 4367
^ 09710-28012-01 (09710-07031) 09950-40011 (09951-04020, 09952-04010, 09953-04020,
09954-04010, 09955-04031, 09957-04010, 09958-04011)
HINT:
If necessary, use a press to remove the axle hub from the steering knuckle.
C. Remove the dust cover from the steering knuckle.
D. 4WD:
Remove the bearing spacer and ABS speed sensor rotor (W/ABS) or spacer (W/O ABS).
NOTE:
Take care not to scratch the serration of the speed sensor rotor.
14. REMOVE OIL SEAL (OUTSIDE)
Using a screwdriver, remove the oil seal (outside) from the steering knuckle.
15. REMOVE BEARING FROM STEERING KNUCKLE
A. Using snap ring pliers, remove the snap ring.
B. Using the following SSTs and a press, remove the bearing from the steering knuckle.
^ 09950-60020 (09951-00810)
^ 09950-70010 (09951-07150)
16. INSTALL NEW BEARING
A. Using the following SSTs and a press, install a NEW bearing to the steering knuckle.
^ 09527-17011
^ 09950-60020 (09951-00910)
Specifications
Fluid Pump: Specifications
Body Clearance Standard 0.07 - 0.15 mm
Maximum 0.3 mm
Tip Clearance Standard 0.11 - 0.14 mm
Maximum 0.3 mm
Side Clearance Standard 0.02 - 0.05 mm
Maximum 0.1 mm
Pump Body Bushing Inside Diameter Maximum 38.19 mm
Stator Shaft Bushing Inside Diameter Front SIde Maximum 21.58 mm
Rear Side Maximum 27.08 mm
Stator Shaft x Oil Pump Body 10 Nm
Oil Pump x Transmission Case 22 Nm
Testing and Inspection
Headlamp Dimmer Switch: Testing and Inspection
INSPECT LIGHT CONTROL SWITCH CONTINUITY
If continuity is not as specified, replace the switch.
INSPECT HEADLIGHT DIMMER SWITCH CONTINUITY
If continuity is not as specified, replace the switch.
Page 1112
Glossary Of Terms And Symbols (Part 1)
Page 6600
The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit
breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery
power is supplied to each system are explained. Since all System Circuit diagrams start from the
power source, the power source system must be fully understood.
Page 3110
Throttle Position Sensor: Testing and Inspection
ON-VEHICLE INSPECTION
1. REMOVE THROTTLE BODY COVER
2. INSPECT SYSTEM OPERATION
a. Check that the throttle linkage moves smoothly.
b. Inspect the throttle control motor for operating sound.
1. Turn the ignition switch ON. 2. When turning the accelerator pedal position sensor lever, check
the running sound of the motor. Also, check that there is no friction sound.
If operation is not as specified, check the throttle control motor (See step 3), wiring and ECM.
c. Inspect the accelerator pedal position sensor.
1. Connect the TOYOTA hand-held tester to the DLC3. 2. Check that the MIL does not light up. 3.
When turning the accelerator pedal position sensor lever to the full-open position, check that the
throttle valve opening percentage
(THROTTLE POS) of the CURRENT DATA shows the standard value.
Standard throttle valve opening percentage: 60 % or more
If operation is not as specified, check that the accelerator pedal position sensor (See step 5), wiring
and ECM.
Page 2200
Page 3756
Transmission Mode Indicator - A/T: Diagnostic Aids
Voltage Check
Voltage Check
Voltage Check
A. Establish conditions in which voltage is present at the check point.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(SW 2 OFF)
B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or
component terminal. This check can be done with a test light instead of a voltmeter.
Continuity and Resistance Check
Continuity and Resistance Check
Continuity And Resistance Check
A. Disconnect the battery terminal or wire so there is no voltage between the check points. B.
Contact the two leads of an ohmmeter to each of the check points.
Page 3910
B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(Connect the Relay) and SW 2 OFF (or Disconnect SW 2)
D. Disconnect and reconnect the connectors while watching the test light.
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
E. Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION:
a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals
are touched, the IC may be destroyed by
static electricity.)
b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact
with the terminals of leads from the IC, etc. of the replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
Special Tool
1. PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown.
2. DISCONNECT CONNECTOR
3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
a. Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the
secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
A: For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
Page 1754
3. Start the engine and warm it up to normal operating temperatures before test-driving.
4. Perform a thorough test drive with several accelerations from a stop with "light throttle"
application until proper transmission shifting is verified.
Reset Procedure 2
1. Disconnect the negative battery cable for 5 minutes.
2. Reconnect battery cable.
3. Start the engine and warm it up to normal operating temperatures before test-driving.
4. Perform a thorough test drive with several accelerations from a stop with "light throttle"
application until proper transmission shifting is verified.
Page 1861
2. REMOVE CRANKSHAFT POSITION SENSOR
a. Disconnect the crankshaft position sensor connector. b. Remove the bolt and crankshaft position
sensor.
INSTALLATION
1. INSTALL CRANKSHAFT POSITION SENSOR
a. Install the crankshaft position sensor with the bolt.
Torque: 6.5 N.m (65 kgf.cm, 58 in.lbf)
b. Connect the crankshaft position sensor connector.
2. INSTALL ENGINE UNDER COVER
Page 2815
CHART 11
Page 2148
Exhaust: N = T + (A - 0.30 mm (0.012 inch))
3. Select a new shim with thickness as close as possible to the calculated value.
HINT: Shims are available in 41 increments of 0.020 mm (0.0008 inch), from 2.00 mm (0.0787
inch) to 2.80 mm (0.1102 inch).
e. Place a new adjusting shim on the valve. f.
Place the valve lifter.
A/C - Insufficient Cabin Cooling
Heater Control Valve: Customer Interest A/C - Insufficient Cabin Cooling
HEATING & AIR CONDITIONING AC004-04
May 20, 2004
Title: POOR PERFORMANCE OF A/C SYSTEM
Models: '01 - '04 Sequoia & '00 - '04 Tundra
May 20, 2004
Introduction Some Sequoia and Tundra vehicles may exhibit a condition where the air conditioning
system does not sufficiently cool the cabin. Adjustment of the water control valve is necessary to
correct the condition.
Applicable ^
2001 - 2004 model year Sequoia vehicles produced BEFORE the Production Vehicles Change
Effective VINs shown below.
^ 2000 - 2004 model year Tundra vehicles produced BEFORE the Production Change Effective
VINs shown below.
Production Change Information
Warranty Information
Applicable Warranty*:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36
months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Repair Procedure
ABS/TCS - Zero Point Calibration Information
Yaw Rate Sensor: Technical Service Bulletins ABS/TCS - Zero Point Calibration Information
T-SB-0020-08
March 25, 2008
Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment
Service Category Brake
Section Brake Control/Dynamic Control System
Market USA
Applicability
Introduction
The purpose of this TSB is to provide information on when and how to perform the zero point
calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting
the battery is a necessary step for performing the zero point calibration.
Warranty Information
Required Tools & Equipment
^ Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE).
^ The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the
service procedures listed in this bulletin.
Preliminary Information
Perform this procedure if any of these repairs have been performed on the vehicle:
^ Wheel alignment has been adjusted.
^ Any chassis components have been removed/installed or replaced.
Page 6007
Component Inspection
Evaporator Case: Testing and Inspection Component Inspection
INSPECTION
1. CHECK EVAPORATOR FINS FOR BLOCKAGE
If the fins are clogged clean them with compressed air.
2. CHECK FITTING FOR CRACKS FOR SCRATCHES
If necessary repair or replace.
3. INSPECT THERMISTOR RESISTANCE
a. Place the thermistor in cold water and while changing the temperature of the water, measure
resistance at the connector and at the same time,
measure temperature of the water with a thermometer.
b. Compare the 2 readings on the chart.
If resistance value is not as specified, replace the thermistor.
Page 4351
11. 4WD: Remove oil seal (inside).
A. Mount the axle hub in a soft jaw vise.
HINT: Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further
(refer to the illustration above).
B. Using a screwdriver, remove the oil seal (inside).
12. 2WD: Remove lock nut and ABS speed sensor rotor (with ABS) or spacer (without ABS). Using
a chisel and hammer, loosen the staked part of the lock nut.
NOTE:
Be careful not to damage the bushing.
A. Using the following SST, remove the lock nut. SST P/N: 00002-00909 (09318-12010)
NOTE:
Do NOT use air wrench.
B. Remove the ABS speed sensor rotor or spacer.
NOTE:
Take care not to scratch the serration of the speed sensor rotor.
13. Remove axle hub from steering knuckle.
A. Remove the 4 bolts and shift the dust cover toward the hub side (outside).
B. Using the following SSTs, remove the axle hub from the steering knuckle.
SST P/N: 09710-28012-01 (09710-07031)
SST P/N: 09950-40011(09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04031,
09957-04010, 09958-04011)
HINT: If necessary, use a press to remove the axle hub from the steering knuckle.
C. Remove the dust cover from the steering knuckle.
D. 4WD: Remove the bearing spacer and ABS speed sensor rotor (with/ABS) or spacer (without
ABS).
NOTE:
Take care not to scratch the serration of the speed sensor rotor.
14. Remove oil seal (outside). Using a screwdriver, remove the oil seal (outside) from the steering
knuckle.
15. Remove bearing from steering knuckle.
Page 5738
Radio And Player
Engine Controls - A/F And O2 Sensor Identification
Oxygen Sensor: All 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 4781
Glossary Of Terms And Symbols (Part 2)
Page 2391
Applicable Vehicles
Page 633
CHART 25
Instruments - Oil Pressure Gauge Reads Abnormally Low
Oil Pressure Sender: All Technical Service Bulletins Instruments - Oil Pressure Gauge Reads
Abnormally Low
ELECTRICAL EL017-03
December 23, 2503
Title OIL PRESSURE GAUGE READS LOW
Models '01 - '04 Sequoia & '00 - '02 Tundra
TSB UPDATE NOTICE:
This TSB updates EL006-03. TSB EL006-03 is now obsolete and should be discarded.
Introduction
Some customers with Sequoia or Tundra vehicles may encounter an oil pressure gauge that reads
abnormally low at idle. An updated oil pressure sender has been created to address this condition.
Applicable Vehicles ^
2001 - 2004 model year Sequoia vehicles produced BEFORE the Production Change Effective
VINs shown below.
^ 2000 - 2002 model year Tundra vehicles produced BEFORE the Production Change Effective
VIN shown below.
Production Change Information
Parts Information
Repair Procedure
1. Replace the Oil Pressure Sender.
2. Verify proper operation of the Oil Pressure Gauge.
Warranty Information
Applicable Warranty*:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36
months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Service and Repair
Transmission Temperature Sensor/Switch: Service and Repair
ON-VEHICLE REPAIR
1. 5VZ-FE:
DISCONNECT OIL COOLER PIPE
a. Remove the 3 bolts and clamps.
b. Disconnect the oil cooler pipe. c. Remove the elbow from the transmission.
2. DISCONNECT ATF TEMPERATURE SENSOR CONNECTOR 3. REMOVE ATF
TEMPERATURE SENSOR
a. Remove the ATF temperature sensor. b. Remove the O-ring from the ATF temperature sensor.
4. INSTALL ATF TEMPERATURE SENSOR
a. Coat a new O-ring with ATF and install it to the ATF temperature sensor. b. Install the ATF
temperature sensor.
Torque: 15 Nm (150 kgf-cm, 11 ft. lbs.)
5. CONNECT ATF TEMPERATURE SENSOR CONNECTOR
NOTICE: Be careful not to twist the wire harness.
6. CONNECT OIL COOLER PIPE
a. Install the elbow to the transmission.
Fuel System - Fuel Injector Cleaning Procedure
Fuel Injector: Technical Service Bulletins Fuel System - Fuel Injector Cleaning Procedure
PRODUCT GENERAL INFORMATION PG011-05 REVISED
October 13, 2005
Title: FUEL INJECTOR CLEANING
Models: '90 - '06 Toyota & Scion Models With Port Electronic Fuel Injection
TSB REVISION NOTICE:
^ June 9, 2006: In the Required Tools & Material section, part numbers have been updated (TYG
S-Line Device and Toyota Adaptor Pak), and the note with ordering information has been updated.
Previous versions of this TSB should be discarded.
Introduction
Due to fuel quality concerns, some Toyota and Scion vehicles with Port Electronic Fuel Injection
may experience clogged or blocked fuel injectors. The following procedure has been developed to
clean the fuel injectors.
Applicable Vehicles: ^
All 1990 - 2006 Toyota and Scion models equipped with Port Electronic Fuel Vehicles Injection
(EFI).
Required Tools & Material
Warranty Information
Repair Procedure
1. If the fuel injector nozzles are visibly blocked or if the injectors do NOT pass the fuel injector
volume test, complete the fuel injector power flush using the following instructions:
A. Before an injector cleaning is performed, it is recommended that the following items be cleaned
with Toyota Throttle Plate Cleaner (P/N 00289-1TP00):
^ Idle air control device
^ Throttle plate (both sides if possible)
^ Throttle body
B. Bring the engine to operating temperature.
C. Disconnect the fuel pump electrical connector.
Page 5128
Suspension Spring ( Coil / Leaf ): Service and Repair
REMOVAL
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
Instruments - Oil Pressure Gauge Reads Abnormally Low
Oil Pressure Sender: Customer Interest Instruments - Oil Pressure Gauge Reads Abnormally Low
ELECTRICAL EL017-03
December 23, 2503
Title OIL PRESSURE GAUGE READS LOW
Models '01 - '04 Sequoia & '00 - '02 Tundra
TSB UPDATE NOTICE:
This TSB updates EL006-03. TSB EL006-03 is now obsolete and should be discarded.
Introduction
Some customers with Sequoia or Tundra vehicles may encounter an oil pressure gauge that reads
abnormally low at idle. An updated oil pressure sender has been created to address this condition.
Applicable Vehicles ^
2001 - 2004 model year Sequoia vehicles produced BEFORE the Production Change Effective
VINs shown below.
^ 2000 - 2002 model year Tundra vehicles produced BEFORE the Production Change Effective
VIN shown below.
Production Change Information
Parts Information
Repair Procedure
1. Replace the Oil Pressure Sender.
2. Verify proper operation of the Oil Pressure Gauge.
Warranty Information
Applicable Warranty*:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36
months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Page 2364
Step 1
Page 3513
Transmission Position Switch/Sensor: Service and Repair
ON-VEHICLE REPAIR
1. DISCONNECT OIL COOLER PIPE 2. REMOVE PARK/NEUTRAL POSITION SWITCH
a. Disconnect the connector. b. Pry off the lock washer and remove the nut. c. Remove the bolt and
park/neutral position switch.
3. INSTALL PARK/NEUTRAL POSITION SWITCH
a. Install the park/neutral position switch and bolt.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)
b. Install a new lock plate and the nut.
Torque: 3.9 Nm (40 kgf-cm, 35 inch lbs.)
c. Bend claws on the lock plate to fix the nut. d. Connect the connector. e. Check that the engine
can be started with the shift lever only in the N or P position, but not in other positions. If not as
stated, carry out the
adjustment procedure. See: Testing and Inspection/Initial Inspection and Diagnostic Overview
4. CONNECT OIL COOLER PIPE 5. FILL ATF AND CHECK FLUID LEVEL 6. TEST DRIVE
VEHICLE
Engine/Transmission Controls - Resetting ECM Memory
Engine Control Module: All Technical Service Bulletins Engine/Transmission Controls - Resetting
ECM Memory
TRANSMISSION & CLUTCH TC002-03 REVISED
Title: ECM RESET MEMORY FUNCTION
Models: '00 - '05 All Models
June 10, 2003
TSB REVISION NOTICE:
^ December 20, 2004: Applicable Vehicles section has been updated - 2004 and 2005 model years
added, models and model years updated for various models; and Reset Procedure 2 has been
revised.
^ January 16, 2004: Tundra vehicles were added to the Applicable Vehicles chart.
^ December 17, 2003: T-100 vehicles were removed from the Applicable Vehicles chart.
Previous versions of this TSB should be discarded.
Introduction
Whenever an automatic transmission is replaced, overhauled or individual components are
replaced, use this procedure to clear Engine Control Module ( ECM, SAE term: Powertrain Control
Module, PCM) "Learned Values" to minimize subsequent performance concerns.
CAUTION:
Failure to follow the procedure below may lengthen the time to readjust the ECM "Learned Values,"
potentially resulting in performance concerns.
Required SSTs
Warranty Information
Applicable Vehicles
Specifications
Exhaust Manifold: Specifications
Maximum Warpage 0.50 mm
RH Exhaust Manifold W/ Nuts 44 Nm
LH Exhaust Manifold W/ Nuts 44 Nm
Page 376
Refrigerant Pressure Sensor / Switch: Service and Repair
REMOVAL
1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM
HINT: At the time of installation, please refer to the following item. Evacuate air from refrigeration
system. Charge system with refrigerant and inspect for leakage of refrigerant.
Specified amount: 600 ± 50 g (21.16 ± 1.76 oz.)
2. REMOVE PRESSURE SWITCH FROM LIQUID TUBE
Disconnect the connector and remove the pressure switch.
Torque: 10 N.m (100 kgf.cm, 7 ft.lbf)
HINT: Lock the switch mount on the tube with an open end wrench, being careful not to deform the tube,
and remove the switch.
- At the time of installation, please refer to the following item. Lubricate a new O-ring with the
compressor oil and install them to the switch.
INSTALLATION
Installation is in the reverse order of removal.
Page 5873
2. If reusing the moulding:
CLEAN MOULDING
a. Using a heat light, heat the moulding to 20 - 30 °C (68 - 86 °F).
NOTE: Do not heat the body excessively.
b. Remove the adhesive tape from the moulding. c. Wipe off stains with cleaner. d. Apply a new
adhesive tape to the moulding as shown in the illustration.
3. INSTALL MOULDING
a. Using a heat light, heat the body and moulding.
Body : 40 - 60 °C (104 - 140 °F) Moulding : 20 - 30 °C (68 - 86 °F)
NOTE: Do not heat the moulding excessively.
b. Lift the moulding release sheet from face of the moulding.
NOTE: When the moulding release sheet is removed, make sure that no dirt or dust can get onto
the uncoated area.
c. Align the bosses with their corresponding holes in the body, and press firmly on the moulding.
NOTE: Do not apply excessive force onto the moulding, but steady pressure with your thumbs.
Page 2456
Engine Bank Identification
Page 466
If operation is not as specified, replace the MAF meter.
6. Turn the ignition switch OFF. 7. Disconnect the negative (-) terminal cable from the battery. 8.
Disconnect the MAF meter connector.
4. REINSTALL MAF METER
Install the MAF meter with the 2 screws.
5. RECONNECT MAF METER CONNECTOR
Page 6217
Problem Symptom Confirmation (Road Test)
PROBLEM SYMPTOM CONFIRMATION (Road Test)
Engine Controls - O2 Sensor Monitor Threshold Values
Oxygen Sensor: All Technical Service Bulletins Engine Controls - O2 Sensor Monitor Threshold
Values
SPECIAL SERVICE TOOLS SS002-03
December 17, 2003
Title O2S TEST RESULTS (MODE 05)
Models All '96 - '03, '04 Corolla, ECHO, Matrix, Sienna & Scion xA & xB
Introduction
This Service Bulletin contains Oxygen Sensor (O2S) Monitor threshold values for all models from
1996 to 2003 and some 2004 models. Starting in 2004, the O2S Monitor threshold values can be
found in the repair manual. These values are used when analyzing the O2S test results to
determine the O2S condition.
Applicable Vehicles ^
All 1996 - 2003 model year Toyota vehicles.
^ 2004 model year Corolla, ECHO, Matrix and Sienna vehicles.
^ 2004 model year Scion xA and xB vehicles.
Function Description
Checking O2S Test Results
To view O2S test results, the O2S Monitor must be completed and the test results must be
checked within the same key cycle. If the ignition key is cycled OFF, the O2S test results will be set
to the minimum or maximum limits, and all test results will be erased. The O2S test results are
stored in the ECU (SAE term: Powertrain Control Module/PCM) when the monitor is completed.
The test results are static and will not change once the monitor is complete.
The process for checking 02S test results is described in the following three basic steps:
1. Completing the O2S Readiness Monitor.
2. Accessing O2S Test Results.
3. Comparing O2S Test Results to Failure Thresholds.
Required SSTs
NOTE:
Additional Diagnostic Tester Kits, Program Cards or other SSTs may be ordered by calling
SPX-OTC at 1-800-933-8335.
Warranty Information
Completing O2S Readiness Monitor
1. Clear any stored Diagnostic Trouble Codes (DTCs) using the Toyota Diagnostic Tester.
Page 5814
Trailer Towing
Page 5094
Page 5446
Wiring Diagram
Page 1090
b. Push the secondary locking device or terminal retainer in to the full lock position.
5. CONNECT CONNECTOR
Disconnection of Male and Female Connectors
Disconnection of Male and Female Connectors
Disconnection Of Male And Female Connectors
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Locations
Vehicle Speed Sensor: Locations
Vehicle Speed Sensor NO.1
Vehicle Speed Sensor NO.2
Vehicle Speed Sensor NO.1
Page 2090
2. REMOVE CRANKSHAFT POSITION SENSOR
a. Disconnect the crankshaft position sensor connector. b. Remove the bolt and crankshaft position
sensor.
INSTALLATION
1. INSTALL CRANKSHAFT POSITION SENSOR
a. Install the crankshaft position sensor with the bolt.
Torque: 6.5 N.m (65 kgf.cm, 58 in.lbf)
b. Connect the crankshaft position sensor connector.
2. INSTALL ENGINE UNDER COVER
Page 19
Instrument Panel
Ground Location
IE Left Kick Panel
IF Left Kick Panel
IG Instrument Panel Brace RH
IH Right Kick Panel
II Right Kick Panel
Body
Ground Location (Access Cab)
Page 3669
11. REPLACE BEARING CASE
a. Remove the outer side oil seal (See step 5.). b. Remove the bearing (See step 6.). c. Remove
the serration bolts (See step 1.). d. Remove the bearing case. e. Position the backing plate on a
new bearing case and using 2 socket wrenches and a press, install the serration bolts. f.
Install a new bearing (See step 6.).
g. Install a new outer side oil seal (See step 7.).
12. REPLACE OIL DEFLECTOR
a. Using a brass bar and hammer, remove the hub bolts, oil deflector and gasket. b. Position a new
gasket and oil deflector on the axle shaft and install a washer and nut to the hub bolt and install the
hub bolt by torquing the nut. c. Remove the nut and washer.
13. INSTALL REAR AXLE SHAFT IN BACKING PLATE
a. Coat the new outer side oil seal lip with MP grease. b. Install the backing plate and bearing
retainer on the rear axle shaft. c. Using SST and a press, install the rear axle shaft into the backing
plate.
SST 09316-60011 (09316-00051)
d. Using snap ring expander, install a new snap ring.
14. w/ ABS: INSTALL ABS SPEED SENSOR ROTOR AND BEARING RETAINER
(DIFFERENTIAL SIDE)
Using SST and a press, install a new sensor rotor and new bearing retainer to the axle shaft. SST
09316-60011 (09316-00051) Standard length: 122.2 ± 1.0 mm (4.811 ± 0.039 inch)
Page 3371
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 1767
J. The top half of the CUW screen displays the calibrations currently stored on the Diagnostic
Tester Program Card. The bottom half of the screen displays the new calibration to be loaded onto
the Diagnostic Tester Program Card (see Figure 13). Click NEXT to continue the process.
K. Confirm the calibration file to be sent to the Diagnostic Tester Program Card (Figure 14). Click
SEND.
Page 5628
a. Check the functioning of SST.
CAUTION: When activating the seat belt pretensioner, always use the specified SST: SRS Airbag
Deployment Tool.
SST 09082-00700,09082-00740
1. Connect the SST to the battery.
Connect the red clip of the SST to the battery positive (+) terminal and the black clip to the battery
negative (-) terminal.
HINT: Do not connect the yellow connector which will be connected with the seat belt pretensioner.
2. Press the SST activation switch, and check the LED of the SST activation switch lights up.
CAUTION: If the LED lights up when the activation switch is not being pressed, SST malfunction is
probable, so definitely do not use the SST.
b. Standard cab:
Disconnect the pretensioner connector. 1. Remove the front door scuff plate. 2. Remove the front
pillar garnish. 3. Remove the back panel upper garnish. 4. Remove the front seat outer belt floor
anchor. 5. Remove the quarter trim.
Page 5595
Instrument Panel
Connector Location
IA1 Engine Room Main and Cowl Wire (Left Kick Panel)
IA2 Engine Room Main and Cowl Wire (Left Kick Panel)
IA3 Engine Room Main and Cowl Wire (Left Kick Panel)
IA4 Engine Room Main and Cowl Wire (Left Kick Panel)
IB1 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IB2 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IB3 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IC1 Cowl Wire and Roof Wire (Left Side of Instrument Panel)
Instrument Panel
Connector Location
ID1 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH)
ID2 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH)
IE1 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IE2 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IE3 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IF1 Front Door RH Wire and Cowl Wire (Right Kick Panel)
IF2 Front Door RH Wire and Cowl Wire (Right Kick Panel)
IF3 Front Door RH Wire and Cowl Wire (Right Kick Panel)
Page 6854
Daytime Running Lamp Relay: Testing and Inspection
Terminal Identification
Connector Disconnected: INSPECT DAYTIME RUNNING LIGHT RELAY CIRCUIT Disconnect the
connector from the relay and inspect the connector on the wire harness side. If circuit is as
specified, perform inspections.
Connector Connected: INSPECT DAYTIME RUNNING LIGHT RELAY CIRCUIT Connect the wire
harness side connector to the relay and inspect wire harness side connector from the back side, as
shown. If circuit is not as specified, try replacing the relay with a new one.
Page 6477
Steps 1 - 2
Page 2616
J. The top half of the CUW screen displays the calibrations currently stored on the Diagnostic
Tester Program Card. The bottom half of the screen displays the new calibration to be loaded onto
the Diagnostic Tester Program Card (see Figure 13). Click NEXT to continue the process.
K. Confirm the calibration file to be sent to the Diagnostic Tester Program Card (Figure 14). Click
SEND.
Page 6602
Glossary Of Terms And Symbols (Part 2)
Page 66
Continuity And Resistance Check
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Continuity And Resistance Check
C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the
electrical circuit.
Finding A Short Circuit
Finding A Short Circuit
Finding A Short Circuit
A. Remove the blown fuse and disconnect all loads of the fuse.
Page 1781
B: Junction Connector
Indicates a connector which is connected to a short terminal.
Junction connector in this include a short terminal which is connected to a number of wire
harnesses. Always perform inspection with the short terminal installed. (When installing the wire
harnesses, the harnesses can be connected to any position within the short terminal grouping.
Accordingly, in other vehicles, the same position in the short terminal may be connected to wire
harness from a different part.) Wire harness sharing the same short terminal grouping ha the same
color.
C: Parts Code
The first letter of the code is taken from the first letter of part, and the numbers indicates its order in
parts which start with the same letter.
D: Connector Color
Connectors not indicated are milky white in color.
How to Read Ground Points
HOW TO READ GROUND POINTS
Page 1976
O2S Application Table
O2S Failure Threshold Charts
Page 6722
The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit
breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery
power is supplied to each system are explained. Since all System Circuit diagrams start from the
power source, the power source system must be fully understood.
Page 2077
Camshaft Position Sensor: Description and Operation
The Camshaft Position Sensor
Camshaft position sensor (G signal) consists of a magnet iron core and pickup coil.
The G signal plate has 1 tooth on its outer circumference and is installed on the LH camshaft timing
pulley. When the camshafts rotate, protrusion on the signal plate and air gap on the pickup coil
change, causing fluctuations in the magnetic field and generating an electromotive force in the
pickup coil.
The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor
generates 34 signals at every engine revolution. The ECM detects the standard angle of the
crankshaft based on the G signal and the actual angle of the crankshaft and the engine speed by
the NE signal.
Page 210
^ Confirm cable connections between the vehicle and Diagnostic Tester are secure. (Reference
TSB No. SS004-01, "ECU Flash Reprogramming Error Message.")
^ Do not disconnect or turn off the Diagnostic Tester or the vehicle ignition during reprogramming.
^ Set the parking brake.
^ Complete ALL flash calibration updates provided for each ECU.
If the battery's state of charge or capacity are in question, test with SST No. 00002-MP815-T,
"Midtronics Battery Tester," and follow TSB No. PG017-02, "Battery Maintenance for In-Stock
Vehicles & Pre-Delivery."
To ensure stable battery voltage, a battery charger may be connected during reprogramming if:
^ Voltage does not fall below 11.4 volts.
^ Voltage does not rise above 16.0 volts.
^ Setting is on SLOW charge and not BOOST.
A. Connect the Diagnostic Tester to the vehicle and select CURRENT ECU CAL from the ECU
REPROGRAM MAIN MENU. Determine the vehicle's current ECU calibration. (See Figure 17.)
NOTE:
The vehicle may contain up to 3 separate calibration ID numbers. In the example shown, the
vehicle ECU contains only 2 calibration IDs.
Page 3883
Step 3
Page 1972
Page 1553
4. Cycle the temperature control knob several times and confirm proper water control valve
adjustment.
Specifications
Wheel Bearing: Specifications
On models with serviceable wheel bearings, use a Lithium Multipurpose Grease.
Page 5617
Seat Belt Reminder Lamp: Testing and Inspection
INSPECT DRIVER'S SEAT BELT WARNING LIGHT a. Disconnect the connector B from the
combination meter. b. Connect the negative (-) lead from the battery to terminal 9. c. Turn the
ignition switch ON and check that the warning light lights UP.
If the warning light does not light up, inspect the bulb or wire harness.
INSPECT PASSENGER SEAT BELT WARNING LIGHT a. Remove the center cluster finish panel.
b. Disconnect the connectors from the center cluster integration. c. Connect the positive (+) lead
from the battery to the terminal 4 and negative (-) lead terminal 16, and check that the warning light
lights UP.
If the warning light does not light up, inspect the bulb or wire harness
Page 4281
3. BLEED BRAKE LINE
(a) Connect the vinyl tube to the caliper. (b) Depress the brake pedal several times, then loosen the
bleeder plug with the pedal held down.
SST 09751-36011
(c) At the point when fluid stops coming out, tighten the bleeder plug, then release the brake pedal.
(d) Repeat (b) and (c) until all the air in the fluid has been bled out.
Torque: (Bleeder plug) 11 Nm (110 kgf-cm, 8 ft. lbs.)
(e) Repeat the procedure on the previous page to bleed the air out of brake line for each wheel.
4. CHECK FLUID LEVEL IN RESERVOIR
Check the fluid level and add fluid if necessary. Fluid: SAE J1703 or FMVSS No. 116 DOT3
LOAD SENSING PROPORTIONING AND BY-PASS VALVE ON-VEHICLE INSPECTION
1. SET REAR AXLE LOAD
Rear axle load (includes vehicle weight): Standard cab: 950 kg (2,094 lbs.) Access cab:
5VZ-FE engine: 1,000 kg (2,205 lbs.) 2UZ-FE engine: 1,050 kg (2,315 lbs.)
2. INSTALL LSPV GAUGE (SST) AND BLEED AIR
SST 09709-29018
3. RAISE FRONT BRAKE PRESSURE TO 7,845 kPa (80 kgf/cm2, 1,138 psi) AND CHECK REAR
BRAKE PRESSURE
Rear brake pressure: 5,110 ± 490 kPa (52.1 ± 5 kgf/cm2, 741 ± 71 psi)
Page 4381
12. 2WD: REMOVE LOCK NUT AND ABS SPEED SENSOR ROTOR (W/ABS) OR SPACER (W/O
ABS)
Using a chisel and hammer, loosen the staked part of the lock nut.
NOTE:
Be careful not to damage the bushing.
A. Using the following SST, remove the lock nut.
^ 00002-00909 (09318-12010)
NOTE:
Do NOT use air wrench.
B. Remove the ABS speed sensor rotor or spacer.
NOTE:
Take care not to scratch the serration of the speed sensor rotor.
13. REMOVE AXLE HUB FROM STEERING KNUCKLE
A. Remove the 4 bolts and shift the dust cover toward the hub side (outside).
B. Using the following SSTs, remove the axle hub from the steering knuckle.
^ 09710-28012-01 (09710-07031)
^ 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04031,
09957-04010, 09958-04011)
HINT
If necessary, use a press to remove the axle hub from the steering knuckle.
C. Remove the dust cover from the steering knuckle.
D. 4WD: Remove the bearing spacer and ABS speed sensor rotor (W/ABS) or spacer (W/O ABS).
NOTE:
Take care not to scratch the serration of the speed sensor rotor.
Page 4623
Engine Room R/B
Details
Page 3468
Terminal Retainer
Push the terminal retainer down to the temporary lock position.
c. Release the locking lug from terminal and pull the terminal out from rear.
4. INSTALL TERMINAL TO CONNECTOR
a. Insert the terminal.
HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug
locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position.
Page 5955
Page 1234
e. Install the injector to the delivery pipe and lower intake manifold as shown in the illustration.
Before installing the injector, must apply spindle oil or gasoline on the place where a delivery pipe
or an intake manifold touches an O-ring of the injector.
f. Observe these precautions when disconnecting the fuel tube connector (quick type): 1. Check
that there is any dirt or the like on the pipe and around the connector before disconnecting them
and clean the dirt away. 2. Be sure to disconnect by hands. 3. When the connector and the pipe
are stuck, turn and pull the connector to free to disconnect and pull it out. Do not use any tools at
this
time.
4. Inspect if there is any dirt or the like on the seal surface of the disconnected pipe and clean it
away.
5. Prevent the disconnected pipe and connector from being damaged or mixed with foreign objects
by covering them with a vinyl bag.
g. Observe these precautions when connecting the fuel tube connector (quick type):
1. Do not reuse the retainer removed from the pipe. 2. Must use hands to remove the retainer from
the pipe. 3. Check that there is any damage or foreign objects on the connected part of the pipe.
Page 4596
B: Junction Connector
Indicates a connector which is connected to a short terminal.
Junction connector in this include a short terminal which is connected to a number of wire
harnesses. Always perform inspection with the short terminal installed. (When installing the wire
harnesses, the harnesses can be connected to any position within the short terminal grouping.
Accordingly, in other vehicles, the same position in the short terminal may be connected to wire
harness from a different part.) Wire harness sharing the same short terminal grouping ha the same
color.
C: Parts Code
The first letter of the code is taken from the first letter of part, and the numbers indicates its order in
parts which start with the same letter.
D: Connector Color
Connectors not indicated are milky white in color.
How to Read Ground Points
HOW TO READ GROUND POINTS
Page 6092
Page 679
Vehicle Speed Sensor: Description and Operation
Vehicle Speed Sensor NO.1
Vehicle Speed Sensor NO.1 Circuit Description
The vehicle speed sensor outputs a 4-pulse signal for every revolution of the rotor shaft, which is
rotated by the transmission output shaft via the driven gear. After this signal is converted into a
more precise rectangular waveform by the waveform shaping circuit inside the combination meter,
it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency
of these pulse signals.
Vehicle Speed Sensor NO.2
Vehicle Speed Sensor NO.2 Circuit Description
The No.2 vehicle speed sensor detects the rotation speed of the transmission output shaft and
sends signals to the ECM. The ECM determines the vehicle speed based on these signals.
Page 178
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.
Component Tests and General Diagnostics
Engine Control Module: Component Tests and General Diagnostics
Terminals Of ECM - Connector View
Terminals Of ECU - Connector Pinouts (Part 1)
Page 2080
4. REMOVE CAMSHAFT POSITION SENSOR
Remove the bolt, stud bolt and camshaft position sensor.
INSTALLATION
1. INSTALL CAMSHAFT POSITION SENSOR
Install the camshaft position sensor with the bolt and stud bolt Torque: 7.5 N.m (80 kgf.cm, 66
in.lbf)
2. INSTALL LH NO.3 TIMING BELT COVER
3. INSTALL DRIVE BELT
4. FILL ENGINE COOLANT
5. CHECK ENGINE COOLANT FOR LEAKS
6. CHECK IGNITION TIMING
Page 6081
Paint: 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 5107
Page 5029
6. DISCONNECT LOWER BALL JOINT FROM LOWER SUSPENSION ARM
a. Remove the cotter pin and nut. b. Using SST, disconnect the lower ball joint from the lower
suspension arm.
SST 09628-62011
7. REMOVE LOWER SUSPENSION ARM
a. Place matchmarks on the front and rear cam plates and chassis frame. b. Remove the 2 cam
plates, bolts, cams and lower suspension arm while slightly shifting the power steering gear
rearward.
NOTICE: Do not damage the power steering gear tubes.
REPLACEMENT
1. REPLACE BUSHING
a. Using a chisel and hammer, pry up the flange of the bushing.
b. Using SST and a press, remove the bushing.
SST 09613-26010, 09632-36010, 09950-00020
c. Using SST, a press and steel plate, install a new No.1 bushing.
SST 09502-12010, 09631-12090
HINT: Before installing the bushing, set it in the correct direction, as shown in the illustration.
Page 2644
Engine Control Module: Description and Operation
DESCRIPTION
The Engine Control Module (ECM) controls all phases of electrical engine operation. In order to
accomplish this control, the ECM relies on the input from a variety of engine operation sensors.
The ECM compares input signals with those stored in memory to determine what steps should be
taken to achieve maximum performance, fuel economy, and meet emission standards. The ECM
outputs the necessary signals to the fuel system, ignition system, emission control systems, etc..
Page 2550
Refer to Reset Procedure 2 for the vehicles with Electronically Controlled Automatic
Transmissions:
Reset Procedure 1
1. Connect the Toyota Diagnostic Tester to the vehicle.
2. Reset the ECM (PCM). Refer to the procedures below.
Page 4382
14. REMOVE OIL SEAL (OUTSIDE)
Using a screwdriver, remove the oil seal (outside) from the steering knuckle.
15. REMOVE BEARING FROM STEERING KNUCKLE
A. Using snap ring pliers, remove the snap ring.
B. Using the following SSTs and a press, remove the bearing from the steering knuckle.
^ 09950-60020 (09951-00810)
^ 09950-70010 (09951-07150)
16. INSTALL NEW BEARING
A. Using the following SSTs and a press, install a NEW bearing to the steering knuckle.
^ 09527-17011
^ 09950-60020 (09951-00910)
B. Using Snap ring pliers, install a NEW snap ring.
17. INSTALL NEW OIL SEAL (OUTSIDE)
A. Using the following SSTs and a plastic hammer, install a NEW oil seal (outside).
^ 09223-15030
Page 134
3. Start the engine and warm it up to normal operating temperatures before test-driving.
4. Perform a thorough test drive with several accelerations from a stop with "light throttle"
application until proper transmission shifting is verified.
Reset Procedure 2
1. Disconnect the negative battery cable for 5 minutes.
2. Reconnect battery cable.
3. Start the engine and warm it up to normal operating temperatures before test-driving.
4. Perform a thorough test drive with several accelerations from a stop with "light throttle"
application until proper transmission shifting is verified.
Page 4270
Brake Shoe: Specifications
Brake Shoe Lining Thickness Standard Thickness 6 mm
Minimum Thickness 1 mm
Shoe Clearence 0.5 mm
Testing and Inspection
Brake Fluid Level Sensor/Switch: Testing and Inspection
INSPECT BRAKE FLUID LEVEL WARNING SWITCH CONTINUITY a. remove the reservoir tank
cap and strainer. b. Disconnect the connector. c. Check that no continuity exists between the
terminals with the switch OFF (float up). d. Use siphon, etc. to take fluid out of the reservoir tank. e.
Check that continuity exists between the terminals with the switch ON (float down) f.
Pour the fluid back in the reservoir tank. If operation is not as specified, replace switch.
Electrode Gap Specification
Spark Plug: Specifications Electrode Gap Specification
Electrode Gap
Correct Gap .........................................................................................................................................
........................................................................ 0.8 mm
Page 6372
- Do not release the airbag activation prevention mechanism unless specifically directed by the
troubleshooting procedure.
- If the inserted paper is too thick the terminal and short spring may be damaged, so always use
paper with the same thickness as the male terminal.
Page 6659
BJ Inside of Rear Door LH
BK Inside of Rear Door RH
BL Surrounding of the Front of the Fuel Tank
Connector Location
BA1 Front Door LH Wire and Wire Harness (Connector Location)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel)
BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel)
BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel)
BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Page 4173
SST P/N: 09527-17011
B. Coat MP grease to the oil seal lip.
18. Install new dust cover and axle hub to steering knuckle.
A. Install the NEW dust cover to the steering knuckle with the 4 bolts.
Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)
B. Using the following SST and a press, install the axle hub to the steering knuckle.
SST P/N: 09649-17010
19. Install ABS speed sensor rotor (with ABS) or spacer (without ABS).
NOTE:
Take care not to scratch the serration of the speed sensor rotor and ensure the speed sensor is
installed completely.
20. 2WD:
Install new lock nut.
A. Using the following SST, install and torque a NEW lock nut to the axle hub.
SST P/N: 00002-00909 (09318-12010)
Torque: 274 N.m (2,800 kgf.cm, 203 ft.lbf)
NOTE:
Do NOT use air wrench.
B. Using a chisel and hammer, stake the lock nut.
Page 4806
Glossary Of Terms And Symbols (Part 2)
Page 5417
Impact Sensor: Description and Operation
FRONT AIRBAG SENSOR
The front airbag sensor is mounted inside each of the aprons. The sensor unit is a mechanical
type. When the sensor detects deceleration force above a predetermined limit, contact is made in
the sensor, sending a signal to the airbag sensor assembly. The sensor cannot be disassembled.
Page 6879
Lamp Control Module: Diagnostic Aids
Voltage Check
Voltage Check
Voltage Check
A. Establish conditions in which voltage is present at the check point.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(SW 2 OFF)
B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or
component terminal. This check can be done with a test light instead of a voltmeter.
Continuity and Resistance Check
Continuity and Resistance Check
Continuity And Resistance Check
A. Disconnect the battery terminal or wire so there is no voltage between the check points. B.
Contact the two leads of an ohmmeter to each of the check points.
Paint - Gray Bumper Paint Colors
Paint: Technical Service Bulletins Paint - Gray Bumper Paint Colors
PAINT PA001-03
January 23, 2003
Title 1995-2003 GRAY BUMPER PAINT CODES
Models '95- '03 Tacoma & '00 - '03 Tundra
Introduction Following are color codes for gray painted steel bumpers installed on the 1995 - 2003
model year Tacoma and 2000 - 2003 model year Tundra. These bumpers are factory installed
usually on base trim level models.
Applicable Vehicles ^ 1995 - 2003 model year Tacoma vehicles. ^ 2000 - 2003 model year Tundra
vehicles.
Parts Information
Warranty Information
Page 2731
Page 6160
b. Inspect the connector on the wire harness side.
If circuit is not as specified, inspect the circuits connected to other parts.
Page 975
Hose/Line HVAC: Service and Repair
REPLACEMENT
1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM
2. REPLACE FAULTY TUBE OR HOSE
NOTE: Cap the open fittings immediately to keep moisture or dirt out of the system
3. TIGHTEN JOINT OF BOLT OR NUT AT SPECIFIED TORQUE
NOTE: Connections should not be torqued tighter than the specified torque.
4. EVACUATE AIR IN REFRIGERATION SYSTEM AND CHARGE SYSTEM WITH
REFRIGERANT
Specified amount: 600 ± 50 g (21.16 ± 1.76 oz.)
5. INSPECT FOR LEAKAGE OF REFRIGERANT
Using a gas leak detector, check for leakage of refrigerant.
6. INSPECT AIR CONDITIONING OPERATION
Page 695
Mass Air Flow Meter: Description and Operation
Mass Air Flow Meter
The mass air flow meter uses a platinum hot wire. The hot wire air flow meter consists of a
platinum hot wire, thermistor and a control circuit installed in a plastic housing. The hot wire air flow
meter works in principle that the hot wire and thermistor located in the intake air bypass of the
housing detect any changes in the intake air temperature.
The hot wire is maintained at the set temperature by controlling the current flow through the hot
wire. This current flow is then measured as an output voltage of the mass air flow meter.
The circuit is constructed so that the platinum hot wire and thermistor provide a bridge circuit, with
the power transistor, and controlled so that the potential of A and B remains equal in order to
maintain the set temperature.
Page 2890
Transmission Position Switch/Sensor: Service and Repair
ON-VEHICLE REPAIR
1. DISCONNECT OIL COOLER PIPE 2. REMOVE PARK/NEUTRAL POSITION SWITCH
a. Disconnect the connector. b. Pry off the lock washer and remove the nut. c. Remove the bolt and
park/neutral position switch.
3. INSTALL PARK/NEUTRAL POSITION SWITCH
a. Install the park/neutral position switch and bolt.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)
b. Install a new lock plate and the nut.
Torque: 3.9 Nm (40 kgf-cm, 35 inch lbs.)
c. Bend claws on the lock plate to fix the nut. d. Connect the connector. e. Check that the engine
can be started with the shift lever only in the N or P position, but not in other positions. If not as
stated, carry out the
adjustment procedure. See: Transmission and Drivetrain/Automatic
Transmission/Transaxle/Testing and Inspection/Initial Inspection and Diagnostic Overview
4. CONNECT OIL COOLER PIPE 5. FILL ATF AND CHECK FLUID LEVEL 6. TEST DRIVE
VEHICLE
Page 6198
Splice Point
J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel,
and "B" for the Body).
The Location of splice Point I5 is shaded.
K: Indicates a shielded cable.
L: Indicates the pin number of the connector.
The numbering system is different for female and male connectors.
M: Indicates a ground point.
The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for
the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body
and Surrounding area.
How to Read Connector List
HOW TO READ CONNECTOR LIST
A: Indicates connector to be connected to a part. (The numeral indicates the pin No.)
Page 4063
Repair Procedure
1. REMOVE FRONT WHEEL
2. 4WD:
REMOVE GREASE CAP
Using a screwdriver and hammer, remove the grease cap.
3. 4WD:
DISCONNECT DRIVE SHAFT
A. Remove the cotter pin and lock cap.
B. While applying the brakes, remove the lock nut.
4. W/ABS DISCONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP FROM
STEERING KNUCKLE
Remove the 2 bolts and disconnect the ABS speed sensor and wire harness clamp from the
steering knuckle.
5. DISCONNECT BRAKE LINE
Using the SST, disconnect the brake line. Use a container to catch the brake fluid.
Page 2591
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.
Electrical Specifications
Resistance
Electrical - SRS And HV Wiring Repairs
Battery System, Hybrid Drive: Technical Service Bulletins Electrical - SRS And HV Wiring Repairs
TITLE: SRS & HV WIRING REPAIRS
SECTION: ELECTRICAL
BULLETIN # 156
MODELS: ALL TOYOTA LEXUS and SCION MODELS
DATE: AUGUST 2007
There are no approved repairs to Supplemental Restraint System (SRS) or High Voltage (HV)
wiring or connectors. SRS system wiring and connectors are color coded yellow and HV wiring is
orange however vehicle-specific wiring diagrams are the best source for identifying wiring in these
circuits. Wiring diagrams are available through the Technical Information System (TIS)
www.techinfo.toyota.com.
If SRS or HV wiring or connectors are suspected of damage they should be inspected thoroughly.
Damaged wiring and/or connectors require replacement of the affected harness. Follow all
precautions and procedures outlined in model-specific repair manuals for replacing SRS wiring or
components. Only Certified Hybrid Service Technicians are qualified to replace HV system wiring
and components.
Page 203
B. You have the option to delete calibrations off the tester before downloading a new calibration.
The CUW also provides this option if there is not enough memory for the new calibration. To delete
one or all of the calibrations, follow the screen flow shown (Figure 5).
C. If this is the first time you have downloaded a calibration file from TIS to the Diagnostic Tester
Program Card, you MUST first install the latest version of the Calibration Update Wizard (CUW)
onto your TIS workstation PC, as shown in Figure 6.
This step is also required if you are using a version of CUW earlier than version 6.0. CUW 6.0 is
the only version compatible with Diagnostic Tester software version 10.2a and later. If necessary,
select the link to the TIS Diagnostic Applications Installer and follow the on-screen prompts to
install or reinstall CUW.
Page 5487
Before installation of the fluorocarbon resin tape, it is necessary to pre-release the colored film
about 5 mm for each side. (Not fully released.)
B. By pulling up the seat belt, put the fluorocarbon resin tape through the hole of the shoulder belt
anchor. Match the shoulder belt anchor to the center of the tape.
C. Remove the upper side colored film from the fluorocarbon resin tape, and securely affix the tape
to the outside of the shoulder belt anchor.
D. Remove the lower side colored film from the fluorocarbon resin tape, and securely affix the tape
to the outside of the shoulder belt anchor.
NOTE:
^ Be sure to affix the fluorocarbon tape securely along all edges.
^ Pay attention not to make any wrinkles or slack in the fluorocarbon resin tape.
E. Remove the clip.
F. By pulling the seat belt up and down several times, as shown in the illustration, securely affix the
fluorocarbon resin tape and confirm the smoothness of the belt movement.
Page 2822
Testing and Inspection
Igniter: Testing and Inspection
ON-VEHICLE INSPECTION
NOTE: "Cold" and "Hot" in these sentences express the temperature of the coils themselves.
"Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F).
INSPECT IGNITION COIL (WITH IGNITER) AND SPARK TEST
Check that the spark occurs.
1. Remove the ignition coils (with igniter). 2. Remove the spark plugs. 3. Install the spark plugs to
each ignition coil (with igniter), and connect the ignition coil (with igniter) connector. 4. Disconnect
the 8 injector connectors. 5. Ground the spark plug. 6. Check that spark occurs while engine is
being cranked.
NOTE: To prevent gasoline from being injected out of injectors during this test, crank the engine for
no more than 5 - 10 seconds at a time.
If the spark does not occur, do the test as per the given flow chart.
7. Using a 16 mm plug wrench, install the spark plugs.
Torque: 17.5 N.m (180 kgf.cm, 13 ft.lbf)
8. Reinstall the ignition coils (with igniter).
Page 2691
Crankshaft Position Sensor: Testing and Inspection
INSPECTION
NOTE: "Cold" and "Hot" in these sentences express the temperature of the coils themselves.
"Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F).
INSPECT CRANKSHAFT POSITION SENSOR
Resistance
Using an ohmmeter, measure the resistance between the terminals.
If the resistance is not as specified, replace the crankshaft position sensor.
Page 4335
14. REMOVE OIL SEAL (OUTSIDE)
Using a screwdriver, remove the oil seal (outside) from the steering knuckle.
15. REMOVE BEARING FROM STEERING KNUCKLE
A. Using snap ring pliers, remove the snap ring.
B. Using the following SSTs and a press, remove the bearing from the steering knuckle.
^ 09950-60020 (09951-00810)
^ 09950-70010 (09951-07150)
16. INSTALL NEW BEARING
A. Using the following SSTs and a press, install a NEW bearing to the steering knuckle.
^ 09527-17011
^ 09950-60020 (09951-00910)
B. Using Snap ring pliers, install a NEW snap ring.
17. INSTALL NEW OIL SEAL (OUTSIDE)
A. Using the following SSTs and a plastic hammer, install a NEW oil seal (outside).
^ 09223-15030
Diagrams
Removal And Installation
Evaporator Case: Service and Repair Removal And Installation
Cooling Unit
REMOVAL
1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM
HINT: At the time of installation, please refer to the following item. Evacuate air from refrigeration
system. Charge system with refrigerant and inspect for leakage of refrigerant.
Page 847
a. Loosen the front and/or rear adjusting cam set bolts. b. Adjust the camber and caster by front
and/or rear adjusting cams (See adjustment chart).
HINT: Try to adjust the camber and caster to the center of the specified values.
c. How to read adjustment chart (Example).
1. Find the applicable wheel alignment standard value for the particular model. 2. Mark the selected
standard value on the adjustment chart.
Example: Camber: 0°10'(0.17°) Caster: 3°00'
3. Measure the present wheel alignment value with the vehicle in non-loaded condition. 4. Mark the
measured present value on the adjustment chart.
Example: Camber: 0°30'(0.50°) Caster: 2°40'(2.67°)
Page 3764
Electronically Controlled Transmission And A/T Indicator (Part 2)
Page 1606
Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
INSPECTION
1. DRAIN ENGINE COOLANT
2. REMOVE THROTTLE BODY COVER
3. REMOVE INTAKE AIR CONNECTOR
4. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS
a. Disconnect the accelerator cable from the throttle body. b. Remove the 2 bolts and 2 nuts, and
disconnect the throttle body from the intake manifold. c. Remove the gasket
5. REMOVE ECT SENSOR
a. Disconnect the ECT sensor connector. b. Remove the ECT sensor and gasket.
6. INSPECT ECT SENSOR
Using an ohmmeter, measure the resistance between the terminals.
Resistance: Refer to the graph
If the resistance is not as specified, replace the ECT sensor.
7. REINSTALL ECT SENSOR
a. Install a new gasket and the ECT sensor.
Page 4091
Warranty Information
Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This
warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's
in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Page 4631
The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit
breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery
power is supplied to each system are explained. Since all System Circuit diagrams start from the
power source, the power source system must be fully understood.
Page 2349
Engine Control Module: Description and Operation
DESCRIPTION
The Engine Control Module (ECM) controls all phases of electrical engine operation. In order to
accomplish this control, the ECM relies on the input from a variety of engine operation sensors.
The ECM compares input signals with those stored in memory to determine what steps should be
taken to achieve maximum performance, fuel economy, and meet emission standards. The ECM
outputs the necessary signals to the fuel system, ignition system, emission control systems, etc..
Page 5265
NOTE: -
Do not use tools like screwdriver to remove the tube.
- Cap the open fittings immediately to keep moisture or dirt out of the system.
HINT: At the time of installation, please refer to the following item. Lubricate 2 new O-rings with compressor oil and install them to the tubes.
- After connection, check the fitting for claw of the piping clamp.
3. DISCONNECT SUCTION TUBE FROM COOLING UNIT FITTINGS
Loosen the nut and disconnect both the tube.
Torque: 32 N.m (330 kgf.cm, 24 ft.lbf)
NOTE: Cap the open fittings immediately to keep moisture or dirt out of the system.
HINT: At the time of installation, please refer to the following item. Lubricate a new O-ring with
compressor oil and install them to the tube.
4. REMOVE GLOVE COMPARTMENT PARTS
5. REMOVE LOWER NO.2 FINISH PANEL
6. REMOVE LOWER CENTER COVER
7. REMOVE LOWER LH FINISH PANEL
8. REMOVE LOWER COVER
Page 1997
CHART 25
Page 4148
Brake Caliper: Service and Repair Disassembly and Assembly
DISASSEMBLY
1. REMOVE CYLINDER BOOT SET RINGS AND BOOTS
Using a screwdriver, remove the 4 cylinder boot set rings and boots.
2. REMOVE PISTONS FROM CYLINDER
(a) Prepare the wooden plate to hold the pistons.
Page 2960
4. Match the axis of the connector with axis of the pipe, and push in the connector until the
connector makes a "click" sound. In case that the
connections is tight, apply small amount of fresh engine oil on the tip of the pipe.
5. After having finished the connection, check if the pipe and the connector are securely connected
by pulling them. 6. Check if there is any fuel leakage.
h. Observe these precautions when handling nylon tube.
1. Pay attention not to turn the connected part of the nylon tube and the quick connector by force
when connecting them. 2. Pay attention not to kink the nylon tube. 3. Do not remove the EPDM
protector from the outside of the nylon tube. 4. Must not close the piping with the nylon tube by
bending it.
i. Check that there is any fuel leak after maintenance anywhere on the fuel system. 1. Connect a
TOYOTA hand-held tester to the DLC3. 2. Turn the ignition switch ON and push the TOYOTA
hand-held tester main switch ON.
NOTE: Do not start the engine.
3. Select the ACTIVE TEST mode on the TOYOTA hand-held tester. 4. Please refer to the
TOYOTA hand-held tester operator's manual for further details.
Page 4130
1. REMOVE FRONT WHEEL
2. 4WD: REMOVE GREASE CAP
Using a screwdriver and hammer remove the grease cap.
3. 4WD: DISCONNECT DRIVE SHAFT
A. Remove the cotter pin and lock cap.
B. While applying the brakes, remove the lock nut.
4. W/ABS DISCONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP FROM
STEERING KNUCKLE
Remove the 2 bolts and disconnect the ABS speed sensor and wire harness clamp from the
steering knuckle.
5. DISCONNECT BRAKE LINE
Using the SST, disconnect the brake line. Use a container to catch the brake fluid.
^ 09023-00100
6. REMOVE BRAKE,CALIPER AND DISC
Page 3637
Fluid - Differential: Fluid Type Specifications
Differential Fluid
Front Grade .........................................................................................................................................
.............................................................. GL-5 or equivalent Viscosity .................................................
..........................................................................................................................................................
SAE 75W-90 Rear Grade ....................................................................................................................
................................................................................... GL-5 or equivalent Above -18° C (0° F) ..........
..............................................................................................................................................................
........................... SAE 90 Below -18° C (0° F) ....................................................................................
......................................................................................... SAE 85W-90 or 80W
Page 5731
Radio/Stereo: Diagnostic Aids
Voltage Check
Voltage Check
Voltage Check
A. Establish conditions in which voltage is present at the check point.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(SW 2 OFF)
B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or
component terminal. This check can be done with a test light instead of a voltmeter.
Continuity and Resistance Check
Continuity and Resistance Check
Continuity And Resistance Check
A. Disconnect the battery terminal or wire so there is no voltage between the check points. B.
Contact the two leads of an ohmmeter to each of the check points.
Page 546
Page 2217
Data Link Connector: Description and Operation
The vehicle's ECM uses the ISO 9141-2 communication protocol. The terminal arrangement of the
DLC3 complies with SAE J1962 and matches the ISO 9141-2 format.
Page 1272
A. Using a breaker bar or ratchet with a 14 mm socket, apply counterclockwise force on the
accessory drive belt tensioner to release tension and remove the accessory drive belt.
HINT:
The pulley bolt for the belt tensioner has a left hand thread.
B. Using the accessory drive belt routing label located on the passenger side of the radiator core
support as a guide, install the new accessory drive belt.
2. Check belt tensioner operation.
A. Check that the belt tensioner moves downward when the drive belt is pressed down at the points
indicated in the illustration with approximately 98 N (10 kgf, 22.0 lbf) of force.
B. Ensure proper alignment of the belt with the ribbed grooves of each pulley.
C. Check by hand to ensure that the belt has not slipped out of the groove on the bottom of each
pulley.
D. Check that the arrow mark on the belt tensioner falls within area "A" of the scale (see
illustration).
E. If the arrow mark falls outside area "A," the drive belt is incorrect.
HINT:
When a new belt is installed, it should lie within area "B." If not, the drive belt is incorrect.
Page 2693
2. REMOVE CRANKSHAFT POSITION SENSOR
a. Disconnect the crankshaft position sensor connector. b. Remove the bolt and crankshaft position
sensor.
INSTALLATION
1. INSTALL CRANKSHAFT POSITION SENSOR
a. Install the crankshaft position sensor with the bolt.
Torque: 6.5 N.m (65 kgf.cm, 58 in.lbf)
b. Connect the crankshaft position sensor connector.
2. INSTALL ENGINE UNDER COVER
Page 5179
Wheel Bearing: Tools and Equipment
Wheel Bearing Nut Socket
AST tool# TOY 185
Page 2759
CHART 14
Page 5967
Page 3998
REMOVAL
1. REMOVE BRAKE LINE COVER
2. DISCONNECT CONNECTOR
Pull out the release bar, and disconnect the connector.
3. DISCONNECT BRAKE LINES
Using SST, disconnect the 5 brake lines from the ABS actuator. SST 09023-00100 Torque: 15 Nm
(155 kgf-cm, 11 ft. lbs.)
4. REMOVE ABS ACTUATOR ASSEMBLY
Remove the 3 nuts and ABS actuator assembly. Torque: 19 Nm (195 kgf-cm, 14 ft. lbs.)
5. REMOVE ABS ACTUATOR
(a) Remove the 3 nuts and ABS actuator from the actuator bracket.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
(b) Remove the 3 holders and 3 cushions from the ABS actuator.
INSTALLATION
Page 5057
Page 4659
Splice Point
J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel,
and "B" for the Body).
The Location of splice Point I5 is shaded.
K: Indicates a shielded cable.
L: Indicates the pin number of the connector.
The numbering system is different for female and male connectors.
M: Indicates a ground point.
The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for
the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body
and Surrounding area.
How to Read Connector List
HOW TO READ CONNECTOR LIST
A: Indicates connector to be connected to a part. (The numeral indicates the pin No.)
Page 4881
6. INSTALL VANE PLATES AND GASKET
a. Install the 10 plates with the round end facing outward. b. Install a new gasket on the front
housing.
NOTICE: Be careful of the direction of the gasket.
7. INSTALL SIDE PLATE
Align the holes of the plate and 2 straight pins.
8. INSTALL WAVE WASHER
Install the washer so that its protrusions fit into the slots in the side plate.
9. INSTALL REAR HOUSING
a. Coat 2 new O-rings with power steering fluid and install them to the rear housing. b. Install the
rear housing with the 4 bolts.
Torque: 24 Nm (240 kgf-cm, 17 ft. lbs.)
10. INSTALL SPRING, FLOW CONTROL VALVE AND PRESSURE PORT UNION
a. Install the spring to the front housing. b. Install the flow control valve facing the correct direction.
c. Coat a new O-ring with power steering fluid and install it to the pressure port union. d. Install the
pressure port union.
Torque: 83 Nm (850 kgf-cm, 61 ft. lbs.)
11. INSTALL 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 with the bolt.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)
12. MEASURE PS VANE PUMP ROTATING TORQUE
Testing and Inspection
Windshield Washer Spray Nozzle: Testing and Inspection
INSPECTION
1. INSPECT WASHER NOZZLE
a. While operating the washer, check whether the upper point where the washer fluid hits the
windshield and the surge area are within the range
indicated by the hatched line.
b. Check if the lower point where the washer fluid hits the windshield is within the range of the
wiping pattern (the area of the glass which is
wiped by the wiper blades).
2. ADJUST WASHER NOZZLE
Using a tool like the one shown in the illustration, change the direction of the nozzle hole to adjust
the point where washer fluid hits the windshield.
Page 3793
Steps 1 - 2
Page 3465
B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(Connect the Relay) and SW 2 OFF (or Disconnect SW 2)
D. Disconnect and reconnect the connectors while watching the test light.
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
E. Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION:
a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals
are touched, the IC may be destroyed by
static electricity.)
b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact
with the terminals of leads from the IC, etc. of the replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
Special Tool
1. PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown.
2. DISCONNECT CONNECTOR
3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
a. Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the
secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
A: For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
Removal and Installation
Compressor Clutch: Service and Repair Removal and Installation
COMPRESSOR AND MAGNETIC CLUTCH
Compressor And Magnetic Clutch (Part 1)
Page 2961
5. Pinch the fuel return hose.
The pressure in the high pressure line will rise to approx. 392 kPa (4 kgf/sq.cm, 57 psi). In this
state, check to see that there are no leaks from any part of the fuel system.
NOTE: Always pinch the hose. Avoid bending as it may cause the hose to crack.
6. Turn the ignition switch OFF. 7. Disconnect the TOYOTA hand-held tester from the DLC3.
Page 1738
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 1911
Page 2474
Page 2994
D. Start the engine. After the engine has stalled, turn the ignition switch OFF.
E. Disable the fuel return line by blocking the line or installing the appropriate plug in the return
outlet, if applicable.
NOTE:
Do NOT clamp plastic lines.
F. Install the device adapter to the fuel line and then secure the swivel fitting on the end of the
hose.
G. Make sure the ball valve on the device is turned OFF (valve handle is crosswise to device).
Screw the can of EFI cleaner (P/N 00289-1PF14) onto the device can adapter.
H. Open the valve on the device, start the vehicle, and allow it to run until the engine stalls.
I. Turn the ball valve OFF and remove the empty can.
J. Place a shop towel over the can adapter and slowly open the ball valve to depressurize the
system.
K. Remove supply and return line adapters, reconnect vehicle fuel supply and return lines
(replacing any fuel line gaskets and seals), and connect the fuel pump electrical connector.
L. Before starting the vehicle, pressurize the fuel system and check for leaks.
Run the engine for 4 - 5 minutes, and then snap the throttle several times to dislodge any carbon
that may remain in the system.
2. Add 1 can of Toyota Non-Pressurized Fuel Injector Cleaner Fuel Tank Additive (P/N
08813-0080DS) to the fuel tank.
3. Road test the vehicle to verify normal operation.
Page 4207
Torque: 50 N.m (510 kgf.cm, 37 ft.lbf)
25. Install shock absorber with coil spring.
A. Install the upper side of shock absorber to the chassis frame with the 3 nuts.
Torque: 64 N.m (650 kgf.cm, 47 ft.lbf)
B. Connect the lower side of shock absorber to the lower suspension arm with bolt, washer, and
nut.
Torque: 135 N.m (1,400 kgf.cm, 100 ft.lbf)
26. Inspect and install the brake rotor and install the brake caliper with new mounting bolts.
A. Inspect the brake rotors and machine using an on-the-car brake lathe. Replace the rotor if it is
below minimum thickness values
Minimum Thickness: 26.0 mm (1.024 in.)
NOTE:
It is necessary to turn the rotors using the on-the-car brake lathe to ensure even and uniform rotor
run out. DO NOT turn the rotor using an off-the-car brake lathe.
B. Install the disc, brake caliper, and 2 NEW bolts.
Torque: 123 N.m (1,259 kgf.cm, 90 ft.lbf)
C. Install the brake line clamp to the steering knuckle with the bolt.
Torque: 28 N.m (285 kgf.cm, 21 ft.lbf)
27. Install new brake line.
Using the SST, connect NEW brake line.
SST P/N: 09023-00100
Torque: 15 N.m (155 kgf.cm, 11 ft.lbf)
28. With ABS:
Connect the ABS speed sensor and wire harness clamp to the steering knuckle with the 2 bolts.
Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
29. 4WD:
Install drive shaft lock nut.
A. While applying the brakes, tighten the nut.
Torque: 235 N.m (2,400 kgf.cm, 173 ft.lbf)
B. Install the lock cap and a NEW cotter pin. If the holes for the cotter pin are not aligned, tighten
the nut further up to 600.
30. 2WD:
Install grease cap.
31. Install front wheel.
NOTE:
Do NOT use an air wrench.
Torque: 110 N.m (1,150 kgf.cm, 83 ft.lbf)
Page 2831
CHART 26
Page 4560
Starter (Part 2)
Page 4131
A. Remove the bolt and brake line clamp from the steering knuckle.
B. Remove the 2 bolts, brake caliper and disc.
7. REMOVE SHOCK ABSORBER
A. Disconnect Shock Absorber from lower suspension arm.
B. Remove the shock absorber lower side set nut and washer.
NOTE:
Do not remove the bolt.
C. Wrap the bolt's head with vinyl tape to prevent the drive shaft boot from being damaged.
D. Pry down the lower suspension arm to remove the bolt and disconnect the shock absorber.
E. Remove the 3 nuts and shock absorber with the coil spring.
NOTE:
Do not damage the brake tube.
8. DISCONNECT LOWER BALL JOINT
Testing and Inspection
Four Wheel Drive Selector Switch: Testing and Inspection
INSPECTION
1. INSPECT 2WD -> 4HI SHIFT
a. Ignition switch ON. b. Check that the 4HI indicator lights come on when the touch select 2-4
switch is in ON position. c. Check that the 4HI indicator lights go off when the touch select 2-4
switch is in OFF position.
HINT: If the light does not light up, even though the switch has been turned ON, the vehicle should be
moved back and forth.
- If switching is not completed after 3 seconds of shift operation, the 4HI indicator light will flash.
2. INSPECT 4HI -> 4LO SHIFT
Page 2503
Page 1924
CHART 18
CHART 19
Page 2447
CHART 29
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 837
Alignment: Specifications
Page 1643
4. REMOVE WATER INLET AND INLET HOUSING ASSEMBLY
a. Disconnect the water bypass hose from the water inlet housing. b. Remove the 2 bolts holding
the water inlet housing to the water pump. c. Disconnect the water inlet housing from the front
water bypass joint, and remove the water inlet and inlet housing assembly. d. Remove the O-ring
from the water inlet housing.
5. REMOVE WATER PUMP
a. Remove the 5 bolts, 2 stud bolts, nut, water pump and gasket. b. Remove the O-ring from the
water bypass pipe.
INSPECTION
1. INSPECT WATER PUMP
a. Visually check the air hole and water hole for coolant leakage. If leakage is found, replace the
water pump and timing belt. b. Turn the pulley, and check that the water pump bearing moves
smoothly and quietly.
If necessary, replace the water pump.
2. INSPECT FLUID COUPLING
a. Remove the 4 nuts and fan from the fluid coupling.
Page 2724
Engine Bank Identification
Page 4909
Key Reminder Switch: Splice Locations
Engine Compartment
Splice Location
E1 Engine Room Main Wire
E2 Engine Room Main Wire
E3 Engine Room Main Wire
E4 Engine No. 2 Wire
E5 Engine Wire
E6 Engine Wire
E7 Engine Wire
E8 Engine Wire
Instrument Panel
Page 1727
B. Continue to update the ECU calibration file following the screen flow (Figure 18). Details for
selected screens are shown in Figure 19.
NOTE:
^ Each flash calibration update will take approximately 15 to 45 minutes.
^ Screens E through J (Figure 18) will need to be repeated for each flash calibration update
(calibration ID number).
^ All updates must display "YES" to complete the entire calibration file update for the vehicle ECU.
^ Failure to complete all updates may result in PERMANENT ECU DAMAGE!
CONFIRM UPDATE
4. Confirm successful flash calibration update and affix calibration update sticker.
Follow these steps to confirm the calibration was reprogrammed to the ECU.
Page 4206
21. 4WD:
Using the following SSTs and a press, install the bearing spacer.
SST P/N: 09950-60010 (09951-00650)
SST P/N: 09950-70010 (09951-07150)
22. 4WD:
Install new oil seal (inside).
A. Using the following SST and a plastic hammer, install a NEW oil seal (inside).
SST P/N: 09527-17011
NOTE:
Lightly strike the SST on its circumference evenly.
B. Coat MP grease to the oil seal lip.
23. Install steering knuckle.
A. 4WD:
Insert the drive shaft into the axle hub and temporarily tighten the nut.
NOTE:
Be careful not to damage the oil seal and drive shaft boot.
B. Connect the steering knuckle to the upper suspension arm.
C. Install the nut and a NEW cotter pin. If the holes for the cotter pin are not aligned, tighten the nut
further up to 600.
Torque: 105 N.m (1,100 kgf.cm, 77 ft.lbf)
24. Connect the lower ball joint to the steering knuckle with 4 bolts.
Page 350
Coolant Temperature Sensor/Switch (For Computer): Description and Operation
Engine Coolant Temperature Sensor
A thermistor that is built into the engine coolant temperature sensor changes the resistance value
according to the engine coolant temperature.
The lower the engine coolant temperature sensor, the greater the thermistor resistance value, and
the higher the engine coolant temperature sensor temperature, the lower the thermistor resistance
value.
The engine coolant temperature sensor is connected to the ECM. The 5 V power source voltage in
the ECM is applied to the engine coolant temperature sensor from the terminal THA via a resistor
R. That is, the resistor R and the engine coolant temperature sensor are connected in series.
When the resistance value of the engine coolant temperature sensor changes in accordance with
changes in the engine coolant temperature, the potential at terminal THA also changes. Based on
this signal, the ECM increases the fuel injection volume to improve driveability during cold engine
operation.
Page 3334
D. The Calibration Update Wizard (CUW) launches automatically when a calibration file link is
selected (or clicked). Verify that the CUW version is 6.0 or higher. If not, refer to the Note below.
The CUW will guide you through the steps to download the calibration file to the Diagnostic Tester
Program Card. Click NEXT on the first screen (Figure 7).
NOTE:
If the CUW does not launch, or the version is older than 6.0, install Diagnostic Software (TIS
Diagnostic Applications Installer). Specific installation instructions (Reprogramming with CUW 6.0)
are located under Diagnostics ECU Flash Reprogramming (Figure 6).
Page 2833
CHART 27
Page 3102
b. Install a new gasket and the throttle body with the 2 bolts and 2 nuts.
Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)
c. Install the ventilation cap. d. Connect the water bypass hose and PCV hose to the throttle body.
e. Connect the throttle position sensor connector. f.
Connect the throttle control motor connector.
g. Connect the accelerator pedal position sensor connector. h. Connect the accelerator pedal
position sensor wire to the 2 clamps on wire brackets.
2. CONNECT ACCELERATOR CABLE TO THROTTLE BODY
3. INSTALL INTAKE AIR CONNECTOR
4. FILL WITH ENGINE COOLANT
5. START ENGINE AND CHECK FOR ENGINE COOLANT LEAKS
6. INSTALL THROTTLE BODY COVER
Page 1905
2. Start the engine.
3. Perform the drive pattern to run and complete the Oxygen Sensor (O2S) Monitor.
HINT:
The 02S Monitor is completed when the following conditions are met:
^ Two (2) minutes or more passed after the engine start.
^ The Engine Coolant Temperature (ECT) is 167°F (75°C) or more.
^ Cumulative running time at 30 mph (48 km/h) or more exceeds 6 minutes.
^ Vehicle is in closed loop.
^ The fuel-cut is operated for 8 seconds or more (for Rear O2S Monitor).
A. Allow the engine to idle for two minutes.
B. Warm up the engine until the Engine Coolant Temperature (ECT) reaches 167°F (75°C).
C. Drive the vehicle over 30 mph (48 km/h) for more than 40 seconds.
D. Stop the vehicle and allow the engine to idle for more than 20 seconds.
E. Repeat steps C and D at least 8 times in one driving cycle. (Do not cycle the ignition key.)
In addition, perform the following steps for the Rear O2S Readiness Monitor:
A. Select second gear.
B. Allow the vehicle to run at 30 mph (48 km/h) or more.
C. Keep the accelerator pedal "off-idle" for more than 10 seconds.
D. Immediately after step C, release the accelerator pedal for at least 10 seconds without
depressing the brake pedal (to execute the fuel-cut).
E. Decelerate the vehicle until the vehicle speed reaches less than 6mph (10km/h).
F. Repeat steps B - E at least twice in one driving cycle.
Accessing O2S Test Results
1. On the Diagnostic Tester* screen, select the following menus:
^ DIAGNOSTICS
^ CARB OBD II
Testing and Inspection
Interior Light Switch: Testing and Inspection
INSPECT FRONT PERSONAL LIGHT SWITCH CONTINUITY
a. Disconnect the connector from the personal light. b. Push the personal light switch ON, check
that continuity exists between terminal 3 and body terminal 1.
c. Turn the light switch to DOOR, check that continuity exists between terminal 2 and 3.
If operation is as specified, replace the switch.
INSPECT ROOM LIGHT SWITCH
a. Disconnect the connector from the interior light assembly. b. Turn the interior light switch ON,
check that continuity exists terminal 2 and body ground.
c. Turn the interior light switch to DOOR, check that continuity exists between terminals 1 and 2.
If operation is not as specified, replace the switch.
Page 5882
1. REMOVE REAR BODY SIDE PANEL PROTECTOR
Using a moulding remover, remove the 2 protectors.
NOTE: The protector has 21 clips as shown in the Illustration.
- Be careful not to damage the clips.
2. REMOVE TAIL GATE PROTECTOR
a. Remove the 6 pins. b. Using a clip remover, remove the protector and 10 clips.
INSTALLATION
Installation is in the reverse order of removal procedure.
Page 5625
Seat Belt Tensioner: Testing and Inspection Replacement Requirements
REPLACE REQUIREMENTS
In the following cases, replace the seat belt pretensioner.
- If the seat belt pretensioner has been activated.
- If the seat belt pretensioner has been found to be faulty in troubleshooting.
- If the front seat outer belt has been found to be faulty during checking item functioning of SST.
- If the front seat outer belt has been dropped.
CAUTION: Be sure to follow the correct procedure, for removal and installation of the seat belt
pretensioner.
Page 2487
CHART 15
Page 3816
a. Ignition switch ON. b. Shift the transmission shift lever in N position. c. Turn the touch select 2-4
switch ON. d. Check that the 4LO indicator lights come on and the 4HI indicator lights go off when
the touch select high-low switch is in ON position. e. Check that the 4LO indicator lights go off and
the 4HI indicator lights come on when the touch select high-low switch is in OFF position.
HINT: Inspection should be performed with the vehicle stopped, and transmission shift lever in N position.
- If switching is not completed after 3 seconds of shift operation, the 4LO indicator light will flash.
3. INSPECT TOUCH SELECT 2 - 4 AND HIGH-LOW SWITCH CONTINUITY
a. Remove center integration panel assembly. b. Inspect the continuity between the each terminals.
Touch select 2-4 switch
Touch select high-low switch:
If continuity is not as specified, replace the center integration panel assembly.
4. INSPECT ACTUATOR RESISTANCE
a. Using an ohmmeter, measure the resistance between terminals 1 and 2.
Standard resistance: 0.3 - 100 Ohms
b. Using an ohmmeter, measure the resistance between terminals 1 or 2 and body ground.
Standard resistance: More than 0.5 M Ohms If resistance value is not as specified, replace the
actuator assembly.
Page 3245
Electronically Controlled Transmission And A/T Indicator (Part 3)
Page 58
Wiring Harness Connector
E: Indicates the wiring harness and wiring harness connector. The wiring harness with male
terminal is shown with arrows.
Outside numerals are pin numbers.
The first letter of the code for each wiring harness and wiring harness connector(s) indicates the
component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and
Surrounding area, and "B" for the Body and Surrounding area.
When more than one code has the first and second letters in common, followed by numbers (e.g,
IH1, IH2), this indicates the same type of wiring harness and wiring harness connector.
F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in
parts position.
G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside
it). Junction Blocks are shaded to clearly separate
them from other parts.
H: When 2 parts both use one connector in common, the parts connector name used in wire
routing is shown in square brackets [ ].
Wiring Color
I: Indicates the wiring color.
Wire colors are indicated by an alphabetical code.
B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR =
Brown SB = Sky Blue LG = Light Green GR = Gray
The first letter indicates the basic wire color and the second letter indicates the color of the stripe.
Page 212
B. Continue to update the ECU calibration file following the screen flow (Figure 18). Details for
selected screens are shown in Figure 19.
NOTE:
^ Each flash calibration update will take approximately 15 to 45 minutes.
^ Screens E through J (Figure 18) will need to be repeated for each flash calibration update
(calibration ID number).
^ All updates must display "YES" to complete the entire calibration file update for the vehicle ECU.
^ Failure to complete all updates may result in PERMANENT ECU DAMAGE!
CONFIRM UPDATE
4. Confirm successful flash calibration update and affix calibration update sticker.
Follow these steps to confirm the calibration was reprogrammed to the ECU.
Specifications
Page 733
Step 1
Page 3573
Continuity And Resistance Check
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Continuity And Resistance Check
C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the
electrical circuit.
Finding A Short Circuit
Finding A Short Circuit
Finding A Short Circuit
A. Remove the blown fuse and disconnect all loads of the fuse.
Page 1556
4. REMOVE WATER VALVE
Remove the bolt and water valve.
INSTALLATION
Installation is in the reverse order of removal.
Page 5793
Splice Location
B11
Page 3156
Knock Sensor: Description and Operation
P0325 - Knock Sensor 1 Circuit Malfunction (Bank 1) CIRCUIT DESCRIPTION
DTC Detection Condition
One of the knock sensors is fitted to the right bank and another to the left bank of the cylinder block
to detect the engine knocking. This sensor contains a piezoelectric element which generates
voltage when it becomes deformed. This occurs when the cylinder block vibrates due to knocking.
If the engine knocking occurs, ignition timing is retarded to suppress it.
Wiring Diagram
Brakes - Front Brake Caliper Identification
Brake Caliper: All Technical Service Bulletins Brakes - Front Brake Caliper Identification
BRAKES BR001-03 REVISED
January 8, 2003
Title: FRONT BRAKE COMPONENT IDENTIFICATION
Models: '00 - '05 Tundra, '01 - '05 Sequoia
TSB UPDATE NOTICE:
The information contained in this TSB supercedes TSB No. BR003-00. TSB No. BR003-00 is now
obsolete and should be discarded.
TSB REVISION NOTICE:
March 25, 2005: Parts Information - Part titles and part numbers have been updated and "Note"
added.
The previous TSB should be discarded.
Introduction
There are two caliper designs that are in use for Tundra and Sequoia vehicles. The brake pads and
fitting kits for these two calipers are not interchangeable. The pictures and parts lists below are
intended to assist you in identifying and ordering the correct replacement pads and fitting kits.
Applicable Vehicles: ^
2000 - 2005 model year Tundra vehicles.
^ 2001 - 2005 model year Sequoia vehicles.
Warranty Information
Pressure Specification
Fuel Pressure: Specifications
Fuel Pressure No Vacuum 38 to 44 psi
Page 4103
32. Depress brake pedal several times.
33. Fill the brake reservoir with brake fluid and bleed brake system.
34. Check ABS Speed Sensor Signal (refer to the Technical Information System (TIS):
2000 - 2005 model year Tundra Repair Manual: Diagnostics: Anti-lock Brake System: Pre-Check).
Repair Procedure No. 2
1. Resurface the disc rotors with the "On-Car Lathe" to within serviceable limits.
NOTE:
It is necessary to turn the rotors using only an on-the-car brake lathe to ensure even and uniform
rotor run out. DO NOT turn the rotor using an off-the-car brake lathe.
2. If the disc rotors are unserviceable or below minimum thickness (per specification stamped on
the rotor), replace the rotors using the service parts from the Parts Information table.
3. Check any new disc rotor for runout.
4. If the disc rotor runout is over 0.03 mm (0.0012 in.), perform a phase matching procedure.
5. Replace the front brake caliper LH and RH assemblies using the service parts from the Parts
Information table.
6. Perform a road test.
Testing and Inspection
Hazard Warning Switch: Testing and Inspection
INSPECT HAZARD WARNING SWITCH CONTINUITY
a. Remove the center cluster finish panel. b. Disconnect the connector from the center cluster
integration. c. Check that continuity exists between terminal 17 and terminal 1 with the switch ON.
d. Check that no continuity exists between terminal 17 and terminal 1 with the switch OFF.
If continuity is not as specified, replace the switch.
Page 2577
A. The new calibration file should be displayed as the current ECU calibration file.
B. Using a permanent marker or ball point pen, enter the required information on the Authorized
Modifications Label (Figures 21 and 22).
C. Affix this label under the hood in the location determined by the specific vehicle TSB or
Campaign.
NOTE:
Wait 60-90 seconds for ink to set before handling.
Page 21
Audible Warning Device Control Module: Splice Locations
Engine Compartment
Splice Location
E1 Engine Room Main Wire
E2 Engine Room Main Wire
E3 Engine Room Main Wire
E4 Engine No. 2 Wire
E5 Engine Wire
E6 Engine Wire
E7 Engine Wire
E8 Engine Wire
Instrument Panel
Service and Repair
Fuel Pressure Release: Service and Repair
SFI SYSTEM
PRECAUTION
1. BEFORE WORKING ON FUEL SYSTEM, DISCONNECT NEGATIVE (-) TERMINAL CABLE
FROM BATTERY
HINT: Any diagnostic trouble code retained by the computer will be erased when the negative (-)
terminal cable is removed from the battery.
Therefore, if necessary, read the diagnosis before removing the negative (-) terminal cable from the
battery.
2. DO NOT SMOKE OR WORK NEAR AN OPEN FLAME WHEN WORKING ON THE FUEL
SYSTEM
3. KEEP GASOLINE AWAY FROM RUBBER OR LEATHER PARTS
4. FUEL SYSTEM
a. When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so
observe these procedures:
1. Disconnect the fuel pump connector. 2. Start the engine. After the engine has stopped on its
own, turn the ignition switch OFF.
3. Put a container under the connection. 4. Slowly loosen the connection. 5. Disconnect the
connection. 6. Plug the connection with a rubber plug. 7. Reconnect the fuel pump connector.
b. When connecting the union bolt (fuel pressure pulsation damper) on the high pressure pipe
union, observe these procedures:
1. Always use 2 new gaskets.
Page 4662
The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit
breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery
power is supplied to each system are explained. Since all System Circuit diagrams start from the
power source, the power source system must be fully understood.
Page 4566
Using vernier calipers, measure the brush length.
Standard length
Minimum length
If the length is less than minimum, replace the brush holder and field frame.
11. INSPECT BRUSH SPRING LOAD
Take the pull scale reading the instant the brush spring separates from the brush.
Standard spring installed load
Minimum spring installed load
If the installed load is less than minimum, replace the brush springs.
Page 3492
Step 4
O/D OFF indicator light does not light up
Steps 1 - 2
O/D OFF indicator light remains ON
Page 464
Mass Air Flow Meter: Description and Operation
Mass Air Flow Meter
The mass air flow meter uses a platinum hot wire. The hot wire air flow meter consists of a
platinum hot wire, thermistor and a control circuit installed in a plastic housing. The hot wire air flow
meter works in principle that the hot wire and thermistor located in the intake air bypass of the
housing detect any changes in the intake air temperature.
The hot wire is maintained at the set temperature by controlling the current flow through the hot
wire. This current flow is then measured as an output voltage of the mass air flow meter.
The circuit is constructed so that the platinum hot wire and thermistor provide a bridge circuit, with
the power transistor, and controlled so that the potential of A and B remains equal in order to
maintain the set temperature.
Description and Operation
Braking Sensor/Switch: Description and Operation
Stop Light Switch
This stop light switch senses whether the brake pedal is depressed or released, and sends the
signal to the ECU.
Page 209
L. The calibration file will now be downloaded to the Diagnostic Tester Program Card. This process
takes approximately 2-6 minutes (see Figure 15).
M. The CUW will prompt when the calibration file is completely downloaded. Click OK to close the
CUW (Figure 16).
NOTE:
With the calibration file loaded on the Diagnostic Tester Program Card, it is not necessary to repeat
the above steps to reprogram a different vehicle needing the same calibration file. The steps above
are only required when a new calibration file must be loaded onto the Diagnostic Tester Program
Card.
The Diagnostic Tester now has the calibration file stored and you may proceed to the next step to
reprogram the vehicle ECU.
REPROGRAM ECU WITH TESTER
3. Reprogram the vehicle ECU with the Diagnostic Tester.
NOTICE:
Errors during the flash reprogramming process can permanently damage the vehicle ECU.
Minimize the risks by following the steps below.
^ Battery voltage MUST NOT FALL BELOW 11.4 volts during reprogramming.
^ Confirm battery voltage is higher than 11.4 volts, but be sure voltage DOES NOT RISE ABOVE
16.0 volts during reprogramming.
^ Turn off all electrical accessories (e.g. Audio system, A/C, interior lights, DRL, etc.).
^ Do not add to or significantly change the vehicle's electrical load while reprogramming.
^ Confirm the hood is open and ensure under hood temperatures do not exceed 158°F.
Page 3967
STANDARD VALUE OF ECU TERMINAL
Page 185
Then click Start.
I. Do NOT disturb the vehicle during flash reprogramming.
NOTE
^ ECU flash reprogramming may take anywhere from 3 - 30 minutes per calibration file.
^ Reprogramming time will vary depending on model and ECU communication protocol. Vehicles
using CAN communication protocol will reprogram much faster (2 - 7 minutes).
NOTE
^ If vehicle requires only ONE calibration update, then proceed to step N in this bulletin.
^ If vehicle requires a SECOND calibration update, then continue as follows:
^ For serial communication vehicles, go to step J.
^ For CAN communication vehicles, go to step L.
ABS/TCS - Zero Point Calibration Information
Alignment: Technical Service Bulletins ABS/TCS - Zero Point Calibration Information
T-SB-0020-08
March 25, 2008
Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment
Service Category Brake
Section Brake Control/Dynamic Control System
Market USA
Applicability
Introduction
The purpose of this TSB is to provide information on when and how to perform the zero point
calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting
the battery is a necessary step for performing the zero point calibration.
Warranty Information
Required Tools & Equipment
^ Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE).
^ The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the
service procedures listed in this bulletin.
Preliminary Information
Perform this procedure if any of these repairs have been performed on the vehicle:
^ Wheel alignment has been adjusted.
^ Any chassis components have been removed/installed or replaced.
Page 2987
e. Install the injector to the delivery pipe and lower intake manifold as shown in the illustration.
Before installing the injector, must apply spindle oil or gasoline on the place where a delivery pipe
or an intake manifold touches an O-ring of the injector.
f. Observe these precautions when disconnecting the fuel tube connector (quick type): 1. Check
that there is any dirt or the like on the pipe and around the connector before disconnecting them
and clean the dirt away. 2. Be sure to disconnect by hands. 3. When the connector and the pipe
are stuck, turn and pull the connector to free to disconnect and pull it out. Do not use any tools at
this
time.
4. Inspect if there is any dirt or the like on the seal surface of the disconnected pipe and clean it
away.
5. Prevent the disconnected pipe and connector from being damaged or mixed with foreign objects
by covering them with a vinyl bag.
g. Observe these precautions when connecting the fuel tube connector (quick type):
1. Do not reuse the retainer removed from the pipe. 2. Must use hands to remove the retainer from
the pipe. 3. Check that there is any damage or foreign objects on the connected part of the pipe.
Page 5513
D. Verify the male pin of the tongue plate stopper has deformed evenly in the hole of the female
part and is firmly held to the belt webbing.
Page 2275
F. Confirm the Diagnostic Tester software version and connections to the TIS workstation are
correct.
* NOTE:
This screen displays the required version of Diagnostic Tester software that is compatible with the
selected calibration file, and the other required steps to properly connect the Diagnostic Tester to
your PC.
^ Type I calibration files are only compatible with software version 10.1a and older versions.
^ Type II calibration files are only compatible with software version 10.2a and newer versions.
G. Place the Diagnostic Tester in the "GET CAL FROM PC" mode to receive the calibration file
(Figure 10).
Click NEXT on the TIS workstation. Once communications begin between the PC and the
Diagnostic Tester, the Diagnostic Tester display will flash CONNECTED.
H. The CUW determines if there is enough memory to store the calibration file on the Diagnostic
Tester Program Card. If there is insufficient
Page 193
Refer to Reset Procedure 1 for the vehicles with Electronically Controlled Automatic
Transmissions:
Page 102
Driver Side J/B And Integration Relay
Page 5605
Glossary Of Terms And Symbols (Part 1)
Page 3078
Mass Air Flow (MAF) Meter
Page 2256
3. Start the engine and warm it up to normal operating temperatures before test-driving.
4. Perform a thorough test drive with several accelerations from a stop with "light throttle"
application until proper transmission shifting is verified.
Reset Procedure 2
1. Disconnect the negative battery cable for 5 minutes.
2. Reconnect battery cable.
3. Start the engine and warm it up to normal operating temperatures before test-driving.
4. Perform a thorough test drive with several accelerations from a stop with "light throttle"
application until proper transmission shifting is verified.
Page 4301
SST P/N: 09527-17011
B. Coat MP grease to the oil seal lip.
18. Install new dust cover and axle hub to steering knuckle.
A. Install the NEW dust cover to the steering knuckle with the 4 bolts.
Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)
B. Using the following SST and a press, install the axle hub to the steering knuckle.
SST P/N: 09649-17010
19. Install ABS speed sensor rotor (with ABS) or spacer (without ABS).
NOTE:
Take care not to scratch the serration of the speed sensor rotor and ensure the speed sensor is
installed completely.
20. 2WD:
Install new lock nut.
A. Using the following SST, install and torque a NEW lock nut to the axle hub.
SST P/N: 00002-00909 (09318-12010)
Torque: 274 N.m (2,800 kgf.cm, 203 ft.lbf)
NOTE:
Do NOT use air wrench.
B. Using a chisel and hammer, stake the lock nut.
Page 5944
Page 2457
A/F and 02 Sensor Identification
Page 4778
The ground points circuit diagram shows the connections from all major parts to the respective
ground points. When troubleshooting a faulty ground point, checking the system circuits which use
a common ground may help you identify the problem ground quickly. The relationship between
ground points (EA, IB and IC) can also be checked this way.
How to Read Power Source
HOW TO READ POWER SOURCE
Page 2568
D. The Calibration Update Wizard (CUW) launches automatically when a calibration file link is
selected (or clicked). Verify that the CUW version is 6.0 or higher. If not, refer to the Note below.
The CUW will guide you through the steps to download the calibration file to the Diagnostic Tester
Program Card. Click NEXT on the first screen (Figure 7).
NOTE:
If the CUW does not launch, or the version is older than 6.0, install Diagnostic Software (TIS
Diagnostic Applications Installer). Specific installation instructions (Reprogramming with CUW 6.0)
are located under Diagnostics ECU Flash Reprogramming (Figure 6).
Page 1837
Camshaft Position Sensor
Specifications
Idle Speed: Specifications
Idle Speed 700 +/- 50 rpm
Page 2002
Page 1710
A. Test the CAN Interface Module (P/N 01002744) for continuity.
^ If there is no continuity, the CAN Interface Module needs to be replaced.
^ If there is continuity, the CAN Interface Module is OK. Re-check Cable Tests 1, 2, 3, and 4 while
wiggling and flexing the cables.
Page 3763
Transmission Mode Indicator - A/T: Electrical Diagrams
Electronically Controlled Transmission And A/T Indicator (Part 1)
Page 1986
CHART 15
Page 3309
^ 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 1769
^ Confirm cable connections between the vehicle and Diagnostic Tester are secure. (Reference
TSB No. SS004-01, "ECU Flash Reprogramming Error Message.")
^ Do not disconnect or turn off the Diagnostic Tester or the vehicle ignition during reprogramming.
^ Set the parking brake.
^ Complete ALL flash calibration updates provided for each ECU.
If the battery's state of charge or capacity are in question, test with SST No. 00002-MP815-T,
"Midtronics Battery Tester," and follow TSB No. PG017-02, "Battery Maintenance for In-Stock
Vehicles & Pre-Delivery."
To ensure stable battery voltage, a battery charger may be connected during reprogramming if:
^ Voltage does not fall below 11.4 volts.
^ Voltage does not rise above 16.0 volts.
^ Setting is on SLOW charge and not BOOST.
A. Connect the Diagnostic Tester to the vehicle and select CURRENT ECU CAL from the ECU
REPROGRAM MAIN MENU. Determine the vehicle's current ECU calibration. (See Figure 17.)
NOTE:
The vehicle may contain up to 3 separate calibration ID numbers. In the example shown, the
vehicle ECU contains only 2 calibration IDs.
Page 6725
Brake Lamp: Diagnostic Aids
Voltage Check
Voltage Check
Voltage Check
A. Establish conditions in which voltage is present at the check point.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(SW 2 OFF)
B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or
component terminal. This check can be done with a test light instead of a voltmeter.
Continuity and Resistance Check
Continuity and Resistance Check
Continuity And Resistance Check
A. Disconnect the battery terminal or wire so there is no voltage between the check points. B.
Contact the two leads of an ohmmeter to each of the check points.
Page 3707
3. Rear propeller shaft:
INSPECT CENTER SUPPORT BEARING FOR WEAR OR DAMAGE Check that the bearing turns
freely. If the bearing is damaged, worn, or does not turn freely, replace it.
4. Rear propeller shaft:
INSPECT WITH DOUBLE CARDAN JOINT PROPELLER SHAFT a. Inspect the shaft for wear or
damage. b. Inspect the double cardan joint for wear or damage. If any problem is found, replace
the propeller shaft assembly.
HINT: Double cardan joint is used on rear propeller shaft.
REASSEMBLY
NOTICE: Be careful not to grip the propeller shaft tube too tightly in a vise as this will cause
deformation.
HINT: When removing or installing any part, make sure that each joint is facing to the correct
direction.
1. Rear propeller shaft:
INSTALL CENTER SUPPORT BEARING ON INTERMEDIATE SHAFT
HINT: Install the center support bearing in the direction.
2. Rear propeller shaft: INSTALL FLANGE ON INTERMEDIATE SHAFT
a. Coat the splines of the intermediate shaft with MP grease.
Page 6176
Tail Gate
Electrical Specifications
Resistance
Page 4201
A. Disconnect shock absorber from lower suspension arm.
B. Remove the shock absorber lower side set nut and washer.
NOTE:
Do not remove the
C. Wrap the bolt's head with vinyl tape to prevent the drive shaft boot from being damaged.
D. Pry down the lower suspension arm to remove the bolt and disconnect the shock absorber.
E. Remove the 3 nuts and shock absorber with the coil spring.
NOTE:
Do not damage the
8. Disconnect lower ball joint. Remove the 4 bolts and disconnect the lower ball joint.
Specifications
Axle Nut: Specifications
Front Drive Shaft Lock Nut 235 Nm (173 ft.lb)
Page 673
Continuity And Resistance Check
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Continuity And Resistance Check
C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the
electrical circuit.
Finding A Short Circuit
Finding A Short Circuit
Finding A Short Circuit
A. Remove the blown fuse and disconnect all loads of the fuse.
Page 529
Page 2279
^ Confirm cable connections between the vehicle and Diagnostic Tester are secure. (Reference
TSB No. SS004-01, "ECU Flash Reprogramming Error Message.")
^ Do not disconnect or turn off the Diagnostic Tester or the vehicle ignition during reprogramming.
^ Set the parking brake.
^ Complete ALL flash calibration updates provided for each ECU.
If the battery's state of charge or capacity are in question, test with SST No. 00002-MP815-T,
"Midtronics Battery Tester," and follow TSB No. PG017-02, "Battery Maintenance for In-Stock
Vehicles & Pre-Delivery."
To ensure stable battery voltage, a battery charger may be connected during reprogramming if:
^ Voltage does not fall below 11.4 volts.
^ Voltage does not rise above 16.0 volts.
^ Setting is on SLOW charge and not BOOST.
A. Connect the Diagnostic Tester to the vehicle and select CURRENT ECU CAL from the ECU
REPROGRAM MAIN MENU. Determine the vehicle's current ECU calibration. (See Figure 17.)
NOTE:
The vehicle may contain up to 3 separate calibration ID numbers. In the example shown, the
vehicle ECU contains only 2 calibration IDs.
Page 4202
9. Remove steering knuckle.
A. Remove the cotter pin and loosen the nut.
B. Using the following SSTs, disconnect the steering knuckle.
SST P/N: 09950-40011 (09951-04010, 09952-04010, 09553-04020, 09554-04010 09955-04031,
09958-04011)
C. Remove the nut and steering knuckle.
NOTE:
4WD: Be careful not to damage the oil seal and drive shaft boot.
HINT: 4WD: When it is difficult to disconnect the drive shaft, tap the tip of the drive shaft with a
plastic hammer.
10. 2WD: Remove grease cap.
A. Mount the axle hub in a soft jaw vise.
NOTE:
Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further (refer to
the illustration).
HINT: Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further
(refer to the illustration).
B. Using a screwdriver, remove the grease cap.
NOTE:
Be careful not to damage the grease cap.
Page 6247
Instrument Panel
Ground Location
IE Left Kick Panel
IF Left Kick Panel
IG Instrument Panel Brace RH
IH Right Kick Panel
II Right Kick Panel
Body
Ground Location (Access Cab)
Page 5823
promoters. However, the application of adhesion promoters on earlier model bumpers made from
PP/TPU (Polypropylene/Thermoplastic Urethane) and PUR (Polyurethane) is also recommended.
Page 4984
SST 09082-00700
CAUTION: When deploying the airbag, always use the specified SST: SRS Airbag Deployment
Tool.
1. Connect the red clip of the SST to the battery positive (+) terminal and the black clip to the
battery negative (-) terminal.
HINT: Do not connect the yellow connector which will be connected with the supplemental restraint
system.
2. Press the SST activation switch, and check that the LED of the SST activation switch lights up.
CAUTION: If the LED lights up when the activation switch is not being pressed, SST malfunction is
probable, so definitely do not use the SST.
3. Disconnect the SST from the battery.
e. Install the SST.
CAUTION: Place the disc wheel on the level ground
1. Connect the connectors of the 2 SST to the steering wheel pad connector.
SST 09082-00700, 09082-00760
NOTE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of
the twin lock. Also, secure some slack for the SST wire harness inside the disc wheel.
Page 3648
4. REMOVE OIL SEAL
Using SST, remove the oil seal. SST 09308-10010
5. REMOVE FRONT BEARING
Using SST, remove the front bearing from the drive pinion. SST 09556-22010
6. REMOVE BEARING SPACER
a. Remove the 2 washers. b. Remove the bearing spacer.
7. INSTALL NEW BEARING SPACER
a. Install a new bearing spacer. b. Install the 2 washers.
8. INSTALL FRONT BEARING
a. Place the front bearing. b. Using SST and the companion flange, install the front bearing then
remove the companion flange.
SST 09950-30011 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03050)
9. INSTALL NEW OIL SEAL
a. Coat a new oil seal lip with MP grease. b. Using SST and a plastic hammer, install the oil seal
until its surface is flush with the differential carrier end.
SST 09316-12010, 09649-17010
HINT: Connect 2 SST with vinyl tape.
Page 6785
Headlamp Dimmer Relay: Testing and Inspection
INSPECT HEADLIGHT CONTROL RELAY CONTINUITY If continuity is not as specified, replace
the relay.
Page 6073
Page 611
Page 4573
Page 635
CHART 26
Page 166
During ECU flash reprogramming, the Error screen shown may be displayed on the Diagnostic
Tester for one of the following reasons:
1. Immobilizer key not properly registered or auto-registration mode left open.
2. Ignition ON/OFF cycling not followed correctly during the flash reprogramming procedure.
3. The Diagnostic Tester cable is damaged, causing an open communication circuit.
NOTE:
The Diagnostic Tester may operate properly in other modes such as OBD, OBDII, or CARB, with a
damaged cable.
To eliminate the possibility of the first 2 reasons causing the error message, do the following:
1. Confirm the Immobilizer Transponder Master Key is properly registered and auto registration
mode is closed. Follow the appropriate Repair Manual procedure and consult TSB SS001-99,
"Scan tool Immobilizer key Code Utility
2. Conduct the ECU flash reprogramming process explicitly following key operation instructions.
Refer to TSB SS002-01, "ECU Flash Reprogramming Process, "for more details.
To determine if the Diagnostic Tester cable is damaged, follow the test procedures below to check
the electrical integrity of the cable. Conduct all continuity tests with an Ohm meter. For all five test
procedures, the resistance values must be below 6.0 ohms to pass.
Test CABLE TEST 1.
Page 5954
Testing and Inspection
Wiper Switch: Testing and Inspection
INSPECT FRONT WIPER AND WASHER SWITCH CONTINUITY
w/ MIST
w/ INTERMITTENT
If continuity is not as specified, replace the switch.
Page 4869
Part 2 of 2
Page 1682
^ 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 3882
Steps 1 - 2
Page 896
a. Check only the valves indicated.
- Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
- Record the out-of-specification valve clearance measurements. They will be used later to
determine the required replacement adjusting shim.
Valve clearance (Cold):
b. Turn the crankshaft 1 revolution (360°) and align the mark. (See procedure in step 8) c. Check
only the valves indicated as shown. Measure the valve clearance. (See procedure in step (a))
10. ADJUST VALVE CLEARANCE
a. Remove the timing belt. b. Remove the camshafts. c. Remove the valve lifter and adjusting shim.
d. Determine the replacement adjusting shim size according to these Formula or Charts:
1. Using a micrometer, measure the thickness of the removed shim. 2. Calculate the thickness of a
new shim so that the valve clearance comes within the specified value.
T ..........................................................................................................................................................
................. Thickness of removed shim A ...........................................................................................
.................................................................................. Measured valve clearance N ............................
......................................................................................................................................................
Thickness of new shim
Service and Repair
Valve Guide Seal: Service and Repair
For further information regarding this component and the system that it is a part of, please refer to
Cylinder Head Assembly; Service and Repair.
Page 436
Brake Light Switch: Pinout Values and Diagnostic Parameters
ABS
A6, A7 ABS SPEED SENSOR FRONT LH, RH
1 - 2 : 1.40 - 1.80 kOhms (20°C, 68°F)
A19 ABS SPEED SENSOR REAR
1 - 2 : 0.89 - 1.29 kOhms (20°C, 68°F)
3 - 4 : 0.89 - 1.29 kOhms (20°C, 68°F)
A5 ABS ACTUATOR WITH ECU
6 - GROUND : 10 - 14 volts with ignition SW at ON or ST position
24 - GROUND : 10 - 14 volts with stop light SW on (Brake pedal depressed)
2, 18 - GROUND : Always continuity
S4 STOP LIGHT SW
2 - 1 : Closed with brake pedal depressed
Page 1475
5. Pinch the fuel return hose.
The pressure in the high pressure line will rise to approx. 392 kPa (4 kgf/sq.cm, 57 psi). In this
state, check to see that there are no leaks from any part of the fuel system.
NOTE: Always pinch the hose. Avoid bending as it may cause the hose to crack.
6. Turn the ignition switch OFF. 7. Disconnect the TOYOTA hand-held tester from the DLC3.
Page 141
A. Test J1962 OBDIII CAN Interface Module (P/N 01002744) for continuity.
^ If there is continuity, the cable and CAN Interface Module are OK. Re-check Cable Tests 1, 2,
and 3 while wiggling and flexing the cables.
^ If there is no continuity, proceed to CABLE TEST 4.
CABLE TEST 4.
A. Disconnect the CAN Interface Module (P/N 01002744) from the J1962 OBDII cable using a
Phillips screwdriver.
B. Test J1962 OBDII cable (P/N 02003180) for continuity.
^ If there is no continuity, the cable needs to be replaced.
^ If there is continuity, proceed to CAN Interface Module Test 5.
CAN INTERFACE MODULE TEST 5.
Page 2753
CHART 5
CHART 6
Page 6677
Transmission Mode Indicator - A/T: Diagnostic Aids
Voltage Check
Voltage Check
Voltage Check
A. Establish conditions in which voltage is present at the check point.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(SW 2 OFF)
B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or
component terminal. This check can be done with a test light instead of a voltmeter.
Continuity and Resistance Check
Continuity and Resistance Check
Continuity And Resistance Check
A. Disconnect the battery terminal or wire so there is no voltage between the check points. B.
Contact the two leads of an ohmmeter to each of the check points.
Ground Locations
Transmission Mode Indicator - A/T: Ground Locations
Engine Compartment
Ground Location
EA Front Left Fender
EB Rear Bank of Right Cylinder
EC Rear Bank of Left Cylinder
Connector Location
EA1 Cowl Wire Harness and Wire Harness (Connector Location)
EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B)
EC1 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC2 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC3 Engine No. 2 Wire and Engine Wire (Near the Starter)
ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission)
Page 5734
Non-Waterproof Type Connector
"Case 1" Raise the terminal retainer up to the temporary lock position.
Non-Waterproof Type Connector
"Case 2" Open the secondary locking device.
Page 5398
Clockspring Assembly / Spiral Cable: Service and Repair Deployment and Disposal
Airbag Deployment When Scrapping Vehicle
DISPOSAL
HINT: When scrapping vehicle equipped with an SRS or disposing of a steering wheel pad (with
airbag), always first deploy the airbag in accordance with the procedure described. 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 steering wheel pad which has an undeployed airbag.
- The airbag produces a sizeable exploding sound when it deploys, so perform the operation
out-of-doors and where it will not create a nuisance to nearby residents.
- When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool).
Perform the operation in a place away from electrical noise. SST 09082-00700
- When deploying an airbag, perform the operation at least 10 m (33 ft) away from the steering
wheel pad.
- The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30
minutes after deployment.
- Use gloves and safety glasses when handling a steering wheel pad with the deployed airbag.
- Always wash your hands with water after completing the operation.
- Do not apply water, etc. to a steering wheel pad with the deployed airbag.
AIRBAG DEPLOYMENT WHEN SCRAPPING VEHICLE
HINT: Have a battery ready as the power source to deploy the airbag.
Page 5267
Evaporator Case: Service and Repair Disassembly and Reassembly
COOLING UNIT
DISASSEMBLY
1. REMOVE BLOWER RESISTOR
Remove the 2 screws and blower resistor.
2. SEPARATE UPPER AND LOWER UNIT CASES
a. Disconnect the connector clamp from upper unit case. b. Using a knife, cut off the each packing.
c. Remove the 3 clips and 3 screws. d. Separate the upper and lower unit case, then pull out the
thermistor from evaporator.
3. REMOVE EVAPORATOR FROM LOWER UNIT CASE
HINT: At the time of reassembly, please refer to the following item. If evaporator is replaced, add
compressor oil to compressor.
Add 40 - 50 cc (1.4 - 1.7 fl.oz)
Compressor oil: ND-OIL 8 or equivalent
4. REMOVE EXPANSION VALVE
Using a hexagon wrench (5.0 mm, 0.20 in.), remove the 2 bolts and separate the expansion valve,
evaporator and tubes.
Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
HINT: At the time of reassembly, please refer to the following item. Lubricate 4 new O-rings with
compressor oil and install them to the tubes and valve.
REASSEMBLY
Reassembly is in the reverse order of disassembly.
Removal and Installation
Steering Gear: Service and Repair Removal and Installation
Page 3594
Transmission Speed Sensor: Service and Repair
Vehicle Speed Sensor NO.1
1. DISCONNECT NO. 1 VEHICLE SPEED SENSOR CONNECTOR
2. REMOVE NO. 1 VEHICLE SPEED SENSOR
Remove the bolt and No.1 vehicle speed sensor.
3. DISASSEMBLE NO. 1 VEHICLE SPEED SENSOR
a. Remove the O-ring from the speedometer driven gear assembly. b. Remove the clip and
speedometer driven gear from the speedometer driven gear sleeve.
4. ASSEMBLE NO. 1 VEHICLE SPEED SENSOR
a. Install the speedometer driven gear and clip to the speedometer driven gear sleeve. b. Coat a
new O-ring with ATF. c. Install the O-ring to the speedometer driven gear assembly.
5. INSTALL NO. 1 VEHICLE SPEED SENSOR
Engine Controls - A/F And O2 Sensor Identification
Oxygen Sensor: All 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 4725
Auxiliary Power Outlet: Electrical Diagrams
Service Hints
CIGARETTE LIGHTER AND POWER OUTLET
C7 CIGARETTE LIGHTER
2 - GROUND : Approx. 12 volts with ignition SW at ON or ACC position 1 - GROUND : Always
continuity
P6, P7 POWER OUTLET
2 - GROUND : Approx. 12 volts with the ignition SW at ON or ACC position 1 - GROUND : Always
continuity
Page 4167
B. Slowly apply the PKB while driving until the brake begins to engage and slow the vehicle. Do not
apply the PKB past this point of initial engagement.
NOTE:
Remember with a foot PKB (on automatic transmission), the pedal must be pressed a second time
to disengage the parking brake.
HINT:
When diagnosing a Tundra with a foot PKB, slowly apply the PKB until the first "click". Then press
the PKB pedal a second time so it will disengage when it is released. At this time the PKB can be
pressed to the desired level for continued diagnosis.
C. Hold the PKB at this point of initial engagement for a few seconds to slowly reduce the vehicle
speed and allow adequate time to monitor the ride condition.
D. Disengage the PKB.
E. If brake vibration is felt during step (C), then it indicates that the rear brake drums are one
source of brake vibration on this vehicle.
Refer to TSB No. BR003-02, "Rear Brake Vibration," for parts and repair information relating to
Tundra rear brake vibration.
F. If no vibration is felt during step (C), then the front brake assemblies are the most likely cause of
brake vibration on this vehicle.
G. Determine if TSB BROO4-02 has already been performed.
Repair Procedure No. 1
1. Remove the front wheel.
2. 2WD:
Using a screwdriver and hammer remove the grease cap.
3. 4WD:
Disconnect drive shaft.
A. Remove the cotter pin and lock cap.
B. While applying the brakes, remove the lock nut.
Page 2766
CHART 22
Page 4044
Warranty Information
Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This
warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's
in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Page 4199
B. Slowly apply the PKB while driving until the brake begins to engage and slow the vehicle. Do not
apply the PKB past this point of initial engagement.
NOTE:
Remember with a foot PKB (on automatic transmission), the pedal must be pressed a second time
to disengage the parking brake.
HINT:
When diagnosing a Tundra with a foot PKB, slowly apply the PKB until the first "click". Then press
the PKB pedal a second time so it will disengage when it is released. At this time the PKB can be
pressed to the desired level for continued diagnosis.
C. Hold the PKB at this point of initial engagement for a few seconds to slowly reduce the vehicle
speed and allow adequate time to monitor the ride condition.
D. Disengage the PKB.
E. If brake vibration is felt during step (C), then it indicates that the rear brake drums are one
source of brake vibration on this vehicle.
Refer to TSB No. BR003-02, "Rear Brake Vibration," for parts and repair information relating to
Tundra rear brake vibration.
F. If no vibration is felt during step (C), then the front brake assemblies are the most likely cause of
brake vibration on this vehicle.
G. Determine if TSB BROO4-02 has already been performed.
Repair Procedure No. 1
1. Remove the front wheel.
2. 2WD:
Using a screwdriver and hammer remove the grease cap.
3. 4WD:
Disconnect drive shaft.
A. Remove the cotter pin and lock cap.
B. While applying the brakes, remove the lock nut.
Page 2061
If operation is not as specified, replace the MAF meter.
6. Turn the ignition switch OFF. 7. Disconnect the negative (-) terminal cable from the battery. 8.
Disconnect the MAF meter connector.
4. REINSTALL MAF METER
Install the MAF meter with the 2 screws.
5. RECONNECT MAF METER CONNECTOR
Page 1057
An airbag activation prevention mechanism is built into the connector for the squib circuit of the
SRS.
When release of the airbag activation prevention mechanism is directed in the troubleshooting
procedure, as shown in the illustration of the connectors, insert paper which has the same
thickness as the male terminal, between the terminal and the short spring.
CAUTION: Never release the airbag activation prevention mechanism on the steering wheel pad
connector.
NOTE:
Page 4724
b. Push the secondary locking device or terminal retainer in to the full lock position.
5. CONNECT CONNECTOR
Disconnection of Male and Female Connectors
Disconnection of Male and Female Connectors
Disconnection Of Male And Female Connectors
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Testing and Inspection
Turn Signal Switch: Testing and Inspection
INSPECT TURN SIGNAL SWITCH CONTINUITY If continuity is not as specified, replace the
switch.
Instruments - Coolant Temperature Gauge Inaccurate
Temperature Gauge: All Technical Service Bulletins Instruments - Coolant Temperature Gauge
Inaccurate
ELECTRICAL EL009-01
October 12, 2001
Title: TEMPERATURE GAUGE INACCURATE
Models: '00 - '01 Tundra
Introduction Some 2000 - 2001 model year Tundra trucks may experience a condition in which the
engine coolant temperature gauge displays an abnormally high reading during normal engine
operating temperatures. To address this condition, an updated Temperature Gauge has been
made available.
Applicable Vehicles ^
2000 - 2001 model year Tundra trucks, built prior to the VIN shown.
Production Change Information
Parts Information
Repair Procedure
IMPORTANT:
Verify that the engine is operating at a normal temperature with the Scan Tool before replacing the
temperature gauge.
1. Remove the four bolts securing the combination meter assembly.
2. Replace the Temperature Gauge.
3. Reassemble the combination meter.
Warranty Information
Applicable Warranty *:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36
months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Locations
EFI Main Relay: Locations
Engine Room R/B
Engine Controls - A/F And O2 Sensor Identification
Oxygen Sensor: All 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
Service and Repair
Lifter / Lash Adjuster: Service and Repair
For further information regarding this component and the system that it is a part of, please refer to
Cylinder Head Assembly; Service and Repair.
Page 6711
Splice Location
B11
Page 6508
Seat Belt Reminder Buzzer: Splice Locations
Engine Compartment
Splice Location
E1 Engine Room Main Wire
E2 Engine Room Main Wire
E3 Engine Room Main Wire
E4 Engine No. 2 Wire
E5 Engine Wire
E6 Engine Wire
E7 Engine Wire
E8 Engine Wire
Instrument Panel
Page 3508
Step 3
Page 4552
a. Install the 4 rubber insulators on the lead wires.
NOTE: Be careful of the rubber insulators installation direction.
b. Install the rectifier with the 4 screws.
Torque: 2.94 N.m (30 kgf.cm, 26 in.lbf)
c. Install the cord clip with the nut.
Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
6. INSTALL BRUSH HOLDER AND VOLTAGE REGULATOR
a. Place the seal plate on the rectifier end frame.
Page 473
Camshaft Position Sensor
Page 6087
Paint: Technical Service Bulletins Body - Paintless Dent Repair Information
TITLE: PAINTLESS DENT REPAIR
SECTION: EXTERIOR BULLETIN # 146
MODELS: TOYOTA, SCION AND LEXUS
DATE: SEPTEMBER 2006
Toyota has developed the following guidelines for the use of "Paintless Dent Repair (PDR)
procedures on all Toyota, Scion and Lexus vehicles.
PDR is used to reduce the cost of repairing minor dents and to avoid color match and refinish
issues that may arise. Be sure to choose your PDR service provider carefully and always review
their professional qualifications to ensure they are up to date on the latest PDR techniques and
procedures.
Repair Precautions
^ Always refer to the specific vehicle schematic (available from your PDR provider) for locations
where PDR is possible.
^ Pay close attention to the locations of accessories and subassemblies that may utilize wire
harnesses or drain hoses, etc.
^ PDR is often complicated by panel contour, placement of reinforcements, and location of
electrical and mechanical components.
^ PDR Technicians should be aware of and take the necessary precautions to prevent damage to
electrical and mechanical components while performing PDR repairs.
General Repair Guidelines
^ The PDR process should only be considered when the exterior paint surface is not broken or
cracked. A 30X power hand held microscope (available from most body shop jobbers) should be
used to determine if the paint surface shows evidence of cracking.
^ Pushing and prying on the back side of body panels can disrupt the factory rust and corrosion
protective coatings. PDR technicians must take steps to prevent corrosion coating damage or
restore it with approved equivalent materials. PDR service companies performing PDR repairs
should be knowledgeable and capable of restoring corrosion protective coatings damaged during
PDR repairs.
PLEASE ROUTE THIS BULLETIN TO YOUR COLLISION REPAIR CENTER MANAGER AND
COLLISION REPAIR TECHNICIANS
^ Prying, pushing, or pulling on body panels may cause stretching beyond the flexible limits of the
paint coatings causing delamination (paint coating separation) or micro-cracking. These conditions
may not be immediately detectable (use a 30X magnifying hand-held microscope to inspect for
cracks).
Important:
The PDR process uses special tools to access otherwise inaccessible areas. Drilling of holes,
prying away or cutting reinforcements or welded structural components to gain access to perform a
PDR is strictly prohibited and, if done, may void the manufacturer's corrosion protection warranty.
^ Using blocks or wedges between window moldings and door glass (for tool access) is also
prohibited. This process can damage window moldings and reduce the factory designed-in
pressure of the inner belt molding on the base of the door glass.
^ Window guard protectors must be used to protect window glass during PDR operations.
Specific Repair Guidelines
^ Panels with multiple dents, including hail damage, may be considered for PDR as long as the
original panel integrity (strength) is maintained. If a panel exhibits any evidence of loss of strength
due to the number of dents, the panel should not be considered for PDR. If after performing a PDR
repair the panel exhibits evidence of loss of strength, the panel must be repaired using
conventional body shop processes.
^ Round/oval dents may be removed if they are 2 inches or more away from panel edges or body
lines and are no larger than the diameter of a soft ball.
^ Creases that are up to 4 long may be considered for removal.
Note:
Sharp creases cannot be removed using PDR.
^ Dents or protrusions, of up to 6mm, from the reverse side, on hoods, trunks, fenders, and quarter
panels may be considered, but extreme caution must
Page 5868
Wheel Arch Moulding
Page 5303
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 4668
Non-Waterproof Type Connector
"Case 1" Raise the terminal retainer up to the temporary lock position.
Non-Waterproof Type Connector
"Case 2" Open the secondary locking device.
Page 3757
Continuity And Resistance Check
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Continuity And Resistance Check
C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the
electrical circuit.
Finding A Short Circuit
Finding A Short Circuit
Finding A Short Circuit
A. Remove the blown fuse and disconnect all loads of the fuse.
Diagram Information and Instructions
Radio/Stereo: Diagram Information and Instructions
Key to Diagrams
A: System Title
B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to
distinguish it from the J/B
Example: 1 Indicates Relay Block No.1
C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type,
or specification is different.
D: Indicates related system.
Page 6436
Key Reminder Switch: Component Tests and General Diagnostics
INSPECTION
1. INSPECT IGNITION SWITCH CONTINUITY
If continuity is not as specified, replace the switch.
2. INSPECT KEY UNLOCK WARNING SWITCH CONTINUITY
If continuity is not as specified, replace the switch.
3. Key unlock warning system:
INSPECT COMBINATION METER OPERATION a. Disconnect the connector from the combination
meter. b. Ground terminal 1 and 10 on the wire harness side connector. c. Check the buzzer
sounds.
Page 4865
Power Steering Fluid: Service and Repair
BLEEDING
1. CHECK FLUID LEVEL 2. JACK UP FRONT OF VEHICLE AND SUPPORT IT WITH STANDS 3.
TURN STEERING WHEEL
With the engine stopped, turn the wheel slowly from lock to lock several times.
4. LOWER VEHICLE 5. START ENGINE
Run the engine at idle for a few minutes.
6. TURN STEERING WHEEL
a. With the engine idling, turn the wheel to left or right full lock position and keep it there for 2 - 3
seconds, then turn the wheel to the opposite
full lock position and keep it there for 2 - 3 seconds.
b. Repeat a. several times.
7. STOP ENGINE
8. CHECK FOR FOAMING OR EMULSIFICATION
If the system has to be bled twice specifically because of foaming or emulsification, check for fluid
leaks in the system.
9. CHECK FLUID LEVEL
Description and Operation
Transmission Position Switch/Sensor: Description and Operation
PARK / NEUTRAL POSITION SWITCH
Engine Control System
The park/neutral position switch comes on when the shift lever is in the N or P position. When it
comes on, terminal NSW of the ECM is grounded to the body ground via the starter relay, thus the
terminal NSW voltage becomes 0 V. When the shift lever is in the D, 2, L or R position, the
park/neutral position switch goes off, so the voltage of the terminal NSW becomes battery voltage
and the voltage of the ECM internal power source. If the shift lever is moved from the N position to
the D position, this signal is used for air-fuel ratio correction and for idle speed control (estimated
control), etc.
Transmission Control System
The park/neutral position switch detects the shift lever position and sends signals to the ECM.
The ECM receives signals (NSW, R, D, 2 and L) from the park/neutral position switch.
Page 4049
A. Disconnect shock absorber from lower suspension arm.
B. Remove the shock absorber lower side set nut and washer.
NOTE:
Do not remove the
C. Wrap the bolt's head with vinyl tape to prevent the drive shaft boot from being damaged.
D. Pry down the lower suspension arm to remove the bolt and disconnect the shock absorber.
E. Remove the 3 nuts and shock absorber with the coil spring.
NOTE:
Do not damage the
8. Disconnect lower ball joint. Remove the 4 bolts and disconnect the lower ball joint.
Page 6802
Splice Location
B11
Page 6873
Splice Point
J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel,
and "B" for the Body).
The Location of splice Point I5 is shaded.
K: Indicates a shielded cable.
L: Indicates the pin number of the connector.
The numbering system is different for female and male connectors.
M: Indicates a ground point.
The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for
the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body
and Surrounding area.
How to Read Connector List
HOW TO READ CONNECTOR LIST
A: Indicates connector to be connected to a part. (The numeral indicates the pin No.)
Page 409
Glossary Of Terms And Symbols (Part 1)
Page 910
11. REMOVE NO.2 TIMING BELT COVER
Remove the 2 bolts and No.2 timing belt cover.
12. w/ A/C: DISCONNECT A/C COMPRESSOR FROM ENGINE
13. REMOVE FAN BRACKET
Remove the 2 bolts, 2 nuts and fan bracket.
14. IF RE-USING TIMING BELT, CHECK INSTALLATION MARKS ON TIMING BELT
Check that there are 3 installation marks on the timing belt by turning the crankshaft pulley as
shown in the illustration.
HINT: If the installation marks have disappeared, place a new installation mark on the timing belt
before removing each part.
15. LOOSEN CRANKSHAFT PULLEY BOLT Using SST, loosen the pulley bolt.
SST 09213-70010 (90100-08076), 09330-00021
16. SET NO.1 CYLINDER TO TDC/COMPRESSION
Page 3472
Electronically Controlled Transmission And A/T Indicator (Part 3)
Page 4293
Parts Information
Page 612
O2S Application Table
O2S Failure Threshold Charts
Page 3182
Crankshaft Position Sensor: Description and Operation
Crankshaft Position Sensor
Crankshaft position sensor (NE signal) consists of a signal plate and pick up coil.
The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor
generates 34 signals of every engine revolution.
The ECM detects the standard crankshaft angle based on the G signals, and the actual crankshaft
angle the engine speed by the NE signals.
Page 1532
Torque: 20.4 N.m (208 kgf.cm, 15 ft.lbf)
b. Connect the ECT sensor connector.
8. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS
a. Install a new gasket and the throttle body with the 2 bolts and 2 nuts.
Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)
b. Connect the accelerator cable to the throttle body.
9. REINSTALL INTAKE AIR CONNECTOR
10. REFILL WITH ENGINE COOLANT
11. REINSTALL THROTTLE BODY COVER
Page 5326
Blower Motor Relay: Testing and Inspection
HEATER MAIN RELAY
INSPECTION
1. REMOVE HEATER MAIN RELAY FROM NO.2 RELAY BLOCK
2. INSPECT HEATER MAIN RELAY (Making: HTR) CONTINUITY
If continuity is not as specified, replace the relay.
Page 560
CHART 18
CHART 19
Page 2441
Page 5243
a. Check the continuity exists between terminals 1 and 3 of blower switch connector, when turn the
mode selector to DEF. position and F/DEF.
position. If no continuity exists, proceed to next step.
b. Check the continuity exists between terminals of A/C mode switch.
If no continuity exists, replace the A/C mode switch. If continuity exists, check or replace heater
control housing base.
Page 2858
Vehicle Speed Sensor NO.2
Diagram Information and Instructions
Relay Box: Diagram Information and Instructions
Key to Diagrams
A: System Title
B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to
distinguish it from the J/B
Example: 1 Indicates Relay Block No.1
C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type,
or specification is different.
D: Indicates related system.
Page 3965
c. 4HI -> 4LO shift: Connect lines via a relay, then check that the actuator fork shaft moves to 4HI
-> 4LO position.
d. 4LO 4HI shift: Connect lines via a relay, then check that the actuator fork shaft moves to 4LO ->
4HI position.
HINT: When inspecting the operation described, use a heater main relay.
NOTICE: Connect the terminals being careful not to touch the neighboring terminals or metallic
parts of relay housing.
Locations
Engine Room R/B
Engine Controls - Bank 1/Bank 2 O2 Sensor identification
Oxygen Sensor: All Technical Service Bulletins Engine Controls - Bank 1/Bank 2 O2 Sensor
identification
ENGINE EG034-07
Title: ENGINE BANK 1 AND BANK 2 A/F AND O2 IDENTIFICATION
Models: '93 - '08 Applicable Models
June 28, 2007
The information contained in this TSB supercedes TSB No. EG037-04. TSB No. EG037-04 is now
obsolete and should be discarded.
Introduction
This service bulletin provides information on the proper identification of engine bank 1 and engine
bank 2 for correct A/F sensor and oxygen sensor replacement.
This bulletin contains information that identifies engine bank 1 and engine bank 2 on the following
engines: 1AZ-FE, 2AZ-FE, 2AZ-FE (PZEV), 1GR-FE, 2GR-FE, 2GR-FSE, 2JZ-GE, 1MZ-FE,
3MZ-FE, 1UR-FSE, 3UR-FE, 2UZ-FE, 3UZ-FE, 5VZ-FE, and 1ZZ-FE.
^ Bank 1 (B1) refers to the bank that includes cylinder No. 1.
^ Bank 2 (B2) refers to the bank opposite bank 1.
^ Sensor 1 (S1) refers to the sensor that is located before the catalytic converters.
^ Sensor 2 (S2) refers to the sensor that is located after the catalytic converters.
Warranty Information
Page 3042
Fuel Return Line: Service Precautions
FUEL TANK AND LINE
PRECAUTION
- Always use new gaskets when replacing the fuel tank or component parts.
- Apply the proper torque to all parts tightened.
Page 632
CHART 24
Recall - Rear Cross-Member Corrosion
Technical Service Bulletin # SC90M Date: 091116
Page 1799
Engine Control Module: Service and Repair
VEHICLE REPROGRAMMING
Beginning with some 2001 models and expanding to all models by 2007, Toyota/Scion and Lexus
vehicles are equipped with flash reprogrammable Powertrain Control Modules (PCM).
Reprogramming should only be performed if a Technical Service Bulletin or Service Campaign
provides direction to do so.
Flash reprogramming may be accomplished using one of the following methods: Toyota/Lexus factory scantool
- Vetronix Mastertech
- J2534 Compatible Vehicle Interface (Toyota validated and approved)
REPROGRAMMING WITH SCANTOOL
Toyota/Scion/Lexus ECMs can be reprogrammed using either the Toyota/Lexus factory scantool,
or the Vetronix Mastertech scantool. The ECM reprogramming function is only available with the
authentic Toyota factory scantool software which runs on either of the above mentioned scantools.
Scantool software version requirements are specified in applicable Technical Service Bulletin
(TSB)/Service Communication (SC) documents.
The Toyota/Lexus factory scantool and/or authentic factory software program cards can be
purchased through the official Toyota and Lexus Special Service Tool provider, SPX Corp. To
order, call (800) 933-8335 and request either: P/N 01001271 for the Toyota/Lexus factory scantool including factory software program card
- P/N 01002593-005 for the "stand alone" program card
Program cards are provided with the latest production version software available at time of
purchase.
Vehicle recalibration using a scantool requires use of the following: Personal Computer running a Microsoft Windows 2000 or Windows XP operating system
- Toyota Diagnostic Tester or Vetronix Mastertech Scantool with Toyota factory software
- Toyota/Lexus factory scantool program card
- PC Interface Cable (P/N 01001090) to transfer data from PC to scantool
- Calibration CD (00456-REPRG-001)
REPROGRAMMING WITH J2534 INTERFACE
Toyota/Scion/Lexus ECMs that can be reprogrammed with a scantool can also be reprogrammed
using a Toyota validated J2534-1 interface. Vehicle recalibration requires the use of the following: Toyota validated J2534 interface
- Toyota Calibration Update Wizard software (available on calibration CD)
- Personal Computer running Microsoft Windows 2000/XP or later operating system
- Calibration CD (00456-REPRG-001)
Toyota strongly recommends USING ONLY VALIDATED INTERFACE DEVICES that appear on
this list.
Validated J2534 Devices Toyota works closely with J2534 interface manufacturers to ensure that
their hardware works safely and efficiently with their products. Every device listed on this page has
been thoroughly tested and validated on Toyota, Scion and Lexus vehicles.
It is important to understand that only the specific devices, firmware, DLLs and APIs listed here
have been tested by Toyota. Toyota does not recommend use of any other J2534 device, firmware,
DLL or API that is not listed here. Changes to J2534 hardware/software is outside of Toyota's
control; in some cases, changes made to device hardware/software can negatively impact
reprogramming performance. Toyota makes every effort to continue to work with J2534 interface
manufacturers to ensure continued product compatibility as the respective products evolve.
Requirement for device:
Supplier Device Name Version (Firmware* / DLL* / API*)
Drew Technologies CarDAQ Plus (01.08.06 / 01.08.06 / 04.04)
Actia PassThru+ XS (02.01 / 02.01 / 04.04)
Vetronix Corporation ES6510 Flasher (06.12 / 04.23 / 04.04)
EASE Diagnostics Universal Reprogrammer (JPI1_11b / 1.3.0.13 / 04.04)
Snap-On Pass Thru Pro (02.01 / 02.01 / 04.04)
Blue Streak Electronics Inc. BSE-2534 Global Programmer (01.21 / 02.27 / 04.04)
* Original validated firmware/DLL versions may be superceded by the device manufacturer.
Contact the device manufacturer if you are unable to find the versions listed above.
Support OS:
OS Name and Version:
Engine - Squealing Noise On Cold Start Up
Drive Belt: Customer Interest Engine - Squealing Noise On Cold Start Up
ENGINE EG003-05
Title: 2UZ-FE ACCESSORY DRIVE BELT NOISE
Models: '00 - '05 Tundra & '01 - '05 Sequoia
February 9, 2005
Introduction
Some customers may experience abnormal squeal noise from the engine accessory drive belt
area, usually during cold start-up. An improved accessory drive belt has been developed to correct
this condition.
Applicable Vehicles
^ 2000 - 2005 model year Tundra vehicles equipped with 2UZ-FE engine produced BEFORE the
Production Change Effective VIN shown below.
^ 2001 - 2005 model year Sequoia vehicles equipped with 2UZ-FE engine produced BEFORE the
Production Change Effective VIN shown below.
Production Change Information
Parts Information
Warranty Information
Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This
warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's
in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific
complaint.
Repair Procedure
Replace the accessory drive belt with the improved part.
1. Remove existing accessory drive belt.
Page 3963
a. Ignition switch ON. b. Shift the transmission shift lever in N position. c. Turn the touch select 2-4
switch ON. d. Check that the 4LO indicator lights come on and the 4HI indicator lights go off when
the touch select high-low switch is in ON position. e. Check that the 4LO indicator lights go off and
the 4HI indicator lights come on when the touch select high-low switch is in OFF position.
HINT: Inspection should be performed with the vehicle stopped, and transmission shift lever in N position.
- If switching is not completed after 3 seconds of shift operation, the 4LO indicator light will flash.
3. INSPECT TOUCH SELECT 2 - 4 AND HIGH-LOW SWITCH CONTINUITY
a. Remove center integration panel assembly. b. Inspect the continuity between the each terminals.
Touch select 2-4 switch
Touch select high-low switch:
If continuity is not as specified, replace the center integration panel assembly.
4. INSPECT ACTUATOR RESISTANCE
a. Using an ohmmeter, measure the resistance between terminals 1 and 2.
Standard resistance: 0.3 - 100 Ohms
b. Using an ohmmeter, measure the resistance between terminals 1 or 2 and body ground.
Standard resistance: More than 0.5 M Ohms If resistance value is not as specified, replace the
actuator assembly.
Page 2402
A/F and 02 Sensor Identification
Page 3716
2WD and 4WD front propeller shaft:
b. Using a hammer, tap the yoke until there is no clearance between the bearing outer race and
snap ring.
7. CHECK SPIDER BEARING
a. Check that the spider bearing moves smoothly.
Body - Paintless Dent Repair Information
Paint: Technical Service Bulletins Body - Paintless Dent Repair Information
TITLE: PAINTLESS DENT REPAIR
SECTION: EXTERIOR BULLETIN # 146
MODELS: TOYOTA, SCION AND LEXUS
DATE: SEPTEMBER 2006
Toyota has developed the following guidelines for the use of "Paintless Dent Repair (PDR)
procedures on all Toyota, Scion and Lexus vehicles.
PDR is used to reduce the cost of repairing minor dents and to avoid color match and refinish
issues that may arise. Be sure to choose your PDR service provider carefully and always review
their professional qualifications to ensure they are up to date on the latest PDR techniques and
procedures.
Repair Precautions
^ Always refer to the specific vehicle schematic (available from your PDR provider) for locations
where PDR is possible.
^ Pay close attention to the locations of accessories and subassemblies that may utilize wire
harnesses or drain hoses, etc.
^ PDR is often complicated by panel contour, placement of reinforcements, and location of
electrical and mechanical components.
^ PDR Technicians should be aware of and take the necessary precautions to prevent damage to
electrical and mechanical components while performing PDR repairs.
General Repair Guidelines
^ The PDR process should only be considered when the exterior paint surface is not broken or
cracked. A 30X power hand held microscope (available from most body shop jobbers) should be
used to determine if the paint surface shows evidence of cracking.
^ Pushing and prying on the back side of body panels can disrupt the factory rust and corrosion
protective coatings. PDR technicians must take steps to prevent corrosion coating damage or
restore it with approved equivalent materials. PDR service companies performing PDR repairs
should be knowledgeable and capable of restoring corrosion protective coatings damaged during
PDR repairs.
PLEASE ROUTE THIS BULLETIN TO YOUR COLLISION REPAIR CENTER MANAGER AND
COLLISION REPAIR TECHNICIANS
^ Prying, pushing, or pulling on body panels may cause stretching beyond the flexible limits of the
paint coatings causing delamination (paint coating separation) or micro-cracking. These conditions
may not be immediately detectable (use a 30X magnifying hand-held microscope to inspect for
cracks).
Important:
The PDR process uses special tools to access otherwise inaccessible areas. Drilling of holes,
prying away or cutting reinforcements or welded structural components to gain access to perform a
PDR is strictly prohibited and, if done, may void the manufacturer's corrosion protection warranty.
^ Using blocks or wedges between window moldings and door glass (for tool access) is also
prohibited. This process can damage window moldings and reduce the factory designed-in
pressure of the inner belt molding on the base of the door glass.
^ Window guard protectors must be used to protect window glass during PDR operations.
Specific Repair Guidelines
^ Panels with multiple dents, including hail damage, may be considered for PDR as long as the
original panel integrity (strength) is maintained. If a panel exhibits any evidence of loss of strength
due to the number of dents, the panel should not be considered for PDR. If after performing a PDR
repair the panel exhibits evidence of loss of strength, the panel must be repaired using
conventional body shop processes.
^ Round/oval dents may be removed if they are 2 inches or more away from panel edges or body
lines and are no larger than the diameter of a soft ball.
^ Creases that are up to 4 long may be considered for removal.
Note:
Sharp creases cannot be removed using PDR.
^ Dents or protrusions, of up to 6mm, from the reverse side, on hoods, trunks, fenders, and quarter
panels may be considered, but extreme caution must
Page 5009
a. Lift up the vehicle.
b. Place the lever under the tire, and inspect the tree play while lifting the tire using a wooden stick,
etc., as a fulcrum.
3. Inspect the Suspension Arm Ball Joint Free Play
A. Lift up the vehicle
B. Inspect the free play while moving the control arm by hand.
(Reference) Free Play Inspection Method (Gauge Installation)
^ Position the dial gauge between the arm (upper or lower) and the knuckle, and measure free
play.
(This illustration shows how to measure free play for vehicles with double wishbone type
suspension with coil spring.)
4. Inspect Ball Joint Dust Cover Check for cracks and grease leaks on the dust cover (boots).
Turning Torque Inspection
Inspect Ball Joint Turning Torque
Move the stud back and forth 5 times, and then turn the stud continuously at 3-5 seconds per turn,
and measure the turning torque at the 5th turn.
HINT:
Refer to the table for standard values for the turning torque.
Page 2190
Crankshaft Position Sensor: Mechanical Specifications
Torque: ................................................................................................................................................
.................................. 6.5 N.m (65 kgf.cm, 58 in.lbf)
Page 6340
Instrument Panel
Connector Location
IA1 Engine Room Main and Cowl Wire (Left Kick Panel)
IA2 Engine Room Main and Cowl Wire (Left Kick Panel)
IA3 Engine Room Main and Cowl Wire (Left Kick Panel)
IA4 Engine Room Main and Cowl Wire (Left Kick Panel)
IB1 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IB2 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IB3 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IC1 Cowl Wire and Roof Wire (Left Side of Instrument Panel)
Instrument Panel
Connector Location
ID1 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH)
ID2 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH)
IE1 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IE2 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IE3 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IF1 Front Door RH Wire and Cowl Wire (Right Kick Panel)
IF2 Front Door RH Wire and Cowl Wire (Right Kick Panel)
IF3 Front Door RH Wire and Cowl Wire (Right Kick Panel)
Page 1511
REMOVAL
1. DRAIN ENGINE COOLANT 2. REMOVE TIMING BELT 3. REMOVE NO.2 IDLER PULLEY
Page 1439
b. Hold the tensioner with both hands and push the push rod strongly as shown to check that it
doesn't move. If the push rod moves, replace the
tensioner.
NOTICE: Never hold the tensioner push rod facing downward.
c. Measure the protrusion of the push rod from the housing end.
Protrusion: 10.5 - 11.5 mm (0.413 - 0.453 inch) If the protrusion is not as specified, replace the
tensioner.
4. INSPECT WATER PUMP
INSTALLATION
1. INSTALL CRANKSHAFT TIMING PULLEY
a. Align the timing pulley set key with the key groove of the pulley. b. Using SST and a hammer,
tap in the timing pulley, facing the flange side inward.
SST 09223-46011
2. INSTALL NO.1 IDLER PULLEY AND NO.2 IDLER PULLEY
a. Apply adhesive 2 or 3 threads of the pivot bolt.
Adhesive: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
b. Using a 10 mm hexagon wrench, install the plate washer and No.1 idler pulley with the pivot bolt.
Torque: 34.5 Nm (350 kgf-cm, 25 ft. lbs.)
c. Install the No.2 idler pulley with the bolt.
Torque: 34.5 Nm (350 kgf-cm, 25 ft. lbs.)
d. Check that the No.1 and No.2 idler pulleys moves smoothly.
Page 5019
Ball Joint: Service and Repair Upper
REMOVAL
1. REMOVE STEERING KNUCKLE WITH AXLE HUB
Page 4410
Hydraulic Control Assembly - Antilock Brakes: Diagrams
ABS ACTUATOR REPLACEMENT AND OVERHAUL W/ RELATED COMPONENTS
Part 1 of 2
Testing and Inspection
Blower Motor Resistor: Testing and Inspection
BLOWER RESISTOR
INSPECTION
1. REMOVE GLOVE COMPARTMENT PARTS
2. REMOVE LOWER NO.2 FINISH PANEL
3. REMOVE LOWER CENTER COVER
4. REMOVE LOWER LH FINISH PANEL
5. REMOVE LOWER COVER
6. REMOVE NO.4 HEATER TO REGISTER DUCT
7. REMOVE BLOWER RESISTOR
a. Disconnect the connector. b. Remove the 2 screws and blower resistor.
8. INSPECT BLOWER RESISTOR RESISTANCE
If resistance is not as specified, replace the blower resistor.
9. INSTALL BLOWER RESISTOR
a. Install the blower resistor with the 2 screws. b. Connect the connector.
10. INSTALL NO.4 HEATER TO REGISTER DUCT
Page 5765
Body
Connector Location (Standard Cab)
BA1 Front Door LH Wire and Speaker Tweeter Wire LH (Inside of Front Door LH)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Seat
Connector Location
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
BJ1 Seat No. 1 Wire and Seat No. 2 Wire (Under the Driver's Seat)
Brakes - Vibration From Rear
Brake Shoe: All Technical Service Bulletins Brakes - Vibration From Rear
BRAKES BR001-01
January 12, 2001
Title: REAR BRAKE VIBRATION
Models: '00 - '01 Tundra
TSB Update Notice:
The information contained in this TSB updates BR006-00, dated November 17, 2000.
Revised text is underlined.
New parking brake struts (star wheel adjusters) have been developed to reduce the possibility of
rear brake vibration on 2000 and 2001 model year Tundra vehicles. The number of teeth on the
star wheel adjuster has been reduced from 30 to 26 teeth.
Applicable Vehicles ^
2000 - 2001 model year Tundra vehicles.
Production Change Information
Parts Information
Repair Procedure
1. Grind rear brake drums with brake lathe to within serviceable limits.
2. If the drums are unserviceable or above maximum inside diameter, replace the drums.
3. If there is uneven wear on the lining, replace the left and right brake shoes.
4. Replace the parking brake shoe strut sets.
5. Adjust the parking brake to specifications.
6. Reinstall the rear wheels, and torque wheel nuts to:
Torque: 113 Nm (1,150 kgf cm, 83 ft.lbf)
7. Road test.
Warranty Information
Page 3958
b. Connect the oil cooler pipe.
Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.)
c. Install the 3 clamps with the 3 bolts.
7. FILL ATF AND CHECK FLUID LEVEL
Page 5639
e. Install the front pillar garnish.
1. Install the front pillar garnish.
2. Using a torx driver, install the assist grip with the 2 torx screws.
Torx driver: T30 (Part No. 09041-00030 or locally manufactured tool)
3. Install the caps.
f. Install the front door scuff plate with 5 screws.
Page 5637
a. Install the retractor of front seat outer belt.
1. Install the retractor of front seat outer belt with the bolt.
Torque: 42 N.m (430 kgf.cm, 31 ft.lbf)
2. Connect the pretensioner connector as shown in the illustration.
b. Install the front door rear scuff plate and cover.
1. Install the front door rear scuff plate with the clip. 2. Install the cover with the clip.
c. Install the roof side rail garnish.
1. Install the roof side rail garnish. 2. Using a torx driver, install the assist grip with the 2 torx
screws.
Torx driver: T30 (Part No. 09041-00030 or locally manufactured tool)
3. Install the caps.
d. Install the front seat outer belt shoulder anchor.
1. Install the front seat outer belt shoulder anchor with the bolt.
Torque: 42 N.m (430 kgf.cm, 31 ft.lbf)
2. Install the cap.
e. Install the front seat outer belt floor anchor with the bolt.
Torque: 42 N.m (430 kgf.cm, 31 ft.lbf)
f. Install the rear door scuff plate with the 3 screws.
g. Install the front door scuff plate with the 4 screws.
2. Standard cab:
INSTALL FRONT SEAT OUTER BELT
Page 1700
Refer to Reset Procedure 1 for the vehicles with Electronically Controlled Automatic
Transmissions:
Page 4997
Steering Wheel: Service and Repair Steering Wheel Off Center Procedures
REPAIR PROCEDURES
HINT: This is the repair procedure for steering off center.
1. INSPECT STEERING WHEEL OFF CENTER
a. Apply masking tape on the top center of the steering wheel and steering column upper cover. b.
Drive the vehicle in a straight line for 100 meters at a constant speed of 35 mph (56 km/h), and
hold the steering wheel to maintain the course.
c. Draw a line on the masking tape as shown in the illustration.
d. Turn the steering wheel to its straight position.
HINT: Refer to the upper surface of the steering wheel, steering spoke and SRS airbag line for the
straight position.
Page 4182
Parts Information
Diagnosis Procedure
1. Confirm the customer complaint.
2. Determine if vibration is from front or rear (while brakes are still warm from confirmation driving).
The following procedure will isolate the drum brakes from the rest of the hydraulic system by using
the parking brake (PKB).
NOTE:
Remember, with a foot PKB (on automatic transmission) the pedal must be pressed a second time
to disengage the parking brake.
HINT:
When diagnosing a Tundra with a foot PKB, slowly apply the PKB until the first "click, " then press
the PKB pedal a second time so it will disengage if it is released. At this time the PKB can be
pressed to the desired level for continued diagnosis.
A. Drive the Tundra along a smooth, level section of road at approximately 40 mph - 50 mph.
B. Slowly apply the PKB while driving until the brake begins to engage and slow the vehicle. Do not
apply the PKB past this point of initial engagement.
C. Hold the PKB at this point of initial engagement for a few seconds to slowly reduce the vehicle
speed and allow adequate time to monitor the ride condition.
D. Disengage the PKB.
E. If brake vibration is felt during step (C), then it indicates that the rear brake drums are one
source of brake vibration on this vehicle.
Refer to TSB BR003-02 for parts and repair information relating to Tundra rear brake vibration.
F. If no vibration is felt during step (C), then the front brake assemblies are the cause of brake
vibration on this vehicle.
Proceed to the following repair procedure.
Repair Procedure
Page 6262
The ground points circuit diagram shows the connections from all major parts to the respective
ground points. When troubleshooting a faulty ground point, checking the system circuits which use
a common ground may help you identify the problem ground quickly. The relationship between
ground points (EA, IB and IC) can also be checked this way.
How to Read Power Source
HOW TO READ POWER SOURCE
Page 5030
d. Using SST, a press and steel plate, install a new No2 bushing.
SST 09631-12090, 09950-60020 (09951-00680)
HINT: Before installing the bushing, set it in the correct direction, as shown in the illustration.
2. REPLACE NO.1 AND NO.2 SPRING BUMPERS ON-VEHICLE
a. Remove the front wheel. b. Using SST, replace the No.1 spring bumper.
SST 09922-10010
HINT: At the time of installation, use a torque wrench with a fulcrum length of 345 mm (13.58 inch).
Torque: 23 Nm (235 kgf-cm, 17 ft. lbs.)
c. Replace No.2 spring bumper.
1. Remove the stabilizer bar. 2. Using SST, replace the No.2 spring bumper.
SST 09922-10010
HINT: At the time of installation, use a torque wrench with a fulcrum length of 345 mm (13.58 inch).
3. Install the stabilizer bar
d. Install the front wheel.
Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.)
INSTALLATION
1. INSTALL LOWER SUSPENSION ARM TO CHASSIS FRAME
Install the lower suspension arm with the 2 cams, bolts and cam plates while slightly shifting the
power steering gear rearward. Torque: 130 Nm (1,325 kgf-cm, 96 ft. lbs.)
NOTICE: Do not damage the power steering gear tubes.
HINT: After stabilizing the suspension, align the matchmarks on the front and rear cam plates and
chassis frame, and torque the bolts.
Testing and Inspection
Cargo Lamp Switch: Testing and Inspection
INSPECT CARGO LIGHT SWITCH CONTINUITY
a. Remove the center cluster finish panel. b. Disconnect the connector from the center cluster
integration. c. Check the continuity exists between terminal 12 and terminal 1, with the switch ON.
d. Check that no continuity exists between terminal 12 and terminal 1, with the switch OFF.
If continuity is not as specified, replace the switch.
Page 2276
memory, the CUW will ask you to select the calibration file(s) to delete from the Diagnostic Tester
Program Card to make room for the new calibration file.
If necessary, check the calibration file(s) to delete, as shown in Figure 11. Click DELETE.
NOTE:
If there is adequate memory to store the calibration file, skip to Step J.
I. The CUW will now delete the calibration file(s) selected (see Figure 12).
Specifications
Wheel Fastener: Specifications
Wheel Nut Torque 110 Nm (83 ft.lb)
Page 2670
Camshaft Position Sensor: Description and Operation
The Camshaft Position Sensor
Camshaft position sensor (G signal) consists of a magnet iron core and pickup coil.
The G signal plate has 1 tooth on its outer circumference and is installed on the LH camshaft timing
pulley. When the camshafts rotate, protrusion on the signal plate and air gap on the pickup coil
change, causing fluctuations in the magnetic field and generating an electromotive force in the
pickup coil.
The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor
generates 34 signals at every engine revolution. The ECM detects the standard angle of the
crankshaft based on the G signal and the actual angle of the crankshaft and the engine speed by
the NE signal.
Page 1110
The ground points circuit diagram shows the connections from all major parts to the respective
ground points. When troubleshooting a faulty ground point, checking the system circuits which use
a common ground may help you identify the problem ground quickly. The relationship between
ground points (EA, IB and IC) can also be checked this way.
How to Read Power Source
HOW TO READ POWER SOURCE
Page 4908
BJ Inside of Rear Door LH
BK Inside of Rear Door RH
BL Surrounding of the Front of the Fuel Tank
Connector Location
BA1 Front Door LH Wire and Wire Harness (Connector Location)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel)
BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel)
BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel)
BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Page 2434
CHART 21
Page 6820
Waterproof Type Connector
B: For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White
: Gray
Black or White : Dark Gray
Gray or White : Black
Waterproof Type Connector
"Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up
to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Waterproof Type Connector
"Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 5544
Technical Service Bulletin # BO002-01 Date: 010126
Seat Belts - Extenders
BODY BO002-01
January 26, 2001
Title: SEAT BELT EXTENDER
Models: '99 - '01 Model Year
TSB UPDATE NOTICE:
The information contained in this TSB updates B0020-00 dated August 11, 2000.
Revised text is underlined.
Introduction
Toyota customers who find it necessary to increase the length of their seal belts may obtain Seat
Belt Extenders at no cost through their local Toyota dealer.
^ The extender is available in 6 inch, 9 inch, 12 inch, 15 inch and 18 inch lengths.
^ The extender is available only in black.
^ Owners are informed of the Seat Belt Extender availability through the Toyota Owner's Manual
included in each vehicle.
The customer (individual requiring the extender) must visit a Toyota dealership to have the required
measurements made and to complete the Seat Belt Extender worksheet. The worksheet will allow
the proper fitting and selection of a Seat Belt Extender for the customer. The dealership personnel
should then determine the applicable part number and place a Critical Order through the TDN Parts
Network.
The dealership service department should complete the affixed Seat Belt Extender Customer
Information Label and review the Owner Instruction Sheet" with the customer. The dealership
should give a copy of the completed worksheet to the customer and keep the original in the
customer's file.
To assure utmost owner satisfaction, it is recommended that a dealership designate one person to
coordinate all activities related to the Seat Belt Extender issue.
It is recommended that dealerships do not stock Seat Belt Extenders due to the need for proper
fitting to individual customers.
This bulletin contains the following information:
Procedure and Sample Label Application Charts Part Number Information Owner Instructions Seat
Belt Extender Worksheet
Applicable Vehicles ^
1999 through 2001 model year Toyota vehicles.
Page 6433
Key Reminder Switch: Description and Operation
KEY REMINDER AND SEAT BELT WARNING
SYSTEM OUTLINE
Current always flows to TERMINAL (B) 5 of the combination meter through the DOME fuse.
1. SEAT BELT WARNING SYSTEM
When the ignition SW is turned on, current flows from the GAUGE fuse to TERMINAL (A) 7 of the
combination meter. This current activates the combination meter and the current flowing through
the seat belt warning light flows from TERMINAL (A) 12 to GROUND, causing the warning light to
light up. A buckle SW off signal is input to TERMINAL (B) 9 of the combination meter to TERMINAL
(A) 12 to GROUND, causing the warning light to light up. A buckle SW off signal is input to
TERMINAL (B) 9 of the combination meter, the current flowing to TERMINAL (B) 5 of the
combination meter flows from TERMINAL (A) 12 to GROUND and the seat belt warning buzzer
sounds. However, if the seat belt is put on during this period (While the buzzer is sounding), signal
input to TERMINAL (B) 9 of the combination meter stops and the current flow from TERMINAL (B)
5 of the combination meter to TERMINAL (A) 12 to GROUND is cut, causing the buzzer to stop.
2. KEY REMINDER SYSTEM
With the ignition key inserted in the key cylinder (Unlock warning SW on), the ignition SW still off
and driver's door open (Door courtesy SW on), when a signal is input to TERMINAL (B) 10 of the
combination meter, the combination meter operates, current flows from TERMINAL (B) 5 of the
combination meter to TERMINAL (A) 12 to GROUND and key reminder buzzer sounds.
Page 169
A. Test the CAN Interface Module (P/N 01002744) for continuity.
^ If there is no continuity, the CAN Interface Module needs to be replaced.
^ If there is continuity, the CAN Interface Module is OK. Re-check Cable Tests 1, 2, 3, and 4 while
wiggling and flexing the cables.
Page 3286
b. Connect the oil cooler pipe.
Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.)
c. Install the 3 clamps with the 3 bolts.
7. FILL ATF AND CHECK FLUID LEVEL
Page 789
Step 3
Page 6223
Cruise Control: Testing and Inspection
Cruise Control System Check Sheet
Page 4067
^ 09710-28012-01 (09710-07031) 09950-40011 (09951-04020, 09952-04010, 09953-04020,
09954-04010, 09955-04031, 09957-04010, 09958-04011)
HINT:
If necessary, use a press to remove the axle hub from the steering knuckle.
C. Remove the dust cover from the steering knuckle.
D. 4WD:
Remove the bearing spacer and ABS speed sensor rotor (W/ABS) or spacer (W/O ABS).
NOTE:
Take care not to scratch the serration of the speed sensor rotor.
14. REMOVE OIL SEAL (OUTSIDE)
Using a screwdriver, remove the oil seal (outside) from the steering knuckle.
15. REMOVE BEARING FROM STEERING KNUCKLE
A. Using snap ring pliers, remove the snap ring.
B. Using the following SSTs and a press, remove the bearing from the steering knuckle.
^ 09950-60020 (09951-00810)
^ 09950-70010 (09951-07150)
16. INSTALL NEW BEARING
A. Using the following SSTs and a press, install a NEW bearing to the steering knuckle.
^ 09527-17011
^ 09950-60020 (09951-00910)
Page 400
Body
Connector Location (Access Cab)
BA1 Front Door LH Wire and Wire Harness (Connector Location)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel)
BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel)
BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel)
BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Page 2210
Data Link Connector: Diagnostic Aids
Voltage Check
Voltage Check
Voltage Check
A. Establish conditions in which voltage is present at the check point.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(SW 2 OFF)
B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or
component terminal. This check can be done with a test light instead of a voltmeter.
Continuity and Resistance Check
Continuity and Resistance Check
Continuity And Resistance Check
A. Disconnect the battery terminal or wire so there is no voltage between the check points. B.
Contact the two leads of an ohmmeter to each of the check points.
Page 5555
Instrument Panel
Ground Location
IE Left Kick Panel
IF Left Kick Panel
IG Instrument Panel Brace RH
IH Right Kick Panel
II Right Kick Panel
Body
Ground Location (Access Cab)
Page 6346
Splice Point
J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel,
and "B" for the Body).
The Location of splice Point I5 is shaded.
K: Indicates a shielded cable.
L: Indicates the pin number of the connector.
The numbering system is different for female and male connectors.
M: Indicates a ground point.
The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for
the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body
and Surrounding area.
How to Read Connector List
HOW TO READ CONNECTOR LIST
A: Indicates connector to be connected to a part. (The numeral indicates the pin No.)
Page 5883
Upper Side Moulding / Trim: Service and Repair Roof Drip Side Finish Moulding
ROOF DRIP SIDE FINISH MOULDING
Roof Drip Side Finish Moulding
COMPONENTS
REMOVAL
1. REMOVE ENDS OF MOULDING
Locations
Page 4712
Splice Point
J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel,
and "B" for the Body).
The Location of splice Point I5 is shaded.
K: Indicates a shielded cable.
L: Indicates the pin number of the connector.
The numbering system is different for female and male connectors.
M: Indicates a ground point.
The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for
the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body
and Surrounding area.
How to Read Connector List
HOW TO READ CONNECTOR LIST
A: Indicates connector to be connected to a part. (The numeral indicates the pin No.)
Page 3714
HINT: Remove the bearing on the opposite side in the same procedure.
4. SELECT SPIDER BEARING
Select the appropriate bearing according to the existence of drill mark on the yoke.
5. INSTALL SPIDER BEARING
a. Apply MP grease to a new spider and bearings.
HINT: Be careful not to apply too much grease.
b. Align the matchmarks on the yoke and shaft. c. Fit the spider into the yoke.
d. Using SST, install the bearing on the spider.
SST 09332-25010
e. Using SST, adjust both bearings so that the snap ring grooves are at maximum and equal in
width.
Page 4993
Inner diameter: 360 mm (14.17 in.)
CAUTION: Do not use tires with disc wheels.
NOTE: The tires may be marked by the airbag deployment, so use the redundant tires.
f. Deploy the airbag. 1. Connect the SST red clip to the battery positive (+) terminal and the black
clip to the battery negative (-) terminal. 2. Check that no one is within 10 m (33 ft) area around the
disc wheel which the steering wheel pad is tied to. 3. Press the SST activation switch and deploy
the air- bag.
HINT: The airbag deploys simultaneously as the LED of the SST activation switch lights up.
g. Dispose the steering wheel pad (with airbag).
CAUTION: The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30
minutes after deployment.
- Use gloves and safety glasses when handling a steering wheel pad with the deployed airbag.
- Always wash your hands with water after completing the operation.
- Do not apply water, etc. to a steering wheel pad with the deployed airbag. 1. Remove the steering
wheel pad from the disc wheel. 2. Place the steering wheel pad in a vinyl bag, tie the end tightly
and dispose of it in the same way as other general parts disposal.
Disposing of Steering Wheel Pad With Airbag Deployed
DISPOSAL
HINT: When scrapping vehicle equipped with an SRS or disposing of a steering wheel pad (with
airbag), always first deploy the air-bag in accordance with the procedure described below. If any
abnormality occurs with the airbag deployment, contact the SERVICE DEPT of TOYOTA MOTOR
SALES, U.S.A., INC.
CAUTION:
- Never dispose of a steering wheel pad which has an undeployed airbag.
- The airbag produces a sizeable exploding sound when it deploys, so perform the operation
out-of-doors and where it will not create a nuisance to nearby residents.
Specifications
Output Shaft: Specifications
Output Shaft Thrust Play 0.27 - 0.86 mm
Page 5964
Page 6352
Clock: Diagnostic Aids
Voltage Check
Voltage Check
Voltage Check
A. Establish conditions in which voltage is present at the check point.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(SW 2 OFF)
B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or
component terminal. This check can be done with a test light instead of a voltmeter.
Continuity and Resistance Check
Continuity and Resistance Check
Continuity And Resistance Check
A. Disconnect the battery terminal or wire so there is no voltage between the check points. B.
Contact the two leads of an ohmmeter to each of the check points.
Engine Controls - A/F And O2 Sensor Identification
Oxygen Sensor: All 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 24
Splice Location
B11
Page 4547
Alternator: Service and Repair Disassembly and Reassembly
DISASSEMBLY
1. REMOVE REAR END COVER
a. Remove the nut and terminal insulator. b. Remove the bolt 3 nuts, plate terminal and end cover.
2. REMOVE BRUSH HOLDER
a. 100 A type: Remove the brush holder cover from the brush holder.
b. Remove the 2 screws and brush holder. c. Remove the seal plate from the rectifier end frame.
3. REMOVE VOLTAGE REGULATOR
Remove the 3 screws and voltage regulator.
4. REMOVE RECTIFIER HOLDER
Page 2614
F. Confirm the Diagnostic Tester software version and connections to the TIS workstation are
correct.
* NOTE:
This screen displays the required version of Diagnostic Tester software that is compatible with the
selected calibration file, and the other required steps to properly connect the Diagnostic Tester to
your PC.
^ Type I calibration files are only compatible with software version 10.1a and older versions.
^ Type II calibration files are only compatible with software version 10.2a and newer versions.
G. Place the Diagnostic Tester in the "GET CAL FROM PC" mode to receive the calibration file
(Figure 10).
Click NEXT on the TIS workstation. Once communications begin between the PC and the
Diagnostic Tester, the Diagnostic Tester display will flash CONNECTED.
H. The CUW determines if there is enough memory to store the calibration file on the Diagnostic
Tester Program Card. If there is insufficient
Page 2367
Knock Sensor: Service and Repair
1. REMOVE THROTTLE BODY COVER
2. REMOVE INTAKE AIR CONNECTOR
3. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS
4. REMOVE UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY
5. INSPECT KNOCK SENSOR 1,2
Disconnect the knock sensor connectors.
1. REPLACE THE SENSOR WITH SST.
SST 09816-30010
Torque: 45 N.m (450 kgf.cm, 33 ft.lbf)
Reconnect the knock sensor connectors.
2. REINSTALL UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY
3. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS
4. REINSTALL INTAKE AIR CONNECTOR
5. REINSTALL THROTTLE BODY COVER
Replacement Requirements
Impact Sensor: Service and Repair Replacement Requirements
REPLACEMENT REQUIREMENTS
In the following cases, replace the front airbag sensor.
- If the SRS has been deployed in a collision. (Replace both the left and right airbag sensors.)
- If the front airbag sensor has been found to be faulty in troubleshooting.
- If the front airbag sensor has been found to be faulty during checking items.
- If the front airbag sensor has been dropped.
CAUTION: Be sure to follow the correct procedure for removal and installation of the front airbag
sensor.
Page 5791
Splice Location
I1 Cowl Wire
I2 Cowl Wire
I3 Cowl Wire
I4 Cowl Wire
I5 Cowl Wire
I6 Cowl Wire
I7 Engine Wire
I8 Engine Wire
I9 Engine Wire
I10 Engine Wire
I11 Engine Wire
I12 Engine Wire
I13 Engine Wire
I14 Engine Wire
I15 Engine Wire
I16 Cowl Wire
Body
Splice Location (Access Cab)
B1 Speaker Tweeter Wire LH
B2 Front Door LH Wire
B3 Front Door LH Wire
B4 Roof Wire
B5 Speaker Tweeter Wire RH
B6 B7
Front Door RH Wire
B8 Front Door RH Wire
B9 Rear Door No. 1 Wire RH
B10 Frame Wire
Page 2621
A. The new calibration file should be displayed as the current ECU calibration file.
B. Using a permanent marker or ball point pen, enter the required information on the Authorized
Modifications Label (Figures 21 and 22).
C. Affix this label under the hood in the location determined by the specific vehicle TSB or
Campaign.
NOTE:
Wait 60-90 seconds for ink to set before handling.
Page 2571
memory, the CUW will ask you to select the calibration file(s) to delete from the Diagnostic Tester
Program Card to make room for the new calibration file.
If necessary, check the calibration file(s) to delete, as shown in Figure 11. Click DELETE.
NOTE:
If there is adequate memory to store the calibration file, skip to Step J.
I. The CUW will now delete the calibration file(s) selected (see Figure 12).
Page 6662
Body
Splice Location (Standard Cab)
B1 Speaker Tweeter Wire LH
B2 Front Door LH Wire
B3 Front Door LH Wire
B4 Roof Wire
B5 Speaker Tweeter Wire RH
B6 B7
Front Door RH Wire
B10 Frame Wire
Seat
Testing and Inspection
Parking Brake Lever: Testing and Inspection
ON-VEHICLE INSPECTION
1. CHECK PARKING BRAKE LEVER TRAVEL
Pull the parking brake lever all the way up, and count the number of clicks. Parking brake lever
travel at 196 N (20 kgf, 44 lbs.): 6 - 14 clicks If incorrect, adjust the parking brake.
2. IF NECESSARY, ADJUST PARKING BRAKE
HINT: Before adjusting the parking brake, make sure that the rear brake shoe clearance has been
adjusted. For shoe clearance adjustment, see step 3.
(a) Tighten one of the adjusting nuts of the intermediate lever while loosening the other one until
the travel is correct.
Tighten the 2 adjusting nuts.
(b) After adjusting the parking brake, confirm that the bellcrank stopper screw comes into contact
with the backing plate.
For shoe clearance adjustment, see step 3 on page
Page 2504
CHART 28
Engine Controls - Error When Reprogramming ECU
Engine Control Module: All Technical Service Bulletins Engine Controls - Error When
Reprogramming ECU
SPECIAL SERVICE TOOLS SS004-01 REVISED
May 25, 2001
Title: ECU FLASH REPROGRAMMING ERROR MESSAGE
Models: Applicable Models
TSB REVISION NOTICE:
September 23, 2003: Models added - 2002 (and later) Solara, 2003 (and later) Corolla and Matrix,
and 2004 models; Test Procedures updated for new CAN Interface Module. The previous TSB
should be discarded.
Introduction
During ECU flash reprogramming, an error message may be displayed on the Diagnostic Tester
that will not allow ECU flash reprogramming to complete. This bulletin provides test procedures to
determine the cause for the error message.
Applicable Vehicles ^
2001 (and later) model year 4Runner, Highlander, Land Cruiser, RAV4, Sequoia and Tundra
vehicles.
^ 2002 (and later) model year Camry, Solara and Tacoma vehicles.
^ 2003 (and later) model year Corolla and Matrix vehicles.
^ All 2004 (and later) model year Toyota vehicles except Celica, MR2 Spyder, Avalon, and Tacoma
(3RZ-FE engine)
Required SSTs
NOTE:
Additional Diagnostic Tester Kits, CAN Interface Modules, Program Cards or other SSTs may be
ordered by calling SPX/OTC at 1-800-933-8335.
Warranty Information
Test Procedure
Specifications
Fluid Pan: Specifications
Oil Pan W/ Bolts 7.4 Nm
Page 4418
Hydraulic Control Assembly - Antilock Brakes: Service and Repair Disassembly and Assembly
Page 6675
Glossary Of Terms And Symbols (Part 1)
Page 6680
Non-Waterproof Type Connector
"Case 1" Raise the terminal retainer up to the temporary lock position.
Non-Waterproof Type Connector
"Case 2" Open the secondary locking device.
Collision / Non-Collision Inspections
Impact Sensor: Testing and Inspection Collision / Non-Collision Inspections
INSPECTION
1. VEHICLES NOT INVOLVED IN COLLISION
Do a diagnostic system check. *
2. VEHICLES INVOLVED IN COLLISION
a. Do a diagnostic system check. *
b. If the front fender of the car or its periphery is damaged, do a visual check for damage to the
front airbag sensor, which includes the following
items even if the airbag was not deployed: Check the bracket deformation.
- Check the paint peeling off the bracket.
- Check the cracks, dents or chips in the case.
- Check the cracks, dents, chipping and scratches in the connector.
- Check the peeling off of the label or damage to the serial number.
* Refer to SRS Warning Light Check, and How to Display and Read Diagnostic Trouble Codes.
See: Restraint Systems/Air Bag Systems/Testing and Inspection/Reading and Clearing Diagnostic
Trouble Codes/Displaying & Reading Trouble Codes
Page 4788
b. Push the secondary locking device or terminal retainer in to the full lock position.
5. CONNECT CONNECTOR
Disconnection of Male and Female Connectors
Disconnection of Male and Female Connectors
Disconnection Of Male And Female Connectors
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Page 4463
Vacuum Brake Booster: Testing and Inspection
ON-VEHICLE INSPECTION
1. OPERATING CHECK
(a) Depress the brake pedal several times with the engine off and check that there is no change in
the pedal reserve distance. (b) Depress the brake pedal and start the engine. If the pedal goes
down slightly, operation is normal.
2. AIR TIGHTNESS CHECK
(a) Start the engine and stop it after 1 or 2 minutes. Depress the brake pedal several times slowly.
If the pedal goes down farthest the 1st time, but gradually rises after the 2nd or 3rd time, the
booster is air tight.
(b) Depress the brake pedal while the engine is running, and stop the engine with the pedal
depressed. If there is no change in the pedal reserve
travel after holding the pedal for 30 seconds, the booster is air tight.
Page 1872
Step 1
Engine Controls - A/F And O2 Sensor Identification
Oxygen Sensor: All 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
Specifications
Idle Speed: Specifications
Idle Speed 700 +/- 50 rpm
Page 477
4. REMOVE CAMSHAFT POSITION SENSOR
Remove the bolt, stud bolt and camshaft position sensor.
INSTALLATION
1. INSTALL CAMSHAFT POSITION SENSOR
Install the camshaft position sensor with the bolt and stud bolt Torque: 7.5 N.m (80 kgf.cm, 66
in.lbf)
2. INSTALL LH NO.3 TIMING BELT COVER
3. INSTALL DRIVE BELT
4. FILL ENGINE COOLANT
5. CHECK ENGINE COOLANT FOR LEAKS
6. CHECK IGNITION TIMING
Page 2433
Page 1630
Page 3724
Flex Plate: Service and Repair
For further information regarding this component and the system that it is a part of, please refer to
Torque Converter; Service and Repair.
Description and Operation
Throttle Position Sensor: Description and Operation
Throttle Position Sensor
Throttle position sensor is mounted on the throttle body and it has 2 sensors to detect the throttle
opening angle and a malfunction of the throttle position sensor's own.
Voltage applied to the terminals VTA and VTA2 of the ECM changes between 0 V and 5 V in
proportion to the opening angle of the throttle valve.
The ECM judges the current opening angle of the throttle valve from these signals output from
terminals VTA and VTA2, and the ECM controls the throttle motor to make the throttle valve
opening angle properly in accordance with the driving condition.
If this DTC is stored, the ECM cuts down the power for the throttle motor and the electromagnetic
clutch, and the throttle valve is fully closed by the return spring. However, the opening angle of the
throttle valve can be controlled by the accelerator pedal through the throttle cable.
Page 5178
6. 4WD: INSTALL BEARING SPACER
Using SST and a press, install the bearing spacer. SST 09950-60010 (09951-00650), 09950-70010
(09951-07150)
7. 2WD: INSTALL GREASE CAP
8. 4WD: INSTALL NEW OIL SEAL (INSIDE)
a. Using SST and a plastic hammer, install a new oil seal (inside).
SST 09527-17011
HINT: Lightly strike the SST on its circumference evenly.
b. Coat MP grease to the oil seal lip.
Page 4910
Splice Location
I1 Cowl Wire
I2 Cowl Wire
I3 Cowl Wire
I4 Cowl Wire
I5 Cowl Wire
I6 Cowl Wire
I7 Engine Wire
I8 Engine Wire
I9 Engine Wire
I10 Engine Wire
I11 Engine Wire
I12 Engine Wire
I13 Engine Wire
I14 Engine Wire
I15 Engine Wire
I16 Cowl Wire
Body
Splice Location (Access Cab)
B1 Speaker Tweeter Wire LH
B2 Front Door LH Wire
B3 Front Door LH Wire
B4 Roof Wire
B5 Speaker Tweeter Wire RH
B6 B7
Front Door RH Wire
B8 Front Door RH Wire
B9 Rear Door No. 1 Wire RH
B10 Frame Wire
Page 3754
Glossary Of Terms And Symbols (Part 1)
Page 221
Splice Point
J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel,
and "B" for the Body).
The Location of splice Point I5 is shaded.
K: Indicates a shielded cable.
L: Indicates the pin number of the connector.
The numbering system is different for female and male connectors.
M: Indicates a ground point.
The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for
the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body
and Surrounding area.
How to Read Connector List
HOW TO READ CONNECTOR LIST
A: Indicates connector to be connected to a part. (The numeral indicates the pin No.)
Page 4416
REMOVAL
1. REMOVE BRAKE LINE COVER
2. DISCONNECT CONNECTOR
Pull out the release bar, and disconnect the connector.
3. DISCONNECT BRAKE LINES
Using SST, disconnect the 5 brake lines from the ABS actuator. SST 09023-00100 Torque: 15 Nm
(155 kgf-cm, 11 ft. lbs.)
4. REMOVE ABS ACTUATOR ASSEMBLY
Remove the 3 nuts and ABS actuator assembly. Torque: 19 Nm (195 kgf-cm, 14 ft. lbs.)
5. REMOVE ABS ACTUATOR
(a) Remove the 3 nuts and ABS actuator from the actuator bracket.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
(b) Remove the 3 holders and 3 cushions from the ABS actuator.
INSTALLATION
Page 236
Engine Control Module: Description and Operation
DESCRIPTION
The Engine Control Module (ECM) controls all phases of electrical engine operation. In order to
accomplish this control, the ECM relies on the input from a variety of engine operation sensors.
The ECM compares input signals with those stored in memory to determine what steps should be
taken to achieve maximum performance, fuel economy, and meet emission standards. The ECM
outputs the necessary signals to the fuel system, ignition system, emission control systems, etc..
Page 1172
b. Install the LH camshafts.
1. Apply MP grease to the thrust portion of the intake and exhaust camshafts. 2. Place the intake
and exhaust camshafts.
3. Engage the intake gear to the exhaust gear by meeting the timing marks (2 dot marks) on each
gear.
4. Remove any old packing (FIPG) material. 5. Apply seal packing to the front bearing cap.
Seal packing:Part No. 08826-00080 or equivalent Install a nozzle that has been cut to a 1.5 mm (0.06 inch) opening.
- Parts must be assembled within 5 minutes of application. Otherwise the material must be
removed and reapplied.
- Immediately remove nozzle from the tube and reinstall cap.
NOTICE: Do not apply seal packing to the front bearing cap grooves.
6. Install the front bearing cap.
HINT: Installing the front bearing cap will determine the thrust portion of the camshaft.
7. Install the other bearing cap in the sequence shown with the arrow mark facing forward.
HINT: Align the arrow marks at the front and rear of the cylinder head with the mark on the bearing
cap.
8. Push in the camshaft oil seal.
Engine Controls - Bank 1/Bank 2 O2 Sensor identification
Oxygen Sensor: All Technical Service Bulletins Engine Controls - Bank 1/Bank 2 O2 Sensor
identification
ENGINE EG034-07
Title: ENGINE BANK 1 AND BANK 2 A/F AND O2 IDENTIFICATION
Models: '93 - '08 Applicable Models
June 28, 2007
The information contained in this TSB supercedes TSB No. EG037-04. TSB No. EG037-04 is now
obsolete and should be discarded.
Introduction
This service bulletin provides information on the proper identification of engine bank 1 and engine
bank 2 for correct A/F sensor and oxygen sensor replacement.
This bulletin contains information that identifies engine bank 1 and engine bank 2 on the following
engines: 1AZ-FE, 2AZ-FE, 2AZ-FE (PZEV), 1GR-FE, 2GR-FE, 2GR-FSE, 2JZ-GE, 1MZ-FE,
3MZ-FE, 1UR-FSE, 3UR-FE, 2UZ-FE, 3UZ-FE, 5VZ-FE, and 1ZZ-FE.
^ Bank 1 (B1) refers to the bank that includes cylinder No. 1.
^ Bank 2 (B2) refers to the bank opposite bank 1.
^ Sensor 1 (S1) refers to the sensor that is located before the catalytic converters.
^ Sensor 2 (S2) refers to the sensor that is located after the catalytic converters.
Warranty Information
Page 2654
EFI Main Relay: Testing and Inspection
EFI MAIN RELAY
INSPECTION
1. REMOVE RELAY BOX COVER
2. REMOVE EFI MAIN RELAY (Marking: EFI)
3. INSPECT EFI MAIN RELAY CONTINUITY
a. Using an ohmmeter, check that there is continuity between terminals 1 and 2.
If there is no continuity, replace the relay.
b. Check that there is no continuity between terminals 3 and 5.
If there is continuity, replace the relay.
4. INSPECT EFI MAIN RELAY OPERATION
a. Apply battery voltage across terminals 1 and 2. b. Using an ohmmeter, check that there is
continuity between terminals 3 and 5.
If there is no continuity, replace the relay.
5. REINSTALL EFI MAIN RELAY
6. REINSTALL RELAY BOX COVER
Page 4675
Driver Side J/B And Integration Relay Inner Circuit
Page 2807
Page 884
Spark Plug: Specifications Torque Specification
Spark Plug x Cylinder Head ................................................................................................................
......................................................................... 18 Nm
Page 2297
^ 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 2549
Refer to Reset Procedure 1 for the vehicles with Electronically Controlled Automatic
Transmissions:
Page 20
BJ Inside of Rear Door LH
BK Inside of Rear Door RH
BL Surrounding of the Front of the Fuel Tank
Connector Location
BA1 Front Door LH Wire and Wire Harness (Connector Location)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel)
BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel)
BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel)
BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Page 3507
Steps 1 - 2
Page 5201
Blower Motor: Service and Repair Disassembly and Reassembly
DISASSEMBLY
1. REMOVE BLOWER MOTOR
Remove the 3 screws and blower motor.
2. REMOVE AIR INLET SERVOMOTOR
Remove the 3 screws and servomotor.
REASSEMBLY
Reassembly is in the reverse order of disassembly.
Page 3746
Body
Connector Location (Standard Cab)
BA1 Front Door LH Wire and Speaker Tweeter Wire LH (Inside of Front Door LH)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Seat
Connector Location
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
BJ1 Seat No. 1 Wire and Seat No. 2 Wire (Under the Driver's Seat)
Page 6266
Audible Warning Device: Diagnostic Aids
Voltage Check
Voltage Check
Voltage Check
A. Establish conditions in which voltage is present at the check point.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(SW 2 OFF)
B. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal,
and the positive lead to the connector or
component terminal. This check can be done with a test light instead of a voltmeter.
Continuity and Resistance Check
Continuity and Resistance Check
Continuity And Resistance Check
A. Disconnect the battery terminal or wire so there is no voltage between the check points. B.
Contact the two leads of an ohmmeter to each of the check points.
Page 2730
Applicable Vehicles
Page 2570
F. Confirm the Diagnostic Tester software version and connections to the TIS workstation are
correct.
* NOTE:
This screen displays the required version of Diagnostic Tester software that is compatible with the
selected calibration file, and the other required steps to properly connect the Diagnostic Tester to
your PC.
^ Type I calibration files are only compatible with software version 10.1a and older versions.
^ Type II calibration files are only compatible with software version 10.2a and newer versions.
G. Place the Diagnostic Tester in the "GET CAL FROM PC" mode to receive the calibration file
(Figure 10).
Click NEXT on the TIS workstation. Once communications begin between the PC and the
Diagnostic Tester, the Diagnostic Tester display will flash CONNECTED.
H. The CUW determines if there is enough memory to store the calibration file on the Diagnostic
Tester Program Card. If there is insufficient
Testing and Inspection
Fog/Driving Lamp Switch: Testing and Inspection
INSPECT FOG LIGHT SWITCH CONTINUITY If continuity is not as specified, replace the switch.
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 5537
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 contact your local Toyota dealer so that the dealer can order the proper required length for
the extender. Bring the heaviest coat you expect to wear for proper measurement and selection of
length. Additional ordering information is available at your Toyota dealer.
The Seat Belt Extender must not be used:
a. By anyone other than for whom it was provided (name recorded on Seat Belt Extender).
b. In any vehicle and/or seat position other than the one for which it was provided.
c. When the Seat Belt Extender is provided for rear seat positions (with automatic locking
retractor), make sure the retractor is locked when in use.
CAUTION:
When using the Seat Belt Extender, observe the following. Failure to follow these instructions could
result In reduced effectiveness of the seat belt restraint system in case of vehicle accident,
increasing the chance of personal injury.
^ Never use the Seat Belt Extender if you can COMFORTABLY fasten the seat belt without it.
^ The Seat Belt Extender must never be used with any child safety seats.
^ Remember that the extender provided for you may not be safe when used on a different vehicle,
or for another person or at a different seating position than the one originally intended for.
To connect the extender to the seat belt, insert the tab into the seat belt buckle so that the
"PRESS" signs on the buckle-release buttons of the extender and the seat belt are both facing
outward as shown.
You will hear a click when the tab locks into the buckle.
When releasing the seat belt, press the buckle-release button on the extender, not on the seat belt.
This helps prevent damage to the vehicle interior and extender itself.
When not in use, remove the extender and store in the vehicle for future use.
Page 5712
Instrument Panel
Ground Location
IE Left Kick Panel
IF Left Kick Panel
IG Instrument Panel Brace RH
IH Right Kick Panel
II Right Kick Panel
Body
Ground Location (Access Cab)
Page 5294
3. DISCONNECT WATER HOSES FROM HEATER RADIATOR PIPES
a. Using pliers, grip the claw of clip and slide the clip along the hose. b. Disconnect the water
hoses.
HINT: At the time of installation, please refer to the following items. Push the water hose onto the heater radiator pipe as far as the second ridge on the pipe.
- Install the hose clip in a position, as shown in the illustration.
4. REMOVE INSTRUMENT PANEL AND REINFORCEMENT.
5. REMOVE DEFROSTER NOZZLE AND HEATER TO REGISTER DUCT
Access Cab, Standard Cab Shown
6. REMOVE HEATER UNIT
Remove the 3 nuts and heater unit.
INSTALLATION
Installation is in the reverse order of removal.
Page 617
CHART 8
CHART 9
Page 1884
Applicable Vehicles
Page 2417
Page 4330
Parts Information
Diagnosis Procedure
1. Confirm the customer complaint.
2. Determine if vibration is from front or rear (while brakes are still warm from confirmation driving).
The following procedure will isolate the drum brakes from the rest of the hydraulic system by using
the parking brake (PKB).
NOTE:
Remember, with a foot PKB (on automatic transmission) the pedal must be pressed a second time
to disengage the parking brake.
HINT:
When diagnosing a Tundra with a foot PKB, slowly apply the PKB until the first "click, " then press
the PKB pedal a second time so it will disengage if it is released. At this time the PKB can be
pressed to the desired level for continued diagnosis.
A. Drive the Tundra along a smooth, level section of road at approximately 40 mph - 50 mph.
B. Slowly apply the PKB while driving until the brake begins to engage and slow the vehicle. Do not
apply the PKB past this point of initial engagement.
C. Hold the PKB at this point of initial engagement for a few seconds to slowly reduce the vehicle
speed and allow adequate time to monitor the ride condition.
D. Disengage the PKB.
E. If brake vibration is felt during step (C), then it indicates that the rear brake drums are one
source of brake vibration on this vehicle.
Refer to TSB BR003-02 for parts and repair information relating to Tundra rear brake vibration.
F. If no vibration is felt during step (C), then the front brake assemblies are the cause of brake
vibration on this vehicle.
Proceed to the following repair procedure.
Repair Procedure
Page 4760
Driver Side J/B And Integration Relay
Page 4562
Page 4018
Repair Procedure
1. Disconnect the cable from the negative (-) battery terminal for MORE THAN two (2) seconds.
2. Reconnect the cable to the negative (-) battery terminal.
3. Perform the applicable zero point calibration of the yaw rate sensor and/or the steering angle
sensor.
HINT Refer to the applicable TSB or Repair Manual for the zero point calibration procedure.
4. Re-initialize all applicable systems available on the vehicle (power window sunroof power lift
door etc.).
Page 3471
Electronically Controlled Transmission And A/T Indicator (Part 2)
Page 6844
Lamp Control Module: Description and Operation
LIGHT AUTO TURN OFF
SYSTEM OUTLINE
With the ignition SW turned on, the current flows to TERMINAL 9 of the integration relay through
ECU IG fuse.
Voltage is applied at all times to TERMINAL 6 of the integration relay through the TAIL fuse, and
through the HEAD relay coil side [w/o daytime running light] or through the daytime running light
relay (Main) [w/ daytime running light].
1. NORMAL LIGHTING OPERATION
With the light control SW turned to TAIL position, a signal is input into the integration relay. Due to
this signal, the current flowing to TERMINAL 6 of the relay flows to TERMINAL 14 of the light
control SW to TERMINAL 16 to GROUND, and taillights to turn on.
With the light control SW turned to HEAD position, a signal is input into the integration relay. Due to
this signal, the current flowing to the relay flows to TERMINAL 13 of the light control SW to
TERMINAL 16 to GROUND in the headlight circuit, and causes taillight and HEAD relay to turn the
lights on. The taillight circuit is same as above.
2. LIGHT AUTO TURN OFF OPERATION
With light on and ignition SW turned off (Input signal goes to TERMINAL 9 of the relay), when the
driver's door is opened (Input signal goes to TERMINAL 14 of the relay), the relay operates and the
current is cutoff which flows from TERMINAL 6 of the relay to taillight circuit and headlight circuit.
As a result, all lights are turned off automatically.
Page 509
Steps 2 - 3
INSPECTION PROCEDURE
HINT:
- DTC P0325 is for the left bank knock sensor circuit.
- DTC P0330 is for the right bank knock sensor circuit.
- Read freeze frame data using TOYOTA hand-held tester or OBD II scan tool, as freeze frame
data records the engine conditions when a malfunction is detected. When troubleshooting it is
useful for determining whether the vehicle was running or stopped, the engine was warmed up or
not, the air-fuel ratio was lean or rich, etc. at the time of the malfunction.
Page 3171
Camshaft Position Sensor
Page 3687
DISASSEMBLY
1. 2WD: REMOVE GREASE CAP
a. Mount the axle hub in a soft jaw vise.
HINT: Close the vise until it holds hub bolts. Do not tighten further.
b. Using a screwdriver, remove the grease cap.
2. 4WD: REMOVE OIL SEAL (INSIDE)
a. Mount the axle hub in a soft jaw vise.
HINT: Close the vise until it holds hub bolts. Do not tighten further.
b. Using a screwdriver, remove the oil seal (inside).
Page 1146
Wheel Bearing: Tools and Equipment
Wheel Bearing Nut Socket
AST tool# TOY 185
Page 2170
Camshaft Position Sensor: Mechanical Specifications
Torque: ................................................................................................................................................
.................................. 7.5 N.m (80 kgf.cm, 66 in.lbf)
Page 779
Repair Procedure
1. Disconnect the cable from the negative (-) battery terminal for MORE THAN two (2) seconds.
2. Reconnect the cable to the negative (-) battery terminal.
3. Perform the applicable zero point calibration of the yaw rate sensor and/or the steering angle
sensor.
HINT Refer to the applicable TSB or Repair Manual for the zero point calibration procedure.
4. Re-initialize all applicable systems available on the vehicle (power window sunroof power lift
door etc.).
Specifications
Firing Order: Specifications
Firing Order 1 - 8 - 4 - 3 - 6 - 5 - 7 - 2
Page 4916
Body
Connector Location (Standard Cab)
BA1 Front Door LH Wire and Speaker Tweeter Wire LH (Inside of Front Door LH)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Seat
Connector Location
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
BJ1 Seat No. 1 Wire and Seat No. 2 Wire (Under the Driver's Seat)
Page 2805
Page 2875
Vehicle Speed Sensor: Description and Operation
Vehicle Speed Sensor NO.1
Vehicle Speed Sensor NO.1 Circuit Description
The vehicle speed sensor outputs a 4-pulse signal for every revolution of the rotor shaft, which is
rotated by the transmission output shaft via the driven gear. After this signal is converted into a
more precise rectangular waveform by the waveform shaping circuit inside the combination meter,
it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency
of these pulse signals.
Vehicle Speed Sensor NO.2
Vehicle Speed Sensor NO.2 Circuit Description
The No.2 vehicle speed sensor detects the rotation speed of the transmission output shaft and
sends signals to the ECM. The ECM determines the vehicle speed based on these signals.
Page 754
Impact Sensor: Service and Repair Removal and Installation
Front Airbag Sensor
REMOVAL
NOTE:
- If the wiring connector of the SRS is disconnected with the ignition switch at ON or ACC position,
DTCs will be recorded.
- Never use SRS parts from another vehicle. When replacing parts, replace them with new parts.
- Never reuse the sensor involved in a collision when the SRS has deployed.
- Never repair a sensor in order to reuse it.
Page 6289
Instrument Panel
Connector Location
IA1 Engine Room Main and Cowl Wire (Left Kick Panel)
IA2 Engine Room Main and Cowl Wire (Left Kick Panel)
IA3 Engine Room Main and Cowl Wire (Left Kick Panel)
IA4 Engine Room Main and Cowl Wire (Left Kick Panel)
IB1 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IB2 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IB3 Front Door LH Wire and Cowl Wire (Left Kick Panel)
IC1 Cowl Wire and Roof Wire (Left Side of Instrument Panel)
Instrument Panel
Connector Location
ID1 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH)
ID2 Cigarette Lighter Wire and Cowl Wire (Instrument Panel Brace LH)
IE1 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IE2 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IE3 Engine Wire and Cowl Wire (Right Side of Instrument Panel)
IF1 Front Door RH Wire and Cowl Wire (Right Kick Panel)
IF2 Front Door RH Wire and Cowl Wire (Right Kick Panel)
IF3 Front Door RH Wire and Cowl Wire (Right Kick Panel)
Page 2493
CHART 22
Page 3554
BJ Inside of Rear Door LH
BK Inside of Rear Door RH
BL Surrounding of the Front of the Fuel Tank
Connector Location
BA1 Front Door LH Wire and Wire Harness (Connector Location)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel)
BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel)
BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel)
BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Page 4931
Terminal Retainer
Push the terminal retainer down to the temporary lock position.
c. Release the locking lug from terminal and pull the terminal out from rear.
4. INSTALL TERMINAL TO CONNECTOR
a. Insert the terminal.
HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug
locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position.
Page 2342
B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(Connect the Relay) and SW 2 OFF (or Disconnect SW 2)
D. Disconnect and reconnect the connectors while watching the test light.
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
E. Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION:
a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals
are touched, the IC may be destroyed by
static electricity.)
b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact
with the terminals of leads from the IC, etc. of the replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
Special Tool
1. PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown.
2. DISCONNECT CONNECTOR
3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
a. Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the
secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
A: For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
Page 204
D. The Calibration Update Wizard (CUW) launches automatically when a calibration file link is
selected (or clicked). Verify that the CUW version is 6.0 or higher. If not, refer to the Note below.
The CUW will guide you through the steps to download the calibration file to the Diagnostic Tester
Program Card. Click NEXT on the first screen (Figure 7).
NOTE:
If the CUW does not launch, or the version is older than 6.0, install Diagnostic Software (TIS
Diagnostic Applications Installer). Specific installation instructions (Reprogramming with CUW 6.0)
are located under Diagnostics ECU Flash Reprogramming (Figure 6).
Page 2392
Page 2203
Wiring Harness Connector
E: Indicates the wiring harness and wiring harness connector. The wiring harness with male
terminal is shown with arrows.
Outside numerals are pin numbers.
The first letter of the code for each wiring harness and wiring harness connector(s) indicates the
component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and
Surrounding area, and "B" for the Body and Surrounding area.
When more than one code has the first and second letters in common, followed by numbers (e.g,
IH1, IH2), this indicates the same type of wiring harness and wiring harness connector.
F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in
parts position.
G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside
it). Junction Blocks are shaded to clearly separate
them from other parts.
H: When 2 parts both use one connector in common, the parts connector name used in wire
routing is shown in square brackets [ ].
Wiring Color
I: Indicates the wiring color.
Wire colors are indicated by an alphabetical code.
B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR =
Brown SB = Sky Blue LG = Light Green GR = Gray
The first letter indicates the basic wire color and the second letter indicates the color of the stripe.
Page 4392
Brake Caliper: Specifications
Caliper Anchor Bolts 123 Nm
Bleeder Screw 11 Nm
Hydraulic Brake Line 15 Nm
Page 4315
Parts Information
Diagnosis Procedure
1. Confirm the customer complaint.
2. Determine if vibration is from front or rear (while brakes are still warm from confirmation driving).
The following procedure will isolate the drum brakes from the rest of the hydraulic system by using
the parking brake (PKB).
NOTE:
Remember, with a foot PKB (on automatic transmission) the pedal must be pressed a second time
to disengage the parking brake.
HINT:
When diagnosing a Tundra with a foot PKB, slowly apply the PKB until the first "click, " then press
the PKB pedal a second time so it will disengage if it is released.
At this time the PKB can be pressed to the desired level for continued diagnosis.
A. Drive the Tundra along a smooth, level section of road at approximately 40 mph - 50 mph.
B. Slowly apply the PKB while driving until the brake begins to engage and slow the vehicle. Do not
apply the PKB past this point of initial engagement.
C. Hold the PKB at this point of initial engagement for a few seconds to slowly reduce the vehicle
speed and allow adequate time to monitor the ride condition.
D. Disengage the PKB.
E. If brake vibration is felt during step (C), then it indicates that the rear brake drums are one
source of brake vibration on this vehicle.
Refer to TSB BR003-02 for parts and repair information relating to Tundra rear brake vibration.
F. If no vibration is felt during step (C), then the front brake assemblies are the cause of brake
vibration on this vehicle.
Proceed to the following repair procedure.
Page 5837
2. Scrub the bumper covers with the soap and water solution, making sure all difficult-to-reach
areas are thoroughly cleaned.
3. Rinse the entire bumper cover with clean deionized water, making sure all difficult-to-reach
areas are thoroughly rinsed.
4. Dry the surface with a clean towel before water dries on the surface. Clean, dry compressed air
from an oil-less compressor may be substituted for
drying with a towel.
5. Degrease the surface with a wax, grease, and silicone remover.
Note: Lacquer thinner or brake cleaner will NOT remove silicone. You MUST use a wax, grease,
and silicone remover. Carefully follow application instructions on the container label. Fish eyes or
other paint irregularities may result from not following instructions.
6. Apply a generous amount of sanding paste with a gray 3M ScotchBrite pad. Only a gray pad
should be used during the sanding process. Sand the
entire bumper cover surface. Be sure all difficult-to-reach areas are thoroughly sanded.
7. Clean the entire bumper cover with car wash soap and water. Be sure all difficult-to-reach areas
are thoroughly cleaned.
8. Rinse the entire bumper with clean deionized water. Be sure all difficult-to-reach areas are
thoroughly rinsed.
9. Degrease the surface with an anti-static plastic parts cleaner and a white body shop towel or
paper towel.
Note: Never use a red shop towel to wipe the surface (contains silicone).
10. Assure the bumper is firmly held in place to a steady fixture.
11. Apply a plastic parts adhesion promoter to the surface, according to the manufacturer's
recommendations.
12. Apply plastic parts primer to the surface, according to the paint manufacturer's
recommendations.
13. Since bumpers are made of flexible plastic urethane material, use a two-part urethane finish
paint system with plasticizer (flex agent) for all
bumper and cladding repairs. Apply the appropriate top coat to the surface, according to the paint
manufacturer's recommendations.
14. If heat is applied to cure the paint, assure the surface temperature does not exceed 80°C
(176°F.)
For additional information concerning the refinish process for plastic bumpers/cladding, please
contact your respective refinish paint manufacturer's local representative.
Inspection
Seat Belt Tensioner: Testing and Inspection Inspection
INSPECTION
1. PRETENSIONER IS NOT ACTIVATED
a. Perform a diagnostic system check. b. Perform a visual check which includes the following items
with the front seat outer belt removed from the vehicle.
- Standard cab: Check for cuts and cracks in, or marked discoloration on the quarter trim.
- Access cab: Check for cuts and cracks in, or marked discoloration on the front door rear scuff
plate.
- Check for cuts and cracks in wire harness, and for chipping in connectors.
- Standard cab: Check for deformation of the quarter panel.
- Access cab: Check for deformation of the ELR bracket.
Page 2540
^ 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 6670
Wiring Harness Connector
E: Indicates the wiring harness and wiring harness connector. The wiring harness with male
terminal is shown with arrows.
Outside numerals are pin numbers.
The first letter of the code for each wiring harness and wiring harness connector(s) indicates the
component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and
Surrounding area, and "B" for the Body and Surrounding area.
When more than one code has the first and second letters in common, followed by numbers (e.g,
IH1, IH2), this indicates the same type of wiring harness and wiring harness connector.
F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in
parts position.
G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside
it). Junction Blocks are shaded to clearly separate
them from other parts.
H: When 2 parts both use one connector in common, the parts connector name used in wire
routing is shown in square brackets [ ].
Wiring Color
I: Indicates the wiring color.
Wire colors are indicated by an alphabetical code.
B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR =
Brown SB = Sky Blue LG = Light Green GR = Gray
The first letter indicates the basic wire color and the second letter indicates the color of the stripe.
Page 1721
F. Confirm the Diagnostic Tester software version and connections to the TIS workstation are
correct.
* NOTE:
This screen displays the required version of Diagnostic Tester software that is compatible with the
selected calibration file, and the other required steps to properly connect the Diagnostic Tester to
your PC.
^ Type I calibration files are only compatible with software version 10.1a and older versions.
^ Type II calibration files are only compatible with software version 10.2a and newer versions.
G. Place the Diagnostic Tester in the "GET CAL FROM PC" mode to receive the calibration file
(Figure 10).
Click NEXT on the TIS workstation. Once communications begin between the PC and the
Diagnostic Tester, the Diagnostic Tester display will flash CONNECTED.
H. The CUW determines if there is enough memory to store the calibration file on the Diagnostic
Tester Program Card. If there is insufficient
Page 3155
Knock Sensor (Part 2)
Axle Shaft Assembly, Constant Velocity Type
Axle Shaft: Service and Repair Axle Shaft Assembly, Constant Velocity Type
Removal and Installation
REMOVAL
1. REMOVE FRONT WHEEL 2. REMOVE ENGINE UNDER COVER 3. DRAIN DIFFERENTIAL
OIL
Specifications
Wheel Fastener: Specifications
Wheel Nut Torque 110 Nm (83 ft.lb)
Electrical Specifications
Page 4783
Continuity And Resistance Check
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Continuity And Resistance Check
C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the
electrical circuit.
Finding A Short Circuit
Finding A Short Circuit
Finding A Short Circuit
A. Remove the blown fuse and disconnect all loads of the fuse.
Page 2026
Vehicle Speed Sensor NO.2
Page 1849
Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
INSPECTION
1. DRAIN ENGINE COOLANT
2. REMOVE THROTTLE BODY COVER
3. REMOVE INTAKE AIR CONNECTOR
4. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS
a. Disconnect the accelerator cable from the throttle body. b. Remove the 2 bolts and 2 nuts, and
disconnect the throttle body from the intake manifold. c. Remove the gasket
5. REMOVE ECT SENSOR
a. Disconnect the ECT sensor connector. b. Remove the ECT sensor and gasket.
6. INSPECT ECT SENSOR
Using an ohmmeter, measure the resistance between the terminals.
Resistance: Refer to the graph
If the resistance is not as specified, replace the ECT sensor.
7. REINSTALL ECT SENSOR
a. Install a new gasket and the ECT sensor.
Page 5157
Wheel Bearing: Tools and Equipment
Wheel Bearing Nut Socket
AST tool# TOY 185
Page 6721
The ground points circuit diagram shows the connections from all major parts to the respective
ground points. When troubleshooting a faulty ground point, checking the system circuits which use
a common ground may help you identify the problem ground quickly. The relationship between
ground points (EA, IB and IC) can also be checked this way.
How to Read Power Source
HOW TO READ POWER SOURCE
Page 5018
4. REMOVE LOWER BALL JOINT
a. Remove the cotter pin and nut from the lower ball joint. b. Using SST, disconnect the lower ball
joint from the lower suspension arm.
SST 09628-62011
c. Remove the 4 lower ball joint set bolts. d. While lifting the upper suspension arm and steering
knuckle, remove the lower ball joint. e. Support the upper suspension arm and steering knuckle
securely.
INSPECTION
1. INSPECT LOWER BALL JOINT BOOT FOR DAMAGE
2. INSPECT LOWER BALL JOINT FOR ROTATION CONDITION
a. As shown in the illustration, flip the ball joint stud back and forth 5 times before installing the nut.
b. Using a torque wrench, turn the nut continuously 1 turn per 2 - 4 seconds and take the torque
reading on the 5th turn.
Turning torque: 0.1 - 2.5 Nm (11 - 25 kgf-cm, 1 - 22 inch lbs.)
INSTALLATION
1. INSTALL LOWER BALL JOINT
a. While lifting the upper suspension arm and steering knuckle, install the lower ball joint. b.
Temporarily install the 4 bolts to the lower ball joint. c. Install the set nut to hold the lower ball joint
to the lower suspension arm and a new cotter pin.
Torque: 140 Nm (1,450 kgf-cm, 103 ft. lbs.) If the holes for the cotter pin are not aligned, tighten the
nut further up to 60°.
2. CONNECT TIE ROD END
Connect the tie rod end to the lower ball joint with the nut and a new cotter pin. Torque: 91 Nm
(930 kgf-cm, 67 ft. lbs.) If the holes for the cotter pin are not aligned, tighten the nut further up to
60°.
3. TIGHTEN LOWER BALL JOINT SET 4 BOLTS
Torque: 80 Nm (820 kgf-cm, 59 ft. lbs.)
4. INSTALL FRONT WHEEL
Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.)
5. CHECK FRONT WHEEL ALIGNMENT
Page 1319
Engine Oil: Service and Repair
REPLACEMENT
CAUTION: Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the
skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially
harmful contaminants which may cause skin cancer.
- Care should be taken, therefore, when changing engine oil to minimize the frequency and length
of time your skin is exposed to used engine oil. Protective clothing and gloves that cannot be
penetrated by oil should be worn. The skin should be thoroughly washed with soap and water, or
use water-less hand cleaner, to remove any used engine oil. Do not use gasoline, thinners, or
solvents.
- In order to preserve the environment, used oil and used oil filters must be disposed of only at
designated disposal sites.
1. w/ Oil filter change: REMOVE ENGINE UNDER COVER
2. DRAIN ENGINE OIL
a. Remove the oil filler cap. b. Remove the oil drain plug and gasket, and drain the oil into a
container.
3. REPLACE OIL FILTER
a. Using SST, remove the oil filter.
SST 09228-07501
b. Clean the oil filter contact surface on the oil filter mounting. c. Lubricate the filter rubber gasket
with clean engine oil.
d. Tighten the oil filter by hand until the rubber gasket contacts the seat of the filter mounting.
e. Using SST, give it an additional 3/4 turn to seat the filter.
SST 09228-07501
Page 1236
5. Pinch the fuel return hose.
The pressure in the high pressure line will rise to approx. 392 kPa (4 kgf/sq.cm, 57 psi). In this
state, check to see that there are no leaks from any part of the fuel system.
NOTE: Always pinch the hose. Avoid bending as it may cause the hose to crack.
6. Turn the ignition switch OFF. 7. Disconnect the TOYOTA hand-held tester from the DLC3.
Page 3270
Step 4
O/D OFF indicator light does not light up
Steps 1 - 2
O/D OFF indicator light remains ON
Locations
VSV For Evaporative Emission (EVAP)
Page 3708
b. Install the spacer.
c. Place the flange on the shaft and align the matchmarks.
HINT: If replacing either the center flange or intermediate shaft, reassemble it so that the front side
flange yoke of the intermediate shaft and the rear side flange yoke of the propeller shaft are facing
in the same direction.
d. Install the spacer. e. Using SST to hold the flange, press the bearing into position by tightening
down a new nut.
SST 09330-00021 Torque: 181 Nm (1,845 kgf-cm, 133 ft. lbs.)
f. Loosen the nut.
g. Torque the nut again.
Torque: 82 Nm (835 kgf-cm, 60 ft. lbs.)
h. Using a hammer and punch, stake the nut.
3. Rear propeller shaft:
INSTALL PROPELLER SHAFT a. Align the matchmarks on the flanges and connect the flanges
with 4 bolts, washers and nuts.
HINT: If replacing either the center flange or intermediate shaft, reassembly it so that the front side
flange yoke of the intermediate shaft and the rear side flange yoke of the propeller shaft are facing
in the same direction.
b. Torque the bolts.
Torque: 74 Nm (750 kgf-cm, 54 ft. lbs.)
INSTALLATION
1. INSTALL FRONT PROPELLER SHAFT
a. Align the matchmarks on the propeller shaft and differential flanges, and connect the flanges
with the 4 bolts, nuts and washers. b. Torque the 4 bolts.
Torque: 74 Nm (750 kgf-cm, 54 ft. lbs.)
c. Align the matchmarks on the propeller shaft and transfer flanges, and connect the flanges with
the 4 nuts and washers. d. Torque the 4 nuts.
Torque: 74 Nm (750 kgf-cm, 54 ft. lbs.)
2. INSTALL REAR PROPELLER SHAFT
Page 18
Audible Warning Device Control Module: Ground Locations
Engine Compartment
Ground Location
EA Front Left Fender
EB Rear Bank of Right Cylinder
EC Rear Bank of Left Cylinder
Connector Location
EA1 Cowl Wire Harness and Wire Harness (Connector Location)
EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B)
EC1 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC2 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC3 Engine No. 2 Wire and Engine Wire (Near the Starter)
ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission)
Page 5144
b. Install the shock absorber, cushion and retainer with nut.
Torque: 20 Nm (200 kgf-cm, 15 ft. lbs.)
c. Install the lower side of the shock absorber with bolt and nut.
Torque: 87 Nm (890 kgf-cm, 64 ft. lbs.)
2. INSTALL REAR WHEEL
Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.)
3. REMOVE SAFETY STANDS
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 4098
11. 4WD: Remove oil seal (inside).
A. Mount the axle hub in a soft jaw vise.
HINT: Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further
(refer to the illustration above).
B. Using a screwdriver, remove the oil seal (inside).
12. 2WD: Remove lock nut and ABS speed sensor rotor (with ABS) or spacer (without ABS). Using
a chisel and hammer, loosen the staked part of the lock nut.
NOTE:
Be careful not to damage the bushing.
A. Using the following SST, remove the lock nut. SST P/N: 00002-00909 (09318-12010)
NOTE:
Do NOT use air wrench.
B. Remove the ABS speed sensor rotor or spacer.
NOTE:
Take care not to scratch the serration of the speed sensor rotor.
13. Remove axle hub from steering knuckle.
A. Remove the 4 bolts and shift the dust cover toward the hub side (outside).
B. Using the following SSTs, remove the axle hub from the steering knuckle.
SST P/N: 09710-28012-01 (09710-07031)
SST P/N: 09950-40011(09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04031,
09957-04010, 09958-04011)
HINT: If necessary, use a press to remove the axle hub from the steering knuckle.
C. Remove the dust cover from the steering knuckle.
D. 4WD: Remove the bearing spacer and ABS speed sensor rotor (with/ABS) or spacer (without
ABS).
NOTE:
Take care not to scratch the serration of the speed sensor rotor.
14. Remove oil seal (outside). Using a screwdriver, remove the oil seal (outside) from the steering
knuckle.
15. Remove bearing from steering knuckle.
Page 3159
Knock Sensor: Testing and Inspection
INSPECTION
1. REMOVE THROTTLE BODY COVER
2. REMOVE INTAKE AIR CONNECTOR
3. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS
4. REMOVE UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY
5. INSPECT KNOCK SENSOR 1,2
a. Disconnect the knock sensor connectors. b. Using an ohmmeter, check that there is no
continuity between the terminal and body.
If there is continuity, replace the sensor with SST. SST 09816-30010
Torque: 45 N.m (450 kgf.cm, 33 ft.lbf)
c. Reconnect the knock sensor connectors.
6. REINSTALL UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY
7. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS
8. REINSTALL INTAKE AIR CONNECTOR
9. REINSTALL THROTTLE BODY COVER
Electrical - SRS And HV Wiring Repairs
Air Bag Harness: Technical Service Bulletins Electrical - SRS And HV Wiring Repairs
TITLE: SRS & HV WIRING REPAIRS
SECTION: ELECTRICAL
BULLETIN # 156
MODELS: ALL TOYOTA LEXUS and SCION MODELS
DATE: AUGUST 2007
There are no approved repairs to Supplemental Restraint System (SRS) or High Voltage (HV)
wiring or connectors. SRS system wiring and connectors are color coded yellow and HV wiring is
orange however vehicle-specific wiring diagrams are the best source for identifying wiring in these
circuits. Wiring diagrams are available through the Technical Information System (TIS)
www.techinfo.toyota.com.
If SRS or HV wiring or connectors are suspected of damage they should be inspected thoroughly.
Damaged wiring and/or connectors require replacement of the affected harness. Follow all
precautions and procedures outlined in model-specific repair manuals for replacing SRS wiring or
components. Only Certified Hybrid Service Technicians are qualified to replace HV system wiring
and components.
Page 5988
- Do not release the airbag activation prevention mechanism unless specifically directed by the
troubleshooting procedure.
- If the inserted paper is too thick the terminal and short spring may be damaged, so always use
paper with the same thickness as the male terminal.
Specifications
Brake Fluid: Specifications
Required Brake Fluid FMVSS No. 116 DOT3
Page 2446
CHART 28
Page 3456
Wiring Harness Connector
E: Indicates the wiring harness and wiring harness connector. The wiring harness with male
terminal is shown with arrows.
Outside numerals are pin numbers.
The first letter of the code for each wiring harness and wiring harness connector(s) indicates the
component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and
Surrounding area, and "B" for the Body and Surrounding area.
When more than one code has the first and second letters in common, followed by numbers (e.g,
IH1, IH2), this indicates the same type of wiring harness and wiring harness connector.
F: Represents a part (all parts are shown in sky blue). The code is the same as the code used in
parts position.
G: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside
it). Junction Blocks are shaded to clearly separate
them from other parts.
H: When 2 parts both use one connector in common, the parts connector name used in wire
routing is shown in square brackets [ ].
Wiring Color
I: Indicates the wiring color.
Wire colors are indicated by an alphabetical code.
B = Black L = Blue R = Red P = Pink O = Orange W = White V = Violet G = Green Y = Yellow BR =
Brown SB = Sky Blue LG = Light Green GR = Gray
The first letter indicates the basic wire color and the second letter indicates the color of the stripe.
Page 2318
E. Confirm the Diagnostic Tester has the appropriate software for the type of calibration file that
was downloaded.
NOTE:
The calibration type is specific to the software version loaded on your Diagnostic Tester. If you
selected the wrong version when downloading the calibration file, you will receive an error when
attempting to install the file on the Diagnostic Tester.
Page 6274
Audible Warning Device: Description and Operation
KEY REMINDER AND SEAT BELT WARNING
SYSTEM OUTLINE
Current always flows to TERMINAL (B) 5 of the combination meter through the DOME fuse.
1. SEAT BELT WARNING SYSTEM
When the ignition SW is turned on, current flows from the GAUGE fuse to TERMINAL (A) 7 of the
combination meter. This current activates the combination meter and the current flowing through
the seat belt warning light flows from TERMINAL (A) 12 to GROUND, causing the warning light to
light up. A buckle SW off signal is input to TERMINAL (B) 9 of the combination meter to TERMINAL
(A) 12 to GROUND, causing the warning light to light up. A buckle SW off signal is input to
TERMINAL (B) 9 of the combination meter, the current flowing to TERMINAL (B) 5 of the
combination meter flows from TERMINAL (A) 12 to GROUND and the seat belt warning buzzer
sounds. However, if the seat belt is put on during this period (While the buzzer is sounding), signal
input to TERMINAL (B) 9 of the combination meter stops and the current flow from TERMINAL (B)
5 of the combination meter to TERMINAL (A) 12 to GROUND is cut, causing the buzzer to stop.
2. KEY REMINDER SYSTEM
With the ignition key inserted in the key cylinder (Unlock warning SW on), the ignition SW still off
and driver's door open (Door courtesy SW on), when a signal is input to TERMINAL (B) 10 of the
combination meter, the combination meter operates, current flows from TERMINAL (B) 5 of the
combination meter to TERMINAL (A) 12 to GROUND and key reminder buzzer sounds.
Page 641
CHART 30
Page 1798
Terminals Of ECU - Connector Pinouts (Part 2)
INSPECTION
1. REMOVE ECM
2. INSPECT ECM
3. REINSTALL ECM
Page 1284
A. Using a breaker bar or ratchet with a 14 mm socket, apply counterclockwise force on the
accessory drive belt tensioner to release tension and remove the accessory drive belt.
HINT:
The pulley bolt for the belt tensioner has a left hand thread.
B. Using the accessory drive belt routing label located on the passenger side of the radiator core
support as a guide, install the new accessory drive belt.
2. Check belt tensioner operation.
A. Check that the belt tensioner moves downward when the drive belt is pressed down at the points
indicated in the illustration with approximately 98 N (10 kgf, 22.0 lbf) of force.
B. Ensure proper alignment of the belt with the ribbed grooves of each pulley.
C. Check by hand to ensure that the belt has not slipped out of the groove on the bottom of each
pulley.
D. Check that the arrow mark on the belt tensioner falls within area "A" of the scale (see
illustration).
E. If the arrow mark falls outside area "A," the drive belt is incorrect.
HINT:
When a new belt is installed, it should lie within area "B." If not, the drive belt is incorrect.
Page 3946
Transmission Position Switch/Sensor: Service and Repair
ON-VEHICLE REPAIR
1. DISCONNECT OIL COOLER PIPE 2. REMOVE PARK/NEUTRAL POSITION SWITCH
a. Disconnect the connector. b. Pry off the lock washer and remove the nut. c. Remove the bolt and
park/neutral position switch.
3. INSTALL PARK/NEUTRAL POSITION SWITCH
a. Install the park/neutral position switch and bolt.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)
b. Install a new lock plate and the nut.
Torque: 3.9 Nm (40 kgf-cm, 35 inch lbs.)
c. Bend claws on the lock plate to fix the nut. d. Connect the connector. e. Check that the engine
can be started with the shift lever only in the N or P position, but not in other positions. If not as
stated, carry out the
adjustment procedure. See: Automatic Transmission/Transaxle/Testing and Inspection/Initial
Inspection and Diagnostic Overview
4. CONNECT OIL COOLER PIPE 5. FILL ATF AND CHECK FLUID LEVEL 6. TEST DRIVE
VEHICLE
Page 3520
Transmission Speed Sensor: Service and Repair
Vehicle Speed Sensor NO.1
1. DISCONNECT NO. 1 VEHICLE SPEED SENSOR CONNECTOR
2. REMOVE NO. 1 VEHICLE SPEED SENSOR
Remove the bolt and No.1 vehicle speed sensor.
3. DISASSEMBLE NO. 1 VEHICLE SPEED SENSOR
a. Remove the O-ring from the speedometer driven gear assembly. b. Remove the clip and
speedometer driven gear from the speedometer driven gear sleeve.
4. ASSEMBLE NO. 1 VEHICLE SPEED SENSOR
a. Install the speedometer driven gear and clip to the speedometer driven gear sleeve. b. Coat a
new O-ring with ATF. c. Install the O-ring to the speedometer driven gear assembly.
5. INSTALL NO. 1 VEHICLE SPEED SENSOR
Page 2697
Intake Air Temperature Sensor: Description and Operation
Intake Air Temperature Sensor
The intake air temperature sensor is built into the air cleaner cap and senses the intake air
temperature. A thermistor built in the sensor changes the resistance value according to the intake
air temperature.
The lower the intake air temperature, the greater the thermistor resistance value, and the higher
the intake air temperature, the lower the thermistor resistance value.
The intake air temperature sensor is connected to the ECM. The 5 V power source voltage in the
ECM is applied to the intake air temperature sensor from the terminal THA via a resistor R.
That is, the resistor R and the intake air temperature sensor are connected in series. When the
resistance value of the intake air temperature sensor changes in accordance with changes in the
intake air temperature, the potential at terminal THA also changes. Based on this signal, the ECM
increases the fuel injection volume to improve driveability during cold engine operation.
Page 2910
b. Push the secondary locking device or terminal retainer in to the full lock position.
5. CONNECT CONNECTOR
Disconnection of Male and Female Connectors
Disconnection of Male and Female Connectors
Disconnection Of Male And Female Connectors
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.
Page 2625
Engine Control Module (ECM)
Page 857
Fuel Pressure: Testing and Inspection
CHECK FUEL PRESSURE
a. Check the battery positive voltage is above 12 V. b. Disconnect the negative (-) terminal cable
from the battery. c. Remove the front fuel pipe from the LH delivery pipe.
d. Install the front fuel pipe and SST (pressure gauge) to the delivery pipe with 3 lower gaskets and
SST (adapter).
SST 09268-45014 (09268-1190, 90405-06167)
Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)
e. Wipe off any splattered gasoline. f.
Reconnect the negative (-) terminal cable to the battery.
g. Connect a TOYOTA hand-held tester to the DLC3. (See step 1 in check fuel pump operation (a)
to (e)) h. Measure the fuel pressure.
Fuel pressure: 265 - 304 kPa (2.7 - 3.1 kgf/sq.cm, 38 - 44 psi)
If pressure is high, replace the fuel pressure regulator. If pressure is low, check the fuel hoses and
connections, fuel pump, fuel filter and fuel pressure regulator.
i. Disconnect the TOYOTA hand-held tester from the DLC3.
j. Start the engine.
k. Measure the fuel pressure at idle.
Fuel pressure: 265 - 304 kPa (2.7 - 3.1 kgf/sq.cm, 38 - 44 psi)
l. Stop the engine.
m. Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped.
Fuel pressure: 147 kPa (1.5 kgf/sq.cm, 21 psi) or more
If pressure is not as specified, check the fuel pump, pressure regulator and/or injectors.
n. After checking fuel pressure, disconnect the negative (-) terminal cable from the battery and
carefully remove the SST to prevent gasoline from
splashing. SST 09268-45014
o. Reinstall the front fuel pipe to the LH delivery pipe. p. Reconnect the negative (-) terminal cable
to the battery. q. Check for fuel leaks.
Page 422
Key Reminder Switch: Component Tests and General Diagnostics
INSPECTION
1. INSPECT IGNITION SWITCH CONTINUITY
If continuity is not as specified, replace the switch.
2. INSPECT KEY UNLOCK WARNING SWITCH CONTINUITY
If continuity is not as specified, replace the switch.
3. Key unlock warning system:
INSPECT COMBINATION METER OPERATION a. Disconnect the connector from the combination
meter. b. Ground terminal 1 and 10 on the wire harness side connector. c. Check the buzzer
sounds.
Page 4214
Parts Information
Diagnosis Procedure
1. Confirm the customer complaint.
2. Determine if vibration is from front or rear (while brakes are still warm from confirmation driving).
The following procedure will isolate the drum brakes from the rest of the hydraulic system by using
the parking brake (PKB).
NOTE:
Remember, with a foot PKB (on automatic transmission) the pedal must be pressed a second time
to disengage the parking brake.
HINT:
When diagnosing a Tundra with a foot PKB, slowly apply the PKB until the first "click, " then press
the PKB pedal a second time so it will disengage if it is released. At this time the PKB can be
pressed to the desired level for continued diagnosis.
A. Drive the Tundra along a smooth, level section of road at approximately 40 mph - 50 mph.
B. Slowly apply the PKB while driving until the brake begins to engage and slow the vehicle. Do not
apply the PKB past this point of initial engagement.
C. Hold the PKB at this point of initial engagement for a few seconds to slowly reduce the vehicle
speed and allow adequate time to monitor the ride condition.
D. Disengage the PKB.
E. If brake vibration is felt during step (C), then it indicates that the rear brake drums are one
source of brake vibration on this vehicle.
Refer to TSB BR003-02 for parts and repair information relating to Tundra rear brake vibration.
F. If no vibration is felt during step (C), then the front brake assemblies are the cause of brake
vibration on this vehicle.
Proceed to the following repair procedure.
Repair Procedure
Page 6543
Body
Splice Location (Standard Cab)
B1 Speaker Tweeter Wire LH
B2 Front Door LH Wire
B3 Front Door LH Wire
B4 Roof Wire
B5 Speaker Tweeter Wire RH
B6 B7
Front Door RH Wire
B10 Frame Wire
Seat
Page 5049
Page 1554
Heater Control Valve: Testing and Inspection
WATER VALVE
ON-VEHICLE INSPECTION
1. WARM UP ENGINE
2. DISCONNECT WATER VALVE CONTROL CABLE
3. INSPECT WATER VALVE OPERATION
a. Check that warm air blown out the vent when the water valve lever is moved to "WARM"
position. b. Check that cool air blown out when the water valve is moved to the "COOL" position.
If operation is not as specified, replace the water valve.
4. CONNECT WATER VALVE CONTROL CABLE
Page 4010
Wheel Speed Sensor: Diagrams
Page 3691
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 246
EFI Main Relay: Testing and Inspection
EFI MAIN RELAY
INSPECTION
1. REMOVE RELAY BOX COVER
2. REMOVE EFI MAIN RELAY (Marking: EFI)
3. INSPECT EFI MAIN RELAY CONTINUITY
a. Using an ohmmeter, check that there is continuity between terminals 1 and 2.
If there is no continuity, replace the relay.
b. Check that there is no continuity between terminals 3 and 5.
If there is continuity, replace the relay.
4. INSPECT EFI MAIN RELAY OPERATION
a. Apply battery voltage across terminals 1 and 2. b. Using an ohmmeter, check that there is
continuity between terminals 3 and 5.
If there is no continuity, replace the relay.
5. REINSTALL EFI MAIN RELAY
6. REINSTALL RELAY BOX COVER
Page 2479
CHART 2
CHART 3
CHART 4
Page 1632
2. DISCONNECT WATER INLET FROM WATER INLET HOUSING
Remove the 3 nuts and disconnect the water inlet from the water inlet housing.
3. REMOVE THERMOSTAT
a. Remove the thermostat. b. Remove the gasket from the thermostat.
INSPECTION
INSPECT THERMOSTAT
HINT: The thermostat is numbered with the valve opening temperature.
a. Immerse the thermostat in water and gradually heat the water. b. Check the valve opening
temperature.
Valve opening temperature: 80 - 84°C (176 - 183°F) If the valve opening temperature is not as
specified, replace the thermostat.
c. Check the valve lift.
Valve lift: 10 mm (0.39 inch) or more at 95°C (203°F) If the valve lift is not as specified, replace the
thermostat.
d. Check that the valve is fully closed when the thermostat is at low temperatures (below 40°C
(104°F)).
If not closed, replace the thermostat.
INSTALLATION
Page 6202
Glossary Of Terms And Symbols (Part 1)
Page 2632
The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit
breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery
power is supplied to each system are explained. Since all System Circuit diagrams start from the
power source, the power source system must be fully understood.
Page 4332
A. Remove the bolt and brake line clamp from the steering knuckle.
B. Remove the 2 bolts, brake caliper and disc.
7. REMOVE SHOCK ABSORBER
A. Disconnect Shock Absorber from lower suspension arm.
B. Remove the shock absorber lower side set nut and washer.
NOTE:
Do not remove the bolt.
C. Wrap the bolt's head with vinyl tape to prevent the drive shaft boot from being damaged.
D. Pry down the lower suspension arm to remove the bolt and disconnect the shock absorber.
E. Remove the 3 nuts and shock absorber with the coil spring.
NOTE:
Do not damage the brake tube.
8. DISCONNECT LOWER BALL JOINT
Description and Operation
Throttle Position Sensor: Description and Operation
Throttle Position Sensor
Throttle position sensor is mounted on the throttle body and it has 2 sensors to detect the throttle
opening angle and a malfunction of the throttle position sensor's own.
Voltage applied to the terminals VTA and VTA2 of the ECM changes between 0 V and 5 V in
proportion to the opening angle of the throttle valve.
The ECM judges the current opening angle of the throttle valve from these signals output from
terminals VTA and VTA2, and the ECM controls the throttle motor to make the throttle valve
opening angle properly in accordance with the driving condition.
If this DTC is stored, the ECM cuts down the power for the throttle motor and the electromagnetic
clutch, and the throttle valve is fully closed by the return spring. However, the opening angle of the
throttle valve can be controlled by the accelerator pedal through the throttle cable.
Page 4371
Torque: 15 N.m (155 kgf.cm, 11 ft.lbf)
28. W/ABS:
CONNECTABS SPEED SENSOR AND WIRE HARNESS CLAMP
Connect the ABS speed sensor and wire harness clamp to the steering knuckle with the 2 bolts.
Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
29. 4WD:
INSTALL DRIVE SHAFT LOCK NUT
A. While applying the brakes, tighten the nut.
Torque: 235 N.m (2,400 kgf.cm, 173 ft.lbf)
B. Install the lock cap and a NEW cotter pin.
If the holes for the cotter pin are not aligned, tighten the nut further up to 600.
30. 2WD:
INSTALL GREASE CAP
31. INSTALL FRONT WHEEL
NOTE:
Do NOT use air wrench.
Torque: 110 N.m (1,150 kgf.cm, 83 ft.lbf)
32. DEPRESS BRAKE PEDAL SEVERAL TIMES
33. FILL THE BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM
34. CHECK ABS SPEED SENSOR SIGNAL (SEE REPAIR MANUAL)
Page 1508
Part 3 of 3
Page 4741
Engine Compartment
Instrument Panel
Locations
Page 6526
Continuity And Resistance Check
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Continuity And Resistance Check
C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the
electrical circuit.
Finding A Short Circuit
Finding A Short Circuit
Finding A Short Circuit
A. Remove the blown fuse and disconnect all loads of the fuse.
Page 3890
BJ Inside of Rear Door LH
BK Inside of Rear Door RH
BL Surrounding of the Front of the Fuel Tank
Connector Location
BA1 Front Door LH Wire and Wire Harness (Connector Location)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel)
BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel)
BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel)
BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Page 6057
2. Scrub the bumper covers with the soap and water solution, making sure all difficult-to-reach
areas are thoroughly cleaned.
3. Rinse the entire bumper cover with clean deionized water, making sure all difficult-to-reach
areas are thoroughly rinsed.
4. Dry the surface with a clean towel before water dries on the surface. Clean, dry compressed air
from an oil-less compressor may be substituted for
drying with a towel.
5. Degrease the surface with a wax, grease, and silicone remover.
Note: Lacquer thinner or brake cleaner will NOT remove silicone. You MUST use a wax, grease,
and silicone remover. Carefully follow application instructions on the container label. Fish eyes or
other paint irregularities may result from not following instructions.
6. Apply a generous amount of sanding paste with a gray 3M ScotchBrite pad. Only a gray pad
should be used during the sanding process. Sand the
entire bumper cover surface. Be sure all difficult-to-reach areas are thoroughly sanded.
7. Clean the entire bumper cover with car wash soap and water. Be sure all difficult-to-reach areas
are thoroughly cleaned.
8. Rinse the entire bumper with clean deionized water. Be sure all difficult-to-reach areas are
thoroughly rinsed.
9. Degrease the surface with an anti-static plastic parts cleaner and a white body shop towel or
paper towel.
Note: Never use a red shop towel to wipe the surface (contains silicone).
10. Assure the bumper is firmly held in place to a steady fixture.
11. Apply a plastic parts adhesion promoter to the surface, according to the manufacturer's
recommendations.
12. Apply plastic parts primer to the surface, according to the paint manufacturer's
recommendations.
13. Since bumpers are made of flexible plastic urethane material, use a two-part urethane finish
paint system with plasticizer (flex agent) for all
bumper and cladding repairs. Apply the appropriate top coat to the surface, according to the paint
manufacturer's recommendations.
14. If heat is applied to cure the paint, assure the surface temperature does not exceed 80°C
(176°F.)
For additional information concerning the refinish process for plastic bumpers/cladding, please
contact your respective refinish paint manufacturer's local representative.
Page 544
Page 2876
An AC voltage is generated in the No.2 vehicle speed sensor coil as the rotor mounted on the
output shaft rotates, and this voltage is sent to the ECM.
The gear shift point and lock-up timing are controlled by the ECM based on the signals from this
vehicle speed sensor and the throttle position sensor signal.
If the No.2 vehicle speed sensor malfunctions, the ECM uses input signals from the No.1 vehicle
speed sensor as a back-up signal.
Description and Operation
Transmission Position Switch/Sensor: Description and Operation
PARK / NEUTRAL POSITION SWITCH
Engine Control System
The park/neutral position switch comes on when the shift lever is in the N or P position. When it
comes on, terminal NSW of the ECM is grounded to the body ground via the starter relay, thus the
terminal NSW voltage becomes 0 V. When the shift lever is in the D, 2, L or R position, the
park/neutral position switch goes off, so the voltage of the terminal NSW becomes battery voltage
and the voltage of the ECM internal power source. If the shift lever is moved from the N position to
the D position, this signal is used for air-fuel ratio correction and for idle speed control (estimated
control), etc.
Transmission Control System
The park/neutral position switch detects the shift lever position and sends signals to the ECM.
The ECM receives signals (NSW, R, D, 2 and L) from the park/neutral position switch.
Testing and Inspection
Dimmer Switch: Testing and Inspection
INSPECT LIGHT CONTROL RHEOSTAT
a. Connect terminals 1 and 3 through a 3.4 W test bulb. b. Connect the positive (+) lead from the
battery to terminal 1 and the negative (-) lead to terminal 2. c. Turn the rheostat knob to fully
counterclockwise, check that the test bulb goes out. d. Gradually turn the rheostat knob to
clockwise, check that the test bulb brightness changes from dark to bright.
If operation is not as specified, replace the rheostat.
Page 668
The ground points circuit diagram shows the connections from all major parts to the respective
ground points. When troubleshooting a faulty ground point, checking the system circuits which use
a common ground may help you identify the problem ground quickly. The relationship between
ground points (EA, IB and IC) can also be checked this way.
How to Read Power Source
HOW TO READ POWER SOURCE
Page 2774
Ground Locations
Horn: Ground Locations
Engine Compartment
Ground Location
EA Front Left Fender
EB Rear Bank of Right Cylinder
EC Rear Bank of Left Cylinder
Connector Location
EA1 Cowl Wire Harness and Wire Harness (Connector Location)
EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B)
EC1 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC2 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC3 Engine No. 2 Wire and Engine Wire (Near the Starter)
ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission)
Page 6714
Body
Connector Location (Access Cab)
BA1 Front Door LH Wire and Wire Harness (Connector Location)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel)
BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel)
BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel)
BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Page 1782
The ground points circuit diagram shows the connections from all major parts to the respective
ground points. When troubleshooting a faulty ground point, checking the system circuits which use
a common ground may help you identify the problem ground quickly. The relationship between
ground points (EA, IB and IC) can also be checked this way.
How to Read Power Source
HOW TO READ POWER SOURCE
Specifications
Timing Belt Tensioner: Specifications
Timing Belt Tensioner
Torque .................................................................................................................................................
........................................................................ 26 Nm
Page 5760
Body
Splice Location (Standard Cab)
B1 Speaker Tweeter Wire LH
B2 Front Door LH Wire
B3 Front Door LH Wire
B4 Roof Wire
B5 Speaker Tweeter Wire RH
B6 B7
Front Door RH Wire
B10 Frame Wire
Seat
Page 1690
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 4928
B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(Connect the Relay) and SW 2 OFF (or Disconnect SW 2)
D. Disconnect and reconnect the connectors while watching the test light.
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
E. Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION:
a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals
are touched, the IC may be destroyed by
static electricity.)
b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact
with the terminals of leads from the IC, etc. of the replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
Special Tool
1. PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown.
2. DISCONNECT CONNECTOR
3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
a. Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the
secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
A: For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
Page 4487
Repair Procedure
1. Disconnect the cable from the negative (-) battery terminal for MORE THAN two (2) seconds.
2. Reconnect the cable to the negative (-) battery terminal.
3. Perform the applicable zero point calibration of the yaw rate sensor and/or the steering angle
sensor.
HINT Refer to the applicable TSB or Repair Manual for the zero point calibration procedure.
4. Re-initialize all applicable systems available on the vehicle (power window sunroof power lift
door etc.).
Page 5718
Radio/Stereo: Harness Locations
Engine Compartment
Connector Location
EA1 Cowl Wire Harness and Wire Harness (Connector Location)
EB1 Engine No. 2 Wire and Engine Room Main Wire (Under the Engine Room R/B)
EC1 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC2 Engine No. 2 Wire and Engine Wire (Near the Starter)
EC3 Engine No. 2 Wire and Engine Wire (Near the Starter)
ED1 Engine No. 2 Wire and Differential Wire (Near the Transmission)
Page 4949
7. DISCONNECT PRESSURE FEED AND RETURN TUBES
Using Special Service Tool (SST), disconnect the tube. SST 09023-12700
8. REMOVE PS GEAR ASSEMBLY
a. Remove the bolt, nut and stud bolt from the bracket. b. Remove the 2 set bolts, nut, washer and
PS gear assembly.
9. REMOVE BRACKET AND GROMMET
INSTALLATION
1. INSTALL GROMMET AND BRACKET
2. INSTALL PS GEAR ASSEMBLY
a. Install the PS gear assembly with the gear assembly set bolt.
Torque: 165 Nm (1,700 kgf-cm, 123 ft. lbs.)
b. Install the gear assembly set bolt, washer and nut.
Torque: 130 Nm (1,350 kgf-cm, 96 ft. lbs.)
c. Install the stud bolt to the bracket.
Torque: 20 Nm (200 kgf-cm, 15 ft. lbs.)
d. Install the bolt and nut to the bracket.
Torque: 165 Nm (1,700 kgf-cm, 123 ft. lbs.)
3. CONNECT PRESSURE FEED AND RETURN TUBES
Using Special Service Tool (SST), connect the tubes. SST 09023-12700 Torque: 32 Nm (326
kgf-cm, 27 ft. lbs.)
HINT: ^
Use a torque wrench with a fulcrum length of 300 mm (11.81 inch).
^ This torque value is effective in case that SST is parallel to a torque wrench.
4. CONNECT CLAMP PLATE
Connect the clamp plate and install the bolt. Torque: 29 Nm (290 kgf-cm, 21 ft. lbs.)
5. CONNECT NO. 2 INTERMEDIATE SHAFT ASSEMBLY 6. CONNECT RIGHT-HAND AND
LEFT-HAND TIE ROD ENDS
Page 5083
Engine Controls - Error When Reprogramming ECU
PROM - Programmable Read Only Memory: Customer Interest Engine Controls - Error When
Reprogramming ECU
SPECIAL SERVICE TOOLS SS004-01 REVISED
May 25, 2001
Title: ECU FLASH REPROGRAMMING ERROR MESSAGE
Models: Applicable Models
TSB REVISION NOTICE:
September 23, 2003: Models added - 2002 (and later) Solara, 2003 (and later) Corolla and Matrix,
and 2004 models; Test Procedures updated for new CAN Interface Module. The previous TSB
should be discarded.
Introduction
During ECU flash reprogramming, an error message may be displayed on the Diagnostic Tester
that will not allow ECU flash reprogramming to complete. This bulletin provides test procedures to
determine the cause for the error message.
Applicable Vehicles ^
2001 (and later) model year 4Runner, Highlander, Land Cruiser, RAV4, Sequoia and Tundra
vehicles.
^ 2002 (and later) model year Camry, Solara and Tacoma vehicles.
^ 2003 (and later) model year Corolla and Matrix vehicles.
^ All 2004 (and later) model year Toyota vehicles except Celica, MR2 Spyder, Avalon, and Tacoma
(3RZ-FE engine)
Required SSTs
NOTE:
Additional Diagnostic Tester Kits, CAN Interface Modules, Program Cards or other SSTs may be
ordered by calling SPX/OTC at 1-800-933-8335.
Warranty Information
Test Procedure
Page 245
Page 2058
Mass Air Flow (MAF) Meter
Electrical Specifications
Resistance
Diagram Information and Instructions
Auxiliary Power Outlet: Diagram Information and Instructions
Key to Diagrams
A: System Title
B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to
distinguish it from the J/B
Example: 1 Indicates Relay Block No.1
C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type,
or specification is different.
D: Indicates related system.
Page 2480
CHART 5
CHART 6
Page 6559
Continuity And Resistance Check
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Continuity And Resistance Check
C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the
electrical circuit.
Finding A Short Circuit
Finding A Short Circuit
Finding A Short Circuit
A. Remove the blown fuse and disconnect all loads of the fuse.
Page 724
Crankshaft Position Sensor: Testing and Inspection
INSPECTION
NOTE: "Cold" and "Hot" in these sentences express the temperature of the coils themselves.
"Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F).
INSPECT CRANKSHAFT POSITION SENSOR
Resistance
Using an ohmmeter, measure the resistance between the terminals.
If the resistance is not as specified, replace the crankshaft position sensor.
Page 2911
Vehicle Speed Sensor: Description and Operation
Vehicle Speed Sensor NO.1
Vehicle Speed Sensor NO.1 Circuit Description
The vehicle speed sensor outputs a 4-pulse signal for every revolution of the rotor shaft, which is
rotated by the transmission output shaft via the driven gear. After this signal is converted into a
more precise rectangular waveform by the waveform shaping circuit inside the combination meter,
it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency
of these pulse signals.
Vehicle Speed Sensor NO.2
Vehicle Speed Sensor NO.2 Circuit Description
The No.2 vehicle speed sensor detects the rotation speed of the transmission output shaft and
sends signals to the ECM. The ECM determines the vehicle speed based on these signals.
Page 557
CHART 14
Page 4839
5. As shown in the example chart, read the distance from the measured value to the standard
value, and adjust the front and/or rear adjusting
cams accordingly. Amount to turn adjusting cams (by graduation): Example:
Front cam: 1.3 + Direction Rear cam: 3.3 + Direction
d. Torque the front and/or rear adjusting cam set bolts.
Torque: 130 Nm (1,325 kgf-cm, 96 ft. lbs.)
Page 5148
Glass - Windshield and Fixed Glass Bonding
Windshield: Technical Service Bulletins Glass - Windshield and Fixed Glass Bonding
COLLISION REPAIR INFORMATION CRIB127
TITLE: WINDSHIELD AND FIXED GLASS BONDING
SECTION: EXTERIOR BULLETIN #127
MODELS: ALL TOYOTA & LEXUS
DATE: MAY 2003
During windshield and fixed glass removal or replacement, it is crucial to follow proper installation
procedures. These specific procedures are outlined in Toyota and Lexus model-specific repair
manuals. The manuals provide detailed instructions and illustrations for removal and installation
procedures for windshields, backlights and other fixed glass.
Replacement Information
The following recommendations are provided as supplemental in formation to model-specific
Repair Manual documented procedures.
^ Technicians performing glass installations should be well trained andlor certified in glass
installation methods. If training is needed, glass installation
courses are available through I-CAR or through the National Glass Association (NGA).
^ Always inspect glass opening bonding surface for damage or corrosion that may negatively
impact proper glass installation.
^ Consult manuals and disassemble as recommended for removal.
^ Cover interior and exterior panels and components to protect them from glass and bonding
debris.
^ Remove glass making sure not to damage painted finishes.
^ Body filler materials should NOT be used on bond surfaces.
^ Apply a two-part epoxy primer to properly prepared bare metal on the bonding surface and allow
to dry.
^ Test fit replacement glass.
^ Clean, prep, and prime glass as required by adhesive manufacturer.
^ Select proper urethane adhesive with an American National Standards Institute (ANSI) minimum
lap-shear strength rating of 500-750 PSI.
^ Apply urethane bead to glass as specified (width and height) and set glass.
^ Vacuum or blow (with low pressure air) to clean debris from interior and air ducts and then
re-assemble.
Page 6973
Front Door (Part 2)
Page 40
Daytime Running Lamp Relay: Testing and Inspection
Terminal Identification
Connector Disconnected: INSPECT DAYTIME RUNNING LIGHT RELAY CIRCUIT Disconnect the
connector from the relay and inspect the connector on the wire harness side. If circuit is as
specified, perform inspections.
Connector Connected: INSPECT DAYTIME RUNNING LIGHT RELAY CIRCUIT Connect the wire
harness side connector to the relay and inspect wire harness side connector from the back side, as
shown. If circuit is not as specified, try replacing the relay with a new one.
Page 1122
Driver Side J/B And Integration Relay
Page 3607
1. REMOVE DETENT SPRING
Remove the bolt, spring plate and detent spring.
2. REMOVE MANUAL VALVE
3. REMOVE PRESSURE RELEASE VALVE
Remove the bolt, spring seat, spring and ball.
4. REMOVE SOLENOID VALVE
a. Remove the 2 bolts and 3 solenoid valves. b. Turn the valve body, remove the bolt, lock plate
and solenoid valve SLT. c. Remove the 3 O-rings from the 3 solenoid valves.
Page 4297
A. Disconnect shock absorber from lower suspension arm.
B. Remove the shock absorber lower side set nut and washer.
NOTE:
Do not remove the
C. Wrap the bolt's head with vinyl tape to prevent the drive shaft boot from being damaged.
D. Pry down the lower suspension arm to remove the bolt and disconnect the shock absorber.
E. Remove the 3 nuts and shock absorber with the coil spring.
NOTE:
Do not damage the
8. Disconnect lower ball joint. Remove the 4 bolts and disconnect the lower ball joint.
Page 1922
CHART 15
Page 6205
Continuity And Resistance Check
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Continuity And Resistance Check
C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the
electrical circuit.
Finding A Short Circuit
Finding A Short Circuit
Finding A Short Circuit
A. Remove the blown fuse and disconnect all loads of the fuse.
Locations
Page 5609
B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(Connect the Relay) and SW 2 OFF (or Disconnect SW 2)
D. Disconnect and reconnect the connectors while watching the test light.
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
E. Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION:
a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals
are touched, the IC may be destroyed by
static electricity.)
b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact
with the terminals of leads from the IC, etc. of the replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
Special Tool
1. PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown.
2. DISCONNECT CONNECTOR
3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
a. Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the
secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
A: For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
Page 6008
Symptom Related Diagnostic Procedures
SRS Warning Light: Symptom Related Diagnostic Procedures
SRS (Always Light Up, When Ignition Switch Is Lock Position.)
SRS Warning Light Circuit Malfunction (Always lights up, when ignition switch is in LOCK position)
CIRCUIT DESCRIPTION
The SRS warning light is located on the combination meter.
When the SRS is normal, the SRS warning light lights up for approx. 6 seconds after the ignition
switch is turned from the LOCK position to ACC or ON position, and then turns off automatically.
If there is a malfunction in the SRS, the SRS warning light lights up to inform the driver of the
abnormality.
When terminals Tc and E1 of the DLC1 are connected, the DTC is displayed by blinking the SRS
warning light.
Wiring Diagram
Page 5801
Splice Point
J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel,
and "B" for the Body).
The Location of splice Point I5 is shaded.
K: Indicates a shielded cable.
L: Indicates the pin number of the connector.
The numbering system is different for female and male connectors.
M: Indicates a ground point.
The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for
the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body
and Surrounding area.
How to Read Connector List
HOW TO READ CONNECTOR LIST
A: Indicates connector to be connected to a part. (The numeral indicates the pin No.)
Page 1033
Power Steering Fluid: Service and Repair
BLEEDING
1. CHECK FLUID LEVEL 2. JACK UP FRONT OF VEHICLE AND SUPPORT IT WITH STANDS 3.
TURN STEERING WHEEL
With the engine stopped, turn the wheel slowly from lock to lock several times.
4. LOWER VEHICLE 5. START ENGINE
Run the engine at idle for a few minutes.
6. TURN STEERING WHEEL
a. With the engine idling, turn the wheel to left or right full lock position and keep it there for 2 - 3
seconds, then turn the wheel to the opposite
full lock position and keep it there for 2 - 3 seconds.
b. Repeat a. several times.
7. STOP ENGINE
8. CHECK FOR FOAMING OR EMULSIFICATION
If the system has to be bled twice specifically because of foaming or emulsification, check for fluid
leaks in the system.
9. CHECK FLUID LEVEL
Page 3140
Crankshaft Position Sensor: Service and Repair
Crankshaft Position Sensor
REMOVAL
1. REMOVE ENGINE UNDER COVER
Page 5608
Continuity And Resistance Check
If the circuit has diodes, reverse the two leads and check again.
When contacting the negative lead to the diode positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there should be no continuity.
Continuity And Resistance Check
C. Use a volt/ohmmeter with high impedance (10 k ohm/V minimum) for troubleshooting of the
electrical circuit.
Finding A Short Circuit
Finding A Short Circuit
Finding A Short Circuit
A. Remove the blown fuse and disconnect all loads of the fuse.
Page 2046
Vehicle Speed Sensor: Service and Repair
Vehicle Speed Sensor NO.1
1. DISCONNECT NO. 1 VEHICLE SPEED SENSOR CONNECTOR
2. REMOVE NO. 1 VEHICLE SPEED SENSOR
Remove the bolt and No.1 vehicle speed sensor.
3. DISASSEMBLE NO. 1 VEHICLE SPEED SENSOR
a. Remove the O-ring from the speedometer driven gear assembly. b. Remove the clip and
speedometer driven gear from the speedometer driven gear sleeve.
4. ASSEMBLE NO. 1 VEHICLE SPEED SENSOR
a. Install the speedometer driven gear and clip to the speedometer driven gear sleeve. b. Coat a
new O-ring with ATF. c. Install the O-ring to the speedometer driven gear assembly.
5. INSTALL NO. 1 VEHICLE SPEED SENSOR
Page 2295
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 6335
Clock: Splice Locations
Engine Compartment
Splice Location
E1 Engine Room Main Wire
E2 Engine Room Main Wire
E3 Engine Room Main Wire
E4 Engine No. 2 Wire
E5 Engine Wire
E6 Engine Wire
E7 Engine Wire
E8 Engine Wire
Instrument Panel
Page 2096
Knock Sensor: Description and Operation
P0325 - Knock Sensor 1 Circuit Malfunction (Bank 1) CIRCUIT DESCRIPTION
DTC Detection Condition
One of the knock sensors is fitted to the right bank and another to the left bank of the cylinder block
to detect the engine knocking. This sensor contains a piezoelectric element which generates
voltage when it becomes deformed. This occurs when the cylinder block vibrates due to knocking.
If the engine knocking occurs, ignition timing is retarded to suppress it.
Wiring Diagram
Page 2752
CHART 2
CHART 3
CHART 4
Page 1886
Engine Bank Identification
Page 3994
Hydraulic Control Assembly - Antilock Brakes: Testing and Inspection
NOTE: This article contains corrected data processed from TSB# PG001-05.
ABS ACTUATOR ON-VEHICLE INSPECTION
1. CONNECT TOYOTA HAND-HELD TESTER
a. Connect the TOYOTA hand-held tester to the DLC3. b. Start the engine and run it at idle. c.
Select the ACTIVE TEST mode on the TOYOTA hand- held tester.
HINT: Please refer to the TOYOTA hand-held tester operator's manual for further details.
2. INSPECT ABS ACTUATOR MOTOR OPERATION
a. Check that the operation sound of the ABS actuator motor can be heard when the motor relay is
turned ON by the TOYOTA hand-held tester.
NOTICE: Do not keep motor relay ON for more than 5 seconds continuously. When operating it
continuously, set the interval of more than 20 seconds.
If the operation sound cannot be heard, replace the ABS actuator because the motor operation is in
failure.
b. Turn the motor relay OFF.
3. INSPECT RIGHT FRONT WHEEL SOLENOID
a. Depress the brake pedal and hold it for about 15 seconds, and check that the brake pedal does
not go down further.
If the brake pedal goes down, replace the ABS actuator because the sealing condition of the
reduction solenoid valve is abnormal.
b. Check that the brake pedal does not pulsate when the motor relay is turned ON by the TOYOTA
hand-held tester.
NOTICE: Do not keep motor relay ON for more than 5 seconds continuously. When operating it
continuously, set the interval of more than 20 seconds.
If there is a pulsation in the brake pedal, replace the ABS actuator because the sealing condition of
the reduction solenoid valve is abnormal.
c. Turn the motor relay OFF. d. Depress the brake pedal and hold it until the step (g) is completed.
e. Check that the brake pedal does not go down further when the SFRH solenoid is turned ON by
the TOYOTA hand-held tester.
NOTICE: Do not keep solenoid ON for more than 2 seconds continuously. When operating it
continuously, set the interval of more than 20 seconds.
If the brake pedal goes down, replace the ABS actuator because the holding solenoid valve
operation is abnormal.
HINT: To prevent the solenoids, TOYOTA hand-held tester turns OFF automatically 2 secs. after
has been turned ON simultaneously.
f. Check that the brake pedal goes down further when the SFRR solenoid is turned ON by the
TOYOTA hand-held tester.
If the brake pedal does not go down, replace the ABS actuator because the reduction solenoid
valve operation is abnormal.
g. Check that the brake pedal returns when the motor relay is turned ON by the TOYOTA
hand-held tester.
NOTICE: Do not keep motor relay ON for more than 5 seconds continuously. When operating it
continuously, set the interval of more than
Page 3484
Steps 1 - 2
Page 3751
B: Junction Connector
Indicates a connector which is connected to a short terminal.
Junction connector in this include a short terminal which is connected to a number of wire
harnesses. Always perform inspection with the short terminal installed. (When installing the wire
harnesses, the harnesses can be connected to any position within the short terminal grouping.
Accordingly, in other vehicles, the same position in the short terminal may be connected to wire
harness from a different part.) Wire harness sharing the same short terminal grouping ha the same
color.
C: Parts Code
The first letter of the code is taken from the first letter of part, and the numbers indicates its order in
parts which start with the same letter.
D: Connector Color
Connectors not indicated are milky white in color.
How to Read Ground Points
HOW TO READ GROUND POINTS
Page 2079
Camshaft Position Sensor: Service and Repair
Camshaft Position Sensor
REMOVAL
1. DRAIN ENGINE COOLANT
2. REMOVE DRIVE BELT
3. REMOVE LH NO.3 TIMING BELT COVER
Page 1645
b. Apply seal packing to the sealing groove of water inlet housing as shown in the illustration.
Seal packing: Part No. 08826-00100 or equivalent ^
Install a nozzle that has been cut to a 2 - 3 mm (0.08 - 0.12 inch) opening.
^ Parts must be assembled within 5 minutes of application. Otherwise the material must be
removed and reapplied.
^ Immediately remove nozzle from the tube and reinstall cap.
c. Install a new O-ring to the water inlet housing. d. Apply soapy water on the O-ring. e. Attach the
water inlet housing end to the front water bypass joint hole.
f. Install the water inlet and housing assembly with the 2 bolts. Alternately tighten the bolts. Torque:
18 Nm (185 kgf-cm, 13 ft. lbs.)
HINT: Each bolt length is indicated in the illustration.
Bolt length:
76 mm (3.00 inch) for A 22 mm (0.87 inch) for B
g. Connect the water bypass hose to the water inlet housing.
3. INSTALL NO.2 IDLER PULLEY 4. INSTALL TIMING BELT 5. FILL WITH ENGINE COOLANT 6.
START ENGINE AND CHECK FOR ENGINE COOLANT LEAKS 7. RECHECK ENGINE
COOLANT LEVEL
Page 1104
Engine Compartment
Instrument Panel
Locations
Page 4811
Waterproof Type Connector
B: For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White
: Gray
Black or White : Dark Gray
Gray or White : Black
Waterproof Type Connector
"Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up
to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Waterproof Type Connector
"Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 3662
1. CHECK DRIVE SHAFT
a. Check to see that there is no remarkable play in the outboard joint. b. Check to see that the
inboard joint slides smoothly in the thrust direction. c. Check to see that there is no remarkable play
in the radial direction of the inboard joint. d. Check the boots for damage.
2. REMOVE INBOARD AND OUTBOARD JOINT BOOT CLAMPS
a. Using pliers, pinch the claws to compress the large inboard joint boot clamp and remove it. b.
Using a side cutter, cut the small inboard joint boot clamp and remove it. c. Using a side cutter, cut
the 2 outboard joint boot clamps and remove them.
3. REMOVE INBOARD JOINT SHAFT FROM OUTBOARD JOINT SHAFT
a. Place matchmarks on the inboard and outboard joint shafts.
NOTICE: Do not punch the marks.
b. Using a snap ring expander, pull out the outboard joint shaft while expanding the snap ring.
4. REMOVE INBOARD AND OUTBOARD JOINT BOOTS
5. REMOVE DUST SEAL
Using Special Service Tool (SST) and a press, remove the dust seal. SST 09950-00020
Page 3531
REMOVAL
1. REMOVE STEERING COLUMN ASSEMBLY
Restraints - Seat Belt Tongue Plate Stopper Replacement
Seat Belt: All Technical Service Bulletins Restraints - Seat Belt Tongue Plate Stopper Replacement
T-SB-0258-08
September 2, 2008
Seat Belt Tongue Plate Stopper Replacement
Service Category Vehicle Interior
Section Seat Belt
Market USA
Applicability
TSB SUPERSESSION NOTICE
The information contained in this TSB supersedes TSB No. BO017-07.
^ Applicability has been updated to include 2008 model year vehicles.
TSB No. BO017-07 is Obsolete and any printed versions should be discarded. Be sure to review
the entire content of this service bulletin before proceeding.
Introduction
For situations where only the seat belt stopper is broken a new service part has been developed to
eliminate the need to replace the entire seat belt assembly. Follow the installation procedure below
to utilize this new part.
Page 3230
Splice Point
J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel,
and "B" for the Body).
The Location of splice Point I5 is shaded.
K: Indicates a shielded cable.
L: Indicates the pin number of the connector.
The numbering system is different for female and male connectors.
M: Indicates a ground point.
The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for
the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body
and Surrounding area.
How to Read Connector List
HOW TO READ CONNECTOR LIST
A: Indicates connector to be connected to a part. (The numeral indicates the pin No.)
Page 6813
The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit
breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery
power is supplied to each system are explained. Since all System Circuit diagrams start from the
power source, the power source system must be fully understood.
Collision / Non-Collision Inspections
Clockspring Assembly / Spiral Cable: Testing and Inspection Collision / Non-Collision Inspections
VEHICLE NOT INVOLVED IN COLLISION
a. Do a diagnostic system check.
See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Displaying & Reading
Trouble Codes
b. Do a visual check which includes the following item with the steering wheel pad (with airbag)
installed in the vehicle.
Check cuts, minute cracks or marked discoloration on the steering wheel pad top surface and in
the grooved portion.
VEHICLE INVOLVED IN COLLISION AND AIRBAG IS NOT DEPLOYED
a. Do a diagnostic system check.
See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Displaying & Reading
Trouble Codes
b. Do a visual check which includes the following items with the steering wheel pad (with airbag)
removed from the vehicle.
- Check cuts, minute cracks or marked discoloration on the steering wheel pad top surface and in
the grooved portion.
- Check cuts and cracks in wire harnesses, and chipping in connectors.
- Check the deformation of the horn button contact plate on the steering wheel pad.
HINT: If the horn button contact plate of the steering wheel pad is deformed, never repair it. Always
replace the steering wheel pad with a new one.
Page 3097
4. INSPECT THROTTLE POSITION SENSOR
a. Disconnect the throttle position sensor connector. b. Using an ohmmeter, measure the
resistance between terminals VC and E2.
Resistance: 1.25 - 2.35 kohms at 20 °C (68 °F)
If the resistance is not as specified, replace the throttle position sensor.
c. Reconnect the throttle position sensor connector.
5. INSPECT ACCELERATOR PEDAL POSITION SENSOR
a. Disconnect the pedal position sensor connector. b. Using an ohmmeter, measure the resistance
between terminals VC and E2.
Resistance: 1.64 - 3.28 kohms at 20 °C (68 °F)
If the resistance is not as specified, replace the accelerator pedal position sensor.
c. Reconnect the pedal position sensor connector.
6. REINSTALL THROTTLE BODY COVER
Body - Plastic Bumper Refinishing
Front Bumper Cover / Fascia: Technical Service Bulletins Body - Plastic Bumper Refinishing
TITLE: PLASTIC BUMPER REFINISHING
SECTION: REFINISH
BULLETIN # 170
MODELS: ALL TOYOTA LEXUS and SCION
DATE: OCTOBER 2008
When it is necessary to replace a damaged plastic bumper, proper consideration should be given
to preparation and refinishing to ensure high quality, long-term durability, and customer
satisfaction. While it is important to follow paint manufacturer recommendations for application of
refinish materials, this bulletin provides Toyota recommended procedures for cleaning and
preparation of original equipment (OE) raw plastic bumpers.
Background:
Toyota bumper covers are manufactured using several types of plastic however, cleaning and
preparation procedures outlined here are applicable to all Toyota, Lexus, and Scion raw plastic OE
bumpers.
Soap-base mold release agent replaced the wax-base type beginning in 1995 to reduce volatile
organic compound (VOC) emissions produced by the use of cleaning solvents. This topic is
covered in Collision Repair Information Bulletin (CRIB) #69. Thorough cleaning with recommended
soap and water removes soap-base mold release agent.
Cleaning and Preparation:
^ Wash new part thoroughly inside and out with a hot water and ph neutral wax-free carwash soap
solution. Rinse well and dry with clean towels.
Cleaning and Preparation, Continued^ Clean exterior surface and all edges thoroughly with paint manufacturer recommended plastic
parts cleaner or water-base wax and grease remover, or a 1-1 mixture of isopropyl alcohol and
deionized water.
^ Scuff exterior surface and all edges with a medium to fine scuff pad (as recommended by paint
manufacturer), with sanding paste and clean water. Repeat wash sequence, rinse well and dry with
clean towels.
^ Examine the bumper closely, especially hard to reach areas. Re-scuff any areas that do not
appear to have been scuffed sufficiently. Repeat wash- rinse-dry sequence.
^ Make final surface inspection and clean with paint manufacturer recommended cleaner or a 1-1
mixture of isopropyl alcohol and deionized water.
^ Apply anti-static measures.
^ Apply adhesion promoter per paint manufacturer7s recommendations.
^ Apply primer and topcoats per paint manufacturer7s recommendations.
Note:
Toyota recommends the use of adhesion promoter and elastifier for all OE raw plastic bumpers to
ensure adhesion, flexibility, and long-term durability of topcoats; and the use of refinish materials
that meet or exceed the Toyota new vehicle limited paint finish warranty.
Toyota, Lexus and Scion bumpers are primarily made from TSOP (Toyota Super Olefin Polymer).
This type of plastic requires the use of adhesion
Recall - Rear Cross-Member Corrosion
Technical Service Bulletin # SC90M Date: 091116
Page 1528
Coolant Temperature Sensor/Switch (For Computer): Mechanical Specifications
New gasket and the ECT sensor. Torque: ..........................................................................................
.................................................................................... 20.4 N.m (208 kgf.cm, 15 ft.lbf)
New gasket and the throttle body with the 2 bolts and 2 nuts. Torque: ...............................................
.................................................................................................................................. 18 N.m (185
kgf.cm, 13 ft.lbf)
Locations
Vehicle Lift And Support Locations
Page 1693
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 630
CHART 23
Page 2477
O2S Application Table
O2S Failure Threshold Charts
Page 5240
3. INSPECT A/C SWITCH CONTINUITY
If operation is not as specified, replace integration circuit bulb.
4. INSPECT A/C INDICATOR OPERATION
a. Connect the positive (+) lead from the battery to terminal A12 and negative (-) lead to A1. b.
Push the A/C button in and check that the A/C indicator lights up.
If operation is not as specified, replace the integration circuit.
c. Connect the positive (+) lead from the battery to terminal A11 and negative (-) lead to terminal
A10, then check that the indicator dimes.
If operation is not as specified, replace the integration circuit.
Page 2003
CHART 28
Diagrams
Access Door
Page 1500
Intake: N = T + (A - 0.20 mm (0.008 inch))
Page 4391
Parts Information
NOTE:
Refer to TSB No. BR004-02, "Front Brake Vibration," when installing new design caliper assembly.
Page 2319
F. Confirm the Diagnostic Tester software version and connections to the TIS workstation are
correct.
* NOTE:
This screen displays the required version of Diagnostic Tester software that is compatible with the
selected calibration file, and the other required steps to properly connect the Diagnostic Tester to
your PC.
^ Type I calibration files are only compatible with software version 10.1a and older versions.
^ Type II calibration files are only compatible with software version 10.2a and newer versions.
G. Place the Diagnostic Tester in the "GET CAL FROM PC" mode to receive the calibration file
(Figure 10).
Click NEXT on the TIS workstation. Once communications begin between the PC and the
Diagnostic Tester, the Diagnostic Tester display will flash CONNECTED.
H. The CUW determines if there is enough memory to store the calibration file on the Diagnostic
Tester Program Card. If there is insufficient
Page 2204
Splice Point
J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel,
and "B" for the Body).
The Location of splice Point I5 is shaded.
K: Indicates a shielded cable.
L: Indicates the pin number of the connector.
The numbering system is different for female and male connectors.
M: Indicates a ground point.
The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for
the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body
and Surrounding area.
How to Read Connector List
HOW TO READ CONNECTOR LIST
A: Indicates connector to be connected to a part. (The numeral indicates the pin No.)
Page 226
Glossary Of Terms And Symbols (Part 2)
Page 123
^ 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 4779
The "Current Flow Chart", describes which parts each power source (fuses, fusible links, and circuit
breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery
power is supplied to each system are explained. Since all System Circuit diagrams start from the
power source, the power source system must be fully understood.
Page 2119
2. Tighten the union bolt by hand.
3. Using SST, tighten the union bolt to the specified torque.
SST 09612-24014 (09617-24011)
Torque: 33 N.m (340 kgf.cm, 24 ft.lbf) for use with SST 39 N.m (400 kgf.cm, 29 ft.lbf)
HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
c. When connecting the flare nut on the high pressure pipe union, observe these procedures:
1. Apply a light coat of engine oil to the flare nut, and tighten the flare nut by hand. 2. Using SST,
tighten the flare nut to the specified torque.
SST 09023-38400
NOTE: Do not rotate the fuel filter outlet, when tightening the flare nut.
Torque: 28 N.m (285 kgf.cm, 21 ft.lbf) for use with SST 34.3 N.m (350 kgf.cm, 25 ft.lbf)
HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
d. Observe these precautions when removing and installing the injectors.
1. Never reuse the O-ring. 2. When placing a new O-ring on the injector, take care not to damage it
in any way. 3. Coat a new O-ring with spindle oil or gasoline before installing-never use engine,
gear or brake oil.
Page 1689
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 3665
Axle Shaft: Service and Repair Axle Shaft, Conventional Fixed/Floating
REMOVAL
1. REMOVE REAR WHEEL 2. REMOVE BRAKE DRUM AND GASKET
Page 1644
b. Check that the fluid coupling is not damaged and that no silicon oil leaks.
If necessary, replace the fluid coupling.
c. Reinstall the fan to the fluid coupling with the 4 nuts.
Torque: 5.4 Nm (55 kgf-cm, 47 inch lbs.)
3. INSPECT FAN PULLEY BRACKET
Check the turning smoothness of the fan pulley. If necessary, replace the pulley bracket.
4. INSPECT TIMING BELT COMPONENTS
INSTALLATION
1. INSTALL WATER PUMP
a. Install a new O-ring to the water bypass pipe end. b. Apply soapy water to the O-ring. c. Connect
the water pump to the water bypass pipe end. d. Install the water pump and a new gasket with the
5 bolts, 2 stud bolts and nut. Uniformly tighten the bolts, stud bolts and nut in several passes.
Torque:
Bolt: 21 Nm (215 kgf-cm, 15 ft. lbs.) Stud bolt and nut: 18 Nm (185 kgf-cm, 13 ft. lbs.)
2. INSTALL WATER INLET AND INLET HOUSING ASSEMBLY
a. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact
surfaces of the water inlet housing and water pump.
^ Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the
gasket surfaces and sealing groove.
^ Thoroughly clean all components to remove all the loose material.
^ Using a non-residue solvent, clean both sealing surfaces.
Page 644
Oxygen Sensor: Mechanical Specifications
Torque: Sensor 1 .................................................................................................................................
...............................................
44 N.m (450 kgf.cm, 32 ft.lbf)
Sensor 2 ..............................................................................................................................................
.................................. 20 N.m (200 kgf.cm, 14 ft.lbf)
Page 118
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.
Testing and Inspection
Door Switch: Testing and Inspection
INSPECT DOOR COURTESY SWITCH CONTINUITY
a. Check that continuity exists between terminals and the switch body with the switch ON (switch
pin released: opened door). b. Check that no continuity exists between terminals and the switch
body with the switch OFF (switch pin pushed in: closed door).
If operation is not as specified, replace the switch.
Page 6811
B: Junction Connector
Indicates a connector which is connected to a short terminal.
Junction connector in this include a short terminal which is connected to a number of wire
harnesses. Always perform inspection with the short terminal installed. (When installing the wire
harnesses, the harnesses can be connected to any position within the short terminal grouping.
Accordingly, in other vehicles, the same position in the short terminal may be connected to wire
harness from a different part.) Wire harness sharing the same short terminal grouping ha the same
color.
C: Parts Code
The first letter of the code is taken from the first letter of part, and the numbers indicates its order in
parts which start with the same letter.
D: Connector Color
Connectors not indicated are milky white in color.
How to Read Ground Points
HOW TO READ GROUND POINTS
Page 2850
Throttle Position Sensor: Service and Repair
Refer to Fuel Delivery and Air Induction / Throttle Body / Service and Repair, for removal and
installation of this component.
Page 550
CHART 2
CHART 3
CHART 4
Capacity Specifications
Steering - Lubricant
Testing and Inspection
Power Window Relay: Testing and Inspection
INSPECT POWER MAIN RELAY CONTINUITY If continuity is not as specified, replace the switch.
Page 5238
Pinouts (Part 2)
b. Connect the connector to A/C control assembly and inspect wire harness side from the back
side, as shown in the chart.
Test condition: Run engine at idle speed
- Set on manifold gauge set
If circuit is as specified, try replacing the amplifier with a new one. If the circuit is not as specified,
inspect the circuits connected to other parts.
Component Inspection
AIR CONDITIONING CONTROL ASSEMBLY (Center Cluster Integration)
INSPECTION
Page 6011
Paint - Paint Colors
Paint: Technical Service Bulletins Paint - Paint Colors
PAINT PA001-02
May 31, 2002
Title PAINT COLORS
Models All '01 - '02 Models & '03 Corolla & Matrix
Introduction Attached for your reference is a list of OEM paint codes for all 2001 - 2002 model year
vehicles and 2003 model year Corolla and Matrix vehicles.
Note: The body color code is on the vehicle Certification Regulation Label, located on the left front
door "B" pillar or door rear lower surface.
Please contact your local paint representative for the actual paint mixing formulas or if you need
help in color matching.
Applicable Vehicles ^ 2001 - 2002 model year vehicles all models. ^ 2003 model year Corolla and
Matrix vehicles.
Warranty Information
Paint Colors
Page 2494
Page 28
Body
Connector Location (Standard Cab)
BA1 Front Door LH Wire and Speaker Tweeter Wire LH (Inside of Front Door LH)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Seat
Connector Location
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
BJ1 Seat No. 1 Wire and Seat No. 2 Wire (Under the Driver's Seat)
Page 977
A/C Clamp Remover for removing special air condition line clamps. Applicable: 1998 and newer
Toyota models with the new style A/C clamps. Comparable to Toyota Tool numbers 09870-00015
and 09870-00025.
- Made in USA
- Fits both Toyota AC Clamps, used on high and low pressure lines.
- Applicable to: 1998 and newer Toyota models
- Stainless Steel release pins
- Identification and Instructions are laser marked on the handle
Contact AST for pricing.
Assenmacher Specialty Tools 1-800-525-2943
Testing and Inspection
Control Module: Testing and Inspection
For further information regarding this component and the system that it is a part of, please refer to
Four Wheel Drive Selector Relay; Testing and Inspection; Procedures.
Page 2345
Terminal Retainer
Push the terminal retainer down to the temporary lock position.
c. Release the locking lug from terminal and pull the terminal out from rear.
4. INSTALL TERMINAL TO CONNECTOR
a. Insert the terminal.
HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug
locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position.
Testing and Inspection
Control Module: Testing and Inspection
For further information regarding this component and the system that it is a part of, please refer to
Four Wheel Drive Selector Relay; Testing and Inspection; Procedures.
Locations
Relay Box: Locations
Driver Side J/B And Integration Relay
Page 6819
Non-Waterproof Type Connector
"Case 1" Raise the terminal retainer up to the temporary lock position.
Non-Waterproof Type Connector
"Case 2" Open the secondary locking device.
Page 1083
Glossary Of Terms And Symbols (Part 2)
Page 1724
L. The calibration file will now be downloaded to the Diagnostic Tester Program Card. This process
takes approximately 2-6 minutes (see Figure 15).
M. The CUW will prompt when the calibration file is completely downloaded. Click OK to close the
CUW (Figure 16).
NOTE:
With the calibration file loaded on the Diagnostic Tester Program Card, it is not necessary to repeat
the above steps to reprogram a different vehicle needing the same calibration file. The steps above
are only required when a new calibration file must be loaded onto the Diagnostic Tester Program
Card.
The Diagnostic Tester now has the calibration file stored and you may proceed to the next step to
reprogram the vehicle ECU.
REPROGRAM ECU WITH TESTER
3. Reprogram the vehicle ECU with the Diagnostic Tester.
NOTICE:
Errors during the flash reprogramming process can permanently damage the vehicle ECU.
Minimize the risks by following the steps below.
^ Battery voltage MUST NOT FALL BELOW 11.4 volts during reprogramming.
^ Confirm battery voltage is higher than 11.4 volts, but be sure voltage DOES NOT RISE ABOVE
16.0 volts during reprogramming.
^ Turn off all electrical accessories (e.g. Audio system, A/C, interior lights, DRL, etc.).
^ Do not add to or significantly change the vehicle's electrical load while reprogramming.
^ Confirm the hood is open and ensure under hood temperatures do not exceed 158°F.
Page 2965
Idle Speed: Testing and Inspection
INSPECTION
1. INITIAL CONDITIONS
a. Engine at normal operating temperature b. Air cleaner installed c. All pipes and hoses of air
induction system connected d. All accessories switched OFF e. All vacuum lines properly
connected f.
SFI system wiring connectors fully plugged
g. Ignition timing checked correctly h. Transmission in neutral position i.
Air conditioning switched OFF
2. CONNECT TOYOTA HAND-HELD TESTER OR OBD II SCAN TOOL 3. INSPECT IDLE SPEED
a. Race the engine speed at 2,500 rpm for approximately 90 seconds. b. Check the idle speed.
Idle speed: 700 ± 50 rpm If the idle speed is not as specified, check the air intake system.
4. DISCONNECT TOYOTA HAND-HELD TESTER OR OBD II SCAN TOOL
Page 5025
Page 636
Page 6720
B: Junction Connector
Indicates a connector which is connected to a short terminal.
Junction connector in this include a short terminal which is connected to a number of wire
harnesses. Always perform inspection with the short terminal installed. (When installing the wire
harnesses, the harnesses can be connected to any position within the short terminal grouping.
Accordingly, in other vehicles, the same position in the short terminal may be connected to wire
harness from a different part.) Wire harness sharing the same short terminal grouping ha the same
color.
C: Parts Code
The first letter of the code is taken from the first letter of part, and the numbers indicates its order in
parts which start with the same letter.
D: Connector Color
Connectors not indicated are milky white in color.
How to Read Ground Points
HOW TO READ GROUND POINTS
Airbag(s) Arming and Disarming
Air Bag(s) Arming and Disarming: Service and Repair Airbag(s) Arming and Disarming
CAUTION: *
Work must be started 90 seconds after the ignition switch is turned to the "LOCK" position and the
negative (-) terminal cable is disconnected from the battery. (The SRS is equipped with a back-up
power source so that if work is started within 90 seconds of disconnecting the negative (-) terminal
cable of the battery, the SRS may be deployed.)
* When the negative (-) terminal cable is disconnected from the battery, the memory of the clock
and audio system will be canceled. So before starting work, make a record of the contents
memorized in the audio memory system. When work is finished, reset the audio systems as before
and adjust the clock. To avoid erasing the memory of each memory system, never use a backup
power supply from outside the vehicle.
* Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during
repairs.
* Do not expose the steering wheel pad, front passenger airbag assembly, airbag sensor assembly
or front airbag sensor directly to hot air or flames.
AIR BAG SYSTEM DISARMING
The Air Bag/Supplemental Restraint System (SRS) incorporates a backup energy source that
maintains sufficient deployment voltage for up to 90 seconds after the ignition is turned Off and the
battery has been disconnected. Before disconnecting battery, note radio station settings, since all
vehicle memory will be lost. Never use a backup power source from outside the vehicle.
1. Turn ignition to Lock, then disconnect battery ground cable. 2. Wait at least 90 seconds after
disconnection before beginning service or diagnostic procedures.
AIR BAG SYSTEM ARMING
1. Ensure ignition is in Lock position. 2. Connect battery ground cable. 3. Wait at least 10 seconds
before turning ignition from Lock position. 4. Turn ignition to ACC or On position and ensure SRS
lamp lights, then goes off after approximately six seconds. If lamp remains lit, an SRS
condition is indicated. Refer to Restraint Systems, Air Bag Systems, Testing And Inspection. See:
Restraint Systems/Air Bag Systems/Testing and Inspection
Page 6587
Splice Location
I1 Cowl Wire
I2 Cowl Wire
I3 Cowl Wire
I4 Cowl Wire
I5 Cowl Wire
I6 Cowl Wire
I7 Engine Wire
I8 Engine Wire
I9 Engine Wire
I10 Engine Wire
I11 Engine Wire
I12 Engine Wire
I13 Engine Wire
I14 Engine Wire
I15 Engine Wire
I16 Cowl Wire
Body
Splice Location (Access Cab)
B1 Speaker Tweeter Wire LH
B2 Front Door LH Wire
B3 Front Door LH Wire
B4 Roof Wire
B5 Speaker Tweeter Wire RH
B6 B7
Front Door RH Wire
B8 Front Door RH Wire
B9 Rear Door No. 1 Wire RH
B10 Frame Wire
Page 3964
5. INSPECT ACTUATOR OPERATION
a. 2WD 4HI shift: Connect lines via a relay, then check that the actuator fork shaft moves to 2WD
-> 4HI position.
b. 4HI -> 2WD shift: Connect lines via a relay, then check that the actuator fork shaft moves to 4HI
-> 2WD position.
Testing and Inspection
Fuel Gauge Sender: Testing and Inspection
INSPECT FUEL SENDER GAUGE RESISTANCE
Measure the resistance between terminals 1 and 2 for each float position. If resistance value is not
as specified, replace the main sender gauge.
INSPECT FUEL LEVEL WARNING SWITCH
a. Apply battery positive voltage between terminal 1 and 3, and through a 3.4 W test bulb, and
check that the bulb lights up.
HINT: It will take a short time for bulb to light up.
b. Submerge the switch in fuel, and check that the bulb goes out.
If operation is not as specified, replace the sender gauge.
Page 1252
Exhaust
Page 5714
Radio/Stereo: Splice Locations
Engine Compartment
Splice Location
E1 Engine Room Main Wire
E2 Engine Room Main Wire
E3 Engine Room Main Wire
E4 Engine No. 2 Wire
E5 Engine Wire
E6 Engine Wire
E7 Engine Wire
E8 Engine Wire
Instrument Panel
Page 2155
Mass Air Flow Meter: Description and Operation
Mass Air Flow Meter
The mass air flow meter uses a platinum hot wire. The hot wire air flow meter consists of a
platinum hot wire, thermistor and a control circuit installed in a plastic housing. The hot wire air flow
meter works in principle that the hot wire and thermistor located in the intake air bypass of the
housing detect any changes in the intake air temperature.
The hot wire is maintained at the set temperature by controlling the current flow through the hot
wire. This current flow is then measured as an output voltage of the mass air flow meter.
The circuit is constructed so that the platinum hot wire and thermistor provide a bridge circuit, with
the power transistor, and controlled so that the potential of A and B remains equal in order to
maintain the set temperature.
Page 268
Airbag Sensor Assembly
Page 3274
Transmission Position Switch/Sensor: Service and Repair
ON-VEHICLE REPAIR
1. DISCONNECT OIL COOLER PIPE 2. REMOVE PARK/NEUTRAL POSITION SWITCH
a. Disconnect the connector. b. Pry off the lock washer and remove the nut. c. Remove the bolt and
park/neutral position switch.
3. INSTALL PARK/NEUTRAL POSITION SWITCH
a. Install the park/neutral position switch and bolt.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)
b. Install a new lock plate and the nut.
Torque: 3.9 Nm (40 kgf-cm, 35 inch lbs.)
c. Bend claws on the lock plate to fix the nut. d. Connect the connector. e. Check that the engine
can be started with the shift lever only in the N or P position, but not in other positions. If not as
stated, carry out the
adjustment procedure. See: Transmission and Drivetrain/Automatic
Transmission/Transaxle/Testing and Inspection/Initial Inspection and Diagnostic Overview
4. CONNECT OIL COOLER PIPE 5. FILL ATF AND CHECK FLUID LEVEL 6. TEST DRIVE
VEHICLE
Page 2898
Splice Point
J: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel,
and "B" for the Body).
The Location of splice Point I5 is shaded.
K: Indicates a shielded cable.
L: Indicates the pin number of the connector.
The numbering system is different for female and male connectors.
M: Indicates a ground point.
The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for
the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body
and Surrounding area.
How to Read Connector List
HOW TO READ CONNECTOR LIST
A: Indicates connector to be connected to a part. (The numeral indicates the pin No.)
Page 6207
Non-Waterproof Type Connector
"Case 1" Raise the terminal retainer up to the temporary lock position.
Non-Waterproof Type Connector
"Case 2" Open the secondary locking device.
Testing and Inspection
Air Bag Deactivation Indicator: Testing and Inspection
INSPECT PASSENGER AIRBAG MANUAL ON-OFF INDICATOR OPERATION
a. Using a service wire, connect B1 and B3. b. Connect the positive (+) lead from the battery to
terminal A13 and negative (-) lead to terminal A1. c. Check that the indicator light lights up.
If the operation is not as specified, replace the indicator.
Page 3031
Fuel Pump Ballast Resistor: Testing and Inspection
FUEL PUMP RESISTOR
INSPECTION
1. REMOVE FUEL PUMP RESISTOR
2. INSPECT FUEL PUMP RESISTOR
Using an ohmmeter, measure the resistance between the terminals.
Resistance: 0.70 - 0.76 ohms at 20 °C (68 °F)
If the resistance is not as specified, replace the resistor.
3. REINSTALL FUEL PUMP RESISTOR
Torque: 8 N.m (82 kgf.cm, 71 in.lbf)
Page 2899
B: Junction Connector
Indicates a connector which is connected to a short terminal.
Junction connector in this include a short terminal which is connected to a number of wire
harnesses. Always perform inspection with the short terminal installed. (When installing the wire
harnesses, the harnesses can be connected to any position within the short terminal grouping.
Accordingly, in other vehicles, the same position in the short terminal may be connected to wire
harness from a different part.) Wire harness sharing the same short terminal grouping ha the same
color.
C: Parts Code
The first letter of the code is taken from the first letter of part, and the numbers indicates its order in
parts which start with the same letter.
D: Connector Color
Connectors not indicated are milky white in color.
How to Read Ground Points
HOW TO READ GROUND POINTS
Page 713
Camshaft Position Sensor: Description and Operation
The Camshaft Position Sensor
Camshaft position sensor (G signal) consists of a magnet iron core and pickup coil.
The G signal plate has 1 tooth on its outer circumference and is installed on the LH camshaft timing
pulley. When the camshafts rotate, protrusion on the signal plate and air gap on the pickup coil
change, causing fluctuations in the magnetic field and generating an electromotive force in the
pickup coil.
The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor
generates 34 signals at every engine revolution. The ECM detects the standard angle of the
crankshaft based on the G signal and the actual angle of the crankshaft and the engine speed by
the NE signal.
Page 4331
1. REMOVE FRONT WHEEL
2. 4WD: REMOVE GREASE CAP
Using a screwdriver and hammer remove the grease cap.
3. 4WD: DISCONNECT DRIVE SHAFT
A. Remove the cotter pin and lock cap.
B. While applying the brakes, remove the lock nut.
4. W/ABS DISCONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP FROM
STEERING KNUCKLE
Remove the 2 bolts and disconnect the ABS speed sensor and wire harness clamp from the
steering knuckle.
5. DISCONNECT BRAKE LINE
Using the SST, disconnect the brake line. Use a container to catch the brake fluid.
^ 09023-00100
6. REMOVE BRAKE,CALIPER AND DISC
Component Tests and General Diagnostics
Brake Light Switch: Component Tests and General Diagnostics
w/o Cruise Control:
INSPECT STOP LIGHT SWITCH CONTINUITY
If continuity is not as specified, replace the switch.
w/ Cruise Control:
INSPECT STOP LIGHT SWITCH CONTINUITY
If continuity is not as specified, replace the switch.
Page 1788
B. Connect a test light in place of the fuse. C. Establish conditions in which the lest light comes ON.
Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON
(Connect the Relay) and SW 2 OFF (or Disconnect SW 2)
D. Disconnect and reconnect the connectors while watching the test light.
The short lies between the connector where the test light stays lit and the connector where the light
goes out.
E. Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION:
a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals
are touched, the IC may be destroyed by
static electricity.)
b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of
your body or clothing comes in contact
with the terminals of leads from the IC, etc. of the replacement part (spare part).
How to Replace Terminal
HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)
Special Tool
1. PREPARE THE SPECIAL TOOL
HINT: To remove the terminal from the connector, please construct and use the special tool or like
object shown.
2. DISCONNECT CONNECTOR
3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
a. Locking device must be disengaged before the terminal locking clip can be released and the
terminal removed from the connector. b. Use a special tool or the terminal pick to unlock the
secondary locking device or terminal retainer.
NOTE: Do not remove the terminal retainer from connector body.
A: For Non-Waterproof Type Connector
HINT: The needle insertion position varies according to the connector's shape (number of terminals
etc.), so check the position before inserting it.
Page 1860
Crankshaft Position Sensor: Service and Repair
Crankshaft Position Sensor
REMOVAL
1. REMOVE ENGINE UNDER COVER
Diagram Information and Instructions
Cruise Control: Diagram Information and Instructions
Key to Diagrams
A: System Title
B: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to
distinguish it from the J/B
Example: 1 Indicates Relay Block No.1
C: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type,
or specification is different.
D: Indicates related system.
Page 4132
Remove the 4 bolts and disconnect the lower ball joint.
9. REMOVE STEERING KNUCKLE
A. Remove the cotter pin and loosen the nut.
B. Using the following SSTs, disconnect the steering knuckle.
^ 09950-40011 (09951-04010, 09952-04010, 09553-04020, 09554-04010, 09955-04031,
09958-04011)
C. Remove the nut and steering knuckle.
NOTE:
4WD: Be careful not to damage the oil seal and drive shaft boot.
HINT:
4WD: When it is difficult to disconnect the drive shaft, tap the tip of the drive shaft with a plastic
hammer.
10. 2WD: REMOVE GREASE CAP
A. Mount the axle hub in a soft jaw vise.
HINT:
Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further.
B. Using a screwdriver, remove the grease cap.
HINT:
Be careful not to damage the grease cap.
11. 4WD: REMOVE OIL SEAL (INSIDE)
A. Mount the axle hub in a soft jaw vise.
HINT:
Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further.
B. Using a screwdriver, remove the oil seal (inside).
Page 4319
11. 4WD:
REMOVE OIL SEAL (INSIDE)
A. Mount the axle hub in a soft jaw vise.
HINT:
Install nuts on the hub bolts, close the vise until it holds the hub nuts. Do not tighten further.
B. Using a screwdriver, remove the oil seal (inside).
12. 2WD:
REMOVE LOCK NUT AND ABS
SPEED SENSOR ROTOR (W/ABS) OR SPACER (W/O ABS) Using a chisel and hammer, loosen
the staked part of the lock nut.
NOTE:
Be careful not to damage the bushing.
A. Using the following SST, remove the lock nut. 00002-00909 (09318-12010)
NOTE:
Do NOT use air wrench.
B. Remove the ABS speed sensor rotor or spacer.
NOTE:
Take care not to scratch the serration of the speed sensor rotor.
13. REMOVE AXLE HUB FROM STEERING KNUCKLE
A. Remove the 4 bolts and shift the dust cover toward the hub side (outside).
B. Using the following SSTs, remove the axle hub from the steering knuckle.
Page 3704
Drive/Propeller Shaft: Service and Repair
REMOVAL
1. REMOVE FRONT PROPELLER SHAFT
a. Place matchmarks on the differential and propeller shaft flange. b. Remove the 4 bolts, washers
and nuts, disconnect the propeller shaft from the differential.
Specifications
Knock Sensor: Specifications
SST 09816-30010
Torque: ................................................................................................................................................
................................. 45 N.m (450 kgf.cm, 33 ft.lbf)
Page 4385
Torque: 64 N.m (650 kgf.cm, 47 ft.lbf)
B. Connect the lower side of shock absorber to the lower suspension arm with bolt, washer and
nut.
Torque: 135 N.m (1,400 kgf.cm, 100 ft.lbf)
26. INSPECT AND INSTALL THE BRAKE ROTOR AND INSTALL THE BRAKE CALIPER WITH
NEW MOUNTING BOLTS
A. Inspect the brake rotors, and machine using an on-the-car brake lathe. Replace the rotor if it is
below minimum thickness values Minimum Thickness: 26.0 mm (1.024 in.)
B. Install the disc, brake caliper and 2 NEW bolts.
Torque: 123 N.m (1,259 kgf.cm, 90 ft.lbf)
C. Install the brake line clamp to the steering knuckle with the bolt.
Torque: 28 N.m (285 kgf.cm, 21 ft.lbf)
27. INSTALL NEW BRAKE LINE
Using the SST, connect NEW brake line.
^ 09023-00100
Torque: 15 N.m (155 kgf.cm, 11 ft.lbf)
28. W/ABS: CONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP
Connect the ABS speed sensor and wire harness clamp to the steering knuckle with the 2 bolts.
Torque: 8.0 N.m (82 kgf.cm, 71 in..lbf)
29. 4WD: INSTALL DRIVE SHAFT LOCK NUT
A. While applying the brakes, tighten the nut.
Torque: 235 N.m (2,400 kgf.cm, 173 ft.lbf)
B. Install the lock cap and a NEW cotter pin.
If the holes for the cotter pin are not aligned, tighten the nut further up to 60°.
30. 2WD: INSTALL GREASE CAP
31. INSTALL FRONT WHEEL
NOTE:
Do NOT use air wrench.
Torque: 110 N.m (1,150 kgf.cm, 83 ft.lbf)
32. DEPRESS BRAKE PEDAL SEVERAL TIMES
33. FILL THE BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM
34. CHECK ABS SPEED SENSOR SIGNAL (SEE REPAIR MANUAL)
Page 6255
Body
Connector Location (Access Cab)
BA1 Front Door LH Wire and Wire Harness (Connector Location)
BB1 Frame Wire and Cowl Wire (Under the Driver's Seat)
BC1 Front Door RH Wire and Speaker Tweeter Wire RH (Inside of Front Door RH)
BD1 Frame Wire and Cowl Wire (Under the Front Passenger's Seat)
BE1 Floor Wire LH and Cowl Wire (Center of Left Rocker Panel)
BF1 Floor Wire RH and Cowl Wire (Center of Right Rocker Panel)
BG1 Floor Wire LH and Rear Door No. 1 Wire LH (Under the Left Quarter Panel)
BH1 Floor Wire RH and Rear Door No. 1 Wire RH (Under the Right Quarter Panel)
BI1 Cowl Wire and Seat No. 1 Wire (Under the Driver's Seat)
Page 1850
Torque: 20.4 N.m (208 kgf.cm, 15 ft.lbf)
b. Connect the ECT sensor connector.
8. REINSTALL THROTTLE BODY TO INTAKE MANIFOLDS
a. Install a new gasket and the throttle body with the 2 bolts and 2 nuts.
Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)
b. Connect the accelerator cable to the throttle body.
9. REINSTALL INTAKE AIR CONNECTOR
10. REFILL WITH ENGINE COOLANT
11. REINSTALL THROTTLE BODY COVER
Service and Repair
Fuel Pressure Release: Service and Repair
SFI SYSTEM
PRECAUTION
1. BEFORE WORKING ON FUEL SYSTEM, DISCONNECT NEGATIVE (-) TERMINAL CABLE
FROM BATTERY
HINT: Any diagnostic trouble code retained by the computer will be erased when the negative (-)
terminal cable is removed from the battery.
Therefore, if necessary, read the diagnosis before removing the negative (-) terminal cable from the
battery.
2. DO NOT SMOKE OR WORK NEAR AN OPEN FLAME WHEN WORKING ON THE FUEL
SYSTEM
3. KEEP GASOLINE AWAY FROM RUBBER OR LEATHER PARTS
4. FUEL SYSTEM
a. When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so
observe these procedures:
1. Disconnect the fuel pump connector. 2. Start the engine. After the engine has stopped on its
own, turn the ignition switch OFF.
3. Put a container under the connection. 4. Slowly loosen the connection. 5. Disconnect the
connection. 6. Plug the connection with a rubber plug. 7. Reconnect the fuel pump connector.
b. When connecting the union bolt (fuel pressure pulsation damper) on the high pressure pipe
union, observe these procedures:
1. Always use 2 new gaskets.
Page 351
Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
INSPECTION
1. DRAIN ENGINE COOLANT
2. REMOVE THROTTLE BODY COVER
3. REMOVE INTAKE AIR CONNECTOR
4. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS
a. Disconnect the accelerator cable from the throttle body. b. Remove the 2 bolts and 2 nuts, and
disconnect the throttle body from the intake manifold. c. Remove the gasket
5. REMOVE ECT SENSOR
a. Disconnect the ECT sensor connector. b. Remove the ECT sensor and gasket.
6. INSPECT ECT SENSOR
Using an ohmmeter, measure the resistance between the terminals.
Resistance: Refer to the graph
If the resistance is not as specified, replace the ECT sensor.
7. REINSTALL ECT SENSOR
a. Install a new gasket and the ECT sensor.
Component Locations
Cruise Control System
Page 5170
Page 2816
CHART 12
CHART 13
Page 6567
Seat Belt Reminder Lamp: Description and Operation
KEY REMINDER AND SEAT BELT WARNING
SYSTEM OUTLINE
Current always flows to TERMINAL (B) 5 of the combination meter through the DOME fuse.
1. SEAT BELT WARNING SYSTEM
When the ignition SW is turned on, current flows from the GAUGE fuse to TERMINAL (A) 7 of the
combination meter. This current activates the combination meter and the current flowing through
the seat belt warning light flows from TERMINAL (A) 12 to GROUND, causing the warning light to
light up. A buckle SW off signal is input to TERMINAL (B) 9 of the combination meter to TERMINAL
(A) 12 to GROUND, causing the warning light to light up. A buckle SW off signal is input to
TERMINAL (B) 9 of the combination meter, the current flowing to TERMINAL (B) 5 of the
combination meter flows from TERMINAL (A) 12 to GROUND and the seat belt warning buzzer
sounds. However, if the seat belt is put on during this period (While the buzzer is sounding), signal
input to TERMINAL (B) 9 of the combination meter stops and the current flow from TERMINAL (B)
5 of the combination meter to TERMINAL (A) 12 to GROUND is cut, causing the buzzer to stop.
2. KEY REMINDER SYSTEM
With the ignition key inserted in the key cylinder (Unlock warning SW on), the ignition SW still off
and driver's door open (Door courtesy SW on), when a signal is input to TERMINAL (B) 10 of the
combination meter, the combination meter operates, current flows from TERMINAL (B) 5 of the
combination meter to TERMINAL (A) 12 to GROUND and key reminder buzzer sounds.
Page 2824
CHART 22
Page 2307
Refer to Reset Procedure 2 for the vehicles with Electronically Controlled Automatic
Transmissions:
Reset Procedure 1
1. Connect the Toyota Diagnostic Tester to the vehicle.
2. Reset the ECM (PCM). Refer to the procedures below.
Page 5662
a. Install the front airbag sensors with the 4 bolts.
Torque: 20 N.m (205 kgf.cm, 15 ft.lbf)
HINT: Install the front airbag sensor with the arrow on the sensor facing toward the front of the
vehicle.
NOTE: Connection of the connector is done after the sensor has been installed.
- Make sure the sensor is installed with the specified torque.
- If the sensor has been dropped, or there are cracks, dents or other defects in the case, brackets
or connector, replace the removed sensor with a new one.
- The front sensor is equipped with an electrical connection check mechanism. Be sure to lock this
mechanism securely when connecting the connector. If the connector is not securely locked, a
malfunction code will be detected by the diagnostic system.
b. Connect the front airbag sensor connectors.
c. Install the air cleaner assembly.
d. 2UZ-FE engine:
Install the battery tray, battery and battery carrier.
Engine Controls - A/F And O2 Sensor Identification
Oxygen Sensor: All 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
Description and Operation
Brake Switch - TCC: Description and Operation
Stop Light Switch Signal
Engine
This signal is used to detect when the brakes have been applied. The STP signal voltage is the
same as the voltage supplied to the stop lights.
The STP signal is used mainly to control the fuel cut-off engine speed (The fuel cut-off engine
speed is reduced slightly when the vehicle is braking.).
Automatic Transaxle
The purpose of this circuit is to prevent the engine from stalling, while driving in lock-up condition,
when brakes are suddenly applied.
When the brake pedal is operated, this switch sends a signal to ECM. Then the ECM cancels
operation of the lock-up clutch while braking is in progress.
Page 6086
Paint: Technical Service Bulletins Body - Acid Rain Paint Damage Prevention/Repair
TITLE: ACID RAIN PAINT FINISH DAMAGE - PREVENTION & REPAIR
SECTION: EXTERIOR
BULLETIN # 165
MODELS: ALL TOYOTA LEXUS and SCION
DATE: MARCH 2008
Condition & Cause
'Acid Rain' is the result of rainwater and other forms of airborne moisture mixing with atmospheric
impurities, often referred to as industrial fallout. The mixing forms varying degrees of corrosive
acidic compounds that can settle on exposed surfaces. Depending on geographic location,
concentration level, and length of exposure; vehicle paint finish damage can occur. Horizontal
surfaces such as roof, hood, and trunk panels are most vulnerable.
Prevention of Finish Damage
While Toyota, Lexus, and Scion paint finishes are engineered to look great and provide long-term
durability, if not cared for properly they can sustain damage as a result of acid rain exposure.
Exposure can occur at any time in the life-cycle of a vehicle, be it transport, storage, or consumer
use.
Dealers should refer to the Toyota Warranty Policy and Procedures Manual,
Policy No.2.3 for information on Storage and Protection of New Vehicles.
Detailed information is also provided on proper finish care in the Owner's Manual of all models.
In brief, following washing and wax application recommendations should keep paint looking good.
Inspection & Repair
Acid rain damage can usually be identified visually and by touch. Stains look similar to hard-water
spotting however, advanced stages of damage result in etching and depressions from the corrosive
effect. Lightly rubbing a finger across a suspected acid rain stain may help to confirm etching.
University of Toyota e-learning course E257- Vehicle Delivery Quality- Paint Finish Repair, provides
detailed information on paint finish types, damage assessment methods, and repair techniques.
And, Collision Repair & Refinish T101 and L101 'Paint Finish Repair' provide hands-on training.
There is no substitute for a good training experience. Visit (www.crrtraining.com) for more
information about hands-on training.
Page 2537
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 6203
Glossary Of Terms And Symbols (Part 2)
Page 5550
Page 3467
Waterproof Type Connector
B: For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.
Example: Terminal Retainer : Connector Body Black or White
: Gray
Black or White : Dark Gray
Gray or White : Black
Waterproof Type Connector
"Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type).
Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up
to the temporary lock position.
HINT: The needle insertion position varies according to the connector's shape (Number of
terminals etc.), so check the position before inserting it.
Waterproof Type Connector
"Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access
hole of terminal retainer as shown.
Page 5934
FOR
SPECIAL SERVICE CAMPAIGN
REAR FRAME CROSS MEMBER &
LOAD SENSING PROPORTIONING & BY-PASS VALVE INSPECTION
2000-2003 MODEL YEAR TUNDRA